Additional Files

1. Feasibility Reports of
proposed project activities

2. Engineering Layout
 FEASIBILITY REPORTS

OF

ROURKELA STEEL PLANT

EXPANSION PROJECT
 TABLE OF CONTENTS

Description Page No

Feasibility Report on Installation of Coke Oven Battery # 7 1 – 138

Feasibility Report on Enhancing the Steel Making Capacity in RSP 139 – 352

Feasibility Report on Installation of Normalizing Facilities in New Plate Mill 353 – 415

Feasibility Report on Installation of New Oxygen Plant 416 – 452

Feasibility Report on Installation of Natural Gas Pipeline Network 453 – 482

Feasibility Report on Installation of 4th Hot Blast Stove In BF # 5 483 – 577

Feasibility Report on Installation of Micro Pellet Plan 578 – 614

 INSTALLATION OF BATTERY NO. 7
ROURKELA STEEL PLANT
ROURKELA

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

JUNE 2019 CET/05/RN/4095/FR/CC/01/R=6

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 Experience that delivers

This document has been prepared for Rourkela Steel Plant by:

Centre for Engineering & Technology

Salil Bhattacharjee–HOD Lead Section, C,C& C
K P Jayakumar, Task Force Leader, C,C & C
Suresh Vechalapu, C, C & C
Sushil Kumar, Mechanical
Arvind Tirkey, Mechanical
Anand Trivedi, Utilities
Somraj Chakravarty, Utilities
[Link] Priya, Electrical
S.K. Meher, Electrical
Sanjay Kumar, Process Control & Automation
Himanshu Brahme, Process Control & Automation
[Link], Structural
CH Deepak Ranga Rao, Structural
Gautam Dutta, Civil
Ms Priyanka Parameswaran, Civil
Sourav Manna, Refractory
A. Mahapatra, Rourkela Sub-Centre
[Link], Rourkela Sub-Centre
M.K. Mishra, Cost Techno-economics
R.K Verma, Project Formulation & Co-ordination

Document Identification No. CET/05/RN/4095/FR/CC/01/R=6

2
 REVISION HISTORY

Revision No. Brief Description Revision Date

R6 Comments of RSP forwarded based on COD June 2019

held on 27/02/2019 on time line of the proposal
considering rebuilding of Coke oven Battery No.
2

R5 Comments of Plant PAG Meeting received on Jan 2018

the number of packages, modifications required
with respect to power source and addition of
laboratory facilities

R4 Comments received from RSP on the technical Nov 2017

specification and the FR

Comments received from RSP for preferring the June 2017

R3
stamp charging technology

R2 Comments received from RSP for changing over Mar 2017

from single chamber to three chamber CDCP

R1 Comments received from RSP and subsequent Oct2016

discussions

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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 Experience that delivers

UPSHOT
Installation of a stamp charge Coke Oven Battery No. 7 along with CDCP and by-product
plant has been proposed to ensure better quality of coke to the bigger Blast Furnace No.5 for
its steady operation with increased productivity. Coal carbonization capacity of the battery
will be 1.0 Mtpa. The project will be executed on turnkey mode with an implementation
period of 42months. The capital cost of the project is estimated at Rs.2,317.64 cr. net of
input tax credit (ITC) of Rs.287.05 cr. including IDC of Rs.304.74 cr. FE component considered
in it is Rs.604.16 cr. The project is techno-economically viable and recommended for
implementation.

The proposed battery will be located adjacent to the existing 7 m tall Coke Oven Battery
No.6. Taking into consideration the requirement of coke for the production of hot metal,
health of current batteries, the proposal of Battery No. 7 is to be taken up as a replacement
of Battery No. 6 during its planned repair and rebuilding, and accordingly its time line is
adjusted to start by 2024-25. After commissioning of this battery, RSP will have 4 small
batteries in old site and 2 high capacity batteries in new site.

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.5

2 Background 2.1-2.6

3 Selection of Alternatives 3.1-3.10

4 Project Description 4.1-4.100

5 Implementation Schedule & Strategy 5.1-5.4

6 Capital Cost & Financial Analysis 6.1-6.3

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure No. Description No. of pages

2.1.5-1 CET letter dated 25/02/2015 6

2.1.6-1 Client’s Letter from RSP 2

2.1.6-2 Acceptance letter from CET 1

2.6-1 Coke balance 1

4.12-1 Risk assessment for the project 1

4.7.1-1 MOEF standards 7

4.7.1-2 List of pollution control facilities 2

5.1.2-1 Implementation schedule for pre-ordering 1

activities after stage-1 approval

5.1.2-2 Implementation schedule for post ordering 1

activities after stage-2 approval

5.4.2-1 Pilot oven test report with top charge and 11

stamp charge setup

6.1.1-1 Summary of Capital cost estimate 1

6.5.1-1 Details of Gross Margin calculation 1

6.6.2-1 Techno-economic indices 1

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DRAWINGS

Sl. No. Drawing No. Description

CET RN 4095 CC2 00 001 R=2 Proposed Layout of COB#7 top

1
charged tall battery (Alternative-1)
(three chamber CDCP)

2 CET RN 4095 CC2 00 002 R=1 Proposed Layout of COB#7 complex

(Sheet 1 of 2) – stamp charge(three chamber
CDCP)

3 CET RN 4095 CC2 00 002 R=1 Proposed Layout of COB#7 complex

(Sheet 2 of 2) – stamp charge(three chamber
CDCP)

CET RN 4095 CC2 00 002A R=0 Proposed Layout of COB#7 complex

4
– stamp charge(three chamber
CDCP)

CET RN 4095 CC2 00 003 R=0 Cross-section along oven- COB#7 (7

5
meter tall battery)

6 CET RN 4095 CC2 00 004 R=0 Cross-section along oven- COB#7

(stamp charge)

7 CET RN 4095 CC2 00 005 R=1 Existing cross section (CDCP system)

CET RN 4095 CC2 00 006 R=0 Existing piping network of COB#6

8
complex

9 CET RN 4095 CC1 00 001 R=1 Proposed Flow Diagram - CCD

10 CET RN 4095 CC1 00 002 R=0 Flow Diagram – COB#6 Gas System

11 CET RN 4095 ME1 00 001 R=1 Flow diagram of coal & spillage
coke handling

CET RN 4095 ME1 00 002 R=2 Elevation of coal & spillage coke
12
conveyor

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Sl. No. Drawing No. Description

13 CET RN 4095 EE1 00 001 R=5 SLD of Electrical Power Distribution

14 CET RN 4095 UT1 00 001 R=1 Scheme for BF gas mixed gas
nitrogen, steam, coke oven gas for
battery, CDCP showing take over
points.

CET RN 4095 UT1 00 002 R=0 Raw water piping layout from lagoon
15
to COB 7

16 CET RN 4095 UT1 00 003 R=0 Make up water system flow diagram

17 CET RN 4095 CA1 00 001 R=1 Schematic system configuration

diagram

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1. SUMMARY
1.1 Rourkela Steel Plant has six top charged batteries. Five are smaller batteries

SUMMARY
of 4.5 m height and one is taller battery of 7.0m height. These batteries are of
compound, regenerative with partial recirculation of waste gases, twin flue,
under jet type.
1.2 Present hot metal production capacity of Rourkela Steel Plant is 4.5 Mtpa, for
which operation of 4 smaller batteries in old site and one 7m tall battery in
new site will be required. However, hot metal production plan of RSP in
future is 4.64Mt, for which either five small battery operations in old site and
one 7m tall battery in new site will be required or three small battery and two
higher capacity batteries will be required. However 5 battery operation is not
feasible on a sustained basis as fifth battery will remain out of operation for
repair /rebuilding
1.3 After commissioning of Battery No.3, RSP is having 4 smaller batteries and
one 7m tall Battery No 6 in operation meeting the demand of BF coke. RSP is
now rebuilding Coke oven battery No. 2 and subsequent to which RSP has a
plan for cold repair of Battery-5 followed by Battery No-1 which will be
followed by Battery No-4 and then Battery No. 6.
1.4 Coke making expert committee constituted vide office order No.
SAIL/OPRNS/13 dated 14th Dec 2012 had recommended for construction of
a new battery, similar to Battery No. [Link] would help to achieve self-
sufficiency of coke requirement and also enable to meet the coke quality
requirement of the new Blast Furnace No.5. In this regard a presentation was
made to RSP on 17th Jan 2015 after examination of two alternatives i.e.,
Rebuilding of Battery No. 2 or Installation of a new tall 7m battery. CET
suggested, installation of a tall 7m battery instead of rebuilding of Battery
No. 2 for the following main reasons:
· Rebuilding of Battery No. 2 immediately after commissioning of Battery
No 3 (Battery No 1, 2, 3, 4, 5 & 6 running) will just match the coke
requirement. But from year 2022-23 onward, there will be a shortfall for
skip coke during repairs of Battery No. 1 & 4.
· Installation of a new tall Battery No. 7 at the new site can be taken up in
2018-19 to meet coke requirement without any shortage of coke during
repair of Battery No.1 & 4. It will meet the coke quality for larger Blast
furnace No.5 also as CDCP facility can be installed. Further, rebuilding of
Battery No. 5 will not be required resulting in replacement of two small
batteries (Battery No. 2 & 5) with one tall battery (Battery No. 7).
1.5 In view of the above, RSP gave an assignment to CET vide their letter dated
26/03/2015 for installation of Battery No 7.
1.6 Following two possible alternatives have been examined.

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Alternative-1 Installation of a 7m tall top charged battery with one

SUMMARY

million tonne coal throughput per annum.

Alternative-2 Installation of a stamp charge battery with one million
tonne coal throughput per annum.

1.7 Alternative 2 has been selected for the following advantages:

· Improvement in bulk density of coal charge
· Improvement in quality and yield of BF coke
· Flexibility in using inferior grades of coal
· Possibility of reduction of imported hard coal in the coal blend, resulting
in lower operating cost on account of cost of coal blend.
· The difference in capital investment is mainly on account of the stamping
cum charging cum pushing (SCP) machines and their associated facilities.
1.7.1 The battery will be stamp charge, twin flue, under jet, compound, and
regenerative heating type with partial recirculation of waste gases heating
system. Battery will be provided with two set oven machines and another 2
nos. of locos being considered for Battery no. 6. The existing coal handling
and coke handling facilities will be utilised with some modification for the
proposed battery.
1.7.2 The indicative salient features of the battery are

No. of ovens/block 46 +46

Oven dimensions (cold)

Height of ovens, mm 5000 (min) to 5500(max)

Length of ovens, mm 14000 (max)

Avg. width of ovens, mm 500 (min) to 550 (max)

Oven taper, mm 20 (min)

Coal cake weight (dry), t 31.5 ( BD=1.0)

Coking period, hrs 25 max

No. of pushing per day 90 max

Pushing sequence 5-2

Heating system Twin flue, under-jet, compound,

regenerative type with re-
circulation of waste gases

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1.7.3 Coal consumption, coke production and coke quality envisaged for the
proposed battery are as indicated below:

Parameter Coal consumption &

coke prod. / year

Dry coal charge 1.02 Mt (min)

Run-off oven coke (dry) 76 % 0.77 Mt

34 mm to 80 mm BF coke (dry) 0.68 Mt

67 %

(-) 34 mm breeze coke (dry) 0.09Mt

Parameter Coke quality

Ash content 14-15 %

Moisture content < 0.5 %

Volatile matter 0.8%

M40 84 % (min)

M10 5.5 (max)

CSR 65 (min)

CRI 25 (max)

1.8 50 tph each three chamber Coke Dry Cooling Plant (CDCP) along with a Back
Pressure Turbine Generator (BPTG) and DM plant have been envisaged for
cooling of hot coke. During cooling of hot coke, 5.0MW (approx.) power and
52 tph (approx.) steam at 18 kg/cm2 and 300 degree will be generated from
CDCP plant.
1.9 A dedicated new By-Product Plant of 50,000 Nm3/h gas handling capacity
along with Ammonia cracking &Claus process based Sulphur recovery unit,
naphthalene recovery facility and a new BOD plant have been envisaged.
1.9.1 Following new oven machines have been considered with the proposed
stamp charge battery:
· Stamping cum charging cum pushing (SCP) machine - 2 nos.
· Gas transfer car - 2 nos.

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· Coke Transfer Car (TC) - 2 nos.

· Electric Loco (EL) - 4 nos.
· Coke Bucket Wagon (BW) for Dry cooling - 2 nos.
SUMMARY

1.10 Installation of a new DM water plant and augmentation of utilities for the
above units like intake well in lagoon along with new water treatment plant
and additional boiler have been considered to meet the utility requirements.
1.11 All the facilities including land based coke pushing emission control will be
incorporated in the proposed battery complex to meet the statutory
requirements of emission norms notified by Govt. of India. However, formal
environmental clearance for the proposed Battery No. 7 along with other
clearances like consent to operate along with CDCP and the by-product plant
will be obtained by RSP.
1.12 It is envisaged to execute the project under the following turnkey packages:-
Package 1 Soil Investigation and Survey

Package 1A Enabling Works

Package 2 Battery Proper along with oven machines & refractories

Package 3 Coke Dry Cooling Plant including BPTG, Boiler and DM Water
Plant

Package 4 By-product Plant including BOD plant and Water supply

System

1.13 Proposed coal blend has already been tested at RDCIS laboratory for the
stamp charge battery and the report is enclosed.
1.14 RSP will hand over the site free of any debris/slag and any other
encroachments at site. Tentative Cost of area development including site
leveling and provision of other facilities has been considered.
1.15 The Project will be implemented within 42 months from date of the Stage - II
approval.
1.16 At RSP, 4 small coke oven batteries and one tall battery are in operation.
After commissioning of this battery, RSP will have 4 small batteries in old site
i.e., Battery Nos. 1, 2, 3, 4, and 2 high capacity batteries in new site i.e.,
Battery Nos. 6 & 7.
Therefore additional manpower is required for operating the Battery, CDCP,
BPTG, DM water plant; Gas based boiler, intake well pump house and BPP.
The total indicative manpower requirement for the proposed facilities would
be 529 (51 executives and 478 non executives). Necessary deployment
strategy, either from existing strength or through fresh recruitment may be
looked into by RSP.

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1.17 The capital cost of the project is estimated at Rs.2,317.64 cr. net of input tax
credit (ITC) of Rs.287.05 cr. including IDC of Rs.304.74 cr. FE component
considered in it is Rs.604.16 cr.
1.18 Techno-economic indices of the project are:
NPV @ 10% (Post tax) : Rs. 2,539.53 cr.
IRR (Post tax): 27.22 %
1.19 Installation of the proposed stamp charge Coke Oven Battery No. 7 along
with CDCP and by-product plant is to be taken up for meeting the quantity
and quality requirements of coke for the bigger Blast Furnace No.-5 and as a
replacement battery for COB#6 during its repair and rebuilding. The battery
will be operated with cheaper coal blend resulting in lower production cost.
1.20 The project is techno-economically viable and recommended for
implementation.

SUMMARY

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2. BACKGROUND
2.1 COKE OVEN BATTERIES AT RSP

2.1.1 There are six top charged coke oven batteries in Rourkela Steel Plant,Rourkela.

BACKGROUND
Five are smallerbatteries located in old site and one is tall battery located in new
site. The dimension and number of ovens of each battery are given in the
following tables (Table No.2.1.1-1 & 2.1.1-2).
Table 2.1.1-1
Parameters Batteries
No. 1 to 3 No. 4 & 5
No. of ovens in each battery 70 80
Oven Dimensions(cold)
Height, mm 4500
Avg. width, mm 400
Length, mm 13590
Taper, mm 60
Useful volume, m3 21.6

Table 2.1.1-2

Parameters Battery
No. 6
No. of ovens 67
Oven Dimensions(cold)
Height, mm 7000
Avg. width, mm 410
Length, mm 16000
Taper, mm 50
Useful volume, cum 41.6

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2.1.2 Age of the batteries is given in Table 2.1.2-1:

Table 2.1.2-1
Battery Date of [Link] Age as on
BACKGROUND

No. rebuilding June., 2019

1 May, 2007 12 years 1 month
2 May, 1995 Closed down in March 2016
3 December 2016 2 years 5 month
4 March,2010 9 years 2 months
5 July, 2000 18 years 10months
6 April 2013 6 years 1 month

2.1.3 Present Condition of Batteries

The present condition of the batteries is described below:
[Link] Battery No.1
Battery No.1 was commissioned after its rebuilding in May, 2007. The battery
has been constructed with pollution control features to take care of emission
norms of coke oven batteries. This battery is presently in operation.
[Link] Battery No.2
Battery No.2 was commissioned in May 1995 when emission norms were yet to
be notified by Govt. of India. It was not equipped with the required facilities for
achieving emission norms. The battery was closed down in March 2016. This
battery is now planned for rebuilding from 2019-20.
[Link] Battery No.3
Battery No 3 was commissioned in May 1992. After completion of 20 yrs. of
operation, the battery was closed down for re-building in 2012 and has been
commissioned in December 2016 with all pollution control facilities.
[Link] Battery No.4
Battery No.4 was commissioned in March, 2010. The battery is having required
facilities to achieve emission norms and is in operation.
[Link] Battery No.5
Battery No.5 was commissioned in July, 2000. Due to aging, its health is not
good. This battery will be put down for cold repair after commissioning of
Battery No-2.

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BACKGROUND
[Link] Battery No.6
Battery No.6 was conceived as a green field battery at a new site along with the
following facilities:
· New coal handling plant
· New coke handling plant
· CDCP unit ( 4 X 50 tonnes)
· Pushing emission control system
· Coal chemical plant of 50000 Nm3/h along with H2S recovery.
The battery along with CDCP and Coal chemical plant was commissioned in
April ’2013with all pollution control facilities.
2.1.4 Action Plan of RSP for Repair/ Rebuilding of Batteries
Hot metal production capacity of RSP has been increased from 2.45 Mtpa to 4.5
Mtpa after commissioning of the new blast furnace of 4060 cum. To feed coke
to this blast furnace, one 7m tall coke oven Battery No 6 has also been installed.
For a hot metal production of 4.5 Mtpa, operation of at least 4 small batteries
and one 7m tall battery is required. After commissioning of Battery No.3, RSP is
having 4 smaller batteries and one 7m tall battery in operation meeting the
demand of BF coke. However, hot metal production plan of RSP in future is
4.64Mt, for which either five small battery operations in old site and one 7m tall
battery in new site will be required or three small battery and two higher
capacity batteries will be required. However 5 battery operations is not feasible
on a sustained basis as fifth battery will remain out of operation for repair
/rebuilding.
Moreover, RSP is now rebuilding Coke oven battery No. 2 and subsequent to
which RSP has a plan for cold repair of Battery-5 followed by Battery No-1
which will be followed by Battery No-4 and then Battery No. 6 so as to have four
operational small batteries at any point of time.
Further, wet quenching facility is in operation for existing Battery No 1 to 5,
whereas, Dry cooling facility has been installed along with Battery No 6. To meet
the coke requirement of the bigger blast furnace, coke from Battery No 6 is
being mixed with coke from Battery No 4 & 5. The mixing of coke from the two
facilities is leading to inconsistency in the quality of coke for the bigger blast
furnace in terms of moisture, M10, M40, CRI & CSR.
2.1.5 Coke making expert committee constituted vide office order no.
SAIL/OPRNS/13 dated 14th Dec 2012 had recommended for construction of a

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new battery similar to Battery No. [Link] would help to achieve self-sufficiency
of coke requirement and also enable to meet the quality requirement of the
new blast furnace. Recommendation of the committee was forwarded to CET
and a presentation was made to RSP on 17th Jan 2015 after examination of two
alternatives i.e. Rebuilding of Battery No. 2 or Installation of a new 7m tall
BACKGROUND

battery. CET recommended installation of a 7m tall battery instead of rebuilding

of Battery No. 2 & Battery No. 5. (Vide CET’s letter dated 25/02/2015) enclosed
as Annexure 2.1.5-1.
[Link] The salient points of the letter are as follows:
1. Total hot metal production envisaged from the existing blast furnaces
(including new Blast Furnace No.5) is 4.5 Mtpa for which total skip coke
requirement will be around 1.958 Mtpa. This requirement can be met by two
alternatives i.e. either by operating existing Batteries No. 1,2,3,4,5 and 6 or by
operating existing Battery No 1,3,4,6 and a new 7 m tall Battery No 7. In case
of first alternative, rebuilding of Battery No. 2 will be taken up from middle of
2015-16 and Battery No. 5 in the middle of 2023-24. The major limitations of
this alternative are:
· Coke quality will be comparatively inferior as the existing batteries (No.
1,2,3,4 & 5) will be operated with wet quenching facility. Installation of
CDCP is not possible in the existing layout.
· Uniformity of coke for better operation of Blast Furnace No.5 of 4060m3
cannot be ensured as around 40% wet quenched coke will be used along
with 60% CDCP coke from Battery No 6.
2. In case of the other alternative, Battery No. 1, 3, 4, 6 & a new 7 m tall Battery
No. 7 will be operated to meet the required coke requirement. As per the
coke balance, there will be a generation of excess skip coke of around 0.350
Mtpa for a consecutive six years if the execution of 7 m tall Battery No. 7 is
taken up from first quarter of 2015-16. However, generation of excess coke
can be avoided to a great extent if the execution of the battery starts from
first quarter of 2018-19.
Major benefits of installation of 7 m tall Battery No. 7 are:
· Layout and logistics are already earmarked for installation of a 7 m tall
battery with CDCP and by product plant at new site.
· It will replace two smaller batteries No.2 & 5
· Nominal investment is required in coal & coke sorting plants as major
facilities have already been installed for 2 tall batteries.
· In comparison of rebuilding of Battery No 2 & 5, the Battery No. 7 will be
more environment friendly as all the pollution control facilities can be
installed. Further, number of pushing operations will be much less

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compared to 2 smaller batteries operation. This battery will serve as a

rebuilding reserve for Battery No 6. In case of repair and rebuilding of
Battery No. 6, adjacent Battery No 7 would be able to supply dry coke to
the new blast furnace.

BACKGROUND
· After commissioning of Battery No. 7, entire coke demand for new Blast
Furnace No. 5 will be met with CDCP quenched coke which will lead to
more productivity as the input coke quality will be consistent with respect
to moisture, M10, M40, CRI& CSR.

2.1.6 Based on above, RSP has given an assignment to CET for installation of Battery
No. 7, vide their letter dated 26/03/2015 (ref no AMR-M&SC/ Consultancy/ 15/
310) copy of which is enclosed as Annexure 2.1.6-1& CET’s acceptance letter
is enclosed as Annexure 2.1.6-2.

2.2 FR (R=0) was submitted to RSP in November 2015 considering following two
alternatives:
Alternative-1 Installation of a 7 m tall top charged battery withone
million tonne coal throughput capacity.
Alternative-2 Installation of a stamp charge battery with one million
tonne coal throughput capacity.
2.3 Lower operating cost on account of using inferior grades of coal and
improvement in quality & yield of BF coke are the basic advantages of a stamp
charge coke oven battery. This was deliberated and stamp charge battery was
proposed in FR (R=0). However, RSP opted for 7 m tall top charged battery,
Alternative -1,for the following reasons
· Coal requirement for stamp charge battery and for tall battery are different.
After installation of COB No.7, total coal requirement will be around 6000
ton/day. Installation of 6 additional silos will make total coking coal storage
capacity of around 12 days only, provided types and coal blend is same for
stamp and top charge batteries. Otherwise, there will be difficulties in
maintaining the stock level of different types of coal.
· Maintaining two different blends with same silos and weigh feeders will
require change in setting of weigh feeders very often. As a result
inconsistency in coal blend and coke quality cannot be ruled out.
· Similar technical expertise of the existing running batteries and uniformity in
maintenance & spare requirement will be added advantages.
· The capital cost of above battery compared to the stamp charge battery
would be less mainly on account of the higher cost of SCP machines.

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2.4 Based on the comments, FR R=0 was revised to top charged Battery from the
stamp charge Battery and revision R=1 was submitted on Oct 2016 which was
again commented by RSP. The major comments were that RSP preferred a three
BACKGROUND

chamber 50 tph CDCP instead of single chamber 120 tph CDCP with wet
quenching tower. Based on the comments, FR R=1 was revised and revision R=2
was submitted in March 2017.
2.5 RSP had again deliberated between the technological option of a top charged
and stamp charge Battery and preferred stamp charging option because of
lower operating cost on account of using inferior grades of coal and
improvement in quality & yield of BF coke. Based on the comments received in
June 2017, FR R=2was revised to FR R=3 and was submitted to RSP in June
2017. Subsequently, TS of all other packages were issued by July 2017. Based on
the comments of RSP, FR R=3 was revised to FR R=4 and submitted in
November 2017.
Plant level PAG held on 02.01.2018 and based on major comments regarding
reduction of number of packages, modifications required with respect to power
source and addition of laboratory facilities, FR (R=4) was revised to FR(R=5).
2.6 On deliberation of this proposal during appraisal, it was observed that Battery
No. 7 is a cost intensive scheme. The complete benefit of this project will accrue
in long term and can be fully realized after Battery No. 6 goes out of operation
for repair likely in 2027. Hence proposal of rebuilding of Battery No. 2 has been
given stage 1 approval on 30th May 2019 and as per coke balance and
rebuilding plan of RSP as indicated in Annexure 2.6-1, the proposal of Battery
No. 7 is to be taken as a replacement of Battery No. 6 during its repair and
rebuilding, and accordingly its time line is adjusted to start by 2024-25.
2.7 Based on the observations of COD meeting held on 27/02/2019 and the
comments of RSP, FR (R=5) has been revised to FR(R=6).
2.8 The co-operation extended by RSP officials in preparation of this feasibility
report is gratefully acknowledged.

RSP 19 no. 2.6

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3. SELECTION OF ALTERNATIVES
3.1 Based on the available alternatives with respect to the various pre carbonisation
technologies, stamp charging is one of the most preferred technologies. This
provides a good alternative to use inferior coal and addresses the problem of
deteriorating raw material quality. The other alternative is to go for the existing
top charged battery as existing in SAIL plants.
3.2 The stamp charging technology is based on the densification of coal charge

SELECTION OF ALTERNATIVES
during preparation of coal cake. This densification reduces void volume between
the coal particles. This reduction in void volume increases the bulk density of
coal charge from 0.74 t/m3 (in top charge batteries) to about 1.05 t/m3. The
increased bulk density of coal charge improves the coke quality.
3.3 Experience shows that contribution of stamp charging technique towards the
improvement of coke quality is more as compared to any other commercially
proven process and that it allows larger raw material flexibility in using poor
coking coals in the charge coal blend. This technique allows reducing the void
volume between the coal particles from more than 40%, which is usual in top
charged operation, to less than 20%. Thus, this technique helps to compact the
coal blend to a very high bulk density. This high bulk density of coal blend plays
a dominant role where coke is to be produced from a larger variety of input
materials.
3.4 The success of stamp charging technology depends on the following factors:
(i) Coal blend quality

(ii) Granulometry of coal blend

(iii) Moisture in coal blend

(iv) Stamping energy imparted to coal blend.

3.5 The list of stamp charge batteries running in major steel plants in India is given
below:
[Link]. Name of Plant Height Avg. width Cake No of
(m) (mm) volume Batteries

(m3)

1 Bhusan Steel 4.3 500 26.86 1

Meramandali,

2 Tata Steel 4.5 460 23.5 7

Jamshedpur 550 36.5
5.0

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[Link]. Name of Plant Height Avg. width Cake No of

(m) (mm) volume Batteries

(m3)

3 Jindal South West 4.3 500 26.86 8

(JSW), Bellary

4 Jindal Stainless 4.3 500 26.86 1

SELECTION OF ALTERNATIVES

Ltd. (JSL), Duburi

3.6 Average Performance Data of stamp charge batteries 8 and 9 at TATA Steel in
2012-13 & 2014-15 is as given below. These batteries have wet quenching facility.
Coal Blend composition, %

2012-13 2014-15

Prime 6.81 3

Medium 43.47 35

Imported Hard 13.08 28

Imported Soft 27.60 27

New Zealand 9.04 7

Coal Quality

Moisture, % 10.71 10.77

VM, % 23.05 23,03

Ash, % 11.52 11.52

FSI 6.49 -

Fluidity, ddpm 219.32 273

Crushing Index (-3.2 mm%) 89.96 89.87

<0.5 mm content in blend, % 49.80 49.9

Ro 1.05/1.06 1.05/1.06

Coke Quality

Moisture, % 3.20 4.78

RSP
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Ash, % 14.63 14.59

VM, % 0.63 0.66

M40 83.48 83.09

M10 5.48 4.98

CRI 27.26 26.51

SELECTION OF ALTERNATIVES
CSR 64.48 65

> 80mm fraction in BF coke 1.85 1.46

3.7 The average performance data of stamp charge batteries in JSW Bellary for the
year 2014-15 is given below. The batteries have CDQ facility for quenching.
Coal blend composition,%

Prime 0.00

Medium 0.00

Imported Hard 55.07

Imported soft 31.53

New Zealand 0

Additives/Briquettes/Tar Sludge 13.4

Coal quality

Moisture,% 9.98

VM,% 23.25

Ash,% 8.21

FSI 6.50

Fluidity, ddpm 364.28

Crushing Index, (-3.2 mm%) 87.52

-0.5 mm content in blend, % 41.61

Coke quality

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Moisture,% 0.68

Ash,% 10.67

VM,% 0.84

M40 86.28

M10 5.77
SELECTION OF ALTERNATIVES

CRI 23.64

CSR 66.31

+ 80 mm fraction in BF coke, % 3.26

3.8 The Average Performance Data of Stamp Charge Batteries for Bhushan Steel,
Meramandli for the year 2014-15 is given below. The battery has wet quenching
facility for quenching of coke.

Coal blend composition,%

0.00
Prime
Medium 0.00

Imported Hard 52

Imported soft 25

New Zealand 0.00

Weak 20

Additives/Briquettes/Tar Sludge/ Non coking 3

Coal quality

Moisture,% 10.76

VM,% 25.33

Ash,% 9.16

FSI 6.01

Crushing Index, (-3.2 mm%) 81.22

-0.5 mm content in blend, % 50.44

Coke quality

RSP
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Moisture,% 5.4

Ash,% 13.18

VM,% 0.66

M40 82.13

M10 6.41

SELECTION OF ALTERNATIVES
CRI 26.13

CSR 65.24

+ 80 mm fraction in BF coke, % 4.5

3.9 Uses of cheaper coal in a stamp charge battery is the main advantage of the
technology. A comparison of coal blend is mentioned below for reference:
Table 3.9.1
LANDED Type of coal Top Stamp charge Stamp charge ASH VM
COST (Rs. charged blend as per blend as per
per ton) blend of the TISCO JSW ( based on
COB#6 at blend (based imported coal)
RSP on indigenous
coal)

7500 Indigenous Prime 3 3 0 19 21

Coking Coal
(PCC)

6650 Indigenous 4 35 0 18.5 24.5

Medium Coking
Coal (MCC)

11236(AVG Australian Hard 64 35 55 9.5 23

OF MAR 16
– FEB 17)

9516(AVG Imported Soft 29 27 35 9.25 29

OF MAR 16
– FEB 17)

7932(AVG PCI coal 10 9 25.5

OF MAR 16

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– FEB 17)

Total % 100 100 100

Blend cost 10441 9054 10304

Rs. /ton

Price difference 1387 137

in Rs /ton W.R.T
SELECTION OF ALTERNATIVES

top charged
blend

Price difference 138.7 13.7

in Crores for 1
Mtpa coal

Top Stamp charge blend ( based

Parameters charged on indigenous coal as per Stamp charge blend (
blend TISCO) based on imported coal)

Coal Blend VM 24.7 25.08 25.35

Coal Blend Ash 10.07 12.87 9.36

COKE QUALITY

Coke Ash 13.71 16.6 12.7

VM, % 0.56 0.66 0.84

M40 84.7 83.09 86.28

M10 7 4.98 5.77

CRI 23.7 26.51 23.64

CSR 64.3 65 66.31

> 80mm fraction in

1.46 3.26
BF coke

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3.10 Based on the above data and information, there can be two possible alternatives
for the proposed new Battery No. 7 at the new site. The two alternatives are :
Alternative-1 Installation of a top charged 7 m tall battery of one

SELECTION OF ALTERNATIVES
million tonne coal throughput

Alternative-2 Installation of a stamp charge battery of one million

tonne coal throughput

3.11 ALTERNATIVE-1
A top charged 7 m tall battery of existing oven dimension and a capacity of one
million tonne coal throughput will be installed at new site. The layout is
indicated at drawing no CET RN 4095 CC2 00 001 R=2. The cross section is
indicated at drawing no CET RN 4095 CC2 00 003 R=0.

3.11.1 The proposed 7 m tall battery will have the following dimensions:
No. of ovens/battery 34+34

Oven dimensions (cold)

Height of ovens, mm 7000

Length of ovens, mm 16000

Avg. width of ovens, mm 410

Oven taper, mm 50

Coal weight (Dry), t 30.9( BD=0.745)

Coking period, hrs 18

No of pushing per day 90

Accordingly, the tentative production parameters will be as follows:

Dry coal, tpd 2789 (min.)

Dry coal, Mtpa 1.02 (min.)

BF coke yield, % 65

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M10 of coke 6.5-7.0

CSR of coke 64 (min)

CRI of coke 23 (max)

3.11.2 Merits:
SELECTION OF ALTERNATIVES

1. Electrical power consumption/ton of coal processed would be less

compared to a stamp charge battery.
2. The capital cost of above battery compared to the stamp charge battery
would be less mainly on account of the higher cost of SCP machines.

3.11.3 Demerits:
1. The cost of blended coal is high for achieving an identical coke quality in
the top charged battery compared to a stamp charge battery. A higher
percentage of costly prime coking coal is required in the blend in case of
a top charged battery.
2. Coke quality will be inferior especially with respect to M10& CSR values
compared to stamped charge battery coke with identical coal blend

3.12 ALTERNATIVE-2
A stamp charge battery of one million tonne coal throughput per annum will be
installed at new site. The layout is indicated at drawing no CET RN 4095 CC2 00
002 R=1 and CET RN 4095 CC2 00 002A R=0. The cross section is indicated at
drawing no CET RN 4095 CC2 00 004 R=0.
3.12.1. The size and capacity of the stamp charge battery and other expected
technological parameters are as follows :
No. of ovens/battery( 2blocks) 46 +46

Oven dimensions (cold)

Height of ovens, mm 5000(min) to 5500(max)

Length of ovens, mm 14000 max

Avg. width of ovens, mm 500min-550 max

Oven taper, mm 20 min

Coal cake weight (dry), t 31.5( BD=1.0)

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Coking period, hrs 25

No of pushing per day 90 max

Accordingly, the tentative production parameters will be as follows:

Dry coal, tpd 2790 (min)

Dry coal, Mtpa 1.02 (min)

SELECTION OF ALTERNATIVES
BF coke yield % 67

M10 of coke 5.5

CSR of coke 65 (min)

CRI of coke 25.0 (max)

3.12.2. Merits:
1. Improvement in specific coal throughput by 12-15%
2. Compared to a top charged battery, BF coke yield is at least higher by two
percentage due to better size distribution of the uncut coke ( +80 mm
fraction is low in uncut coke in case of stamp charge battery). Stamp
charge coke is distinct from top charged coke as it has lower and uniform
mean size in narrower band compare to top charge.
3. Appreciable improvement in quality of coke w.r.t M10, CSR & CRI
resulting in reduction in coke rate and increase in BF productivity.
4. Flexibility in using higher percentages of inferior grades of coal, mainly
imported soft as well as indigenous coals. Stamp charge operation helps
in widening the raw material base. It provides more flexibility in preparing
the coal blend without compromising the coke property.
5. Reduction in consumption of costly imported prime coking [Link] also
permits to use non-coking coal to some extent without compromising the
quality.
6. Oven top will be free from spillage coal thereby protecting the bracing
system of the battery. Undercharging of ovens will be eliminated.
3.12.3. Demerits:
1. Stamp charging demands better technological discipline with respect to
coal blend selection, proper cake making procedures (moisture content,

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crushing index, proper ramming of the coal cake etc.) to prevent cake
breakage.
2. Separate / additional crushing arrangement for achieving 90% crushing
will be required leading to more power consumption. Additional power
also will be required for stamping as well. Total additional power
consumption will be around 5 kWh/t of coal.
3. The capital cost compared to the alternative of top charged battery
SELECTION OF ALTERNATIVES

would be more.
4. Since, the replacement of the prime coking coal (Indian PCC and
imported hard) will primarily be done with imported soft coal and the
input blend cost advantage with respect to the top charged battery being
a major contributor in selecting the technology, the diminishing gap
between the prices of imported hard and soft coal will reduce the price
advantage on account of coal blend.
3.13. SELECTION OF ALTERNATIVE
Alternative-2 has been selected for the proposed battery for the following
advantages:

a) Improvement in bulk density of coal charge

b) Improvement in quality and yield of BF
c) Flexibility in using inferior grades of coal
d) Possibility of reduction of imported hard coal in the coal blend.
3.14. Following facilities have also been considered along with this alternative:
· A new by product plant of 50,000 Nm3/h gas handling capacity.
· Augmentation of existing coal handling and coke sorting facilities of
Battery No. 6 to meet the requirements of new stampcharge battery.
· Installation of 50t capacity (each) three chamber CDCP with BPTG to
facilitate recovery of sensible heat of hot coke, thereby saving of a
considerable amount of energy and overall reduction in emission from
coke oven complex
· Oven machines include two SCP machines, two Gas transfer cars, two
coke transfer cars, two coke bucket wagon and four electric loco (two for
new bucket wagon and two for existing coke bucket car). Land based
Pushing Emission Control system has also been envisaged.
· Installation of a new DM plant and augmentation of intake well for water,
gas based boiler for steam.

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4. PROJECT DESCRIPTION
4.1 Project description asgiven below is based on the selected Alternative
i.e.,“Installation of one Stamp Charge Battery in the new site adjacent to tall
Battery No 6”.
4.2 TECHNOLOGY
4.2.1 The proposed battery will have a coal throughput of approx. 1.02 million ton per
annum. It will be a stamp charge battery with coke dry cooling facility. Required
blended coal will be received from the existing coal handling network for
Battery No. 6 after its suitable modification/extension. Produced coke from the
new CDCP will be discharged in to the existing belts (2 belts of 200 tonnes/ hour
each) underneath the existing CDCP chambers for Battery No 6. Blast Furnace
(BF) grade coke, nut coke and breeze coke will be dispatched to the Blast
furnace No. 5 by the existing BF coke conveyors. Existing gas network will be
used for drawing gas for initial heating and later on for exporting produced

PROJECT DESCRIPTION
clean gas. New By product facilities will be provided for handling the entire gas
from the Battery No 7. Existing plant infrastructure will be used for other
facilities.
4.2.2 The battery will operate for 24 hours a day, 365 days a year. Coal consumption
and coke production and coke quality for proposed battery are as indicated
below:
Parameter Envisaged / year

Dry coal charge : 1.02 Mt (min)

Run-off oven coke (dry) 76 % : 0.77 Mt

34mm to 80mm BF coke : 0.68 Mt

(dry)67 %

(-) 34 mm Breeze coke (dry) : 0.09Mt

The expected quality of metallurgical coke on dry basis is as indicated below:

Parameter Envisaged for Battery No. 7

Ash content : 14-15 %

Moisture content : < 0.5 %

Volatile matter : 0.8%

M40 : 84 % (min)

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Parameter Envisaged for Battery No. 7

M10 : 5.5% (max)

CSR : 65 (min)

CRI : 25 (max)

4.2.3 The important characteristics of coal blend to be used are indicated as below:
Parameter
Envisaged

Ash content 10 to 11 %

Sulphur content 0.57 to 0.58 %

PROJECT DESCRIPTION

Phosphorus 0.092 to 0.093 %

Volatile matter 24 to 26 %

Moisture content 9-11% (avg.)

CSN 4.5 (min)to 6.5 ( max)

Ro (Mean Reflectance) 1-1.05

-3.15 mm 90% min

-0.5 mm 50% maximum

Gas yield 320-340 Nm3/ton of dry

coal

4.2.4 The expected yields and other parameters of various products will be as
mentioned below:
Parameter Envisaged

Oven pushing/day 90 (max)

Dry Bulk density of coal blend 1 t/m3(min)

Cake volume 31.5 m3

Yield of run-off oven coke from dry coal 76%

charge

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Parameter Envisaged

Yield of 34mm to 80 mm BF grade coke 88.1%

from run-off oven coke

Yield of 34mm to 80 mm BF grade coke 67%

from gross dry coal charge

Yield of (-) 34 mm coke from run-off 11.9%

oven coke (dry)

Yield of coke oven gas per ton of dry 320 Nm3

coal blend

Yield of Tar per ton of dry coal blend 32 kg

Yield of elemental Sulphur per ton of dry 1.05 kg

PROJECT DESCRIPTION
coal

Gas 45000 Nm3/h (max)

Tar 37000
ton/annum(max)

Sulphur 1220
tonnes/annum(max)

Tail gas 5000 Nm3/h

4.2.5 Blast furnace (BF) gas calorific value will be about 800 kcal/normal cubic meter.
Mixed gas with calorific value of 1000 kcal/normal cubic meter will be used for
under firing of the battery. Coke oven gas to be used will have calorific value of
minimum 4200 kcal/normal cubic meter.
4.2.6 CDCP unit will produce about 52 ton/hr of steam at about 500oC and 66 ata
pressure which will be fed to a Back Pressure turbine to produce about
minimum 5.0MW of power and also tail steam of same quantity at about 300 oC
and 18-19 kg/cm2 pressure which will be fed to the steam grid.
4.2.7 Battery Area
[Link] Coal preparation
Required blended coal will be received from the existing coal handling network
for Battery No 6 which is having inbuilt capacity to feed coal to Battery No. 6
and future Battery No. 7. However, for provision of required coal blends to the

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proposed stamp charge battery, some modification/ extension is also required

in the existing coal handling circuit.
Existing coal handling plant has been provided with 30 no. of silos of 2500 ton
capacity each. Required coal blend is prepared based on the composition of the
blend and selecting the silos accordingly and feeding the individual coal on the
conveyors below the silos through weigh feeders. These silos have been installed
in 5 rows of 6 nos. each. Provision of another one row of six silos has been kept
in the existing layout. This new six silos will be built along with Battery No 7.
After the installation of new row of silos, the total number of silos for Battery No.
6 &7 would be 30. One row of six silos is dedicated for storing the CDI coal for
new blast furnace for which there exists a separate feeding circuit. The total
storage capacity of coal silos for Battery No. 6 &7 after additional of 6 silos
would be (30X2500) 75000 tonnes. This is equivalent to a storage capacity of
approximately 12 and half days’ coal requirement.
Overall length along with the tracks for reversible shuttle conveyor (RSC 3 & RSC
PROJECT DESCRIPTION

4) would be extended to the new row of six silos along with associated facilities.
A new reversible shuttle conveyor no. RSC 8A would be installed over the
proposed new six silos along with associated facilities. This will enable the
incoming coal conveyor 305 & 306 followed by RSC3 & RSC4 to feed coal on to
the new reversible shuttle conveyor of 1500 tonnes/hr capacity installed over the
proposed new six silos (Refer Drg. no. CET RN 4095 ME1 00 001, R=1).

Polymer liner with air blasters will be provided on each silo at conical portions to
avoid choking / jamming. Radar type high & low level sensors will be provided in
each silo for level sensing. Dedicated air compressor (1w+1s) with all its
accessories will also be provided for compressed air requirement for air blaster
in the coal silos building.
The new silos (F1 to F6) will discharge through individual belt weigh feeder of
capacity 150 tonnes/hr into the new belt BC 310A of 500 tonnes/hr. BC 310A will
deliver the coal to the existing coal belt BC311 or BC312 through a new junction
house JH-8B along with associated facilities. The route for transportation of coal
thereafter up to the existing coal crusher will follow the existing route.
To meet the requirement of stamp charge technology, a primary crushing circuit
for hard coal is also considered. 2 nos. silos will be dedicated for storage of hard
coal. Existing conveyor No. BC-309 will be shortened, leaving the 2 nos. silos at
the back, for installation of new conveyor BC-309A of cap-150tph which will
lead to primary crusher (1W+1S) through reversible conveyor BC-309B.
Thereafter the crushed hard coal will be transported to storage bunker of cap-
350t via conveyors BC-309C &309D. The hard coal will be discharged to existing
conveyors BC-311 or BC-312 as per the blend requirement through weigh
feeder installed beneath it. Primary crusher by-pass facility is also considered.

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Since provision was kept in TP-9 of the existing coal handling plant for tapping
of coal for future battery, coal for Battery No. 7 will be tapped from the existing
junction house TP-9 into either of the two new parallel belt conveyors Y1 and Y2
which will subsequently feed the shuttle conveyor Y3 & Y4 located in the
secondary crusher house. Belt capacity of Y1, Y2 is of 800 tph whereas Y3 and
Y4are of 500 tph each. The envisaged arrangement inside the secondary crusher
house is similar to the existing crusher house. Y3 & Y4 will feed coal to 4 nos.
hammer crushers (2W+2S) of capacity 400tph each through intermediate
storage hopper to achieving 90% (-) 3mm size with a limitation of 0.5 mm fines
to maximum 50 %.

A crusher by-pass facility is also considered in the existing crusher house by

PROJECT DESCRIPTION
converting the reversible belt conveyor RSC-9 and RSC-10 into shuttle conveyor
with increased length. These shuttle conveyors will discharge material to a new
storage cum surge hopper outside the crusher house in addition to the existing
discharge to the intermediate hoppers provided above the crushers. The coal
from the surge hopper will be directly fed to the existing conveyor BC 313 and
BC 314.

Similar crusher by-pass facility is also considered in the secondary crusher house
to give more operational flexibility due to variation in the input coal blend as
follows:

· By-pass the existing crushers and feed input coal directly to the new
crushers
· Crushing of the coal in existing crushers to the desired output for
stamp charge battery with regulation of feed rate and speed of the
crusher and by-passing the new crushers
· Primary crushing of the coal in the existing crushers to the tone of 50-
60% (-)3mm and secondary crushing in the new crushers to achieve
the desired output
The coal blend will be crushed to minimum 90% (-) 3mm and 0.5 mm fines
would be limited to maximum 50 %.The crushed coal from the secondary
crusher house will be transported to the 3300 ton capacity new coal tower using
a series of new coal conveyors Y5, Y6, Y7, which will feed coal to a reversible
conveyor Y8 and subsequently to two shuttle conveyors Y9 & Y10 each having a
capacity of 800 tph.

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Coal conveyors Y-11, Y-12, Y-13, Y-14, Y-15 & Y-16 of 100tph has also been
considered for mechanized handling of coal cake breakage and feeding it to
conveyor Y-7 which leads to coal tower. Y-14 conveyor which is adjacent to
pusher side service bench and is parallel to battery will discharge coal to
succeeding conveyor Y-15 placed in an underground room below the end
bench. Y-15 will cross coke car track through a tunnelbelow it.
Coke spillage chain conveyor both on pusher side and coke side has been
considered. The chain conveyors will discharge spillage coke in to the
succeeding conveyors K-1 placed in the same underground room below the end
bench through the intermediate hopper with actuator. Conveyor K-1 will cross
SCP track through a tunnel below it and will discharge coke into a storage
bunker of 80m3 for further loading into the truck.
[Link] Battery layout
The battery will be located adjacent to Battery No. 6. The battery will be
PROJECT DESCRIPTION

installed in two blocks concept for ease of oven repair and maintenance. Each
block will comprise of 46 ovens each, named as 7A & 7B. End benches will be
provided on either side of the entire battery for locating repair and auxiliary
facilities. Coal tower will be located between the two blocks over the SCP car
track. Separate heating system rooms will be provided for each block.

Three chamber coke dry cooling plant (CDCP) will be located on the coke side
besides the existing four CDCP chambers for Battery No 6. The output coke
from the new CDCP will be fed to the existing conveyors BC-401 and BC-402
already extended for future CDCP chamber and having the in-built capacity of
200tph to cater the coke handling from two batteries. Existing Coke bucket car
repair facilities will be suitably modified/extended to pusher side also along with
a higher capacity crane of minimum 75 tonne to lift the bucket along with filled
up coke in case of emergency. The existing EOT crane of 35tonne along with the
existing coke bucket repair garage will be utilized for handling the empty bucket
as per the present practice. The common area of the existing coke repair garage
over the main coke car track will be modified for the higher capacity of crane (
minimum 75 tonne) to lift the filled up coke bucket in case of emergency( after
spot quenching) and will be shifted to the new coke repair garage facility
considered in the pusher side. Adequate buffers will be provided in the crane
rail so that the new higher capacity crane is prevented from travelling to the
existing coke repair garage.
Total three buckets can be handled in the new bucket car repair facility after the
modification/extension of the bucket car [Link] coke bucket will be
interchangeable with proposed three new chamber of CDCP. The existing self-
driven two coke bucket car will be coupled with two new loco having AC drives

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and will be capable of running in man less mode/remote operated mode and
will also be operator driven.
Two new coke bucket wagon and new loco would be provided for the proposed
Battery No. 7 which will be having AC drives and capable for operating in man
less mode/remote operated mode and will also be operator driven. The existing
DC bus bar system in Battery No. 6 will be replaced with AC bus bar system
once the two new loco having AC drive is attached with the existing man less
coke bucket car having DC [Link] required in the existing bus bar of
Battery No 6 will be provided by RSP.
The details are marked in the composite layout drawing no. showing battery,
CDCP, BPP and all the other facilities in drawing [Link] RN 4095 CC2 00 002
R=1 (Sheet 1 & 2) and CET RN 4095 CC2 00 002A R=0 (Sheet 1 of 1)
[Link] Battery Proper:
It will be a stamp charge, twin flue, under jet, compound, regenerative heating

PROJECT DESCRIPTION
type with partial recirculation of waste gases heating system. Specific heat
consumption per kg of coal blend with 10% moisture content is expected to be
around with 600 kcal with CO gas and 650 kcal with mixed gas. The battery will
have fuel main for heating on both sides of the Battery and will be capable of
heating both with CO gas and BFgas/mixed gas
The indicative salient features of the battery are:
No. of ovens/battery 46 +46

Oven dimensions (cold)

Height of ovens, mm 5000 (min) 5500(max)

Length of ovens, mm 14000 (max)

Avg. width of ovens, mm 500 min to 550(max)

Oven taper, mm 20 min

Coal cake weight (Dry), t 31.5( BD=1.0)

Coking period, hrs 25 max

No of pushing per day 90 max

Pushing sequence 5-2

Heating system Twin flue, under-jet, compound,
regenerative type with re-
circulation of waste gases

36
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Each block of the battery will be fully independent with respect to the heating
system, raw gas evacuation system and flushing liquor system. Two blocks of
battery will share common battery machines (one operating and one stand by)
and a common coal tower.

The battery brickwork will be supported on a concrete nozzle deck with

concrete buttress walls on either side. Brickwork will be held with the help of
oven anchorage system comprising of fabricated buck stays with single piece
flash plates, top cross tie rods (with suitable protection for entire length) and
bottom cross tie rod, longitudinal tie rods and necessary regenerator bracings in
fireclay zone.

Cast iron flash plates will be provided behind buckstays. Flash plates will cover
the wall ends through entire width of oven wall as well as the oven cell and lintel
brickwork. Buck stays will be of fabricated design of welded box type plate
PROJECT DESCRIPTION

construction. They will be provided with springs for applying loads the flash
plates.

Air-cooled oven doors with diaphragm type design will be provided. The doors
will be spring-loaded with self-adjusting sealing arrangement.

Stainless steel foil of 0.2 mm thick will be provided at oven top and regenerator
faces to prevent gas leakage through brick joints. RCC Chimney will be located
at pusher side

At end benches there will be facilities for carrying out the repair of doors, trays
and pushing rams of SCP machine. Stationary hoisting devices will be provided
at theend benches for hoisting from both coke and pusher sides. All along the
length of the two blocks, the SCP machine tracks will be located on pusher
side;whereas the track of transfer car and bucket car, coke dust free pushing
unit trestle will be located on coke side. Hammer exchange station will also be
provided.
[Link] Mode of Coke Oven Battery Operation
After the SCP machine bunker has been filled with blend from the coal tower,
SCP machine moves up to the oven to be pushed. Simultaneously coal cake is
getting formed by means of stamping bars in the SCP (stamping time taken
would vary between 7 – 8 minutes)

Along with the coke pushing, the process of cleaning the extracted doors takes
place. After the coke pushing is over, the frame is being cleaned. Then, the
machine is moved into the position for putting the coal cake, the door of
thestamping chamber is opened, and the coal cake, being placed at the

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charging tray, is moved into the oven chamber. After the coal cake is charged
into the oven chamber, the charging tray is being taken out. The process of
charging is over as soon as the charging tray and supporting post are retracted
into the initial position.
After that, the coal blend is supplied into the stamping chamber, and the
process of stamping the next coal cake begins, after which the SCP machine is
turned into the position for installing the doors.

Duration of all the operations on one oven processing is maximum 12 minutes.

At battery top coke oven gas transfer machine (CGT)will be provided for
servicing the gas withdrawing equipment along with HPLA.

The gases being generated during charging are sucked into the gas collecting
main in coke side through the standpipes of the oven being charged by means

PROJECT DESCRIPTION
of HPLA system as well as through the U tubes of CGT car which will transfer the
gases to another two ovens.

For the purpose of increasing the efficiency of smokeless charging of the

stamped cake into the oven, provision is made for sealing the gaps between the
oven frame and the coal cake by means of installing the special protective
arrangement. The drive for inserting the tray with coal cake into the oven is
VVVF controlled.

In the chamber roofing, there will be a standpipe which is connected to gas

collecting main. Gas off-take system will include ascension pipe lids with water
sealing arrangement to prevent emissions and [Link] liquor
system will be provided for cooling the raw gas in goosenecks and gas
collecting main

The heating wall consists of the vertical heating channels – vertical flues. Each
two neighbouring vertical flues are interconnected by the cross-over port there
in the upper part and with recirculation holes there in the lower part. From the
recirculation holes, the part of waste products from the vertical flue, which is
operating on the downward flow, is sucked into the vertical flue, which is
operating on the upward flow, i.e. the recirculation of waste products takes
place. The degree of recirculation is determined based on the condition of
providing the uniformity of ovens heating along the coal cake height.

Vertical flues and regenerators are interconnected by means of inclined flues.

Two regenerators are provided under each oven. Sliding joint is being provided
at junction point of different materials.

38
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On heating the ovens with mixed gas, mixture of coke oven and blast furnace
gas is supplied from mixed gas pipelines to gas-air valves into gas regenerators,
where from it is getting into vertical flues through inclined flues. Registers of
various widths are installed in the basement of vertical flues for regulating the
amount of gas being supplied. Air for burning is supplied via gas-air valves into
air regenerators; afterwards it is getting into vertical flues via inclined flues.

During the first reversing, burning is taking place in all the heating walls in even
vertical flues, during second reversing (in 20 minutes) – in odd ones.

While moving upwards through even vertical flues via upper port, waste gases
are getting into odd vertical flues and, after getting down into them, are being
withdrawn to regenerators.

From regenerators, waste gases are getting to the sole flues, then to chimney
PROJECT DESCRIPTION

flues, and afterwards – to chimney. In 20 minutes, during second reversing,

direction of gases flow in heating system is getting changed into reverse one.
Reversing valves for switching over the heating gas supply and air supply for de-
graphitizing are being provided within the heating accessories.

Direction of flows in the heating system is getting changed into the reverse one
every 20 minutes. Reversing device is used for switching over the reversing
valves and gas-air valves. Orifice plates and calibration cylinders are being
provided for regulating the gas supply to oven gun flues. Automatic butterfly
will be provided in side flues, and in common flue manual draught regulation
will be provided.

Rarefaction in heating system required for the battery operation is being

provided by the RCC chimney. In chimney, provision is made for sampling of
waste gases for the purpose of analyzing the harmful emissions, light signaling
equipment and lightning protection. There will be provision for continuous
monitoring of CO gas and stack emission in the chimney as per CPCB norms.
Access structural stair case will be provided for taking flue gas samples from
chimney. Suitable instrumentation will be provided for flue gas analysis from
sampling the chimney gases
[Link] Technological Equipment of Coke Oven Batteries
For the purpose of strengthening the coke oven brickwork, increasing its
solidity and prolonging its service life following will be provided:

· Armoring of the coke oven brickwork by means of buckstays with optimal

location of armoring joints throughout the height of heating walls;

RSP 39no. 4.10

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· Installation of a set of springs per each cross tie-rod from pusher side only,
which will improve the conditions of servicing the tie-rods and reduce the
scope of works on loads regulation;
· Cross tie-rods will be laid into special tubes for providing the possibility of
free moving in the process of battery heating-up and operation battery
growth;.
· Armouring of oven roofing brickwork, will be provided;
· Single U-type gas collecting mains on coke side with built-in valve boxes of
ascension pipes as well as cross-over gas pipeline (one from each battery
block).
The following in terms of gas-withdrawing equipment will be provided,
including:

Standpipes along with sealing of standpipes& lids

PROJECT DESCRIPTION
·
· Combined sealing of standpipes spigots (water seal and calking with sealing
material);
· Gas bleeders of gas collecting main equipped with automatic discharge and
ignition of gas at emergency cases;
· Hydraulic reversing device;
· Reversing mechanism with automatic interlocking and signaling system,
· Gas-tight coke ovens doors, with spring cross-bar latches and sealing frame
of increased flexibility
· Stationary and rotary stations assigned for storing the spare doors, and also
the arrangements for repairs of charging trays and stamping bars;
· Door repair station along with hydraulic drive for lowering the doors will
be provided at end bench for the purpose of carrying out the repair
activities on doors;
· Special racks (garages) will be located at the hammer changing station for
carrying out the repairs and replacing the carriages with stamping bars;
· Hoisting and handling devices for hoisting the load to the ovens top for
repair activities along with station for changing the pusher ram changing
facility will be provided;
· Pushing emissions will be controlled by using the coke dust free pushing
units with stationary collector and dry cleaning of dust-laden air in cyclones
and bag filters;

40
RSP Page no. 4.11 CET/05/RN/4095/FR/CC/01/R=6
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· Mechanized evacuation of coal blend spillages during coal blend stamping

by using the scraper and belt conveyors located at service platforms on
pusher side
· Mechanized cleaning of coal blend spillages during stamping and coal cake
charging into the oven. One belt conveyor is located under the coal cake
preparation chamber at SCP machine, the second one along the coke oven
battery service platforms to a hopper from where it will fed in the coal
feeding circuit.
· Coke spillages are removed by means of scraper conveyors located at
service platforms roofing both from coke and pusher sides with further
charging into bunkers and removal by truck
[Link] Coke Oven Machines
For servicing the coke oven batteries the following number of coke oven
machines will be provided:
PROJECT DESCRIPTION

Quantity, pcs.
Description
operating stand-by total

Stamping-Charging-Pushing Machine
1 1 2
(SCP Machine)

Coke Transfer Car (CTC) 1 1 2

Oven Top Service Car i.e. Charging Gas

1 1 2
Transfer Car (CGT)

Electric Loco 2 2 4

Coke Bucket wagon for dry quenching 1 1 2

[Link] Coal Tower

Coal tower will be provided for receiving and storage of coal blend, as well as
for charging the same into SCP machines.

Coal tower is a reinforced concrete structure.

· Capacity of coal tower bunkers - 3300 t

· Number of sections - 2 pcs.
· Number of inlet opening in each row – 4 pcs.
· Number of rows – 2
Coal tower bunkers, sloping parts of bunkers will be lined with SS/polymer for
easy flowability. System of blend pneumatic blow down will be provided

RSP 41no. 4.12

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Installation of Battery No. 7
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Coal blend supply conveyer to the top of coal tower will be equipped with
moisture meter and conveyer scales. At the coal tower top provision will be
made for installation of goods lifting mechanisms for servicing and repairing of
the equipment, and goods lift with minimum 1000kg capacity.
[Link] Coke Oven Battery Benches
End benches, intermediate bench and service benches serve as auxiliary
structures, where industrial and service buildings, auxiliary equipment for doors
and coke oven machines repairs and other utility premises will be
accommodated.

Besides, at the lower level of benches there will be electric rooms, storage yards
for storing the refractory articles and equipment, premises for installing the
equipment for substituting the oils of hydraulic drives of coke oven machines
etc.

PROJECT DESCRIPTION
At intermediate bench coke oven and blast furnace gas pipelines will be located
[Link] Coke Dust Free Pushing Unit
Coke dust free pushing unit is assigned for trapping and treatment of dust-air
mixture being evolved in the process of coke pushing.
The pushing emission control system consists of:
· Hood of special design being installed at the coke guide car.
· Stationary header with gas transfer carriage located along the battery from
coke side;
· Dust cleaning units with smoke fans and equipment of dust dry cleaning;
· Connecting gas pipeline from the header of dust cleaning unit.
[Link] Heating System
Under-firing heating system will be based on both lean gas (mixed gas) and rich
gas (CO gas) one at a time. Two main gas headers one each on coke side and
another on pusher side will be provided for either of the systems. Two way
valves, three way valves, air valves, isolating valves, control valves, CO gas pre
heater, nozzles, diaphragms, orifices and all auxiliary items etc. required for
heating the ovens along with suitable controls will be provided.

Hydraulic reversing mechanism for the reversal of battery heating system will be
provided with provision of standby manual operation for each block. Centralized
grease lubrication system will be provided for each block.

A New gas mixing station will be provided for increasing the calorific value of
lean gas

42
RSP Page no. 4.13 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
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Computerized Heating Control (COHC) system will be provided for ensuring

proper coking. The model will also take care of oven identification, oven
machine interlocking and oven scheduling.

Battery will be provided with temporary oven protection roof during

construction and heating-up period.

Battery will be heated with coke oven gas during start-up. Battery will be
provided with one set of heating up pipe work inclusive of control valves, burner
pipes, regulating cocks for burners, etc. This pipe work will be dismantled once
the battery is under-fired.
[Link] A new two storied control room and a separate administrative building will be
provided having false ceiling, false flooring, wall paneling, double door facility &
package type AC system.
[Link] Coke Processing:
PROJECT DESCRIPTION

The coke output from new CDCP will be fed to the existing conveyors BC-401
and BC-402 which was extended for future CDCP chamber and having the in-
built capacity of 200tph. Thereafter coke handling will follow the same route of
existing coke handling and sorting plant provided with Battery No. 6. The inbuilt
capacity of existing coke handling and sorting plant is sufficient to handle the
coke from two batteries in operation.
4.2.8 Coke Cooling
[Link] General
Coke pushed from the oven will be at around 1050oC temperature. For cooling
this hot coke, cooling systems will be provided. The system will be based on
three chamber coke dry cooling (CDCP). Coke car track being common for
Battery No 6 & 7 the new CDCP can be used to take hot coke from Battery No 6
in the new coke bucket car and quench it in the new CDCP being envisaged for
Battery No. 7 and vice versa.
[Link] Coke Dry Cooling Plant
1. Dry cooling of coke produces a stabilized metallurgical coke of better
strength & low moisture which is useful for Blast Furnace. Three chamber
50 tph CDCP will be provided. Each chamber will have a capacity of about
50 ton of coke per hour. The Coke Dry Cooling Plant will comprise of the
technological units viz., cooling chamber with matching waste heat boiler
followed by a backpressure turbine to handle the steam, dust recovery &
transportations system, feed water storage & supply to waste heat boiler,
ventilation facilities and a new DM water plant and other related facilities.
The power generated from the Back pressure turbine will be uploaded in
the MSDS VI.

RSP 43no. 4.14

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2. Cooling Chamber will be a refractory lined steel vessel Cylindrical and

conical portion of the casing will be lined with refractory bricks. Casing will
be provided with manholes, opening for burners, opening for installation
of instrument etc.
Two loco driven Hot Coke wagon with a single bucket will be provided.
Coke will be received in the bucket, taken to the CDCP where an EOT crane
lifts the bucket, move towards the chamber, the chamber cap opens, hot
coke discharges into the chamber, the crane returns the empty bucket to
the coke car. The entire system will be suitable for achieving an average
cycle time of maximum 8 minutes from bucket lifting to bucket lowering.
Additional three spare buckets will be provided for maintenance purpose.
Refer drg no CET RN 4095 CC2 00 005 R=1
3. The typical technological parameters/ features of Coke Dry Cooling Plant
envisaged are indicated below:

PROJECT DESCRIPTION
Description Unit Value
Dry cooling chamber No 3
Chamber capacity tph 50 -55
0
Temperature of coke charged in the chamber C 950 -
1050
0
Temperature of coke after cooling C <180
0
Temperature of circulating gas before entering C <150
cooling chamber
Pressure of steam generated ata 66
0
Temperature of steam generated C 500
Pre-chamber capacity No Four
of
oven
Cycle time of the charging crane Max 8 min
Generation of steam from boiler t/t Min.
of 0.52
coke
Daily working system of CDQ 24h
Annual working of CDQ: day 345
Annual maintenance day 20

44
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Circulating gas composition after boiler with respect to the following

component would be in the following range for safe operation.
H2 Less than 1 %
CO Less than 1 %
4. Hot Coke is pushed out from Coke Oven into the bucket placed over hot
coke wagon. Cooled Coke is discharged from discharging device of CDCP
on the conveyors below, in the existing conveyor tunnel. The existing belts
in the tunnels are having a capacity of 200tonnes/h.
5. Cooling gas is circulated through the system of dry cooling chamber, dust
catcher and waste heat boiler using a primary fan with another fanof same
capacity as a standby. Generated steam is fed to a back pressure turbine to
produce power and steam. The no. of feed pumps will be 3 (three) catering
the need of working, 1 hot standby and 1 under repair & maintenance for
PROJECT DESCRIPTION

the boiler.
6. Gases are collected from the chamber receiving portion and chamber
discharging portion and fed to a cyclone and bag filter unit to collect dust
and deposit in a bunker and then to the dust disposal unit.
7. Dust collected in the dust catcher is collected in hoppers and is
transported by pneumatically/closed belt system and deposited in the dust
disposal bunker.
8. All dust collected in dust recovery unit, ventilation system and from coke
de-dusting unit will be transported to dust disposal bunker. From this unit
dust will be disposed through trucks / dumpers.
9. Coke dust will be drawn from following units by pneumatic conveying
pipelinesor closed belt conveyor to the central dust catching / disposal
station.
· Dust catchers
· Heat recovery boilers
· Cyclones
· Bag filter station of coke discharge system / Dust free charging of
coke into chamber.
The complete handling and transportation system including the bunkers
with all equipment’s, electrics, automation, civil, structural etc. will be
provided.
One Pay loader of adequate capacity will also be provided to clean the
CDCP and Battery area

RSP 45no. 4.16

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10. Major plant facilities envisaged for the CDCP are given below:
· The coke bucket lifter consisting Lifting mechanism, Travel
mechanisms with motorized bogie, catch mechanism, safety device, Air
Conditioner assembly, Fan assembly, Electrics and control etc.
· The charging device consisting of steel structure, heat & abrasion
resistant metal liners, feed hopper carriage with wheels, rail track and
limit switches.
· For smokeless charging of hot coke into chamber necessary de-
dusting facilities/ system will be provided to arrest dust emission. The
de-dusting system will be provided with bag filter arrangement.
· Coke Cooling Chamber will be cylindrical vessel with a conical top and
will be refractory lined and will be provided with blowing device for

PROJECT DESCRIPTION
inlet of circulating gas through the lower part of the chamber.
· Discharging device consisting of isolation gate, motorized rotary
discharge for discharge of coke from the coke cooling chamber. The
lowest part of the Discharging Device will have connection for dust
removal system consisting of bag filter.
· Dust catcher with baffle wall arrangement will be provided. The dust
catcher will be lined with refractory bricks.
· Waste Heat Boiler (WHB) for cooling the hot inert circulating gases
coming out of the coke cooling chamber. The Waste Heat Boiler
preferably will be of water tube type, forced/natural recirculation and
vertical - single shaft design along with feed water pumps, piping and
other auxiliary units.
· Dust Cyclones will be installed after waste heat boiler along with safety
flaps, for coke dust removal from circulating gas in the Coke Dry
Cooling Plant. Cyclones will be properly lined with abrasion resistant
material.
· Coke dust will be drawn from following units and conveyed pneumatic
through conveying pipelinesor closed belt system to the central dust
catching station, adopting lean phase or dense phase system- Dust
catchers, Heat recovery boilers, Cyclones, Bag filter station of coke
discharge system / Dust free charging of coke into chamber.
11. Sub-units envisaged are:
· Auxiliary building with boiler feed water de-aeration system
· CDCP Air Pollution Control (APC) and Dust Disposal Systems
· Air compressor station for CDCP.
· Air Conditioning and Ventilation Systems (ACVS)

46
RSP Page no. 4.17 CET/05/RN/4095/FR/CC/01/R=6
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· Water Management Systems for CDCP including boiler feed water

system, cooling water systems, DM Water Plant, Pump Houses, etc.
· Waste Water Disposal Systems
· Gas recirculation systems with ID/FD fans, dampers, ducts, cyclones
etc.
· Back pressure turbine generator and its associated system
· Other essential sub units and systems
12. Back pressure turbine generator:
This turbine receives approximately52 ton/hr of steam from the waste heat
boiler. It will generate about 5.0 Mw of power which will feed to the new
GIS substation and discharge 52 ton/hr of steam at a pressure of 18-19
atm and 300 deg. The steam generated will also be suitably interconnected
with the existing steam network of RSP as available in the battery area.
4.2.9 By-Product Plant
PROJECT DESCRIPTION

[Link] General
The existing by-product of Battery No. 6 is having a capacity of 50,000 Nm3/h
with a standby capacity of 50,000 Nm3/h. This by product will be suitably
augmented so that the gas handling capacity of the BPP after augmentation will
be 1,00,000 m3/hr. This augmented BPP will handle gases from Battery No. 6
&7. The gas flow of proposed and existing BPP is enclosed as per drawing no
CET RN 4095 CC1 00 001 R=1& CET RN 4095 CC1 00 002 R=0.
A new stream of by-product plant will be installed to clean the raw coke oven
gas with removal of Tar, Ammonia, Hydrogen Sulphide and Naphthalene. The
coke oven gas will be also cooled finally to 300C at the outlet of Naphthalene
scrubber before export.
Production of clean coke oven gas: will be 50000 Nm3/h (approx.) with a net
Calorific value of 4200 Kcal/Nm3. The new stream will be designed to handle
50,000 Nm3/h coke oven gas and the tail gas generated in the Claus process.
Raw Coke Oven Gas temperature at inlet of Primary Gas Cooler will be 800C to
850C (saturated with water vapour).
Coke Oven Gas composition & impurities at the inlet and outlet of BPP battery
limit will be as hereunder (indicative):
Composition of cleaned Coke Oven Gas % by Volume
Hydrogen 52 to 56
Carbon monoxide 6 to 9
Carbon dioxide 3 to 4
Oxygen 0.3 to 0.7

RSP 47no. 4.18

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Methane 24 to 26
Nitrogen 4 to 7
CnHm 1.5 to 2.5
Impurities in raw Coke Oven Gas gm/Nm3
Tar 100 to 200
Benzol Hydrocarbons 30 to 36
Hydrogen Sulphide 4 to 5
Ammonia 10 to 12
Naphthalene 8 to 10
Impurities in clean Coke Oven Gas gm/Nm3
Tar 0.01

PROJECT DESCRIPTION
Hydrogen Sulphide 0.5
Ammonia 0.03
Naphthalene 0.05
Benzol Hydrocarbons 30 to 36
Quality of Flushing Liquor supplied to
Coke Oven Battery
PH 9 to 9.5
Suspended solids ≈50 ppm
Temperature 80 to 82oC
Tentative Output quantity
Gas 45,000 Nm3/h (max)
Tar 37,000 tonnes/annum(max)
Sulphur 1,220 tonnes/annum(max)
Tail gas 5,000 Nm3/h
The new stream of BPP will mainly consist of following Technological Units.
Name Function

Coarse condensation plant Removal of tar from return ammonia

liquor from battery collection main in
tar separators and decanters

48
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Fine condensation plant Cooling down of COG in Primary

coolers and tar impurities removal in
ETPs
Gas distribution plant Transfer of COG via Exhausters
Tar system plant Storage of produced tar
Detaring ammonia plant Removal of tar impurities from excess
ammonia liquor on sand filters
H2S/NH3 scrubbing plant Removal of H2S/NH3 from COG in
scrubbers into scrubbing liquor
Scrubbed liquor stripping plant Recovery H2S/NH3 from scrubbing
liquor
Sulphur recovery plant NH3 cracking, desulphurization -
production of pure sulphur, based
PROJECT DESCRIPTION

on Claus process
Caustic soda plant Preparing and storing of caustic soda
solution for other units
Naphthalene recovery plant Removal of naphthalene from COG
and subsequent naphthalene
recovery
Water system plant Production of circulating cooling
water for particular process units
Chilled water plant Production of circulating chilled water
for particular process units
Biological treatment plant Biological treatment of process waste
waters
[Link] Gas Condensation Plant (GCP)
1) General
Two streams of coke oven gas and flushing liquor will be provided, for
Battery No 7. Raw gas from two suction main of Battery No 7 will reach a
common header provided with isolating valves near the Gas condensation
plant.
2) Primary Gas Cooler:
Coke Oven Gas (COG) generated from battery gets separated from tar &
liquor and is sucked by the exhauster through 2 no’s Primary Gas Cooler
(PGC). Primary gas coolers will have tubes horizontally placed with certain

RSP 49no. 4.20

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inclination in a rectangular vertical box. The Coke Oven Gas will flow in the
shell side and cooling water/chilled water will flow in the tube side of PGC.
Cooling tower and chilled water plant will be installed for catering the
requirement of PGC and other process equipment. The chilled water plant
will be housed in a separate room. Cooling tower will have standby
provision. Chilling water plant will have standby facilities only for various
pumps, valves, pipe lines etc.
Provision will be made for hot tar flushing to each PGC for removal of
naphthalene deposit on outside of water tubes. Arrangement of LP steam &
Nitrogen purging to PGC will also be made.
3) Electrostatic Tar Precipitator:
2 no’s Electrostatic Tar Precipitators (E.T.P.) is required to remove the
remaining tar fog in gas & the same will be installed before exhauster.

PROJECT DESCRIPTION
Arrangement for removal of deposited tar in the ETP tubes will be provided.
Inert atmosphere by allowing nitrogen flow in Insulator boxes will be
maintained. Provision of steam coming directly in contact with insulator box
will be avoided.
4) Exhauster:
Two no. of electrically driven exhausters out of which one will be dual drive
(1 working + 1 hot standby) will be provided to suck the coke oven gas
leaving PGC and discharge the same with a positive head of about 500 mm
WG of CO Gas at the Battery Limit of BPP for exporting the clean CO gas to
the plant network.
5) Tar &Ammonia Liquor
The coke oven gas in gas collecting main is cooled to 80-850C by spraying
flushing/Ammonia liquor. The Ammonia liquor flows in a closed cycle from
down-comer to Decanter; to intermediate Ammonia liquor tank and then
back to Gas collecting main via Ammonia /flushing liquor pump.
Major portion of tar content in coke oven gas is condensed in Gas main by
flushing liquor/ Ammonia liquor. The tar together with flushing liquor, gas
condensate and coal fines from coke oven flowing through gas collecting
main goes to decanter. The coal fines mixed with tar & flushing liquor is
known as sludge. The decanter serves to separate tar & sludge from
Ammonia liquor by settling tar & sludge being heavier, settle at the bottom
of decanter and sludge is continuously scrapped off by scrapping conveyors
into bunkers from where it is removed by a dumper/truck. Collection &
Mechanized disposal of sludge will be provided for transporting sludge by
dumper/truck. The tar sludge will be disposed by mixing with the feed coal
of the proposed battery in the coal feeding system. The Ammonia liquor

50
RSP Page no. 4.21 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

from the flushing liquor decanter overflows into intermediate flushing liquor
tank and is returned to the gas mains of coke ovens by the flushing liquor
pump. Surplus Ammonia liquor is generated due to moisture present in the
coal. This excess Ammonia liquor will be stored in excess flushing liquor
tanks.
The tar from the flushing liquor decanter flows continuously to pressure
separator tankwith tar heating facilities. Then tar will be stored in tar storage
tanks. Tar storage tanks will be provided with heater.
Excess Ammonia from liquor decanter
Excess Ammonia liquor will be sent to NH3 stripper unit for the removal of
free & fixed ammonia & accompanying acid gases.
Facilities for removal of fixed ammonia will also be provided.
6) Major technological equipment/facilities for gas condensation plant
PROJECT DESCRIPTION

This plant will comprise of the following major technological equipment

Facility Unit Working Standby
Primary Gas Coolers (35000 Nos. 2
Nm3/h)
Electrical motor driven exhausters Nos. 1

Dual drive exhauster 1

E.T.P. (35000 Nm3/h) Nos. 2
Liquor Decanter Nos. 1 1
Intermediate flushing liquor tank Nos. 2
Gas condensate tank with steam Nos. 1
heating coils
Flushing liquor pumps Nos. 1 1 hot+1
cold
Centrifugal pumps for flushing of Nos. 1 1
PGC with tar
Centrifugal pumps for transferring Nos. 1 1
tar
Centrifugal pumps for transferring Nos. 1 1
Liquor
Seal pots Lot 1

RSP 51no. 4.22

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Facility Unit Working Standby

Tar storage tanks with steam coils Nos. 2
(1000 m3)
Liquor tanks Nos. 2 1
Miscellaneous pumps, Lot
intermediate storage tanks etc.
Cooling tower with standby cell Lot 1
and pump house with standby
pumps
Chilled water plant pump house Lot 1
with standby pumps with standby
VAM units

PROJECT DESCRIPTION
Gravel filer Lot 1 1
Apart from the above, Two (2) no of the existing tar storage tanks (1000 m 3
capacity) in the existing tar plant will be replaced.
To prevent gaseous emission from various vessels, tanks equipment &
vents, a suitable pollution control measure will be provided.
[Link] Ammonia & Hydrogen Sulphide removal
1) NH3 & H2S Scrubber
This unit contains two parts – one scrubber for absorbing H2S and another
scrubber for absorbing NH3.
a) H2S absorption:
Coke Oven gas is passed through the H2S scrubber from bottom to top.
Absorption of H2S is performed by the counter current flow of de-
acidified water coming from the proposed new de-acidifier. Further
absorption is carried out by the counter current flow of enriched NH3
water which is coming from NH3 scrubber circuit.
Due to the exothermic nature of H2S absorption, the heat generated is
removed by the counter current flow of washing water. The lower
section of H2S Scrubber will be designed for final cooling stage to
reduce the temperature increased in exhauster. By means of a cooling
loop comprising of cooling stage pumps & cooling Heat Exchanger in
which circulating water is cooled by chilled water, the gas is cooled to a
temperature of 22oC to 230C.
Further removal of H2S and removal of major portion of NH3 can be
achieved in NH3 scrubbing system by means of stripped ammonia
water.

52
RSP Page no. 4.23 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

b) NH3 absorption:
Coke Oven gas from H2S Scrubber is passed through the
NH3scrubber from bottom to top. Stripped ammonia water from
Ammonia stripper is passed counter current. The exothermic reaction
heat is removed by cooling the enriched NH3 water through heat
exchanger which cools it indirectly using chilled water. This enriched
NH3 water is fed to the H2S scrubber. The enriched water from the
H2S scrubber is sent to the stripper/de-acidifier unit.
Finally, the cleaned coke oven gas is directed to the naphthalene
scrubber.
2) Ammonia stripper / de-acidifier unit
This unit consists of two parts – one stripper for ammonia and another
stripper for H2S and other acidic gases.
PROJECT DESCRIPTION

a) De-acidifier unit:
The enriched water from the H2S scrubber is indirectly pre-heated
using hot stripped water coming from NH3 stripper and also hot de-
acidified water coming from de-acidifier. Then it is fed to the top of
de-acidifier. This enriched water flows top-down in counter flow to
rising steam and ammonia containing vapours coming from the
stripping process. The gases leaving de-acidifier now contains H2S,
CO2, HCN & NH3. They are directed to a condenser. The condensate is
returned to the de-acidifier while the gases are directed to the Claus
unit.A part of the de-acidified water is then sent to the stripper for
removal of ammonia.
Sl. Description Unit Capacity Nos.
No.
H2S Scrubber Unit
1. H2S Scrubbing Unit 50, 000 Nm3/h 1

2. Pumps, Heat Exchangers

NH3 Scrubbing Unit
1. NH3 Scrubbing Unit 50, 000 Nm3/h 1
2. Pumps, Heat Exchangers
COMBI Scrubber
1. COMBI Scrubbing Unit 50, 000 Nm3/h 1
Distillation Unit (H2S & NH3 stripper)

RSP 53no. 4.24

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Description Unit Capacity Nos.

No.
1. H2S Stripper 1w+1s
2. NH3 Stripper 1w+1s
3. Heat Exchangers, Pumps

[Link] Ammonia Cracking & Sulphur Removal

The top gases leaving de-acidifier unit and Ammonia stripper (Sour gas) mainly
contain H2S, NH3, HCN, hydrocarbons. Sour gas is brought to Sulphur recovery
unit for recovery of Sulphur from H2S and decomposition of Ammonia to
Nitrogen and Hydrogen and HCN to Hydrogen, Nitrogen and Carbon
Monoxide. The unit is based on Claus process and mainly consists of:

PROJECT DESCRIPTION
· Claus kiln (vapour burner & crack reactor with catalyst)
· Waste heat boiler
· Claus reactor (with catalyst)
· Sulphur condenser
· Sulphur storage tank
· Sulphur palletizing unit.
· Heat exchangers
· Pumps
The Claus kiln is a cylindrical vertical vessel inside lining with refractory. At the
top of the kiln a set of burners are provided for firing with coke oven gas to get
suitable temperature for decomposition of ammonia and HCN.
Sour vapor containing H2S, NH3, HCN is first fed into the Claus kiln where
partial oxidation takes place in which 1/3rd of H2S is burnt with air to form SO2
and rest 2/3rd H2S react with SO2 to give elemental sulphur. The whole reaction
is exothermic. High temperature is maintained in the kiln by chemical reaction
which helps in dissociation of ammonia and HCN. If the sour gas volume is less,
the heat released by chemical reaction will be less which is not sufficient to
maintain the furnace temperature for decomposing ammonia. So a small
amount of coke oven gas is fed to maintain the inside temperature of kiln.
NH3 and HCN vapours are decomposed to H2, N2 and CO at temperature
1150oC by catalytic cracking (Nickel catalyst). Hydrocarbons in sour gas are also
decomposed or burnt. Secondary air is fed at the bottom of the furnace for
further oxidation of process gas. The amount of secondary air is controlled by
H2S/SO2analyser.
High temperature process gas from the Claus kiln is passed through the waste
heat boiler for heat recovery and then it is continuously passed through two

54
RSP Page no. 4.25 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

stages of Claus Reactor to produce elemental sulphur. Then it is passed through

the sulphur condenser and sulphur separator where liquid sulphur is separated.
The tail gas is sent to the process gas cooler where it is cooled to 80oC by
spraying condensate tarry liquor from the upper condensate tank and it goes to
the foul gas main before primary cooler. Liquid sulphur condensed at waste
heat boiler and separator is sent to the sulphur storage tank. Then from sulphur
storage tank, it will be pumped to the sulphur Palletizing unit. These pellets will
be transported to the existing sulphur storage unit. Claus plant will have a
hundred percent standby with respect to the vapour handling capacity
[Link] Naphthalene Scrubber Unit
1) Naphthalene scrubber
The cooled gas from H2S & NH3 scrubbers is taken to naphthalene scrubber
for naphthalene recovery to the extent of 0.05 gm/Nm3. Most part of
naphthalene in CO gas is separated out with tar in hydraulic mains of coke
PROJECT DESCRIPTION

oven battery, primary gas cooler and part of the remaining portion in
naphthalene scrubber. The scrubber is packed with suitable packing to
provide larger surface area. A measured quantity of make-up solar oil is
continuously added from the top of the scrubber (lean solar oil) and
proportionate quantity of naphthalene rich solar oil is removed from the
bottom and top sections of the scrubber to storage tank. Rich solar oil is
then sent to naphthalene stripping section for recovery of naphthalene by
steam stripping and to get lean solar oil for further use in naphthalene
scrubber.
2) Major technological equipment/facilities (Naphthalene Scrubbing unit)
This plant will comprise of the following major technological equipment
Facility Unit Working Standby
Naphthalene scrubber (50000 Nm3/h) Nos. 1 1
Tanks lot 1 1
Centrifugal pumps with stand-by lot 1 1
pumps
Seal pots lot 1 1
Cooling tower lot 1 1
Heat exchangers lot 1 1
3) Naphthalene Stripping
The naphthalenerich oil will be bled continuously from the naphthalene
scrubber and will be brought into this section for recovery of naphthalene.

RSP 55no. 4.26

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

The lean oil thus obtained is returned to the scrubbing section continuously
for reuse.
The naphthalene rich solar oil will be fed to thenaphthalene stripper from
where naphthalene will be stripped off by steam. Almost naphthalene free
solar oil will be taken out from stripping column for reuse in Naphthalene
scrubber after proper cooling.
The naphthalene/ BTX containing vapours leave the stripper at the top and
are directed to condenser where the mixture will cool down up to 80-90 OC
temperature by indirect cooling with cooling water. The naphthalene/
BTX/condensate will be separated through a siphoning [Link] the
top of the siphon naphthalene will flow to cooling water jacketed
naphthalene tray where the naphthalene will cool down. Naphthalene lumps
will be takeout and bagged manually. BTX/condensate separated at the
other end of the siphon will be stored in a BTX/condensate tank and further

PROJECT DESCRIPTION
pumped to tar tank
[Link] Chilled Water Plant
One centralized chilled water plant which will meet the chilled water
requirement of primary gas coolers and other process equipment will be
provided.
The chilled water plant will be based on vapour absorption process complete
with chilled water pumps, refrigerant pumps, condensate pumps, cooling
towers, pipe, valves, instrumentation and other associated accessories. The
chilled water plant will be provided with standby pumps.
[Link] Effluent Treatment Plant/ BOD Plant
All chemically contaminated waste waters from the various units and systems of
the Battery No 7 complex contaminated with various organic and inorganic
contaminants such as phenolic compounds, ammonium salts, coal tar and oils,
etc., generally called phenolic effluents having a high Bio-chemical Oxygen
Demand (BOD) will be suitably handled in an exclusive phenolic effluent
sewerage network of Battery No.7 complex. This network will be designed to
bring all such chemically contaminated waste waters arising out of excess
flushing liquor, coke oven gas condensates, process vessel drains, contaminated
overflows and washings, etc. will be suitably treated in a new Phenolic Effluent
Treatment Plant [PETP), generally called BOD plant. The new BOD plant will have
a treatment capacity to treat all such waste waters and the capacity will be
60m3/hr (min.). BOD plant will be located by the side of the existing BOD plant
of CO-BPP.
The BOD plant will be designed considering the input effluent quality as
indicated with a minimum capacity of 60 m3/hr:

56
RSP Page no. 4.27 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Parameter Unit Quantity

pH mg/l 7.5 to 9
o
Temperature C 50-60
Phenol mg/l 800
Cyanides mg/l 20
Thio-cynides mg/l 350
Free Ammonia mg/l 200
Total Ammonia as N mg/l 550
Oil& Grease mg/l 30 to 40
PROJECT DESCRIPTION

BOD (3 days, 27oC) mg/l 1700

COD mg/l 3700
The treated effluent will generally conform to the following quality parameters:
Parameter Unit Quantity
pH of treated effluent mg/l 6 to 8
o
Temperature C 25 to 30
Phenols mg/l <1
Cyanides mg/l <0.2
Ammonical Nitrogen mg/l <30
Nitrate (NO3) mg/l <10
Free Ammonia mg/l <5
Oil & grease mg/l <5
Nitrate Nitrogen mg/l <10
BOD (3 days, 27oC) mg/l <30
COD mg/l <250
The treated effluents from the BOD plant will be used as industrial make up
water within the Battery No.7 complex in conformity to the zero-discharge
principles. Facilities for recycling the treated effluents to internal consumption
points will be provided accordingly.

RSP 57no. 4.28

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

[Link] Laboratory facilities for COB#7 complex

1 no centralized testing laboratory of adequate size along with all equipment,
utility provisions will be provided in the Coke oven battery 7 complex for
testing/analysis of quality of all input and output materials of battery, by-
product plant and CDCP units.
4.3 MECHANICAL EQUIPMENT
4.3.1 Coal and Spillage Coke Handling
[Link] Refer the write-up of coal processing covered at clause no. [Link] and Drg.
[Link] RN 4095 ME1 00 001 R=1for flow diagram of Coal & Spillage Coke
Handlingand CET RN 4095 ME1 00 002 R=1for elevation of Coal & Spillage
Coke Conveyors.

PROJECT DESCRIPTION
[Link] The major facilities and technical parameters of the equipmentconsidered for
coal and spillage coke handling are as follows:
Sl. Equipment Description Quantity Technical Parameters
No.
Coal Handling
1. Provision of one row of
6 silos with extension of
structural shed over new
silos
2. Extension of monorail
for hoists in new silo 3 nos.
area
3. Increase of length by 14 m over
existing length of 29m, Cap-
Modification of shuttle 1500tph, Belt width-1800mm,
conveyor no. RSC-3 & 2 nos. Lift-0m, Belt speed-2.5m/s,
RSC-4 Trough angle-30, Existing drive
capacity-37kw, Shuttle speed-
10m/s
4. Extension of rail for
shuttle conveyor RSC-3 4*15m 52 kg/m rail
& RSC-4
5. Extension of festoon
cable arrangement for
15m
shuttle conveyor RSC-3
& RSC-4

58
RSP Page no. 4.29 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
6. Length-38m, Cap-1500tph, Belt
New Shuttle conveyor width-1800mm, Lift-0m, Belt
1 no.
RSC 8A speed-2.5m/s, Trough angle-30,
Shuttle speed-10m/s
7. Rail for shuttle conveyor
4*45m 52 kg/m
RSC 8A
8. Charging hatch
6 set MS
assembly for silos
9. Polymer liner in conical
portion of the silos with
6 set 20mm thk UHMWPE
500mm height in vertical
portion
10. Air Blasters in new silos
PROJECT DESCRIPTION

21 nos. 150 Ltrs tank capacity

& 300t hopper
11.
Flow control Unit 7 nos.
12. Pneumatic lines with
dedicated compressor 1W + 1S compressor of capacity
1 set
and receiver for air 200 cum at 7-8 kg/cm2
blaster
13. Chain pulley block for air
1 no. Cap-2t
compressor house
14. Radar type level sensor
in each silos
15. Rod gate and rack
&pinion gate below silo 6 nos. MS
hopper
16. Cap-150tph, Belt width-1200mm,
Belt weigh feeder 6 nos.
Belt speed-0.3m/s
17. Belt Conveyor BC-310A
with conveyor gallery Length-113m, Cap-500tph, Belt
outside the silo building 1 no. width-1200mm, Lift-7m, Belt
and Junction House JH- speed-1.8m/s, Trough angle-45
8B
18. Motorised flap gate at 10mm MS mother plate with
1 no.
head end of BC-310A 6mm SS liner
19. Replacement of
Length-17m, Cap-500tph, Belt
reversible conveyors RC-
2 nos. width-1400mm, Lift-0m, Belt
9 and RC-10 of length
speed-1.6m/s, Trough angle-30
11m by shuttle

RSP 59no. 4.30

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
conveyors
20. Rail for Shuttle
4*25m 52 kg/m
Conveyors
21. Hopper outside the
crusher house to by- Cap –100m3, Mother plate -
1 no.
pass the existing 10mm MS, Liner plate - 6mmSS
crushers
22. Rod gate and Rack &
Pinion gate below Silo 1 no. MS
Hopper
23. Vibro Feeder below
1 no. 800 tph
hopper

PROJECT DESCRIPTION
24. Motorised Flap Gate
below hopper for 10mm MS mother plate with
1 no.
discharging coal directly 6mm SS liner
to BC-313 and BC-314
25. Length-144m, Cap-800tph, Belt
Belt Conveyor Y-1 & Y-
2 nos. width-1400mm, Lift-21m, Belt
2with conveyor gallery
speed-1.6, Trough angle-45
26. Inline Magnetic
Separator at head end of 2 nos.
Y-1 & Y-2
27. Rod gate and Rack &
Pinion gate in
4 nos. MS
discharging chutes of Y-
1 & Y-2
28. Moisture analyzer of
1 set
coal
29. Moisture addition to
1 set
coal
30. EOT Crane in Crusher
1 no. Cap-15t, Span-18m, Lift-40m
House
31. Length-17m, Cap-500tph, Belt
Shuttle Conveyors Y-3 &
2 nos. width-1400mm, Lift-0m, Belt
Y-4
speed-1.6m/s, Trough angle-30
32. Rail for Shuttle Conveyor
4*25m 52 kg/m
Y-3 & Y-4
33. Intermediate storage
4 nos. Cap-50m3, MS-10mm thk
hopper with SS liner

60
RSP Page no. 4.31 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
34. Rod gates and Rack &
Pinion gate below
4 nos. MS
intermediate storage
hopper above Crushers
35. Vibro Feeder for
4 nos. 400 tph each
crushers
36. 400tph, Input coal 50% to 80% (-)
Secondary Coal Crusher 4 nos.
3.2mm, output >90% (-) 3.2mm
37. HT Motor for Coal
4 nos. 500kw (approx)
Crusher
38. Charging hatch
4 nos. MS
assembly for crusher
39. Motorised Flap Gate at
PROJECT DESCRIPTION

10mm MS mother plate with

discharge end of 2 nos.
6mm SS liner
Crusher
40. Electric Hoist in Crusher
1 no. Cap-15t
House
41. Trolley mounted Chain
Pulley Block in Crusher 1 no. Cap-7.5t
House
42. Trolley mounted Chain
Pulley Block in Crusher 1 no. Cap-5t
House
43. Hopper outside the
crusher house to by- Cap–100m3, Mother plate-10mm
1 no.
pass the secondary MS, Liner plate - 6mm SS
crushers
44. Rod gates and Rack &
Pinion gate below 1 no. MS
hopper
45. Vibro Feeder below
1 no. 800 tph
hopper
46. Motorised Flap Gate
below hopper for 10mm MS mother plate with
1 no.
discharging coal directly 6mm SS liner
to conveyor Y-5 and Y-6
47. Length-248m, Cap-800tph, Belt
Belt Conveyor Y-5 & Y-
2 nos. width-1400mm, Lift-28m, Belt
6with conveyor gallery
speed-1.6, Trough angle-45

RSP 61no. 4.32

Page CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
48. Electric Hoist in JH at
1 no. Cap-3t
head end of Y-5 and Y-6
49. Length-175m, Cap-800tph, Belt
Belt Conveyor Y-7with
1 no. width-1400mm, Lift-29m, Belt
conveyor gallery
speed-1.6m/s, Trough angle-45
50. Suspended Magnet at
head end of Y-7
51. Length-9m, Cap-800tph, Belt
Reversible Belt Feeder Y-
1 no. width-1600mm, Lift-0m, Belt
8
speed-1.6m/s, Trough angle-30
52. Length-9m, Cap-800tph, Belt
Shuttle Conveyor Y-9 &
2 nos. width-1600mm, Lift-0m, Belt
Y-10
speed-1.6m/s, Trough angle-30

PROJECT DESCRIPTION
53. Rail for shuttle conveyor
4*15m 52kg/m
Y-9 & Y-10
54.
Chute Vibrator 1 lot
55. 10mm MS mother plate with
Interconnecting chutes
1 lot 6mm SS liner + steel embedded
with liner
rubber liner in impact zone
Primary Crushing Circuit
1. Splitting of existing belt
conveyor BC 309 and Length-120m, Cap-150tph, Belt
provision of new 1 no. width-1000mm, Lift-22.5m, Belt
conveyor BC 309Awith speed-1.6 m/s, Trough angle-35
conveyor gallery
2. Turning of weigh
feeders of 2 silos 2 nos.
towards BC 309A
3. 10mm MS mother plate with
Motorised Flap Gate at
1 no. 6mm SS liner
head end of BC 309A
4. Electric Hoist at head
1 no. Cap-3t, Lift-27m
end of BC 309A
5. Suspended Magnet at 1
head end of BC 309A
6. Length-9m, Cap-150tph, Belt
Reversible BC 309B 1 no. width -1200mm, Lift-0m, Belt
speed-1.6 m/s, Trough angle-30

62
RSP Page no. 4.33 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
7.
Primary Crushers 2 nos. 1W+1S of cap-150tph
8. Electric Hoist for
1 no. Cap-5t, Lift-17m
Crushers
9. Length-63 m, Cap-150tph, Belt
Conveyor BC 309Cwith
1 no. width-1000mm, Lift-7m, Belt
conveyor gallery
speed-1.6 m/s, Trough angle-35
10. Electric Hoist in JH at
1 no. Cap-3t, Lift-21m
head End of BC 309C
11. Length-170 m, Cap-150tph, Belt
Conveyor no. 309Dwith
1 no. width-1000mm, Lift-14m, Belt
conveyor gallery
speed-1.6 m/s, Trough angle-35
12. Electric Hoist in JH at
1 no. Cap-3t, Lift-30m
PROJECT DESCRIPTION

head End of BC 309D

13. Storage Hopper for
1 no. Cap- 350t
crushed hard coal
14. Rod gate and R&P gate 1
MS
below hopper
15. Weigh Feeder below 1
150 tph
hopper
16. Motorised Flap gate 1 10mm MS mother plate with
below weigh feeder 6mm SS liner
17. Interconnecting Chutes 1 lot MS +SS Liner + steel embeded
with liner rubber liner in impact zone
Coal Cake Breakage Handling
1. Length-15 m, Cap-100tph, Belt
Conveyor Y-11 1 no. width-800mm, Lift-1.5m, Belt
speed-1.6m/s, Trough angle-35
2. Length-10 m, Cap-100tph, Belt
Conveyor Y-12 1 no. width-800mm, Lift-1.5m, Belt
speed-1.6 m/s, Trough angle-35
3. Length-15 m, Cap-100tph, Belt
Conveyor Y-13 1 no. width-800mm, Lift-1.5m, Belt
speed-1.6 m/s, Trough angle-35
4. Length-200 m, Cap-100tph, Belt
Conveyor Y-14 1 no. width-800mm, Lift-0, Belt speed-
1.6 m/s, Trough angle-35
5. Underground room with
1 no.
tunnel up to pent house

RSP 63no. 4.34

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Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
6. Conveyor Y-15with Length-54 m, Cap-100tph, Belt
gallery outside the pent 1 no. width-800mm, Lift-6.5, Belt
house speed-1.6 m/s, Trough angle-35
7. Length-147 m, Cap-100tph, Belt
New Conveyor Y-16with
1 no. width-800mm, Lift-29, Belt
conveyor gallery
speed-1.6 m/s, Trough angle-35
8. Interconnecting Chutes 1 lot MS +SS Liner + steel embedded
with liner rubber liner in impact zone
Spillage Coke Handling
1. MS-Carrying trough, Return
Spillage chain conv. on
2 nos. trough
Pusher Side & Coke Side
SS–Liner on carrying trough

PROJECT DESCRIPTION
2. Intermediate storage
hopper with motorised 10mm MS mother plate with
2 nos.
gate at head end of 6mm SS liner
chain conv.
3. Underground room with
1 no.
tunnel upto pent house
4. Length-127 m, Cap-100tph, Belt
Belt conveyor K-1with
1 no. width-800mm, Lift-18.5, Belt
conveyor gallery
speed-1.6 m/s, Trough angle-35
5. Electric Hoist at head
1 no. Cap-3t, Lift-18m
end of K-1
6.
Storage hopper 1 no. 80m3
7. Motorised gate below 10mm MS mother plate with
1 no.
hopper 6mm SS liner
8. Interconnecting chutes MS +SS Liner + steel embedded
1 lot
with liner rubber liner in impact zone
Common Facilities
1. Monorail for manual hoist of 2t capacity in all floors
of Junction Hoses 1 set
2. Illumination, electrics, drive control and automation
of the equipment 1 set
3. PLC based control for logical sequencing,
interlocking, control functions, alarm, annunciation,
real time trending, recording and monitoring of the
conveyors and equipment 1 set

64
RSP Page no. 4.35 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
 Experience that delivers

Sl. Equipment Description Quantity Technical Parameters

No.
4.
Firefighting and DS & DFDS system for new route 1 set
5. Communication system like walky-talky, telephone
etc., Fire detection and alarm system 1 set
6. Drinking water facility 1 set
7. Road and drainage facilities 1 set

4.3.2 Oven Machines

[Link] Following new oven machines are envisaged for the proposed stamp charge
battery:
PROJECT DESCRIPTION

· Stamping-Charging-Pushing Machine (SCP) - 2 Nos.

· Charging Gas Transfer Car (CGT) - 2 Nos.
· Coke Transfer Car (CTC) - 2 Nos.
· Electric Loco (EL) - 4 Nos.
· Coke Bucket Wagon for dry quenching - 2 No.
[Link] While only one set of machine will be required for the normal operation of
battery at any moment, the second set is required in view of their criticality for
operation of the battery. This spare set of machine will be used as and when the
need arises.
[Link] The new oven machines will be equipped with various modern features. The
new machines will also be equipped with facilities, necessary to control
emissions from the battery. These machines will be able to meet the overall
cycle time of battery operation. The features of the oven machines have been
outlined in the subsequent paragraphs.
[Link] General
1. In general, LT speed of all oven machines will be kept on lower side subject
to fulfilment of average pushing rate of 90 ovens per day and other
technical requirements. Cycle time of the machines will be decided
accordingly.
2. Machines will be provided with Interconnecting stairs, platforms, walkways
and other structures.
3. Various cabins (operator/ hydraulic/ electronic etc.) of the oven machines
will be of double walled construction with insulation. Heat resistant safety
glass will be provided on the front and sidewalls of operator’s cabin. The

RSP 65no. 4.36

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hydraulic, electronic and operator’s cabins will be provided with heavy-duty

industrial air conditioner. Other cabins will also be provided with air
circulating arrangement (exhaust).
4. All cabins and other vulnerable areas of the oven machines will be provided
with portable fire extinguisher of suitable size/ rating.
5. Most of the mechanism in oven machines will be hydraulically actuated. The
hydraulic power pack will be provided with one working and one standby
pump with all accessories. In addition, one foot pump and accumulators will
also be considered for emergency purpose. Hydraulic cylinder will be
equipped with distance measuring system (LDT), wherever required for
accurate positioning.
6. All oven machines will be provided with motorized centralized dual line
lubrication system with provision of manual lubrication.

PROJECT DESCRIPTION
7. All oven machines will be provided with compressed air facility with outlet
points and long hose on every floor to facilitated proper cleaning apart
from the regular operational needs.
8. Doors with spring-loaded latch, membrane type sealing frame and flexible
spring-loaded knife-edge have been envisaged. SCP & CTC machines will be
suitable to service the same. Proven design door cleaner and doorframe
cleaner will be considered.
9. Suitable facility (lifter/ elevated platform) in SCP and CTC for regulating the
oven doors will be provided.
10. Rail size and track gauge will be selected suiting to the total weight and
maximum wheel load of oven machines.
11. Emergency stop provision will be provided in all oven machines at suitable
location. Local control switches at service platform level for movements of
vital mechanism have been envisaged.
12. Inter-changeability of components between similar drives will be ensured in
new machines.
13. Apart from auto-positioning system, laser spotting is also envisaged to
facilitate accurate positioning.
14. Proper heat shield and suitable material selection will be ensured for the
components of the machine exposed to high temperature.
15. Good illumination and state of the art PLC interface and control has been
envisaged in all the oven machines.

66
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16. Itemised price list of the recommended spares will be obtained from the
tenderers along with bid for the oven machines to enable procurement of
spares, separately.
17. Supply of ordering specifications/ manufacturing drawings of fast wearing
items and maintenance spares by the successful tenderer will be ensured.
[Link] Stamping-Charging-Pushing Machine (SCP)
1. SCP machine will be portal type designed for two spot operations in 5-2
series. First spot is for opening of the door and pushing operation and
second spot is for charging of coal cake and again to first spot for closing of
door. Approximate length & weight of machine will be 25 m & 1000 t
respectively.
2. SCP machine will be equipped with the following mechanisms to meet the
operational requirement of servicing an oven:
PROJECT DESCRIPTION

· Long travel mechanism capable of accurate positioning within (+5)

mm in front of the oven to be pushed
· Door extractor mechanism for opening/ closing and swiveling of oven
door to parking position and refixing the door after cleaning
· Pushing mechanism to push out the ready carbonised coke
· Door and door frame cleaning mechanism
· Coal hopper for storage of coal equivalent to 4.5 times of a coal cake
weight from stationary coal tower
· Stamping unit to stamp the coal cake
· Charging system to charge the ready stamped coal cake with the help
of charging plate, charging cake locking device and sealing frame. Coal
cake surrounded by sealing frame will be supported over doorframe/
buckstay to minimise air ingress during charging operation.
· Coal cake levelling device
· Spillage chain conveyor below stamping unit for disposal of collected
coal in belt conveyor running parallel to the battery
· Coal cake scrapper unit
· Counter thrust device for clamping the SCP machine with outer rail
during pushing and charging operation
· Compressed air systems for operational needs like pusher ram
cleaning, de-graphitising of oven etc.
· Emergency diesel drive for hydraulic pump/ motor for retraction of
mechanisms from oven

RSP 67no. 4.38

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3. The main frame of the car will house all the above mechanisms along with
various cabins and will be supported on four numbers, 4-wheeled bogies.
Two wheels of each bogie will be connected to the separate LT drive. LT
drive will be provided with VFD control for precise positioning of the
machine. Capacity of LT drive will be selected such that it will be possible to
run the machine even with half of the drives (at reduced
speed/acceleration).
4. Long travel, charging, pushing and stamping unit will have VFD control
drive.
5. Hydraulic motor & hand operated winch for emergency operation of pusher
beam, charging plate etc. has been envisaged. Winches will be provided
with fast unwinding (on no load) by means of suitable gearing.
6. One maintenance beam with 5t hoist will be provided for maintenance
needs. Necessary facilities for replacement of pusher beam/ head, stamping

PROJECT DESCRIPTION
hammers will be provided at a suitable location. Bonding press which is a
special tool required to bond the friction liners to the stamping hammers
will be considered with the machine.
7. Cycle time for the SCP machine has been envisaged as less than or equal to
11 minutes.
[Link] Charging Gas Transfer Car (CGT)
1. CGT machine will run on the battery top. The main function of this machine
is to transfer the excessive gas generated in the charging oven due to high
temperature difference between the charged coal and oven wall
temperature causing evaporation of volatile matters and water to the
neighbor ovens through U-type tube. Approximate length & weight of
machine will be 10 m & 70 t respectively.
2. CGT machine will be equipped with the following mechanisms to meet the
operational requirement of servicing an oven:
· Long travel mechanism capable of accurate positioning within (+5)mm
with the oven to be charged
· Cover lifting device inside the U-tubes to lift (open) / lower (close) the
suction hole caps
· Lifting / lowering device for U-tubes
· Gripping / releasing of the suction hole
· Opening / closing device for HPALA valves
· Opening / closing of by-pass valve
· Regulation of flow rate of HPALA

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· Feeding of water to mini stand pipes

· Sealing frame forward/ backward
· AP cleaner
3. The main frame of the car will house all the above mechanisms along with
various cabins and will be supported on four numbers, 2-wheeled bogies.
One wheel of each bogie will be connected to the LT drive. LT drive will be
provided with VFD control for precise positioning of the machine. Capacity
of LT drive will be selected such that it will be possible to run the machine
even with half of the drives (at reduced speed/acceleration).
4. This machine will work in association with HPALA system, water sealing
system and sealing frame.
5. To ensure proper gas tightness, both ends of U-tubes will be dipped into
water caps of water sealing system provided around the suction hole at
PROJECT DESCRIPTION

oven top.
6. With the application of charging gas transfer unit, the visible emission
during charging will be reduced.
7. Cycle time for the CGT machine has been envisaged as less than or equal to
10 minutes.
[Link] Coke Transfer Car (CTC)
1. CTC machine will run on the coke side of the battery and will service an
oven from single spot. Approximate length & weight of CTC will be 17m &
250 t respectively.
2. CTC machine will be equipped with the following mechanisms to meet the
operational requirement of servicing an oven:
· Long travel mechanism capable of accurate positioning within (+5)mm
in front of the oven to be pushed
· Door extractor mechanism for opening/ closing and swiveling of oven
door to parking position and refixing the door after cleaning
· Door and door frame cleaning mechanism
· Coke guide cage to guide the coke from oven to coke bucket wagon
· Suction hood over door extractor and coke discharge side to trap dust
laden gas and minimise the pushing emission
· Belt lifting car for connection of coke transfer car with suction pipe
running parallel to battery
· Coke spillage collection system

RSP 69no. 4.40

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 Experience that delivers

3. The main frame of the car will house all the above mechanisms along with
various cabins and will be supported on four numbers, 2-3 wheeled bogies.
One wheel of each bogie will be connected to the LT drive. LT drive will be
provided with VFD control for precise positioning of the machine. Capacity
of LT drive will be selected such that it will be possible to run the machine
even with half of the drives (at reduced speed/acceleration).
4. Roof of the CTC machine will be provided with SS sheeting.
5. Manually operated arrangement like hand operated winch is envisaged for
withdrawing the guide cage, in case of emergency. Guide cage and draught
hood repair/ replacement facility will be provided at suitable location at end
bench of the battery.
6. 3 nos. of pyrometer on each side of guide cage will be provided for
measurement of coke mass temperature at different level.

PROJECT DESCRIPTION
7. Cycle time for the CTC has been envisaged as less than or equal to 10
minutes.
[Link] Electric Loco
1. The function of electric loco is to pull and push the coke bucket wagon (for
dry quenching) with load of hot coke from one oven. Haulage capacity of
the loco will be more than 200t. Approximate length & weight of machine
will be 10 m & 60 t respectively.
2. Electric Loco will be equipped with the following mechanisms to meet the
operational requirement of servicing an oven:
· Long travel mechanism capable of accurate positioning within (+5)mm
with the oven to be pushed
· Pneumatic system for provision of compressed air for pneumatic
braking system in electric loco and bucket wagon
3. Either two LT mechanisms connected to one pair of the front and rear
wheels of the Loco or separate LT drive for each travel bogie will be
considered. Capacity of the LT mechanism will be sufficient enough to carry
to run the car with half of drive mechanism only. VFD control will be
provided for the LT drive to facilitate smooth operation and precise
synchronising speed with pusher beam. Wheel specification will be selected
as per latest Indian Railway Standards for broad gauge wagons.
4. Electric loco will have remote wireless operation in addition to operation
from operator’s control desk.
5. Air compressor system of the loco will have two compressors, one working
and one stand-by. Only SS pipes and fittings will be used in pneumatic lines.

70
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6. Height of the loco will be such that it can pass under the hood of the CTC.
At each end of the loco, two springs loaded buffer and one automatic
coupler will be provided as per Indian Railway Standards.
7. A manually operated mechanical braking mechanism for emergency hand
operation from the operator’s cabin, independent of pneumatic brake, will
be provided.
8. Operator will be provided with an emergency stop switch for stopping
pushing operation while oven is being pushed.
9. Top of loco will be totally covered with protection plate against any possible
hot spillage coke.
[Link] Coke Bucket Wagon
1. The function of bucket wagon is to receive the red hot coke from one oven
while pushing and transport the same to the CDCP with the help of electric
PROJECT DESCRIPTION

loco. Approximate length & weight of machine will be 14 m & 50 t (without

bucket) respectively.
2. The machine frame work will mainly consist of the under frame and will hold
one coke bucket at a time. The under frame will accommodate the bogie
frame.
3. Pneumatic braking in each bogie has been [Link] braking will
be actuated from the operator’s cabin of the Loco. Braking of electric loco
and bucket wagon will be actuated in synchronised manner.
4. Each end of the bucket wagon will be fitted with 2 (two) spring loaded end
buffers and one auto coupler conforming to relevant Indian Railway
Standards. Location of coupler and end buffers will match with the electric
locomotives.
4.4 REFRACTORY
4.4.1 Battery Proper
[Link] Refractory work of battery will be a combination of mainly silica and fireclay
bricks. There will be provision of control of air distribution to individual flues for
proper burning of gaseous fuel. Around 550 shapes of refractory will be used in
different zone of coke oven battery. The approximate quantity of refractory
bricks including all shapes is about 30,000 ton which includes silica, fireclay,
alumina and insulation bricks.
[Link] According to the process and operation requirement, the refractories will be
used in different portions of coke oven will also different. Refractory materials of
different zone of coke oven battery are being envisaged as follow.
1) Sole flue:

RSP 71no. 4.42

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Horizontal sole flues and valve controls are used for controlling the supply
of lean gas fuel, such as blast furnace gas or any other lean gas, selectively
to the gas flues in heating zones of the coke oven chamber walls and the
recirculation of waste gas.
There is much temperature difference between upward flow (pre-heated gas
or air) and downward flow (high temperature waste gas out of combustion
chamber) in sole flue, to bear sudden temperature variation and prevent of
gas corrosion on sole flue, the sole flue will be lined with fire-clay brick.
Concrete of sole flue zone will be lined with combination of high strength
and thermal shock resistant fireclay category (3) and mica insulation bricks
to protect the concrete from the excessive heat.
2) Regenerator:-
Regenerator in order to recover and utilize heat of waste gas in coke oven
combustion to pre-heated hot lean gas and air, at the lower part of coke
oven proper, the regenerator is provided.

PROJECT DESCRIPTION
The wall of regenerator will be constructed with silica bricks and checker
chamber of regenerator will be filled with fireclay checker bricks (category 2)
for fully recover heat in waste gas. Regenerator wall will consist with nozzle
bricks which will be covered by special shape silica bricks. Partition walls of
regenerator chamber will be lined with silica bricks. Sliding joints will
provided at the interfaces of silica and fireclay brickwork.
Stainless steel sheet (0.2 mm thick of quality AISI 304) will be provided in
regenerator face wall to improve gas tightness in this area.
3) Corbel Zone:-
It is a channel located between combustion chamber and regenerator.
There are many channels arranged in corbel zone (corbel duct and vertical
gas distribution duct, etc.), they are close to each other, also there is big
pressure difference between upward flow and downward flow, easy for
leakage, therefore the design of corbel zone will be rational so as to ensure
tightness of oven proper.
The corbel zone bears great weight of coke oven upper part, meanwhile it is
located at 1100°C~1300°C high temperature zone, therefore corbel zone
will also be constructed with silica brick. Different type of shape bricks will
be used in this zone for making flue and gas supply channel.
In order to absorb expansion produced along longitudinal direction of coke
oven battery, the expansion joint will be provided at each layer in corbel
zone. The slide joint will be provided between expansion joints so as to be
better for free slide after heated brick layer between expansion joints.
4) Combustion chamber and oven chamber:-
Combustion is the place where the gas burns; heat is supplied to oven
chamber by means of partition wall on both sides of oven chamber.
Combustion chambers will be constructed with complete silica bricks

72
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because it has the good features of high refractoriness under load, good
thermal conductivity, stronger acidic slag corrosion resistance, good thermal
stability under high temperature and no residual shrinkage at the prevailing
temperature in this zone.
Silica brick for construction of oven chamber adopts groove and tongue
structure so as to reduce leakage of crude gas and increase brickwork
strength. Silica brick lining in the heating walls will be totally keyed and
interlocked throughout the design from oven floor to oven roof, to preclude
displacement of the wall.
No expansion joints will be provided for heating wall construction.
5) Oven top:-
Oven top is located at topmost of coke oven battery. It will consist with
inspection hole, standpipe hole, etc.
The lowest layer of oven top is the oven roof layer of oven chamber. It will
be constructed with silica brick so as to ensure the same expansion of oven
PROJECT DESCRIPTION

chamber.
To reduce heat dispersion from oven top, the layer of oven chamber roof
will be constructed with fire clay brick and insulating brick. It will also
minimize cracks formation during heating up and operation of the battery.
The thickness of oven top will be such that it will ensure oven proper
strength and lowering oven top temperature. Special shape fireclay bricks
are used to cover the heating chamber. Stainless steel sheet (0.2 mm thick
of quality AISI 304) will be provided in oven decking to improve gas
tightness in this area.
[Link] Waste gas flue and chimney of coke oven battery will be lined with fireclay
bricks (Category -1) type and mica insulation bricks.
[Link] Oven doors will be lined with suitable refractory.
[Link] Tentative refractory materials specification are given in following tables

a) Specification of Silica Bricks

(i) Physico-Chemical Properties

S. No. Property Unit Type Type B Type C
A
1 Chemical

SiO2, min % 95 95 95

Al2O3, max. % 1.2 1.2 1.2

Fe2O3, max. % 1.4 1.4 1.4

RSP 73no. 4.44

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S. No. Property Unit Type Type B Type C

A
CaO, max. % 2.5 2.5 2.5

2 P.C.E, min. SK 31 31 31
3 Apparent Porosity, %
Av. of 5 samples < 19 23 16
No single value > 20 24 17
4 Specific gravity, -
Av. of 5 samples < 2.34 2.34 2.34
No single value > 2.35 2.35 2.35
5 Bulk Density, min. gm/cm3 1.79 1.76 1.85
6 Cold Crushing Strength

PROJECT DESCRIPTION
Av. of 5 samples, > kg/cm2 350 300 500
No single value < 300 270 450
7 P.L.C for 2 h, max % + 0.2 + 0.2 + 0.2
0
at temp. C 1500 1500 1500
(-) (-) value (-) value
value not not
not allowed allowed
allowe
d
8 R.U.L, .ta value at 2 kg/cm2 ,
min. oC 1650 1650 1650
9 R.T.E, max. at 1000 0C % 1.30 1.30 1.30
10 Residual Quartz content, %
Av. of 5 samples < 1.5 1.5 1.5
No single value > 2.0 2.0 2.0

Type A bricks will be used in heating wall with coke face, Type C in oven sole &
Type B in other areas. Coke face will be indicated in brick shape drawings.

b) Material Specification of Silica Mortar

74
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S. No. Property Unit Value

1 Chemical

SiO2, min % 91

Al2O3+TiO2, max. % 5

Fe2O3, max. % 1.5

2 P.C.E, min. SK 29
3 Drying Shrinkage at 110 oC with
requisite quantity of water, max. % 3
4 Grain composition. % Nil
+2mm % 3
PROJECT DESCRIPTION

+1.0 mm , max. % 65-80

-0.20 mm , % 45-60
-0.08 mm ,
5 Workability - Good
6 R.U.L.

A 10mm thick layer of mortar

contained between 2 silica brick
cylinders each of diameter 50
mm & height 20mm under load
of 2 kg/cm2

Ta Value, min

Te Value, min o
C 1450
o
C 1520

7 Bonding Strength - Satisfactory

True Density 3
8 Kg/m 2600
9 Type - Heat setting

(i) Physico-Chemical properties

Note:The mortars should have good workability and should be evenly ground.
They should be of such quality and plasticity as would enable it to spread
satisfactorily with a trowel when mixed and tempered with adequate amount of

RSP 75no. 4.46

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water.
c) Specification of Fireclay Bricks
(i) Physico-Chemical Properties for Category 1,2& 3 bricks
S. Property Unit Category 1 Category 2 Category 3
No. (Checker
brick)

1 Chemical
Al2O3 , min. % 32 37 36
Fe2O3, max. % 2.5 2.5 2.0
TiO2 max % 2 2 2.0

2 P.C.E, min. SK 30 31 30

PROJECT DESCRIPTION
3 Apparent Porosity %
Av. of 5 samples < 24 22
No single value > 25 22 23
4 C.C.S. min. kg/c 200 200 275
2
m
5 P.L.C , max % + 0.2/ -0.5 + 0.2/ -0.5 + 0.8/ -0.6
0
at temp/time. C/h 1350/5 1350/5 1400/2
6 R.U.L, . at 2 kg/cm2, oC
ta value min. 1350 1350 1400
te value min. 1450 1450 -

7 R.T.E, max. at 1000 0C % 0.68 0.68 -

8 Spalling Resistance :
-at 1000 oC (small cycle +20 +20 +20
prism test) s
- for checkers, at 350
o
C& air cooling on full
brick

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(ii) Physico-Chemical Properties for Category 4, 5 & 6 bricks

S. No. Property Unit Categor Category Category

y4 5 6

1 Chemical
Al2O3 , min. % 36 38 39
Fe2O3, max. % 2.5 2.0 2.5
TiO2 max % 2.0 2.0 2.0

2 P.C.E. min. SK 31 32 32
3 Apparent Porosity %
Av. of 5 samples 17 18 16
< 18 19 17
PROJECT DESCRIPTION

No single value >

4 C.C.S. min. kg/cm2 500 300 400
5 P.L.C , max % + 0.2/ - + 0.2/ -0.5 + 0.2/ -0.5
0 0.5
at temp/time. C/h 1400/5 1400/5
1380/5
6 R.U.L, at 2 kg/cm2, oC
ta value min. 1380 1400 1400
te value min.
1550 - -
7 R.T.E, max. at 1000 % 0.60 - -
0
C
8 Spalling Resistance
at 1000 oC , cycles +20 +20 -
(small prism test)

RSP 77no. 4.48

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d) Specification for Insulation Bricks

S. No Property Unit Fireclay Mica

1 Chemical
Al2O3 + TiO2, min. % 38 -

2 P.C.E, min. SK 34 -

3 A.P. min % - 70

4 Bulk Density, max. g/cm3 1.3 0.65

5 C.C.S. min. kg/cm2 45 8

6 P.L.C. , max % -1.0 -

PROJECT DESCRIPTION
0
at temp/time. C/h 1400/24

7 Thermal Conductivity kcal/mhoC 0.6 0.175

o
at temperature C 600 500
(hot face) (mean face)
o
8 Safe Working Temp. C - 1000
(After 24 hours
contraction <1%)

e) Specification of Fireclay & Insulation Mortar

S. Property Unit Fireclay Insulation
No
1 Chemical %
Al2O3, min. % 30 -
Fe2O3, max. % 2.5 -

2 P.C.E, min. SK 29 30

3 Drying Shrinkage at 110 oC,

max. % 3 -

4 Firing Shrinkage at 1250 oC

for 5 hours, max.. % 3.5 -

78
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S. Property Unit Fireclay Insulation

No
5 Loose Bulk Density kg/m3 - 600-650

6 Grain composition.
+1.0 mm , max. % Nil Nil
-0.5 mm , min % 85% 90%

6 Workability - Good Good

7 Bonding Strength - Satisfactory Satisfactory

Note: The mortars should have good workability and should be evenly
ground. They should be of such quality and plasticity as would enable it
to spread satisfactorily with a trowel when mixed and tempered with
PROJECT DESCRIPTION

adequate amount of water.

f) Specification of Calcium Silicate Insulation (950 oC)
Material Quality As per IS : 9428-1993

[Link] The selection of refractory for oven decking will be such so as to ensure battery
top temperature does not exceed 55oC in the hottest season at a distance of 1m
above oven top.
[Link] Silica Bricks and Silica mortar including all other refractory materials for this
project will be procured by battery designer.
[Link] Inspection & storage of all refractories and auxiliary materials including silica
bricks & silica mortar will be in the scope of battery designer. For entire silica
bricks 100% physical inspection will be done by the battery designer at
manufacturer’s premises.
[Link] It has been envisaged that approximately 16,500 tons silica refractory, 10,000
tons fireclay refractory and 700 tons insulation refractory will be required for
battery proper.
4.4.2 Refractory for Coke Dry Cooling Plant
[Link] Refractory work will be a combination of mainly Fireclay and Insulation bricks.
[Link] Refractory in the CDCP chambers will be totally keyed and interlocked
throughout the design, to preclude displacement of the brick work.
[Link] All refractory shapes, Fireclay and Insulation, are desirable to be machine made.
[Link] Mullite bricks will be used in abrasion prone areas like inclined flue & dust
settling bunker arch, partition wall, all coke facing area and hot gas facing area.
[Link] Saw dust / Ceramic fibre will be used for filling the expansion joints in CDCP.

RSP 79no. 4.50

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[Link] Keeping in line with the material specifications presently in use in CDCP,
Purchaser has identified material specifications for Fireclay & Insulation
refractories. The same are given in following tables.
[Link] Bidder based on his design requirements, may select from the specifications
given in the tables or, bidder will provide bricks of better specification to meet
their design requirement. However purchaser intends to use the Mullite quality
bricks (min 63% Al2O3) in high impact zones of CDCP like inclined flue zone
(Pillar brick area), DCB partition wall areas, Chamber mouth, arch of DCB boiler
side after partition wall up to end of boiler arch. From bottom to top of inclined
flue area (Coke face area) one layer of mullite brick to be provided. All coke
facing area and all hot gas facing area in the chamber will be lined with one
layer mullite bricks (min 63% Al2O3). DSB area will be lined with one layer mullite
bricks (min 63% Al2O3). Ring channel to be provided with one layer mullite
bricks (min 63% Al2O3). Ceramic fibre board (along the inside of shell) &
Insulation bricks will be used as back up lining in cooling chambers in the

PROJECT DESCRIPTION
following areas:- -
a) Cooling zone
b) Inclined flue zone
c) Cylindrical part of pre chamber
d) Conical part of pre chamber
e) Dust collecting bunker
[Link] Specification of Fireclay, Light weight fireclay bricks, Insulation bricks and
Mortars
The bricks and mortars of following specification are being used in the Indian
Coke Dry Cooling Plant. However, bidder will be free to provide bricks of better
specification to meet their design requirement.
1) Specification of fireclay brick

Sl. Value
Properties Unit
No. Category 2 Category 4

1 Chemical composition
Al2O3+TiO2(min.) 39 41
%
TiO2(max.) 2 2.0

Fe2O3(max.) 1.5 1.5

2 Refractoriness (min.) °C 1730 1750

80
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3 Apparent porosity (max.)

% 22 16

4 Cold crushing strength (min.) (2a) 300

Kg/cm2 500
(2b) 400

5 Refractoriness under load at 2

°C Ta 1400 Ta 1440
Kg/cm2 load (min.)

6 Permanent linear change (+) 0.4 (+) 0.3

(max.) % (at 1350 °C (at 1450 °C
for 4 hours) for 4 hours)

7 Spalling resistance (min.) Cycles 20 -

PROJECT DESCRIPTION

2) Fireclay insulation Bricks

Sl.
Properties Unit Value
No.

1 Chemical composition
Al2O3+TiO2(min.) 38
%
TiO2(max.) 2

Fe2O3(max.) 1.5

2 Refractoriness (min.) °C 1750

3 Cold crushing strength (min.) Kg/cm2 75

4 Permanent linear change (max.) (+) 1.0

% (at 1400 °C for 4
hours)

5 Bulk density (max.) g/cm3 1.3

6 kcal/
Thermal conductivity (at 600 °C) (max.)
m/hr/°C 0.6

RSP 81no. 4.52

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 Experience that delivers

3) Specification for Mica Insulation Bricks

SL. Properties Unit Value

No
1 Apparent porosity (max.) % 70

2 Bulk density, (max.) g/cm3 0.65

3 Cold crushing strength (min.) kg/cm2 8

4 Thermal conductivity kcal/m/h/°C 0.175
at 500°C temperature

5 Safe working Temp. °C 1000

(After 24 hours contraction 1%)

PROJECT DESCRIPTION
4) Specification of Fireclay Mortar
Sl.
Properties Unit Value
No.

1 Chemical composition

Al2O3 (min.) % 42

Fe2O3 (max.) 1.5

0
2 Refractoriness (min) C 1750

3 Drying shrinkage should not exceed

(with 22% water dried at 110 +/- % 3
50C). (max)

4 Firing shrinkage at 1250 °C for 5

% 3.5
hours (max.)

5 Fineness (min.) screen size mm (min) passing

through
1
% 100
0.6
95
0.09
60

82
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6 Workability Good

7 Bonding strength Satisfactory

Note - The mortar should be usable as building binder for bricks made
of similar materials.

5) Specification of Mullite Bricks

Sl.
Properties Unit Value
No.

Chemical composition

1 Al2O3 (min.) % 63
PROJECT DESCRIPTION

Fe2O3 (max.) 1

2. Bulk density (min.) g/cm3 2.5

3. Apparent porosity (max.) % 13.5

4. Cold crushing strength (min.) kg/cm2 600

Refractoriness under load at 4 0

5. C 1500
Kg/cm2 load (min.)

Permanent linear change at 1500 0C

6. % +0.2
(max.)

0
7. Refractoriness (min.) C 1825

8. MOR kg/cm2 150-200

kcal/m/hr/0C

9. Thermal conductivity at 1535 0C 1.6

at 1450 0C 1.8

RSP 83no. 4.54

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Installation of Battery No. 7
 Experience that delivers

6) Specification of Ceramic Fibre Board:

S. No. Properties Units Value
1 Chemical
Al2O3 % 38-42
SiO2 % 57-61
Fe2O3+TiO2,Max % 1
Others, Max % 1
2 Service temperature, max °C 1260
3 Bulk Density, max g/cc 0.38
4 Thermal Conductivity W/m°K

PROJECT DESCRIPTION
At 250 oC 0.10
At 550oC 0.11
At 850oC 0.14
At 1000 oC 0.19
5 PLC, 24h at 1200°C, max % 0 to (-) 2

[Link] Procurement, inspection, storage & supply of all refractories and auxiliary
materials will be in the scope of the CDCP Designer

4.5 ELECTRICAL SUPPLY SYSTEM

4.5.1 Power Supply arrangement
The tentative power requirement of the proposed system is as under:
Area Connected Max Emergency Equipment
Load Demand Load Req
(Category-I)

Battery Proper, Oven 10700 kW 7000 kW 0 -

Machines and Coal
Handling facilities

Coke Dry Cooling Plant 7800 kW 3500 kW 1500 kW Lifter and

(CDCP) charging
hatch
lid&boiler

84
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Installation of Battery No. 7
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feed pump

By Product Plant (BPP) 5900 kW 4500 kW 2000 kW Exhauster,

flushing
liquor
pump,
cooling
water pump

Boiler & DM Plant 1400 kW 1000 kW 0

Pump House 1400 kW 700 kW 0

Total 27200 kW 16700 kW 3500 kW

However, the total average load is envisaged as 12 MW approximately

4.5.2 Power Source
PROJECT DESCRIPTION

To meet the normal & emergency power requirement, following power

distribution arrangement has been envisaged:
[Link] 33 kV GIS Substation
One no. double bus 33 kV indoor GIS substation (LBSS-VIII) having two
incomers, one bus coupler, interconnector feeder and required number of
outgoing feeders will be installed to meet normal & emergency power
requirement of the project. Incoming power will be tapped from MSDS-VI and
the MSDS-III. There will be a tie feeder LBSS-IV/feeder#14 (CPP-1 section) to the
new LBSS-VIII. Necessary modification in the LBSS-IV feeder has been
considered.
For the above, extension of 33 kV board of MSDS-VI by 2 nos. 2500A VCB
feeders along with CRP panel is proposed.

At MSDS-III, extension of the 33kV bay by 3 nos. of bays is envisaged.

Modification in 6 nos. of existing Control and relay panels is also
[Link] will be tapped from the extended bay and 33kV cables will be
buried underground, the approximate route length is 1800m.

As LBSS-VIII will be getting category- I power from LBSS-IV/feeder#14 (CPP-1

section), no separate emergency power arrangement is required.

2nos. 33/6.6kV, 25 MVA ONAN power transformers are envisaged in LBSS-VIII.

A new 6.6 kV AIS HT switch board (HT Board-1) is envisaged to be installed in

LBSS-VIII complex. Proposed HT switchboard will be with 2-incomers and 1 bus
coupler. The incoming power to the proposed 6.6 kV board will be fed from new
33 kV GIS.

RSP 85no. 4.56

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Installation of Battery No. 7
 Experience that delivers

[Link] For meeting the power requirement of the pump house at lagoon area, 6.6kV
LILO substation and a double ended LT substation is envisaged. Power will be
brought to the LILO substation by 2 nos. of 6.6kV feeders which will be supplied
by RSP from a distance of approx. 3km which will be subsequently fed to 2 nos.
1MVA 6.6kV/415V dry type transformer. Refer Single Line Diagram no CET RN
4095 EE1 00 001 R=5.

4.5.3 Power Distribution Schedule

Refer Single Line Diagram noCET RN 4095 EE1 00 001 R=5
[Link] HT zonal load centres:
Six nos. of 6.6 kV load centreshave been envisaged for feeding HT drives of:
· HT motors of BPP area
· New hammer crushers

PROJECT DESCRIPTION
· Stamping charging pushing (SPC) machines of oven machine area/ battery
oven machine area
· Power plant auxiliaries of CDCP power plant area.
· HT motors of CDCP area
· Boiler and DM water area
[Link] LT load Centre Substations (LCSS)
New double ended load centre substations with 6.6 kV/ 415V, 2x2000 kVA Dry
type transformers & LT Switch Board (PCC) for feeding following LT Loads:
· Battery Proper including Oven Machines-1 no.
· Coal Handling facilities- 1 no.
· CDCP area- 1 no.
· Boiler & DM plant- 1 no.
· By Product Plant (BPP) - 2 nos.
· New pump house at Lagoon area- 1 no.
4.5.4 Evacuation of CDCP Generated Power
5.0 MW generated power will be hooked to 33 kV HT board at MSDS-6 after
extending the existing board by one 2500A VCB breaker. No adapter panel is
envisaged for extension. For this, 6.6/33 kV, suitably rated generator transformer
has also been considered. Synchronization is considered at BPTG end.
4.5.5 Equipment Specification:
[Link] 33 kV GIS
GIS will be made of tubular cast aluminium enclosures and filled with SF6 gas

86
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for insulation.
The switchgear will be modular in design. Future extensions may be
accomplished by adding extra feeders without dismantling any major parts of
the equipment.
The flanged connections will have gas seals between the flange surfaces.
Each breaker bay will consist of gas tight individual monitored zones.
Each section will be provided with necessary valves to allow evacuation and refill
of gas without evacuation of any other section.
External fixtures will be of non-corrosive material and be capped wherever
required.
For the purpose of gas monitoring and maintenance, the GIS will be provided
with gas density monitoring device along with temperature compensated gas
density switch having two stage contacts in each gas compartment. Pressure
relief devices will be used where ever required.
Conductors will be made of extruded aluminium suitable for the specified
PROJECT DESCRIPTION

voltage and current ratings. The electrical connections between the various gas
sections will be made by means of multiple contact connectors (plug-in type) so
that electrical connection is automatically achieved when bolting one section to
another.
[Link] HT Switchgear
The 6.6 kV switchgear envisaged will be air insulated indoor type sheet metal
clad, draw out type with Vacuum circuit breakers and will be provided with
necessary protection, control gear, metering and audio¬visual alarm
annunciation system. The circuit breaker mechanism will be mechanically and
electrically trip free. The circuit breakers will be electrically operated, stored
energy type and will be operated on 240 V DC control power supply.
HT capacitor Bank will be provided to improve Power factor at 6.6 kV bus of HT
switchboard.
[Link] 415 V Switchgear
The 415 V switchboards will comprise of air circuit breakers, in draw out design
and multi-tier formation. The switchboard will have two bus sections and a bus
coupler breaker with provision for auto changeover in the event of loss of
power on any one bus section.
The circuit breakers will be electrically operated and equipped with
microprocessor / static type direct acting releases for over load and short circuit
as well as earth fault protection.
All motor control centres (MCCs), Motor Control panels (above 90 kW and up to
132 kW) and power distribution boards (PDBs) will be supplied power from the
415V switchboard. The 415V switchgear will confirm to IS-8623 and IS 13947.
Intelligent type MCC & MCP has been considered as per requirement.

RSP 87no. 4.58

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Installation of Battery No. 7
 Experience that delivers

[Link] Cables& Laying

A cable tunnel has been envisaged from the GIS substation upto the battery
premises. Power inside the plant will be distributed through cables to various
premises.. Wherever cables are in large number, concrete cable channels will be
used. GI pipes/pipe blocks will be used at road/ rail crossings and paved area.
Walkable Cable Bridge has been considered between various load centres as per
requirement.
Walkable cable overhead galleries have been considered wherever possible.
However, where not possible, like inside the substations and covered premises,
the cables will be laid in basement or in concrete channels (over cable
supporting structures) and other available structures. Power cables will be laid
on ladder type GI cable trays, whereas control cable will be laid on perforated
cable trays.
All 33 kV & 6.6 kV cables will be heavy duty, XLPE insulated, PVC sheathed multi

PROJECT DESCRIPTION
core, aluminium conductor steel wire armoured and unearthed type suitable for
resistance-earthed system. The 33kV Incomer cables to LBSS-VIII will be double
run. Cables for 415 V systems will be heavy duty, 1.1 kV grade, XLPE insulated
PVC sheathed aluminium conductor, armoured / unarmoured as required.
The control cables will be multi strand copper conductor, PVC insulated and
PVC sheathed.
The HT cables will conform to IS-7098 -1985, whereas LT power and control
cable will confirm to IS-1554-1988.
[Link] Electrical Substation Buildings/Electrical Control rooms have been
envisaged to house the electrical and automation equipment.
GIS room will have package ac maintaining temperature at 35 deg C. HT
rooms and IMCC rooms will have ac maintaining temperature at 35 deg C.
Electrical control room which houses the microprocessor based equipment
such as the programmable logic controllers, automation equipment, etc. will be
air-conditioned. In the ECR's, Cable floors have been envisaged for all the new
units envisaged. Necessary cable tunnels and cable trenches have also been
envisaged for entire project. Ventilation system will be provided for the
cable floors, tunnels, etc. Fire detection & alarm system has been considered.
[Link] SCADA automation for monitoring and control for new 33 kV & 6.6 kV Power
system distribution has been envisaged.
[Link] All illumination will be with energy efficient IP65 enclosure LEDs. Road area
lighting for all connecting roads in COB#7 area is envisaged.
[Link] Earthing& lightning protection has been envisaged as per IS 3043 IS 3043:
1987 and IE rules 1956 as amended up-to-date. The battery chimney will have
lightning protection.

88
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4.5.6 Process Electrics & Drive Automation System

[Link] Battery Area
1. General
Requisite power distribution, process electrics, drives and control system
equipment, HT motors, LT motors, cables, etc. have been envisaged to
provide smooth and efficient operation.
2. LT distribution board/ MCC's/ PCC
Three phase 4 wire 415 V LT power will be distributed through these panels.
These panels will be stand-alone freestanding panels. The motor control
centres will be grouped as per technological areas, which will provide power
to the motors, solenoids and other associated panels/ equipment. Intelligent
motor control centres are envisaged as per the state of art technology,
resulting in significant reduction in Control cables & related accessories.
Intelligent module in the MCC will directly communicate over field bus to
PLC.
PROJECT DESCRIPTION

Separate Power Distribution Boards (PDB) are envisaged mainly for power
supply to Welding Power Points, Hoists, Cranes and other maintenance
facilities of the plant at various locations.
Necessary provision (including Transformer, rectifier, distribution board etc.)
will be made for 24 V DC power supply for Solenoid Valves.
3. Intelligent Type single front, Non-Draw-out types, motor control panels are
envisaged for Motors rated 110 kW to 200 kW. Motor protection relays
(micro-processor based) will be provided for motor protection.
4. AC Motors
HT/LT AC motors will be selected to match the driven equipment as regards
power and duty requirements, speed/torque characteristics etc. and will be
able to accelerate smoothly the driven equipment/machine without undue
heating.
5. AC Drives
AC drives with bypassDOLare considered for HPALA pumps, lifts etc.
6. Local Control Station
Local control stations housing Local-Remote selector switch, push buttons,
indication lamps etc. for all drives. Ammeters will be provided on Local
control stations for all motors rated 15kW and above.
7. Trolley line/ Catenary system
Dedicated Power supply trolley wire / trolley line system for oven machines
including necessary MCCBs, trolley line rails, posts, brackets, trolley line
holders for rail, insulators, permanent jointing plates, steel aluminium strap,
compensators, bi-directional signal lamps (traffic lights) etc. has been
considered.
It is envisaged to provide power to new coke bucket car in COB#7 as well as
to the existing coke bucket cars in COB#6. Hence, conversion of existing DC

RSP 89no. 4.60

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Installation of Battery No. 7
 Experience that delivers

bus bar in COB#6 into AC bus bar in continuation to AC bus bar in COB#7
has been considered.
8. Safety Switch as Limit switches, proximity switches, Conveyor protection
switches like belt sway, pull cord switches, proximity type zero speed
switches, hooters/ sirens, solenoids, level sensors, Junction boxes have been
considered for termination of cables to field devices, brake and brake rectifier
panels etc.
9. Illumination system for battery proper & coal handling conveyors with LEDs.
10. Earthing & lightning protection
4.5.7 Electrics for Oven Machine
Oven Machine electrics will generally comprise of the following:
1. Complete electrics including current collector, control panels, cable reeling
drums, AC motors, brakes, limit and safety switches, sensors, VFD, PLC,
control desk with HMI, radio communication with required hardware and
software, hopper weighing system, UPS, LCS, illumination receptacles /

PROJECT DESCRIPTION
maintenance sockets, all types of cables, earthing etc. for Oven Machines.
2. AC Motors - LT AC motors will be selected to match the driven equipment as
regards power and duty requirements, speed/torque characteristics etc. and
will be able to accelerate smoothly the driven equipment/machine without
undue heating.
3. VFD system for variable speed drives.
4. Programmable logic controller complete with required inputs and outputs for
Oven Machines.
4.5.8 Electrics for Coal Handling
1. Complete electrics including motors for hammer crushers, conveyor drive
units, control panel, PLC, limit switches/sensor, LCS, cabling, earthing etc. for
coal conveyors.
4.5.9 CDCP &Power Plant
1. LTSS and Intelligent draw-out type motor control centres (MCCs) for
control of drives.
2. Intelligent type Motor control panels (MCPs) for control of drives of rating
from 110kW up to 200kW.
3. HT/ LT AC motors as per requirement.
4. VFD System for variable speed drives.
5. Power distribution boards (PDB) for repair network like welding sockets,
maintenance cranes and hoists.
6. Complete electrics for coke bucket car including Main and signal current
collectors, control panels, AC motors, Brakes, Resistances, Limit and safety
switches, sensors, VFD, PLC, Control desk with HMI, Radio communication

90
RSP Page no. 4.61 CET/05/RN/4095/FR/CC/01/R=6
Installation of Battery No. 7
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with required hardware and software, UPS, LCS, Illumination,

receptacles/maintenance sockets, all types of cables, earthing, erection
materials etc.
7. Complete electrics and controls for charging device/ discharging covering
squirrel cage induction motors, brakes, limit switches, cables etc.
8. Complete electrics and controls for mainmill fan drives including HT
squirrel cage induction motors, auxiliary drive motors, local control
panels/stations, cables etc.
9. Generated power evacuation scheme with protection.
10. Complete electrics and controls for feed water pump drives including HT
squirrel cage induction motors, auxiliary drive motors, local control
panels/stations, cables etc.
11. Complete electrics and control for cooling tower system including motors,
PROJECT DESCRIPTION

control panel, bag filters, solenoid valves, limit switches, power and control
cables etc.
12. Complete electrics and control for dust extraction system including
motors, control panel, bag filters, solenoid valves, limit switches, power
and control cables etc.
13. Complete electrics and controls for Pneumatic/ closed belt
conveyortransport system for coke dust.
14. Complete electrics for air conditioning/ ventilation system.
15. Complete electrics and controls for crane and hoists, DSL system for cranes
(minimum 75x75x6 angle) including angles/rails, aluminium
strips/supporting brackets, insulator assembly, danger signal boards and
festoon cable trolley system for hoists.
16. Illumination system of the coke dry cooling plant &power plant with LED
[Link] lighting will be considered only for street lighting
17. HT, LT, Control & special cable as per requirement.
4.5.10 Boiler & DM Plant
a. LTSS and Intelligent draw-out type motor control centres (MCCs) for
control of drives.
b. Intelligent type Motor control panels (MCPs) for control of drives of rating
from 110kW up to 200kW.
c. HT/ LT AC motors as per requirement.
d. VFD System for variable speed drives.

RSP 91no. 4.62

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Installation of Battery No. 7
 Experience that delivers

e. Power distribution boards (PDB) for repair network like welding sockets,
maintenance cranes and hoists.
f. Complete electrics and control for Waste Heat Boilers including squirrel
cage induction motors complete with necessary accessories, electrically
operated valve actuators , various type of limit switches, safety switches,
cables etc.
g. Complete electrics and control for DM water system including Motors,
control panel, bag filters, solenoid valves, limit switches, power and control
cables etc.
h. Illumination system of the sub-station rooms, MCC rooms, control rooms,
cable cellar, cable tunnels / bridge, various technological floors / platforms
/ stairs, pump houses, ventilation rooms, all shop units, office rooms etc.
including illumination of roads, area lighting within the battery limits by
providing Lighting Transformer, Main Lighting Distribution Boards,

PROJECT DESCRIPTION
Lighting Distribution Boards, Sub-lighting Distribution Boards, Light
fittings, Low voltage (240V / 24V) switch socket outlets, conduits, GI
structural lighting towers . LEDs have been envisaged.
i. HT, LT, control & special cable as per requirement.
j. Earthing& lightning protection
k. Solar lighting will be considered only for street lighting
4.5.11 Pump House at Lagoon
1. LTSS and motor control centres (MCCs) for control of drives.
2. Intelligent type motor control panels (MCPs) for control of drives of rating
from 110kW up to 200kW.
3. LT AC motors as per requirement.
4. VFD System for variable speed drives.
5. Power distribution boards (PDB) for repair network like welding sockets,
maintenance cranes and hoists.
6. Illumination &earthing system for new pump house with LEDs.
7. Power & control cables as per requirement.
8. Earthing& lightning protection
9. Solar lighting will be considered only for street lighting
4.5.12 By Product Plant (BPP) Area
1. Intelligent motor control centres (MCCs) for control of drives of various
technological units of By-product plant like Gas condensation plant, flushing
liquor pump house, H2S Plant, Final Gas Cooling Unit,

92
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Installation of Battery No. 7
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NaphthaleneScrubbing Plant, Chilled Water Plant, BOD plant and One

additional MCC will be provided for other Auxiliaries.
2. Intelligent type motor control panels (MCPs) for control of drives of rating
from 110kW up to 200kW.
3. HT/ LT AC motor.
4. VFD system for variable speed drives.
5. Local control stations with in-built ammeter housing local-remote selector
switch, push buttons, indication lamps and other control devices for all
drives including HT drives.
6. 24V DC power supply for Solenoid Valves (including transformer, rectifier,
Distribution board etc.).
7. All flame proof/non-flame proof limit switches, proximity switches,
proximity type zero speed switches, hooters/sirens, solenoids, level sensors,
junction boxes for termination of cables to field devices , brake and brake
rectifier panels etc.
PROJECT DESCRIPTION

8. Complete electrics and controls for exhauster drives including flame proof
HT motors, flame proof auxiliary drive motors, flame proof local control
panels/ local control stations, flame proof signalling & warning panels.
9. Complete electrics and controls for electrostatic tar precipitators including
Transformer Rectifier sets with HT Isolators, high voltage DC cables,
Insulator Boxes, TR controller panel with micro-processor based TR
controller unit opacity optimization software features with energy saving
features etc.
10. Illumination system of the sub-station rooms, MCC rooms, control rooms,
cable cellar, cable tunnels / bridge, various technological floors / platforms /
stairs, pump houses, ventilation rooms, all shop units, office rooms etc.
including illumination of roads, area lighting within the battery limits by
providing Lighting Transformer, Main Lighting Distribution Boards, Lighting
Distribution Boards, Sub-lighting Distribution Boards, Light fittings, Low
voltage (240V / 24V) switch socket outlets, conduits, GI structural lighting
towers . LEDs have been considered.
11. HT, LT, control & special cable as per requirement.
12. Earthing& lightning protection
13. Solar lighting will be considered only for street lighting

4.6 UTILITIES AND SERVICES

4.6.1 The following utilities and services will be provided from the existing facilities
and proposed new facilities at their respective Battery limits:
· Clean Coke Oven gas
· Blast furnace/ Mixed gas
· Steam
· DM Water

RSP 93no. 4.64

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Installation of Battery No. 7
 Experience that delivers

· Nitrogen
· Industrial water/Emergency Water
· Compressed Air
· Flushing Ammonia Liquor
4.6.2 The following utilities generated from the Battery will be suitably transported to
respective area with isolation valve for further processing to make it reusable
with required make-up:
· Raw coke oven gas
· Gas Condensate from Battery
· Steam Condensate
· Return ammonia liquor
· BOD discharge water
4.6.3 Interfaces in Utility & Services
The interfacing / take over points or terminating points and routes of utility pipe

PROJECT DESCRIPTION
lines are shown in the enclosed drawing no. CET RN 4095 UT1 00 001 R=1&
CET RN 4095 UT1 00 002 R=0
[Link] Clean Coke Oven Gas
This line will supply Clean C.O. gas to the battery for under-firing and for
boosting and mixing with Blast Furnace gas. The clean gas line from BPP area
will be suitably connected to existing DN 1200 pipe meant for clean C.O. gas for
Battery No.6.
The CO gas will be tapped near existing trestle, Z3/4TR-36 with an isolation
valve. The tapped DN 1200 pipe will be routed up to coal tower of proposed
battery at +25.0 m level for easy movement of SCP machine. This DN 1200 pipe
will be bifurcated in to two pipes of DN 800 size. In order to isolate the C.O. gas
for maintenance purpose, U-seal with isolation valve will also be provided on
each of the sub battery at suitable height. Provision of water filling, overflow
and drains will also be provided for U-seal.
For pipe routing refer Drawing No.: CET RN 4095 UT1 00 001 R=1.
Explosion flap will be provided in the cellar and at the end of the pipeline. The
pressure of this gas is 400 mm WC (approx.) and temperature ambient
respectively at the tapping point. The calorific value of C.O. gas is about 4200
kcal/Nm3.
CO gas will also be provided for initial heating at CDCP area and claus elemental
sulphur unit of by-product plant. Necessary piping will be laid for above.
[Link] Blast Furnace/ Mixed Gas
This line will supply Blast Furnace/Mixed gas to the battery. The existing BF gas
grid (DN 2600) where surplus gas would be available from BF1 for Battery No 7
is at a working pressure of 400 mm WC. The existing BF gas grid in front of
Battery No. 6 and proposed Battery No. 7 is of 1000 mm WC. The grid size is of
DN 1600 and there is no surplus gas available in this grid to feed Battery No 7.

94
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Installation of Battery No. 7
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Moreover the line size is inadequate to carry another additional 80,000 Nm3/h
of BF gas.
The BF gas at a pressure of 1000 mm WC is transported through DN 2200 pipe
from BF-5 up to the existing BF gas holder. Before BF gas holder, this DN 2200
pipe gets split in to two halves, one is of DN 1600 size which is going towards
the existing Battery No 6 and another is of DN 2200 size which is going to the
BF gas holder through a PRV to reduce the pressure from 1000mm WC to 400
mm WC.
Approximately 75,000-80,000 Nm3/h of BF gas will be required for proposed
Battery No 7, which will be drawn from BF-1 which is under up-gradation at
present. For this, tapping of DN 1800 size pipe will be drawn from DN 1900 pipe
at the downstream of gas cleaning plant (GCP) of BF1 at 1000 mm WC pressure.
Near tapping point, U-seal with isolation valve (encased type goggle valve) will
be provided with necessary platform etc. This DN 1800 pipe will be routed over
new trestles by the road side of new BF-1 recirculating pump house, front and
PROJECT DESCRIPTION

then back of blast furnace cooling towers up to the existing BF gas holder (refer
drg. no. CET RN 4095UT1 00 001, R=1). The pipe will be routed over new bridge
to cross the railway track on the way to BF gas holder. This DN 1800 pipe will be
connected to the above described existing header of DN 2200 size in front of BF
gas holder towards power plant cooling towers. PRV which is installed over this
header of DN 2200 which will be shifted suitably towards power plant cooling
towers side of the header end at the upstream of BF gas holder. This is required
to be done to match the BF gas pressure of BF-1 (1000 mm WC) and BF gas
pressure of BF-5 (1000 mm WC). In this way, DN 2200 will now act as a common
header for BF gases coming from BF-1 and BF-5 at 1000 mm WC pressure. From
above common header of DN 2200 size approximately 80,000 Nm3/h BF gas will
be drawn to meet the BF gas requirement for proposed Battery No 7. Tapping
of DN 1600 size will be drawn from the other end of this DN 2200 header
towards SMS-II in a manner similar to existing Battery No 6. From this point,
new line of DN 1600 size will be laid over new trestles up to existing trestle
Z3/4TR-36 in front of new battery area. Tapping point will have U-seal with
isolation valve (encased type goggle valve) with necessary platform etc. From
this point near trestle Z3/4TR-36, proposed BF gas line of DN 1600 size for
Battery No 7 will be laid over new trestles to be installed in front of the battery
up to coal tower. This BF gas pipe will cross the pusher side road at +25.0 m
level and laid up to coal tower of Battery No 7.
For pipe routing refer drawing No.: CET RN 4095 UT1 00 001 R=1.
Above BF gas line of DN 1600 will be bifurcated in to two halves each of DN
1200 size. In order to isolate the BF gas pipes for maintenance purpose, U-seal
with isolation valve will also be provided on each of the halves at suitable
height. Provision of water filling, overflow and drains will also be provided for U-
seal. Explosion flap will be provided in the cellar and at the end of each of the

RSP 95no. 4.66

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 Experience that delivers

BF gas pipelines for Battery No. 7.

The calorific value of BF gas is approx. 800 kcal/Nm3.
[Link] Steam
RSP has provided a steam balance as per which there is no steam in the grid to
meet the commissioning requirement as well as during operation of battery
CDCP and BPP. One numbers of Medium Pressure (MP) steam generation
source at 18 kg/cm2 (a) and temperature 300oC will be in the scope of this
project.
To meet the requirement of steam for Battery No 7, associated CDCP and BPP
etc., an industrial boiler is envisaged. This will also meet the steam requirement
of Battery No 7 and associated system in case of maintenance as well as
breakdown of CDCP boilers. In case of normal CDCP operation, the steam
generated from industrial boiler will be fed to existing MP steam header of DN
300 size near Column No. A-57 in old BPP area. To route the above proposed

PROJECT DESCRIPTION
steam line of DN 300 size, existing trestles/ structures will be used only as
sliding support along with new trestles, supports etc. This steam line will be laid
over new trestles proposed for BF gas line up to existing trestle Z3/4TR-36 and
then suitably up to existing trestle Z3/4TR-41 towards pusher side and will be
joined to the steam line coming from BPTG described below. Necessary valves
at all the interface points will be provided.
Approximately 52 tph of Steam from BPTG will be made available at 18-19
kg/cm2 (g) pressure and 3000C. Approximately 60 tphof steam from BPTG/
industrial boiler will be made available at 18 kg/cm2(a) and temperature 300oC.
Steam from both the sources will be made available near existing trestle,
Z3/4TR-41 in pusher side. From here tapping will be drawn for gas preheater,
purging gas line in cellar & oven top and other purposes in battery proper &
BPP. The pressure will be suitably reduced to required pressure for its use in
battery area& BPP. Steam lines will be provided for purging gas mains etc. in
stockade. New trestles will be erected to route the above steam lines etc.
For BPP area, steam will be drawn from above DN 300 size steam pipe coming
from BPTG near the existing trestle, Z3/4TR-41. Normally steam from BPTG at
18-19 kg/cm2 (g) pressure and 3000C temperature would be utilised and in
case of any shortfall and shutdown in CDCP area steam from the new gas based
boiler after suitable pressure reduction will be utilised.
High Pressure (HP) steam at a pressure of 66 ata will be generated from
proposed CDCP waste heat recovery boiler. This HP steam will be transported to
the proposed BPTG area. HP steam lines from boilerof proposed CDCP of
Battery No. 7 and existing Battery No. 6 will be interconnected to ensure
interchangeability of steam generated from Battery No 6 CDCP and Battery No
7 CDCP
To accommodate the end bench facilities in the Battery No 7 the existing HP,
MP steam line from Z3/4TR-41 towards BPTG will be rerouted with new trestles.

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[Link] DM Water Plant

Following requirement of DM Water has been envisaged:
To meet the requirements of existing CDCP, new CDCP, new boiler and new
BPP,ion-exchange based 3x120 tph DM Water Plant on 2 Working +1
Regeneration has been envisaged. Major equipment/ facilities are as follows-
1. Makeup water raw water storage tank of 480 m3 capacity along with 3x240
m3/h capacity & 30 m head pumps (1W+2S). The makeup water will be fed
to the DM Water Plant.
2. The Plant will have filtration in the sequence of “Dual Media Filter - Activated
Carbon Filter - Strong Acid Cation Exchanger - Degasser Tower - Degassed
Water Storage Tank - Strong Base Anion Exchanger - Mixed Bed Exchanger -
Demineralized Water Storage Tank”.
3. The DM Water will be stored in MS (Rubber Lined) storage tank of 480 m3
capacity. Same will be fed to different consumers with the help of 3x240
PROJECT DESCRIPTION

m3/h capacity & 30 m head pumps (1W+2S).

[Link] Gas Fired Boiler
To meet the low pressure steam requirement of BPP in the event of scheduled
shutdown of CDCP boiler, 1 no. boiler has been envisaged. The boiler will be
designed for firing with / CO gas/ Mixed gas depending upon their availability.
However, in normal operation boiler will be fired by CO gas (approximately
12,000 – 15,000 Nm3/h). A DN 800 size pipe line will be laid from new by
product plant to carry the above CO gas for the proposed gas fired boiler.
Interconnection of CO gas from existing by product plant will also be there.
Provision for mixed gas will also be provided. For this approximately 13,500 –
17,500 Nm3/h of mixed gas (having 3600 kcal/Nm3 CV) will be drawn suitably
from the existing DN 1400 size pipe in front of COB-6. Tapping of DN 800 size
pipe will be drawn from mixed gas header of DN 1400 size and will be suitably
laid up to the boiler. In normal operation, boiler will feed factory steam to RSP’s
existing steam network (a distance of approx. 1500 m). The termination point
along with tentative piping layout is .shown in Drg no: CET RN 4095 UT1 00
001 R=1. Major equipment/ facilities are as follows:
1. 1 no. bi-drum, bottom supported, natural circulation, balanced draught,
outdoor, water tube, mixed gas / CO gas fired design having 60 tph MCR
discharge steam parameters as
a. Boiler Maximum Continuous Rating – 60 tph
b. 18 kg/cm2(a) pressure &3000C temperature
2. 2x100% capacity Boiler Feed Pumps
3. 1 Deaerator
4. ID fan, FD fan, RCC Chimney
5. DN 300 Steam piping network. The piping will take sliding supports from
the existing trestles at few locations. New supports have been envisaged in

RSP 97no. 4.68

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 Experience that delivers

all locations where thermal load will also appear.

[Link] Fire Fighting Water
The existing fire fighting pump house is located beside the road near trestle
Z3/4TR-41. The fire fighting water will be tapped from the existing network. Fire
hydrant will be located at suitable places in all the areas such as BPP, in front of
the battery, behind the battery, in the Coal Tower, CDCP area, BPTG etc,
emergency quenching of coke near coke bucket repair station.
[Link] Compressed Air
Compressed air DN50 line will be provided in waste heat alleys, cellar, service
platform, winch room, Oven top etc. Existing compressed header on the
stockade in front Battery No 6 will be extended up to Battery No 7. From this
extended line compressed air will be tapped for use in above areas. All
necessary piping, valves, supports etc. will be provided. The pressure and
temperature are 6.2 kg/cm2& ambient respectively.

PROJECT DESCRIPTION
For pneumatic blow down purpose 2 nos. (1W + 1S) air compressors (screw)
having capacity 500 Nm3/h and delivery pressure 7 kg/cm2(g) have been
envisaged along with air receiver, refrigerated driers, necessary piping, valves,
etc. Compressors will be installed suitably under the coal tower at ground level.
Dedicated 2 nos. (1W + 1S) air compressors (screw) having capacity 200 Nm3/h
and delivery pressure 7 kg/cm2 (g) have been envisaged along with air receiver,
refrigerated driers, necessary piping, valves, etc. for air blast system of existing
as well as proposed coal silos. Compressors will be installed in new compressor
house near existing coal silos
[Link] Flushing Ammonia Liquor
Supply ammonia liquor line of DN 600 size will be laid over the new trestles up
to the battery area near existing trestles, Z3/4TR-36 for battery 7 from proposed
supply ammonia liquor pump house in BPP area. From trestle Z3/4TR-36 it will
be routed over a bridge at a height of +25.0 m level up to the coal tower of
Battery No [Link] from it will be brought down to battery top and will be
bifurcated in to two halves each of DN 400 size for Battery 7. Isolation valves will
be provided at the bifurcating point and at the originating point from the
supply ammonia liquor pump house.
Tapping for HPALA pumps will be provided from the common DN 600 line near
to proposed coal tower lift toward pusher side.
[Link] Raw Coke Oven Gas
The Raw C.O. gas generated from the Battery 7 will collected from middle of
each of Gas collecting main. For this DN 1200 size pipe with isolation valve will
be connected separately to both of G. C. main at the coke side over battery top.
These DN 1200 size pipes will be vertically raised at a height of + 25.0 m level.

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After crossing the pusher side road at +25.0 m level both of these DN 1200
pipes will be brought down to suitable height and will be joined together before
BPP. The common pipe of DN 2000 size will be routed over new trestles up to
the PGC. Necessary trestles, isolation valves, supports etc. will be provided.
Compensators in the foul gas lines will be provided in order to compensate the
thermal expansion of pipes.
[Link] Gas Condensate
Gas condensate from the gas pipelines will be collected in the seal pots and will
be disposed suitably as per the existing practice.
[Link] Steam Condensate
All steam condensate collected at different places within Battery will be
connected suitably with the storm water drain. By product plant steam
condensate return will be sent to the output of DM water plant.
PROJECT DESCRIPTION

[Link] Return Ammonia Liquor Line

Gas collecting mains will be there only in the coke side of battery 7. Return
ammonia liquor from Gas collecting mains will be collected at the end bench
side of battery 7 and will be brought down by DN 400. Sludge box will be there
at the end bench side of both the GC mains. From end bench of battery 7 this
DN 400 size pipe will be routed underground towards pusher side up to the
new trestle for FCO gas line in front of Battery No 7. From inter battery bench of
Battery No 7 the DN 400 size pipe will be routed underground towards pusher
side up to the new trestle for FCO gas line in front of Battery No 7. Both of these
DN 400 size pipelines will be routed overhead over the new trestles and joined
before the BPP area to form a common header of DN 600 size. This DN 600 size
pipe will be laid up to the new decanters over new trestles over which flushing
ammonia liquor will also route. All necessary piping, valves, supports etc. will be
provided.
[Link] Water Treatment Plant & Zero water discharge system
The requirement of 560 m3/h makeup water will be met by using lagoon water
after treatment and recycling effluent and blow-down water from various water
circuits. Flow diagram of makeup water system is attached as Drawing Number
CET RN 4095 UT1 00 003, Rev=0.
Treatment system of various units is as explained below-
· Lagoon Water Treatment Plant
Lagoon water to the tune of 435 m3/h is proposed to be utilised in this project.
Lagoon Water Treatment plant of 435 m3/h capacity is envisaged. Lagoon water
will be tapped from Lagoon area by installing Intake well. The intake well will be
placed at sufficient distance from upcoming lagoon water intake well of Hot
Strip Mill to ensure availability of sufficient water in intake channels.

RSP 99no. 4.70

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 Experience that delivers

· Quality of lagoon water is as under:

pH 6.98 – 7.8
Conductivity 396-407 µS/cm
Total Dissolved Solids (TDS) 228-240 ppm
Total Suspended Solids (TSS) 108 – 794 ppm
Oil & grease 2 – 4 ppm
Calcium Hardness 40-62 ppm
Magnesium Hardness 36-38 ppm
M Alkalinity 100-110 ppm
P Alkalinity 0
Chloride 30-32 mg/l Cl

PROJECT DESCRIPTION
Sulphate 38-41 mg/l SO4
Soluble Iron 0.29-1.5 ppm
Ammonical nitrogen (NH3-N) 4.8 – 15.5 ppm
Fluoride 2.16-2.24 mg/l F
Phenol 0.05 – 0.09 ppm
Cyanide 0.05 – 0.2 ppm
BOD 10 – 18 ppm
COD 44 – 92 ppm
Water temperature 320C

· The quality of treated water at the outlet of lagoon water treatment plant will
be as follows-
a) TSS: less than 10 mg/l
b) Oil & Grease: negligible (0.1 mg/l)
c) Iron: 0.2 mg/l
d) Other parameters will remain same

· Lagoon water will be pumped from intake well to water treatment plant near
Battery No 7 towards pusher side in BPP area. Here, water will be aerated,

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flocculated, clarified and filtered. Major equipment/ facilities of treatment

plant are as follows-
a) Intake Well Pump House complete with 4x225m3/h capacity & 80m head
vertical centrifugal Pumps (2W+2S), suction chamber, 3t single girder EOT
crane, electrical room, DG set and control room. The pumps will have high
pressure water sealing for which clear water will be tapped from nearby
intake-well of hot strip mill.
b) 2 x DN 300 piping (1W+1S) from Intake well Pump House to Water
Treatment Plant at Battery No 7 (a distance of approx. 5.5 km). The piping
will be laid over ground at a height of 0.5m. Piping at Road/ Rail crossing
will be laid underground through hume pipes. A tentative route of piping
is enclosed .Drg no: CET RN 4095 UT1 00 002 R=0.
c) The raw water will be aerated in 10m3 capacity overhead tank. The aerated
water will be sent to clarifiers after flocculent dosing. 2 nos. of clarifiers
PROJECT DESCRIPTION

(1W+1S) have been envisaged. Under sludge from the clarifiers will be
treated in filter press.
d) Overflow Clarified water will be collected in a 20m3 capacity tank. From
there, it will be pumped to pressure sand filters of 3x 250 m3/h capacity
(2W+1S).
e) Filtered water will be stored in an underground sump of 500 m 3 capacity.
Same will be provided as makeup water to different facilities of Battery No
7 with the help of 4x250 m3/h capacity & 30m head vertical centrifugal
Pumps (2W+2S).
f) Above treated water pumped at approximately 3 kg/cm2 (g) will be used in
battery proper, BPP, DM water plant and other facilities of Battery No 7.
The water pipe will be routed over the new trestles envisaged for BF gas
line up to existing trestle, Z3/4TR-36 and then up to existing trestle, TR-41.
From here it will be routed up to DM water plant over the new trestles
envisaged for steam line, DM water line, nitrogen line etc. Tapping for
industrial water will be suitably drawn from above pipe for use in battery
proper for emergency cooling of GCM, sealing the AP caps, seal pots,
filling of guide water tank and cleaning purpose at service bench etc.
· Recycling of waste water in zero discharge plant
a) BOD Effluent Water
1) Treated effluent from BOD plant will generally conform to the following
quality parameters:

RSP 101no. 4.72

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 Experience that delivers

Parameter Unit Quantity

pH of treated effluent mg/l 6 to 8
Suspended solids mg/l <100
Phenols mg/l <1
Cyanides mg/l <0.2
Ammonical Nitrogen mg/l <50
Free Ammonia mg/l <5
Oil & grease mg/l <5
Nitrate Nitrogen mg/l <10
BOD (3 days, 27oC) mg/l <30
COD mg/l <250

PROJECT DESCRIPTION
2) The water will be fed to Anoxic Tank then moving bed bioreactor
(MBBR) for oxidation of the remaining biodegradable organics,
thiocyanates, cyanides, and phenols. After oxidation, this water will be
further treated in filtrationand RO plant.
b) Blow downs from various units
Blow down water from cooling towers, boilers and DM plant will be
collected and treated in filtration and RO plant.
c) Filtration & RO plant
1) MBBR treated effluent from BOD plant and blow downs from various
units will be collected in a sump and pumped to filtration & RO plant
for further treatment.
2) Filtration plant will consist of lamella clarifier, thickener, dual media filter
and ultrafiltration system. Sludge from clarifiers will be dewatered in
filter press.
3) Ultra filtered water will be pumped to RO system for removal ofTDS. The
RO Rejects will be sent to the Evaporator cum Crystallizer unit.
4) The quality of treated water at the outlet of RO plant will be as follows-
§ TDS: less than 100 mg/l
§ TSS: Nil
§ Oil & Grease: Nil
[Link] Nitrogen Line/ System

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Total 3500 Nm3/h of Nitrogen is required at 8 kg/cm2 (g) in proposed CDCP,

BPP and other area. The above mentioned nitrogenis not available in
[Link], RSP has indicated that Low pressure Nitrogen at 2500 mm WC will
be made available by RSP from the proposed BOO Oxygen plant which is under
consideration by RSP for meeting the requirement of utilities for 4.2 Mtpa crude
steel production.
Nitrogen line will be tapped from both DN 700 size pipe coming from TOP-II
plant and adjacent proposed pipe network of proposed BOO Oxygen plant.
Anew nitrogen compression unit is envisaged in the proposed BPP area of
Battery No 7. The nitrogen compressor house will comprise two numbers of
compressors (1W + 1S) to compress 3500 Nm3/h of low pressure nitrogen (at
2500 mm WC pressure) to 8 kg/cm2(g) delivery pressure . For this tapping of
DN 500 size will be drawn from above low pressure Nitrogen pipe of DN 700
size near Column No. T-42 located near coke oven gas holders in old BPP area
and existing BOD plant. The above suction pipe of DN 500 size to the nitrogen
PROJECT DESCRIPTION

compressors will be routed over new trestles with necessary supports etc. An
isolation valve will be provided near the take-over point. Delivery pipe from
nitrogen compressors at 8 kg/cm2(g) pressure will be of DN 100 size which will
be routed over new trestles up to the trestles proposed for new BF gas line.
Here from it will be routed over new trestles for BF gas pipe and existing trestles
up to existing trestle, Z3/4TR-41. From this point it will route up to the new
CDCP area over the new trestles considered for steam line from proposed BPTG
to BPP area.
For BPP area, nitrogen at 8 kg/cm2(g) will be suitably tapped from above DN
100 size pipe with necessary isolation valve etc.
For nitrogen compressor cooling, FRP cooling tower of 2- cells, each of 100
m3/h capacity will be installed near to proposed nitrogen compressor house.
Facilities of make-up water will also be provided.
4.6.4 Gas Mixing Station (GMS) for Under Firing in Battery
As the CV of BF gas is low, it is proposed to increase the CV of BF gas by mixing CO
gas into BF gas. For this purpose a GMS having blower of adequate capacity will
be provided with necessary facilities including online calorific value analyser.
For designing the gas mixing station the followings parameters will be
considered:
BF gas pressure : 900-1000 mm WC CV 800 kcal/Nm3
CO gas pressure : 400-500 mm WC CV 4200 kcal/Nm3
CV of Mixed gas : 950 to 1000 kcal/Nm3
The CO gas will be boosted and mixed to BF gas in pipe to pipe concept with
all necessary instrumentation and controls. For this, 2 Nos. (1W + 1S) of CO gas

RSP 103no. 4.74

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 Experience that delivers

booster will be housed in a proposed naturally ventilated structural shed of

approximately 8 m x 8 m size. The Booster fans will be provided with shaft
sealing to prevent gas leakage. The motor of the booster fans will be flameproof
type.
4.6.5 Gas Mixing and Boosting Station for Mix Gas Grid
There exists a mixed gas grid of DN 1400 size pipe in front of existing battery
No.6. Approximately 40,000-45000 Nm3/h of coke oven gas will be generated in
the proposed battery No.7. The availability of CO gas to be used in the following
areas is as under:
Gas Based Industrial Boiler 12,000 – 15,000 Nm3/h
Gas Mixing for under firing in 5500 Nm3/h
battery(in case of BF gas firing)
Gas Mixing & Boosting for plant grid 19,500 Nm3/h

PROJECT DESCRIPTION
(in case of BF gas firing)
CO gas for under firing (in case of CO 15,000-16000 Nm3/h
gas firing)
The coke oven gas and BF gas will be mixed in pipe to pipe concept in
appropriate proportions to obtain mixed gas having calorific value of 3600 –
4300 kcal/ Nm3. This mixed gas will be boosted by For this, 2 Nos. gas booster
(1W + 1S) to be installed in a structural building of approximately 15 m X 10 m
size. The discharge pressure of the mixed gas will be 3000 mm WC. The mixed
and boosted gas will be transported through DN 1400 size pipe over new
trestles up to the existing mixed gas grid in front of Battery No 6 and will
suitably connected to it. U-seal and isolation valves will also be provided at the
tapping point of CO gas, BF gas and near to delivery of gas booster. Necessary
control valves, instruments and controls will be provided separately for mixing
and booster arrangement.
4.6.6 HPALA System
A HPALA pump house is envisaged beside proposed coal tower lift. Two
numbers (1W + 1S) of HPALA pumps will be installed along with 2 Nos. (1W +
1S) of booster pumps for gland sealing of main pump. VFD motors will be
provided for both the HPALA main pumps. Suction line of DN 250 will be
tapped from supply ammonia liquor line of DN 600 size with isolation valve.
Delivery line from HPALA pump of DN 200 size will be routed over the new
trestles over which supply ammonia liquor line and other new lines will be
routed up to existing trestle Z3/4TR-36. From here it will be routed through the
wall of coal tower for Battery No 7. It will be brought to the battery top and will
split in to two halves for supply of high pressure ammonia liquor separately in
battery 7. Necessary isolation valves at all the interfacing point as well as

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tapping point to each of goose neck will be provided. Following are the major
parameters for HPALA Pump:
HPALA Pump:
Body : C.I. (IS 210 – 2008, Grade – FG260)
Impeller : SS (ASTM A 351, CF 8M)
Delivery Pressure : 35 kg/cm2 (g) or {as per system requirement to
maintain 30 kg/cm2 (g) at Goose Neck.
4.6.7 The following pumps has been considered
[Link] Flushing Liquor Pump
Two numbers of Flushing liquor pump (1W + 1S) along with electric drive and
control panel of following capacity including interconnecting pipelines and
valves will be installed in new pump house in BPP area. The broad specification
of the flushing liquor pump is given below:
PROJECT DESCRIPTION

Flow: 1000 -1100 m3/h

Discharge Head = 60 -80 m LC
Temperature: 80-820C
4.6.8 Air-Conditioning and Ventilation System
Air conditioning and ventilation will be provided wherever required in addition
to those specifically mentioned.
[Link] Air-conditioning system has been envisaged in the following areas:
Sl. Premises Type AC system
No.
1. VFD panels room for HPALA system Industrial Grade type air
conditioning unit
2. PLC rooms Industrial Grade type air
conditioning unit
3. Control room for Battery, coal tower Package AC system with
area, By-product, CDCP, BPTG etc. minimum 50% standby.
[Link] Ventilation system is envisaged in the following areas:
Sl. Premises Type of Ventilation system
No.
1. Battery No 7sub-station Dry Pressurized Ventilation System
consisting of Heavy duty Tube Axial
Fans
2. Coal tower switchboard room Dry Pressurized Ventilation System
for housing Battery Proper MCC, consisting of Heavy duty Tube Axial
Trolley Line PDB & MLDB. Fans

RSP 105no. 4.76

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 Experience that delivers

3. Electrical equipment room for Dry Pressurized Ventilation System

housing hydro-jet water consisting of Heavy duty Tube Axial
cleaning system control panel, Fans
auxiliary PDB, LDB, WDB etc.
4 HPALA system electrical room Dry Pressurized Ventilation System
consisting of Heavy duty Tube Axial
Fans
8 HPALA pump house Exhaust ventilation system
9 Pump houses in BPTG, CDCP, Exhaust ventilation system
BPP area, etc.
10 Electrical rooms in BPTG, CDCP, Dry pressurized ventilation system
BPP areas etc. consisting of heavy duty tube axial
fans

PROJECT DESCRIPTION
[Link] Moisture Addition System
2 nos. pumps (1W+1S) of 100 m3/h capacity and 7.0 kg/cm2(g) delivery pressure
has been envisaged along with distribution piping, valves, control systems, etc.
for moisture addition in crushed coal conveyor.
Pumps will be located near DM water plant and will draw water from the treated
effluent from BOD plant and as a standby arrangement it will also be connected
to the sump of inlet water to DM plant.
4.6.9 Fire Fighting
Major Facilities envisaged for fire protection system are as following:
i) Fire detection and alarm system
Microprocessor based fire detection and alarm system for various plant
premises
ii) Fire hydrant system
Fire hydrant system consisting of internal as well as external hydrants will be
provided in entire area of Battery No 7complex comprising of battery proper,
CDCP, BPTG and BPP area. Proposed battery along with all associated
facilities such as battery proper, CDCP, BPTG, BPP etc. will be coming at just
adjacent location of existing COB-6. Existing fire fighting pump house will be
used for the proposed fire hydrant system in Battery No 7. Necessary
extension of existing hydrant lines with all necessary facilities will be
provided.
iii) Automatic clean agent system
Automatic CO2 total flooding system for oil cellars/ hydraulic rooms and
Automatic Clean agent (IG 541- Inergen) total flooding system for computer

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rooms/ PLC room/ control rooms along with associated piping and
equipment are envisaged.
iv) Passive fire protection
Suitable Passive fire protection system will be provided for electrical cables at
every entry and exits.
v) Portable fire extinguishers
As a first aid measure fire extinguishers and sand buckets will be provided in
all electrical & instrument control rooms, all control rooms, shift office and
oven machines as per Statutory /TAC norms.
4.6.10 Back Pressure Turbine Generator (BPTG)
This turbine receives approximately 52 tph of steam at a pressure of 66
ataand500oC temperature from the waste heat boiler associated with CDCP. The
BPTG will generate about 5.0 MW of power which will be fed to the new GIS
PROJECT DESCRIPTION

substation. The BPTG will deliver52 tph of steam at approx. 18-19 kg/cm2(g)
pressure and temperature of 300oC. The above medium pressure (MP) steam
from BPTG will be routed up to existing trestle, Z3/4TR-41 over the new trestles
which will also carry other utilities for proposed facilities to come behind Battery
No 7 towards coke side.
4.7 POLLUTION CONTROL SYSTEM
4.7.1 The new battery will meet the norms published in official gazette dated 31st
march 2012 by Ministry of Environment & Forests, Government of India for by-
product recovery type coke ovens( ANNEXURE 4.7.1-1): A list of pollution
control facilities is enclosed ( ANNEXURE 4.7.1-2)
4.7.2 Fugitive Emission
[Link] For PLD (Percent Leaking Door)
· Air cooled spring loaded diaphragm type doors with self-sealing
arrangement.
· Machine mounted door cleaner for doors and doorframe.
· Hydro jet door cleaner of 600 bar pressure.
· Mechanised frame cleaner.
· Hydraulic governors to control fluctuation of collecting main pressure within + 1
mm WC.
[Link] For PLO (Percent Leaking Off-take)
· Ceramic rope sealing at base socket of AP.
· Water sealed ascension pipe (AP) caps.
· Proper sealing arrangement between IV and goose neck.

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· Arrangement for easy cleaning of gooseneck.

[Link] For PLL (Percent Leaking lids)
· Water seal in the U-tube connecting mechanism in the oven top.
· Manual lid luting arrangement.
4.7.3 For Charging Emissions
· High pressure ammonia liquor aspiration (HPLA) system for on main
charging.
· Gas collecting main along with u tube facility in CGT car for transferring the
gas in adjacent ovens for easy evacuation of gas during on-main charging.
· Speedy coal cake charging along with hood for extracting the gases.
· Charging frame in the SCP car.
4.7.4 Pushing Emissions

PROJECT DESCRIPTION
· Land based pushing emission control system to prevent pushing time
emissions.
· Computerised Heating Control system.
4.7.5 Stack Emissions
[Link] For SO2
· Since coal blend has less sulphur content, SO2 emission is always less than
the stipulated norm. Additionally sulphur removal from by product gases is
envisaged in the by-product plant
[Link] For NOx
· Provision for re-circulation of waste gas in flues.
[Link] For SPM
· Improved design of battery anchorage.
· Load transfer from buckstay to heatingwall through liner bricks and not
through central axis of heating wall.
· Door frame to keep in contact with armour frame through ceramic ropes.
· Proper location of intermediate springs transferring the load on armour
frame from buckstay to ensure a positive load during regular operation.
· Improvement in quality of refractories & mortar particularly with reference to
porosity, bulk density & residual quartz.
[Link] For CO
· Proper combustion by control of air gas mixture.

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· Combustion monitoring as a routine job.

· Temperature monitoring as a routine job.
· Monitoring through computerised heating control system.
[Link] Other pollution control system includes the following:
1) Spillage conveyor on both pusher and coke side service platform and
spillage disposal system of coal from the cake breakage.
2) Ceramic rope in place ofasbestos rope.
3) All noise control measures.
Continuous monitoring of SO2, NOx, CO and SPM
4.8 PROCESS CONTROL & AUTOMATION
4.8.1 The proposed process control & automation system is envisaged to provide
centralised monitoring & accurate control of various process parameters for
PROJECT DESCRIPTION

battery proper, oven machines, coke dry cooling plant (CDCP) & by-product
plant for new Coke Oven Battery No.7.
4.8.2 Process control & automation system will broadly comprise of the following:
· Instrumentation & Control System.
· Radar based Oven Identification System.
· Coke Oven Heating Model
· UPS System.
· VHF Voice Communication
· Fire Detection & Alarm (FDA)
· Telecommunication system (EPABX System).
· CCTV System
4.8.3 The following levels will form the hierarchical control system:
· Level-0: Field instrumentation system.
· Level-1: PLC/ DCS based automation system.
· Level-2: Coke Oven Heating Model with integration of all the isolated
systems for better control over the process to generate MIS reports and to
analyse the process parameters
PLC/ DCS based process control system is being envisaged for monitoring and
control of the complete process. Each PLC/ DCS will have hot-standby CPUs.
PLC/ DCS will also have redundancy in power supply and communication
modules. However, I/O redundancy is not being envisaged in PLC/ DCS system.
The details of PLC/ DCS envisaged for different areas are as follows:-
· Battery proper area including Coal Handling: Instrumentation PLC/ DCS,
Reversing Winch PLC, coal handling PLC. PLC based control has been
envisaged in all oven machines.

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· CDCP area: Instrumentation PLC/ DCS, PLC system for hot bucket car &
coke bucket lifter.
· BPP area: Instrumentation PLC/ DCS
All the above PLC/ DCS system will be based on client-server architecture.
Conceptual automation configuration for Coke Oven Battery No.7 is enclosed as
[Link]. CET RN 4095 CA1 00 001 R=1. All the PLCs/ DCSs will be sitting on a
common bus and will share data among themselves through bus based
communication. Automation system of Coke Oven Battery No. 7 will
communicate with automation system of Coke Oven Battery No. 6 through
ethernet switch.
4.8.4 The following list of measurement for battery proper has been considered:
1. Coke Oven gas under firing
· Pressure and temperature measurement in CO gas header.

PROJECT DESCRIPTION
· CO gas flow measurement to battery Coke side and pusher side.
· CO gas pressure in Coke side and pusher side.
· Temperature and pressure of steam in header.
· Flow of steam in header.
· Temperature of CO gas after heater.
· Gas analyser.

2. Mixed Gas Under firing

· Pressure and temperature of mixed gas.
· Mixed gas flow measurement.

3. Gas collecting mains (GCM)

· Temperature and pressure of CO Gas from Coke side in GCM.
· Temperature and Pressure of suction main.
· Temperature, Pressure and Flow of LPAL to GCM.
4. Waste Gas
· CO, CO2, and O2 Content measurement in waste gas, coke side and
Pusher side.
· SOX, NOX, CO and SPM measurement in chimney.
· Waste gas draught and temperature measurement in coke side and
pusher side.
· Regenerator draught in coke side and pusher side.

5. HPALA System
· Flow measurement of HPALA to battery.
· Pressure of HPALA header.

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· Differential pressure across strainer.

6. Gas Mixing Station

· Pressure and flow measurement of CO gas booster outlet.
· Pressure, flow and temperature measurement of BF gas to GMS.
· Pressure and differential pressure across mixed gas.
· Calorific value measurement.
7. Goose-neck temperature measurement.

8. Computerized heating control system with mathematical model (Level-II).

Level-II system will communicate with Level-I (PLC/ DCS) system for process
data interfacing.

9. Coal moisture analyser

10. Level measurement in 6 numbers of coal silos.

PROJECT DESCRIPTION

4.8.5 The following control loops have been envisaged in battery proper:
· Pressure control in Gas Collecting Main (GCM).
· Ammonia Liquor pressure control of HPAL System.
· Under firing coke oven gas pressure control.
· Temperature controlof under firing coke oven gas after pre-heater.
· Under firing mixed gas pressure control.
· Waste Gas draught control.
· Coke oven gas control for mixing.
· Pressure control in mixed gas header.
· Pressure control of CO gas.
· Differential pressure control of BF gas and CO gas at gas mixing station.
4.8.6 Oven Identification System
Oven identification, machine positioning and machine interlocking system (OIS
and MIS) have been envisaged in 10 no. oven machines (Stamping-Charging-
Pushing Machine (SCP) Car - 2 no., Charging Gas Transfer Car (CGT) – 2 no., Coke
Transfer Car (CTC)– 2 no. and Electric Loco – 4 no). OIS and MIS system in all
machines will communicate with each other. Control of OIS and MIS in all
machines will be from central control room. OIS system in Loco of COB#7 will
also communicate with OIS of COB#6 Loco for inter-changeability between
COB#6 & COB#7. OIS and MIS system will also communicate with L-2 system.
Electric loco (4 no.) will have remote wireless operation in addition to operation
from operator’s control desk.
4.8.7 Coke Dry Cooling Plant
Monitoring, control, alarm & interlocking functions of process parameters &
equipment in Coke Dry Cooling Plant will be achieved through PLC based

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system. All the field equipment/ facilities will accordingly be interfaced with
automation system.
1. Instrumentation & automation system will be installed in the following area
of Coke Dry cooling plant:
· Coke dry cooling plant chamber and circulating gas.
· Thermal power plant system.
· Dust catching and transport system.
· Common and auxiliary facility system.
· Water circulating system.

2. Following are the important measurements envisaged in CDCP:

· Temperature measurement of CDCP chamber and circulating gas.
· Temperature measurement of boiler feed water and superheated

PROJECT DESCRIPTION
steam.
· Temperature measurement of discharged coke.
· Level measurement of coke in CDCP furnace.
· Material level detection of primary dust catcher.
· Steam drums liquid level detection of boiler.
· Flow measurement of boiler feed water and superheated steam.
· Flow measurement of circulating water.
· Flow measurement of demineralized water.
· Flow measurement of gases.
· Pressure measurement of CDCP furnace chamber and circulating gas.
· Analysis of gas for composition of CO, CO2, O2 and H2.

3. Integrated operation of battery and CDCP will be achieved through

exchange of various process parameters & equipment status amongst
respective units. Hardware and software required to interface the CDCP and
battery automation have been considered.
4. Oven identification and positioning system (OIS) will be installed in the
loco. This OIS system in loco will communicate with battery proper, other
oven machines and CDCP to achieve overall positioning system.
5. Monitoring, control and other operational activities of the CDCP will be
carried out from a Central Control Room. Central Control Room will be part
of a Control Building proposed to be suitably located adjacent to the main
unit.
4.8.8 By-Product Plant
Monitoring, control, alarm & interlocking functions of process parameters &

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equipment in by-product plant will be achieved through PLC/ DCS based

system. All the field equipment/ facilities will accordingly be interfaced with
automation system.
1. Instrumentation & automation system will be installed in the following area
of By-Product plant:

· Gas Condensate plant.

· Primary Gas Coolers
· Electrostatic Tar Precipitator
· Exhauster (electrical Driven)
· Tar, Ammonical Liquor and Tar sludge handling system.
· NH3 and H2S Scrubber
· H2s and NH3 Stripper
· Ammonia removal through cracking including Waste heat boiler, Claus
PROJECT DESCRIPTION

Reactor, Sulphur Condenser and Sulphur storage tank.

· Naphthalene removal and solar oil recovery unit
· Chilled water plant
· Cooling water system
· Gas boosting station
· Analysis of Coke oven gas for composition of O2.
· Analysis of tail gas for composition of H2S, HCN & CO.
2. Following are the important measurements envisaged in By-Product Plant:

· Pressure and temperature measurement of CO gas in each stream of

PGC and its control by regulation of damper at exhauster inlet.
· Measurement of temperature and flow of water in the header of each
stream of PGC.
· Measurement of temperature and pressure of CO gas after ETP.
· Measurement and control of temperature of insulator box of ETP
through steam flow control.
· Pressure at the delivery of flushing liquor pumps, ammonia liquor
pump, gas condensate pump and tar transfer pump.
· Flow of flushing liquor to battery.
· Level of intermediate flushing liquor tank and tar tank.
· Pressure and temperature of CO gas in the header at inlet and outlet
of each exhauster.
· Measurement of flow and pressure of water at inlet/outlet of coolers
of each exhauster.

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· Regulating damper at the exhauster inlet.

· Measurement for Gas boosting station
· Pressure measurement of mixed gas
4.8.9 Gas based boiler and DM water
1. Proposed Boiler will be provided with sophisticated instrumentation &
control system adequate for efficient operation as well as monitoring of the
plant. Remote operation, monitoring and intelligent control from central
control room is envisaged. State of the art electronic instrumentation
&control system have been considered comprising of latest generation
field instruments. DCS based systems have been considered for all auto
feedback controls, data acquisition, alarm annunciation as well process
interlocks & drive sequencing for Boiler control.

PROJECT DESCRIPTION
2. DCS complete with hot redundant CPUs, communication controllers and
power supply cards will be provided for boiler and its auxiliaries.

3. Entire plant will be operated from the DCS. However, if standalone system
is required for any offsite area, it will be PLC based system with hardwired
communication link with the DCS system.

4. Boiler will be provided with flame sensors/ scanners and burner

management system for safe operation. The burner management function
and other safety interlocks will be configured in the DCS. Dynamic mimics
will be provided on LED display panel for boiler and auxiliaries. Field
instruments will comprise of latest generation smart transmitters,
pneumatically actuated control valves with smart positioner and built-in
position transmitters, steam & water analysis system, continuous emission
monitoring system (CEMS) etc.

5. DCS based industrial control system will basically consist of:

a) Measurement & control system of boiler & its auxiliaries

b) Human machine interface and plant information system
c) System programming & documentation facility
d) Data communication system
e) Sequence of events recording system
f) Annunciation system

6. List of major important control and measurement parameters will be as

follows:

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· Boiler facilities
a) De-aerator pressure and level control.
b) Pressure & temperature controls in Pressure Reducing and De-
superheating Station (PRDS)
c) Drum level control
d) Steam pressure and temperature control
e) Furnace draft control
f) Fuel/ air ratio control
g) Primary/ secondary air flow control
a) Feed water header pressure
b) BFP suction & discharge pressure
PROJECT DESCRIPTION

c) Feed water flow

d) Drum Level measurement by electronic level indicator (2 nos)
e) Drum pressure
f) De-aerator level measurement by electronic level indicator
g) Feed water temperature before and after economizer
h) Steam and Water Analysis System (SWAS) system
i) SH steam temperature, pressure & flow
j) Fuel gas pressure, flow & temperature
k) Air flow, pressure & temperature
l) Flue gas pressure & temperature at different locations
m) Percentage oxygen measurement in flue gas
n) CEMS system for SOx, NOx& CO and dust concentration in stack
· DM Water System
a) DM water flow to storage tank
b) DM water pH, conductivity & TDS at mixed bed outlet
c) Tank level measurements
d) Flow & pressure of DM water in header to boiler
e) Other instruments as per process requirement
· Water treatment system
a) For Intake well and treatment system-

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b) Intake well level measurement-2 sets

c) Pump suction and discharge pressure measurements-4 sets
d) Differential pressure switches-12 sets
e) Makeup water sump level measurements-2 sets
f) Flow measurements- 2 sets , Pipe size: DN400
g) Conductivity measurement – 2 sets
h) Solenoid valves (DN200) - 40 nos.
4.8.10 Back pressure Turbine Generator
a) Electro Hydraulic Turbine Controls (EHTC) (electronic Governor) for control
of Turbine speed, load, inlet steam pressure and exhaust pressure control.
b) Electronic Over speed protection device (2/ 3 voting logic)

PROJECT DESCRIPTION
c) Dual channel turbine shaft vibration and axial displacement monitoring
system with work station which includes proximity type probes, proximeters
and extension cables for the same.
d) Primary instruments to realize the turbines auxiliaries interlock and
protections for the following drives: Auxiliary Oil pump, Main oil pump,
emergency lube oil pump, jacking oil pump, oil vapour extraction fan and
turning gear.
e) All the primary field instruments and final control elements in Steam
Turbine generator.
· Bearing thermo elements (RTD’s) for monitoring bearing metal
temperatures including turbine generator and gear box.
· Level gauges at main oil tank, overhead oil tank and gland steam
condenser.
· Local pressure and temperature gauges.
f) DCS for the overall control system of power plant including interlock and
protections, closed loop controls signal handling etc. for the steam turbine
and auxiliaries.
4.8.11 Control Rooms
Three numbers of control rooms, one number each for battery proper, coke dry
cooling plant and by product plant have been envisaged under this project. All
control room equipment will be connected to each other through ethernet
switch. Each control room will house the following equipment in general:
· PLC/ DCS system for process control and monitoring.
· Human Machine Interface/ Operator Station/ Engineering Station.
· HMI Server.

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· Network Printer.
· Network Switches.
· FDA panel.
· CCTV monitors and recording.
· EPABX system.
· UPS
· CCTV System

4.8.12 UPS System

Two nos. UPS system along with separate dedicated battery bank has been
considered in each control room to cater PLC/ DCS system and all field
instruments. The output of both the UPS will be provided in each of the control
panels via static switch so that there will be 2 sources of power in each of the
panels. Both the UPS system will have minimum one hour back-up.
PROJECT DESCRIPTION

4.8.13 FDA System

Microprocessor based intelligent addressable type automatic fire detection and
audio-visual alarm system have been considered for early warning in case of
smoke, heat and/ or fire in all fire sensitive locations so that same can be put off
in time. Areas to be covered under such system include control rooms, electrical
rooms, UPS room, PLC/ DCS room, computer room, cable basement/ gallery,
false floor/ ceiling, hydraulic rooms, transformer rooms. The system will consist
of addressable detectors, Linear heat sensing elements, response indicators,
manual call points, repeater panel, main control panel, hooters and flasher
indicators, cables, etc. The system will be hooked up with the centralized fire
station.
4.8.14 Closed circuit television system for surveillance
CCTV system has been envisaged for different areas of the new COB#7:-
· Strategic locations in Battery Proper, By-product & CDCP area
· Electrical substation rooms
· Administrative office building
· Control rooms, MCC/ PLC/ control rooms/ server rooms etc.
The system will consist of IP based cameras, network video recorders (NVR),
switches, monitors, cabling, etc. for centralized monitoring based on HD
recording.
4.8.15 Telecommunication system:
Telecommunication system along with press to talk system and walkie-talkie
sets with base stations has been envisaged for the Battery Proper, By-product
plant & CDCP. The system will mainly consist of the following:-

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· 50 line exchange & interconnection with existing plant exchange

· 20 no. Telephone handsets
· 10 no. press to talk system
· Walkie-talkie system
· Cables and all accessories
4.9 CIVIL WORK
4.9.1 Battery Proper
[Link] Main Battery Units:
1. Battery foundation, Cellar, nozzle deck, flue duct, bench supporting structures
on pusher side, RCC slab for benches and buttress walls at both ends.
Buttress wall and Nozzle deck will be made in Heat resistant concrete (HRC)
of grade M30C. A layer of screed concrete of HRC on top of Nozzle deck will
be provided in RCC of grade M30C.

PROJECT DESCRIPTION
2. Construction of foundation for hydraulic reversing winches including room
for hydraulic winch along with hydraulic winch foundation.
3. Coal tower
New RCC framed Coal Tower building with coal bunker and all auxiliary
facilities. The roof of coal tower will be of RCC construction. RCC access
staircase and lift tower will be provided upto the coal tower top. Necessary
inserts will be provided for fixing of liner. Provision of drinking water at coal
tower top will be provided with pumping arrangement and overhead tank.
4. Chimney
There will be one chimney to serve Battery No.7. The chimney will be of RCC
construction. Approach to inspect chimney tunnel butterfly will be provided.
5. Machine Tracks
Foundations for SCP car, coke transfer car track and coke bucket car track.
6. Waste Heat Flue Tunnel
New Waste Heat Flue tunnel on both pusher and coke side will be connected
to the chimney. The waste gas tunnel will be pressure grouted. Proper de-
watering arrangement will be provided inside the tunnel. Heat resistant
concrete (HRC) of grade M30C will be used.
7. Service Platforms
Service benches on Pusher side and Coke side consisting of RCC slab will be
supported over steel beams & columns.

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8. Red brick panelling with grills at the top portion will be provided between the
service platform columns all along the battery, end benches, inter battery
benches, coal tower.
9. End and Intermediate benches
End benches and inter battery benches will be as per technological
requirement. RCC slab will be supported over steel beams & columns.
10. Spillage conveyor bunker
Foundations for new coke spillage bunker and conveyor trestles for both
pusher side & coke side and will have a provision for installing spillage coke
conveyors on both coke side and pusher side in service benches.
11. HPLA pump house
RCC framed building for HPLA pump house with brick cladding for housing
pumps & electrics and foundations for equipment & finishes as per
PROJECT DESCRIPTION

technological requirement.
12. Compressor house
RCC framed Compressor house with brick cladding including compressor
foundation and finishes as per technological requirement.
13. Office Building
A two storey RCC framed Office building (900sqm approx.) will be provided
with office rooms, mini conference room and toilet blocks for ladies and
gents.
14. RCC framed GIS substation with brick cladding walls and switchyard will be as
per technological requirement.
15. RCC framed main control building & lab building with brick cladding walls
will be as per technological requirement. The control room will be provided
with false ceiling & false flooring as per requirement.
16. All civil works for the extension of existing coke car repair shop including
provision of a new loco repair pit. Further the existing loop line will be
modified and extended
17. All civil works for the PEC and PEC duct support.
18. Foundation for cable gallery.
19. Structural steel framed building with brick cladding for housing gas mixing
station facilities, with finishes as per technological requirements.
20. All joints in rails / tracks of the coke car track will be fish plate joints.
21. Workshop to be provided for heating section

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[Link] Coal Handling System

i. Construction of 6 new RCC silos along with foundations. Part of the
foundations has already been constructed in the earlier project. Piling
and foundation for the new Silos and integration with the existing
foundation has been considered.
ii. Civil works related to hard coal supply system consisting of conveyors,
primary crusher, hoppers etc.
iii. Civil works related to the construction of compressor building,
compressor foundation & air receiver foundation. The compressor
building will be in RCC framed structure with brick cladding and
appropriate finishes.
iv. Civil works related to all coal supply conveyors from silo to coal tower of
Battery No 7; including foundations for trestles, junction houses etc. as

PROJECT DESCRIPTION
per process, system and technological requirements.
[Link] Tapping of BF Gas Line
Trestle foundation for BF gas line and mixed gas line will be constructed for
both 2 legged and 4 legged trestles from BF-1 to Battery No 7 area.
4.9.2 CDCP
The various units considered for CDCP will be as below:
[Link] CDCP Building
All Civil works related to foundations of CDCP structure, coke cooling chamber,
coke bucket lifter, blowing device, coke charging & discharging devices, main
mill fans, columns of the dust catcher, Boiler House and the foundations for the
Boilers etc. will be as per process, system and technological requirements.
Existing RCC underground Coke conveyor tunnel will be utilised with
modification / openings, if any, for transportation of dry coke from the CDCP to
the CDU as per technological requirements. Existing RCC tunnel will be pressure
grouted to make it water proof.
[Link] Auxiliary Building
RCC framed Auxiliary Building with brick cladding and finishes as per the
technological requirements. The building will house Control rooms, Operator
room, Engineering Stations; Servers & Software/Hard-ware related
documentation room, Room for DCS & PLC Panels, I/O panels, Instrumentation
panels, Weighing panels, & all other electronic panels, room for laboratory
facility for coke dry cooling plant etc. Control room floor will also have facility of
Toilet block, Conference room & Pantry. Part of the building will house the
transformer, electrics, de-aerator, Boiler feeding pumps etc. The existing and the
new Auxiliary building will be suitable connected.
[Link] Other Major Units

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1) Foundations for gas line supports.

2) RCC framed CDCP dust collection station with brick cladding along with
foundations for fans, cyclones & bag filters and finishes as per system and
technological requirement.
3) RCC framed Dust Settling Station with brick cladding, equipment
foundation (steam jet ejectors & cyclones) and finishes as per system and
technological requirement.
4) RCC framed Air Compressor Building with brick cladding along with
foundation for the CDCP ventilation unit, foundation and civil works for the
Service water Cooling Tower of air-conditioning system along with basin
for the cooling tower and finishes as per system & technological
requirements.
5) RCC framed circulating water supply pump-house with brick cladding and
finishes as per system and technological requirement.
PROJECT DESCRIPTION

6) RCC framed contaminated condensate pump-house with brick cladding

and finishes as per system and technological requirement.
7) Structural framed back pressure turbine generator building with brick
cladding which will house generator, electrics and associated auxiliaries
including finishes as per system & technological requirements.
8) Foundation for electrical repair cum storage shed and mechanical storage
shed with suitable rooms along with brick cladding, flooring and finishes
as per functional requirement.
9) RCC framed Substation buildings with brick cladding and finishes as per
process, system and technological requirement.
10) Foundation for cable gallery supports.
4.9.3 By-Product Plant
[Link] Civil works and RCC framed buildings with brick cladding and finishes as per
process, system and technological requirement
1. Foundations for the primary gas coolers& associated cooling towers
&chilled water plant.
2. Foundations for the electrostatic tar precipitators.
3. The Exhauster Building with brick cladding along with foundations for
exhauster & other equipment and finishes as per system and
technological requirement. Exhauster foundations will rest on Steel
Helical Spring Foundation. Steel helical springs will rest on the RCC
framed structure.

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4. Foundations for the Tar decanters. Foundations will be made with

necessary pits supporting the tank on the inside and the earth on
outside with all necessary water proofing etc.
5. RCC tank for Coal Water Tank.
6. Flushing Liquor pump house with brick cladding along with foundations
for pumps & other equipment and finishes as per system and
technological requirement.
7. Area Paving with PCC for Tar loading station.
8. Foundations for the Tar storage tanks. Foundations will be made with
necessary pits supporting the tank on the inside and the earth on
outside with all necessary water proofing etc.
9. Foundation for the H2S, Ammonia, Combi& Naphthalene Scrubbers.
Foundations will be made with necessary pits supporting the tank on

PROJECT DESCRIPTION
the inside and the earth on outside with all necessary water proofing
etc.
10. Foundations for the Combined Ammonia stripping and De-acidifier
Units.
11. Foundations for the claus cracking and elemental sulphur plant.
12. RCC tanks for Enriched Water Buffer Tanks.
13. Foundations for the Naphthalene Stripper Unit.
14. Construction of foundations and buildings for various units of Effluent
Treatment Plant. All buildings will RCC framed building with brick
cladding and finishes as per system and technological requirement.
15. MCC & Control rooms for the various units of BPP will be RCC framed
building with brick cladding and finishes as per system and
technological requirement.
16. RCC tanks for Enriched Solar Oil Tanks.
17. Foundations for both pipe supporting trestles and platforms.
18. All liquid storage tanks will be made water proof by necessary injection
of water proofing compound and will be designed as per IS:3370 (Part
1)-2009 and IS:3370(Part 2)-2009.
19. Effluent Treatment Plant
20. Foundation for Cable gallery supports.
[Link] Catch pits with pumping facilities will be provided at strategic locations in the
by-product plant area for preventing escape of leakages from different
units/equipment and untreated waste water into drain directly. The collected

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waste water in catch pits will be pumped to New BOD Plant for treatment for
further utilization.
4.9.4 Water Supply System
1. Civil work for construction of intake well and pump house, temporary coffer
dams during construction, pipe supports from the intake well to the Battery
No 7 area, electrical building and water treatment plant. The pump house
area will be provided with boundary wall of 2.5m height above finished floor
level with concertina coil above the wall with angle iron 'Y' horizontal
barbed wire.
2. The entire intake canal including side walls with intake mouth will be of RCC
construction. No boulder pitching will be provided. The canal will be
partitioned into two parallel paths with a dividing RCC wall with a provision
for intake water supply to all the intake sumps from a single path. Each part
of the canal will be provided with RCC stairs to go down to facilitate manual
PROJECT DESCRIPTION

cleaning. RCC walkway of minimum 2 m wide with side railings for all along
the length of the intake canal for proper access will be provided on both
sides of canal.
3. Construction of RCC tanks for the various stages of water treatment i.e.,
MBBR tank, FM tank, flocculator, tube settler tank, sludge thickener, sludge
sump, clarifier, clarified water tank, RO reject storage tank and UF/Filters
backwash collection sump.
4. Construction of RCC framed buildings with brick cladding & appropriate
finishes, for UF & RO, Chemical house, evaporator & filter press.
5. Tapping of 30KLD water from treated makeup water sump will be taken for
drinking water treatment. Necessary treatment facilities from the above
mentioned tapped drinking water will be provided to ensure quality of
drinking water is as per IS:10500-2012. 30 m3 SMC / GRP panel overhead
water storage tank with steel structure staging will be provided to create a
residual head of 1.5 kg/sq cm (g) with minimum pipe dia of 80mm at
column no TR-41 for distribution to other consumers of all the packages
under this project.
6. Tapping of drinking water for the intake well pump house will be taken from
the upcoming pump house of the intake well of the new HSM. Additionally
one RO system for 6 users will be provided.
4.9.5 Industrial Boiler and Steam Generation
Civil work for construction of foundation of industrial boiler, DM water plant,
nitrogen compressor plant, electrical buildings, pipe supports and other
miscellaneous works.
4.9.6 Rain water harvesting

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Storm water drain and rooftop rainwater harvesting system will be provided.
Rainwater will be collected by a system of drains and pits within the battery limit
of this package and the water thus collected in settling tank cum sump pit and
will be pumped for augmenting the industrial water source.
4.9.7 Site Preparation
Necessary grading and surface dressing will be done around all the new
facilities as required.
4.9.8 General:
1) A new toilet block with provision for gents and ladies toilet. Toilet facility will
be provided at all control rooms, pump houses, substations, offices and all
manned units.
2) One wall mountable RO+UV+UF+TDS water purifier of domestic use type, of
8-Litre storage, with minimum duty cycle of 75 liters/day, will be provided at

PROJECT DESCRIPTION
all control rooms, pump houses, substations, offices and all manned units.
3) Workers rest rooms with drinking water facility
Necessary grading and surface dressing, cutting & clearing of soil mound,
cutting of bushes & clearing, site cleaning & preparation, disposal of debris got
out of dismantling, cleaning of site, dressing, leveling, as per site requirement
4.9.9 Soil Investigation and survey
No soil data is available for the new facilities; therefore a fresh sub-surface soil
investigation has been envisaged to be carried out at the proposed location of
the new facilities to ascertain the engineering properties of the foundation soil
for design & selection of type of foundation. The soil investigation and survey
will be separately conducted through a package prior to the tendering of the
other packages. This report will be made available to all the bidders of all the
packages.
4.9.10 Design Philosophy & Guideline
Both open and pile foundation has been envisaged. However soil investigation
will be carried out separately.
Grade of RCC & PCC for all civil work is envisaged to be of M-25 and M-10
respectively. Buttresses &screeding on deck slab is envisaged to be of HRC of
grade M-30.
In general, cast-in-situ concrete will be used for all RCC works. However, in
exceptional cases, precast elements will be used.
All grouting will be of M25D or M30D or free flowing ready mixed high strength
grouts as per requirement.
4.9.11 Building Materials

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[Link] Most of the building materials to be used in the civil works are available locally.
The easy availability of these materials will be utilized to maximum extent for
minimizing the cost of civil works provided these construction materials
conform to provisions of relevant IS Codes.
[Link] Locally available fly ash brick of kiln burnt quality and having a crushing
strength not less than 7.5 N/sqm have been envisaged for use in the work
subject to fulfilment of requirement of relevant IS: Codes.

4.10 STRUCTURAL WORK

4.10.1 Battery Proper
[Link] New Temporary Oven Protection Roof (TOPR).
[Link] New protective shed.
Structures of TOPR and protective shed will be dismantled and stacked for
future use.
[Link] SCP machine track consisting of crane rails for wheels and guide wheels
PROJECT DESCRIPTION

mounted over steel sleepers/RCC foundation with shock absorbing material and
fixed securely with the foundation will be laid covering the length as defined in
the battery limit. Rails will also be provided for horizontal guide wheels.
[Link] Coke transfer car track consisting of 60 kg/m rail mounted over coke side
service bench outer beam and column on battery side and on steel girder
supported over bracket / column on the other side with walkway / maintenance
platform, access stair, ladder, handrail etc. as per technological requirements
covering the entire length as defined in battery limit.
[Link] Gas transfer car consisting of 60 kg/m rail over oven top covering the entire
length as defined in the battery limit.
[Link] Structural arrangement consisting of trestles, girders and columns to support
pushing emission control duct for entire length as defined in the battery limit.
[Link] Structural supports for cross over and foul coke oven gas mains as per
technological requirement.
[Link] Platform along length over gas mains as per operational and technological
requirement.
[Link] Bracket supports for gas collecting mains on coke side of battery.
[Link] Trolley line / Catenary type supports for power line for coke oven machines. This
includes:
a) SCP machine cable support
b) Catenary supporting structures/ brackets/ portals for coke transfer car.
c) Trolley line bracket supports for Coke bucket car.
d) Catenary supporting structures/ brackets/ portals for gas transfer car
e) Safety guard and net for power lines.
[Link] Service benches on both sides consisting of RCC slab supported over steel

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beams and columns over the entire length as defined. RCC slab will have cast
iron paving. Service bench will have provisions for spillage chain conveyors.
[Link] Trestles, girders, walkways and hopper for spillage belt conveyor system.
[Link] Beam column structural arrangements at oven top and service bench level
platforms in inter battery and end bench areas.
[Link] Cellar platforms over gas mains.
[Link] Trestles, steel structural bridges for all overhead out door utility pipe lines along
with walkway, maintenance platforms, access stairs, ladders, handrails etc. as per
technological requirement.
[Link] Steel structural frame work, roof covering, working platforms, stair etc for
hammer changing station.
[Link] Structural frame work for providing handling facilities for moving materials from
SCP machine side to coke side
[Link] Structural arrangements for overhead electrical cable galleries.
[Link] Canopy over field instruments as per technological requirement

PROJECT DESCRIPTION
[Link] Dismantling of existing sheeting and extension of steel structural shed and
platform over coal silos for extending reversible conveyors RSC - 3 & 4 towards
new silos.
[Link] Steel structural shed and platform over new coal silos for housing new
reversible conveyors RSC – 8A and corresponding handling facilities.
[Link] Covered galleries in coal handling circuit for new double / single belt conveyor
along with CGS roof & side sheeting, chequered plate walkways etc. supported
on structural trestles as per technological scope of work.
[Link] New junction houses in coal handling circuit along with CGS roof, side & gable
end sheeting, RCC floor supported over structural steel beams with access stairs,
handrails & handling facilities as per technological scope of work.
[Link] New crusher house in coal handling circuit along with CGS roof, side & gable
end sheeting, RCC floor supported over structural steel beams at different levels
with access stairs, handrails & handling facilities as per technological scope of
work
[Link] Existing coke bucket car repair station will be extended as shown in layout
drawing as per operational requirement. The part of the existing repair station
building over the main coke car track, i.e. columns on either side of main coke
car track along with other supported structures will be suitably modified. The
extended as also the modified area will be designed for specified higher
capacity of crane to lift the filled up coke bucket. The existing EOT crane along
with the existing coke bucket repair station will be utilized as per the present
practice. Buffers will be provided to prevent new higher capacity crane from
travelling to the existing part of coke repair station.
[Link] Miscellaneous maintenance platforms, access stairs, ladders, handrails &
handling facilities etc. as per technological requirement.
4.10.2 Coke Dry Cooling Plant (CDCP) and BPTG

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[Link] CDCP building structures complete with bucket lifter & bucket transfer facilities
as per technological / technical requirements. The major structures include
beam / column / bracing arrangements for supporting structures for boiler
block, auxiliary block, bucket lifter, crane girder, covered passenger lift
structures, pipe supports, working / maintenance platforms, access stairs,
ladders, handrails & handling facilities etc. as per technological requirements.
[Link] New steel structural BPTG building along with CGS roof, side & gable end
sheeting, RCC floor supported over structural steel beams at different levels with
access stairs, handrails & handling facilities as per technological scope of work.
[Link] Trestles, steel structural bridges for all overhead utility pipelines along with
walkway, maintenance platforms, access stairs, ladders, handrails etc. as per
technological requirement.
[Link] Dismantling of trestles for re-routing of existing pipelines.
4.10.3 By-Product Plant
[Link] Steel Structural work for all By-product units e.g. primary gas coolers, tar
PROJECT DESCRIPTION

precipitators, exhauster, pump houses, ammonia removal, sulphur removal,

scrubber units, chilled water unit, BOD etc.
[Link] Steel structural trestles, bridges and brackets for support of different overhead
gas pipe lines with maintenance walkways, platforms, access stairs, ladders,
handrails & handling facilities etc. as per technological requirement.
[Link] Working / maintenance / access platforms with stairs, ladder & handrail etc. for
different vertical and horizontal vessels, tanks as per technological requirements.
[Link] Structural arrangements for overhead electrical cable galleries.
[Link] Miscellaneous maintenance platforms, access stairs, ladders, handrails &
handling facilities etc. as per technological requirement.
4.10.4 Boiler and DM Water
[Link] Steel Structural frame work, roof and side sheeting, working platforms,
walkways, equipment and duct support, stairs etc. for installation of gas based
boiler.
[Link] Trestles, steel structural bridges for all overhead utility pipelines along with
walkway, maintenance platforms, access stairs, ladders, handrails etc. as per
technological requirement.
[Link] Structural arrangements for overhead electrical cable galleries.
4.10.5 Water Supply
[Link] Structural arrangements for overhead electrical cable galleries
[Link] Steel structural staging work consisting of column and bracing on all sides for
overhead SMC water tank for drinking water storage
4.10.6 Design Considerations
· All steel structures will be designed to meet the technological requirements
with due consideration to the existing plant and facilities.
· Design of steel structures will be as per IS: 800-1984.

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· Conveyor and junction house structures will be designed as per the provision
of IS: 11592-2000.
· Apart from technological loads to be supported on steel structures, self-
weight and superimposed loads for the design will be according to IS: 875-
1987. Structures will be analysed either for wind or seismic as applicable.
Wind load on structures will be considered as per IS: 875-1987 whereas
seismic loads will be taken as per IS: 1893 Part-1 (2002) & Part4 (2005).
· All structural steel work will be of welded construction. Due allowance are to
be kept for impact, vibration and temperature load.
4.10.7 Technical Specification
· Material for structural steel will be as per IS: 2062 –2011 (Grades as
applicable). Roof and Wall will be of pre-painted Al-Zn coated trapezoidal
profile. The base metal will have minimum 550 MPa yield strength with hot
dip metallic coating composed of 55% Al and balance Zn with minor addition
of control elements. Thickness of base metal will be minimum 0.45 mm and

PROJECT DESCRIPTION
total coated thickness will not be less than 0.5 mm. Pre-painted Al-Zn coated
sheet will conform to IS 15965: 2012.
· The welding and the welded work will generally conform to IS: 816 -1969 and
9595 -1996 unless otherwise specified. Electrodes will conform to IS: 814 -
2004. As much work as possible will be welded in shops and the layout and
sequence of operations will be so arranged as to eliminate distortion and
shrinkage stresses.
· Fabrication and erection of steel structures will conform to IS: 800-1984 and
tolerances of fabrication will be as per IS: 7215-1974. All the structures will be
duly inspected and made defect free.
· For battery proper & By-product structures paint system will consist of two
coats of primer paint and one coat of intermediate paint at shop and two
coats of final paint at site. Primer coats will be done with two coats of a single
pack air drying high build chlorinated rubber based zinc phosphate primer to
achieve even shade and a minimum dry film thickness of 100 microns (50
microns/Coat). Intermediate paint will be phenolic-alkyd based compatible
with primer paint and will have dry film thickness of 50 micron. Finishing coat
will be done with two coats of a single pack air-drying plasticized chloro
rubber paint suitably pigmented to achieve even shade and a minimum dry
film thickness of 100 microns (50 microns/Coat). The minimum chlorine
content will be 12 to 15%.
· Structures other than battery proper & By product area will receive two coats
of single pack air drying phenolic modified alkyd composition with zinc
phosphate as a primer with total dry film thickness of 80 microns (DFT/coat
40 micron) and two coats of single pack air drying high gloss phenolic alkyd
modified synthetic enamel paint suitably pigmented with total dry film
thickness 50 microns (DFT/coat 25 micron). One coat of primer will be applied

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at shop before despatch. The other coat will be applied after erection at site.
The finish paint will be applied over the primer coat at site.
· For open trestles/other outdoor structures in addition to the above one
intermediate coat after the primer will be applied. The paint will be single
pack high build phenolic based paint with Micaceous Iron Oxide (MIO).The
dry film thickness will be not less than 75 microns.

4.11 MAN POWER

At RSP, 4 small coke oven batteries and one tall battery are in operation. After
commissioning of the proposed battery, six batteries i.e. Battery Nos. 1,2, 3, 4, 6
& 7 will be in operation as Battery No 5 will be closed down in later date in the
year 2029-30. During the period RSP will have four operational small batteries at
any point of time.
Therefore additional manpower is required for operating the Battery, CDCP, BPTG, DM
PROJECT DESCRIPTION

water, Gas based boiler, intake well pump house and BPP. The total indicative
manpower requirement for the proposed facilities would be 529 (51 executives and 478
non executives). Necessary deployment strategy, either from existing strength or
through fresh recruitment may be looked into by RSP.

4.12 RISK ASSESSMENT

Risk assessment for the project is attached at Annexure- 4.12-1

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE
5.1.1 The project is envisaged to be implemented within a period of 42 months from
stage-2 approval. Pre-ordering activities are envisaged to be completed within 6
months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1& 5.1.2-2 respectively.
5.2 IMPLEMENTATION STRATEGY
5.2.1 It is proposed to execute the project under the following turnkey packages:-
Package 1 Soil Investigation and Survey
Package 1A Enabling Works
Package 2 Battery Proper along with oven machines &
refractory
Package 3 Coke Dry Cooling Plant including BPTG, , Boiler

PROJECT IMPLEMENTATION
and DM Water Plant
Package 4 By-product Plant including BOD plant and Water
supply System
5.2.2 Soil Investigation and Survey (Package-1) consist of jobs pertaining to land
survey and soil analysis of the area within the battery limits has been completed
and report has already been submitted.
5.2.3 Enabling Works (Package-IA) will consist of jobs pertaining to area development
work which includes site leveling, scrap removal, provision of water and power
for construction work.
5.2.4 Package-2 (Battery Proper along with oven machines & refractory) will consist of
following main facilities
· Battery proper area including supply of refractory materials
· Coal Handling conveyors& new silos
· Gas Mixing Station.
· Facility for receiving category-1 power from MSDS-6, distribution to other
substations of other packages
· Supply of all oven machines i.e. SCP machine (2 nos.), Gas transfer car (2
nos.), Coke transfer cars (2 nos.),4 loco including PEC system.
5.2.5 Package-3 (Coke Dry Cooling Plant including BPTG, Boiler and DM Water Plant)
will consist of following facilities.

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[Link] Coke Dry Cooling Plant including BPTG

· Coke Dry Cooling Plant - Dry cooling chamber, boiler, dust disposal system,
coke processing and delivery systems, two coke bucket car along with 3
spare bucket.
· Back pressure turbine generator unit along with power evacuation system.
[Link] Boiler and DM Water Plant
· DM Water Plant ion-exchange based 3x120 tph DM Water Plant on 2W+1S.
· Gas Fired Boiler of 60 tph at 18 kg/cm2(g) pressure & 300 deg temperature
· Steam piping network
5.2.6 Package-4 (By-product Plant including BOD plant and Water supply System) will
consist of major facilities.
[Link] By-product and BOD plant
PROJECT IMPLEMENTATION

Name Function

Coarse condensation plant Removal of tar from return ammonia

liquor from battery collection main in
tar separators and decanters
Fine condensation plant Cooling down of COG in Primary
coolers and tar impurities removal in
ETPs
Gas distribution plant Transfer of COG via Exhausters
Tar system plant Storage of produced tar
Detarring Ammonia Plant Removal of tar impurities from excess
ammonia liquor on sand filters
H2S/NH3 scrubbing plant Removal of H2S/NH3 from CO gas in
scrubbers into scrubbing liquor
Scrubbing liquor stripping plant Recovery of H2S/NH3 from scrubbing
liquor
Sulphur recovery plant NH3 cracking, desulphurization -
production of pure sulphur, based
on Claus process
Caustic soda plant Preparing and storing of caustic soda

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Napthalene recovery plant Removal of naphthalene from CO gas

Water system plant Production of circulating cooling

water for particular process units
Chilled water plant Production of circulating chilled water
for particular process units
Biological treatment plant Biological treatment of process waste
waters
[Link] Water supply System
· Intake Well Pump House.
· 2 x DN 300 piping (1W+1S) from Intake well Pump House to Water
Treatment Plant at Battery No 7 (a distance of approx. 5.5 km).
· The raw water treatment
· Storage of Filtered water will be stored in an underground sump. Pump
house to supply water to various consumers.

PROJECT IMPLEMENTATION
· Zero liquid discharge plant
5.2.7 The following activities package wise can be started after obtaining “Stage-I”
approval:
· Issue of Tender enquiry.
· Receipt of offers.
· Scrutiny and evaluation of Technical & Commercial offers.
· Techno-commercial discussions with the bidder.
· Evaluation of offer and Tender recommendation.
· Opening of price bids and finalisation of successful bidder.
· Package-1 (Survey and soil investigation) has been completed and report has
been submitted and accepted.
5.3 After completion of above activities, investment proposal with firmed up cost
will be put up to Board for “Stage-II” approval.
5.3.1 RSP will take all the required statutory clearances (environmental, pollution,
power, consent to establish consent to operate, etc.) from the concerned
government agencies prior to processing for obtaining stage-II approval. Cost
of engaging Environmental Consultant& fee for Consent to Establish has been
included in FR. Cost with respect to the budget for compliance to EC conditions
& towards Enterprise Social Commitment has also been included in FR.

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5.3.2 Specialist agency will be engaged by RSP to conduct environmental impact

assessment (EIA) studies and prepare environmental management plan (EMP).
This EIA & EMP report will address all the elements proposed under the latest
guidelines. Based on this, required clearances from state and central regulatory
authorities will be obtained.
5.4 Shutdown in staggered manner required in the coal handling, battery, coke
sorting & BPP of existing Battery No. 6 during the modification and
interconnection of various facilities with the existing facilities like tapping from
existing coal handling plant, converting DC bus bar of coke bucket car to AC
and connecting to existing primary cooler, ETP & exhauster has to be provided.
5.4.1 RSP will hand over the site free of any debris/slag and any other encroachments
at site (finished ground level should be at 223.5 m in battery area and finished
ground level should be at 223m for by product area ).
5.4.2 Proposed coal blend had been tested at RDCIS laboratory for the stamp charge
battery and report submitted on 02.07.2018. Report is provided in Annexure
5.4.2-1.
5.4.3 Budgetary Sanction for expenditure for implementing package -1, package -1 A
and expenditure to be done for obtaining environmental clearance for the
PROJECT IMPLEMENTATION

project is to be obtained along with stage -1 approval.

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6. CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:
6.1.1 The capital cost of the project is estimated at Rs.2,317.64 cr. net of input tax
credit (ITC) on GST of Rs.287.05 cr. including IDC of Rs.304.74 cr. FE component
considered in it is Rs.604.16 cr. The summary capital cost estimate is appended
at Annexure-6.1.1-1.
6.1.2 The Capital Cost is based on budgetary quotations for few critical items like SCP
machine, CTC machines, gas booster, CDCP, CCD plant, boiler, DM water plant
and engineering estimates for remaining items. Base date for the estimate is 2 nd
quarter 2019. FE parity has been considered as 1 USD=Rs. 71.18 and 1
EURO=Rs. 80.74 along with forward premium rates as Rs. 6.88 and Rs. 7.88
respectively.
Charges for engaging environmental Consultant, Fee for consent to establish
and provision for compliance to EC conditions & towards Enterprise Social
Commitment has been duly considered. Provision of critical spares has been
duly considered.
6.1.3 Necessary statutory provisions towards taxes & duties have been made in the
estimates as per the details given below:a) Taxes and duties:
i) GST @ 18 % on cost of equipment, structures, civil, erection, engineering
& construction (contractor), supervision and training
ii) Income tax @ 10 % grossed-up on foreign services.
iii) CD @ 7.5% on imported supplies

CAPITAL COST & FINANCIAL ANALYSIS

6.1.4 Freight & insurance charge for indigenous equipment @ 2% of basic cost and
for indigenous structure & refractory @ 9% of basic cost has been considered.
Inland freight & insurance charge for imported equipment has been taken @
3% of CIF cost.
6.1.5 Erection & commissioning charges has been taken @ 12% on basic cost of
indigenous equipment, @ 20% of basic cost of structure and 6% on CIF cost of
imported equipment. Erection for refractory has been taken on unit rate based
on similar jobs executed in SAIL plants.
6.1.6 Engineering & Construction (E&C): E&C (Contractor) @ 5% and E&C (Owner) @
2.5 % on basic cost of equipment, structures, refractory, civil work and erection
& commissioning charges.
6.1.7 Contingencies: @ 5 % on overall basis has been considered.
6.2 MODE OF FINANCING:
The total capital requirement of the project is proposed to be provided from
100% debt with an interest @ 10% per annum.

6.3 PHASING OF CAPITAL EXPENDITURE:

With the project duration of 42 months from the date of Stage – II approval, the
phasing of capital expenditure is proposed as indicated below:

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Rs. cr.

Year Plant cost Equity Loan IDC Total incl. IDC

1st year 229.99 229.99 11.50 241.49

2nd year 689.98 689.98 57.50 747.48

3rd year 919.98 919.98 138.00 1057.97

4th year (6 months) 229.99 229.99 97.75 327.74

Post Comm. 229.99 229.99 229.99

Capital cost 304.74 2604.69

Input tax credit (ITC) on GST 287.05

Capital cost net of ITC on GST 2317.64

6.4 INTEREST DURING CONSTRUCTION (IDC):

Based on the mode of financing and phasing of capital expenditures indicated
above, total IDC has been worked out to Rs.304.74 cr.
6.5 COST - BENEFIT ANALYSIS:
CAPITAL COST & FINANCIAL ANALYSIS

6.5.1 Gross margin calculation for the project is based on the assumption that in case
the proposed Coke Oven Battery is not installed, the entire requirement of BF
coke i.e. 683400 t per annum would be met from purchased coke. Considering
purchase price of equivalent BF coke @ Rs.30,482 / t (average of MMTC price
circular from Nov'17 to Nov’18 duly adjusted for size factor and freight),
reduction in expenditure on account of avoidance of equivalent purchased BF
coke works out to Rs.2,083.16 cr. per annum. Additionally, other credits
considered (reduction in expenditure) per annum are:
Credit for CO gas Rs. 181.37 Cr.
Credit for crude tar Rs. 34.82 Cr.
Credit for electrical power generated from proposed CDCP Rs. 28.62 Cr.
Credit for medium pressure steam generated from CDCP Rs. 42.86 Cr.
Credit for coke breeze generated Rs. 128.46 Cr.
Thus, total benefit works out to Rs. 2,499.28 cr. per annum.
Cost of production of equivalent own BF coke has been computed considering
associated cost of imported & indigenous coal blend (average rate for the period
Nov'17 to Nov'18 as forwarded by Coal Import group) whereas other operating
cost including repair & maintenance and overhead costs have been considered

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same as that of COB # 6, RSP (std. cost sheet 2019-20 of RSP). Considering above,
total production expenditure works out to Rs.1,612.17 cr. per annum.
Based on above, gross margin works out to Rs.887.11 cr. per annum. Detail of gross
margin calculation is shown at Annexure – 6.5.1-1.
6.6 FINANCIAL ANALYSIS:
6.6.1 Cash flow analysis has been carried out for 24 years considering the life of project
of 20 years after its commissioning.
6.6.2 Techno-economic indices are presented at Annexure - 6.6.2-1. Some of the
important indices are indicated below:
NPV @ 10% (Post tax) : Rs. 2,539.53 cr.

IRR (Post tax): 27.22 %

6.6.3 Market price of BF coke is volatile and fluctuates abnormally which gives wide
variation in techno-economic indices.
6.6.4 Sensitivity analysis has been carried out as follow:
Item IRR (Post tax)

Capital Cost (+)10% 25.16%

Gross Margin (-) 10% 25.29%

Combined effect of above 23.35%

Purchase price of BF Coke (-) 5 % 24.94%

CAPITAL COST & FINANCIAL ANALYSIS

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7. RECOMMENDATIONS
7.1 Installation of the proposed stamp charge Coke Oven Battery No. 7 along with
CDCP and by-product plant is to be taken up for meeting the quantity and
quality requirements of coke for the bigger Blast Furnace No.-5 and as a
replacement battery for COB#6 during its repair and rebuilding. The battery will
be operated with cheaper coal blend resulting in lower production cost. The
project is techno-economically viable and recommended for implementation.

RECOMMENDATIONS

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 ANNEXURE NO. 2.1.5-1

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PAGE NO. 1 OF 6
 ENHANCING THE STEEL MAKING CAPACITY IN RSP

ROURKELA STEEL PLANT, ROURKELA

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

AUGUST 2020 CET/05/RN/4706/FR/ST/01/R=0

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 Experience that delivers

This document has been prepared for Rourkela Steel Plant, Rourkela by:

Centre for Engineering & Technology

Pradip Kumar Thakur – HOD Lead section

Pradip Kumar Tamaria (Task Force Leader)
Bajrang Lal Agrawal Steel
Feroz Khan Steel
Satyendra Kumar Gupta Steel
Rahul Mishra Steel
Aslam Ansari Steel
Milind Kumar Verma Steel
[Link] Refractory
Surendra Prasad Refractory
Ravindra Kumar Verma PFC
S. K. Meher Electrical
Ms Ruma Bharti Electrical
Yogesh Kumar Patel Process Control & Automation
[Link] Rourkela Sub-Centre
[Link] Rourkela Sub-Centre
[Link] Rourkela Sub-Centre
Babul Debnath Rourkela Sub-Centre
Raghunath Roy Structural
[Link] Structural
[Link] Structural
A Rituraj Mechanical
Ajay Kumar Mechanical
Sanjay Kumar Mechanical
Akshay Kumar Dubey Rolling Mills
Hemmu Toppo Civil

140
Raju Jaiswal Civil
Gautam Dutta Civil
Ravi Ranjan Kumar Utilities & Services
Anand Trivedi Utilities & Services
Manish Kumar Utilities & Services
M. K. Mishra Cost Techno-Economics & Budget

Document Identification No. CET/05/RN/4706/FR/ST/01/R=0

REVISION HISTORY

Revision No. Brief Description Revision Date

R3

R2

R1

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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 Experience that delivers

UPSHOT
Present potential production capacity of Blast furnaces (BFs) is 4.65 Mtpa hot metal (HM).
Existing steelmaking capacity of RSP is 4.2 Mtpa (SMS-I + SMS-II). With the installation of
proposed 4th Slab caster at SMS II, RSP will produce 3.7 Mtpa of cast slab. The requirement
of down streams mills is 4.53 Mtpa of cast slab. Thus, there is imbalance among the HM
capacity, steel capacity and slab requirement of Mills. SMS-I has become old & obsolete &
it has many constraints to be able to consume the rated capacity of 0.5 Mtpa of Hot metal.
Also due to stringent environmental norms, it is required to be closed down.
For the above reason it is required to be enhance the steelmaking capacity of RSP to fully
utilise the hot metal produced upstream & fulfilling the requirement of downstream mills.
Out of the available HM of 4.65 Mtpa, 3.7 Mtpa will be consumed by SMS-II. The balance
0.87 Mtpa (with the closure of SMS-I) is required to be converted to steel by a new SMS i.e.
the proposed SMS & CCM. This will produce special grade steel.
The project is envisaged to be executed through a numbers of packages due to different
nature of work. Enabling packages will be executed to make available the space to install
the SMS and CCM shop.
The project will be commissioned in 57 months from the date of stage II approval. Seven
days (7) of shutdown is required for implementing of this project. Loss of production due
to shutdown has not been considered since the shutdown is envisaged to be synchronised
with the capital repair period of SMS-I.

The estimated capital cost net of input tax credit (ITC) is Rs. 2896.70 Crore with an IRR and
NPV of 12.80 % and Rs. 370.09 Crore respectively.

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.4

2 Background 2.1-2.5

3 Selection of Alternatives 3.1

4 Project Description 4.1-4.182

5 Implementation Schedule & Strategy 5.1-5.3

6 Capital Cost & Financial Analysis 6.1-6.6

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure No. Description No. of pages

2.1.14-1 Letter from Client 4

2.1.15-1 Letter of Acceptance of Assignment 1

[Link].-1 Material Flow of RSP (Base Case) 1

[Link].-2 Material Flow of RSP (Proposed Case) 1

4.12.1-1 Risk Assessment 1

5.1.2-1 Implementation Schedule- After Stage I 1

Approval

5.1.2-2 Implementation Schedule- Post Stage-II 1

Approval Activity

6.1.1-1 Summary - Capital Cost Estimate 1

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DRAWINGS

Sl. No. Drawing No. Description

1. CET RN 4706 CE0 00 004, R=0 Enhancing The Steel Making Capacity of RSP-
SHEET 1 OF 1 R=0 Location of Proposed Facilities

2. CET RN 4706 ST2 00 001, R=0 Layout of BOF and CCM Shop
SHEET 1 OF 2

3 CET RN 4706 ST2 00 001, R=0 Layout of BOF and CCM Shop- Cross Section A-
SHEET 2 OF 2 A and B-B

4 CET RN 4706 EE1 00 001, R=0 Single Line Diagram of Power Distribution
SH. 1 OF 2 Scheme

5 CET RN 4706 EE1 00 001, R=0 Single Line Diagram Of Power Distribution
SH. 2 OF 2 Scheme

6 CET RN 4706 UT1 00 007 R=0 Rerouting of Mixed Gas Line & Steam Line at
Proposed SMS and CCM Shop

7 CET RN 4706 UT1 00 008, R=0 Rerouting of Make –Up Water Line

8 CET RN 4706 UT1 00 005, R=0 Mixed Gas Tapping & BOF Gas Supply Points

9 CET RN 4706 UT1 00 006, R=0 Steam Line Tapping from CPP-1

10 CET RN 4706 UT1 00 001, Process Flow Diagram for Water Systems
R=0,

11 CET RN 4706 UT1 00 002, R=0 Process Flow Diagram for Water Systems

12 CET RN 4706 UT1 00 003, R=0 Process Flow Diagram for Water Systems

13 CET RN 4706 UT1 00 004, R=0 Utility System Layout

14 CET RN 4706 UT1 00 009, R=0 Schematic Flow Diagram of BOF Gas Recovery
& Cleaning System

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15 CET RN 4706 UT1 00 010, R=0 FES Process Flow Diagram

16 CET RN 4706 CA1 00 001, R=0 Proposed Automation System Configuration

Diagram of Hot Metal De-sulphurisation Unit at
Proposed SMS & CCM shop.

17 CET RN 4706 CA1 00 002, R=0 Proposed Automation System Configuration

Diagram of BOF Converter at proposed SMS &
CCM shop.

18 CET RN 4706 CA1 00 003, R=0 Proposed Automation System Configuration

Diagram of Ladle Furnace at Proposed SMS &
CCM shop.

19 CET RN 4706 CA1 00 004, R=0 Proposed Automation System Configuration

Diagram of RHOB at Proposed SMS & CCM
shop.

20 CET RN 4706 CA1 00 005, R=0 Proposed Automation System Configuration

Diagram of Slab Caster at Proposed SMS &
CCM shop.

21 CET RN 4706 CA1 00 006, R=0 Network Interface Diagram for Proposed SMS
& CCM shop.

22 CET RN 4706 RE0 00 001, R=0 Flux Production Process Flow Diagram (Typical)

23 CET RN 4706 RE0 00 002, R=0 Proposed Location of Lime And Dolo
Plant(Typical)

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1. SUMMARY

1.1 Rourkela Steel Plant (RSP), a unit of Steel Authority of India Limited (SAIL),
presently has two Steel Melting Shops (SMS). Both Steel Melting Shops (SMS)

BACKGROUND
have BOF converters, secondary steel making facilities and slab casters.

1.2 Major technological facilities installed for steel making and continuous
casting at RSP are as given below :

Facilities SMS-I SMS-II

HM De-Sulphurization 6 x 80t BF ladle 2 x 150 t

unit

Primary steel making 2 x 66 t BOF 3 x 150 t BOF

facilities (nos. x heat size)

Secondary steel making 1 x 66 t VOR, 1 x 150 t ARS,

1 x 66 t VAR, 3 x 150 t LF
facilities (nos. x heat size)
1 x 66 t LF 1 x 150 t RH-OB

Continuous Casting 1 x 1-strand slab caster 3 x 1-strand slab

Facilities casters

1.3 A number of projects have been executed under recently concluded the
Modernization & Expansion Plan (MEP) of the plant. In the modernization,
RSP has included new units as well as revamped some of the existing units.
After modernization, envisaged production scenario is as follows :

SMS-I (crude steel) : 0.5 Mtpa

SMS-II (crude steel) : 3.7 Mtpa
Total (crude steel) : 4.2 Mtpa (CC Slabs)
Saleable Steel : 3.99 Mtpa (including semis)

1.4 Introduction of 3rd BOF in the recent MEP has enhanced the capacity in SMS-
II to produce 3.7 Mtpa crude steel. However, existing three casters
downstream can produce only 3.3 Mtpa of crude steel. After installation of

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the proposed 4th slab caster at SMS-II, it will have flexibility to fully utilize the
tapped liquid steel from BOFs.

1.5 The average of last 3 years production of SMS-I is 0.35 Mtpa and that of
SMS-II is 3.10 Mtpa. The production of SMS-I has deteriorated since
BACKGROUND

inception due to aging, obsolescence & inherent design limitation.

1.6 Present potential hot metal capacity of RSP with three Blast Furnaces is 4.65
Mtpa. Combined production from SMS-I and SMS-II for last year i.e 2019-20
is 3.50 Mtpa. The slab requirement for mills is 4.53 Mtpa [with the installation
of new Hot Strip Mill (HSM]; which is under stabilization]. There is an
imbalance among the HM production, crude steel production and slab
requirement of mills. Further, RSP has also planned to stop the production
from SMS-I.

For the above reason it is required to be enhance the steelmaking capacity of

RSP to fully utilise the hot metal produced upstream & fulfilling the
requirement of downstream mills.

1.7 PROPOSAL
1.7.1 A new SMS and CCM shop have been envisaged to enhance the steelmaking
capacity at RSP. The proposed shop will bridge the gap between Hot Metal
production, crude steel production and slab requirement of mills. The
proposed shop will be capable of producing value added steel like API
grades, boiler quality, extra deep drawing (EDD), structural steel, steels for
SWPP / ERW PP / tin plates / galvanised sheets, chequered plates, SAILMA,
HSLA, micro alloyed high tensile strength steel etc.
1.7.2 The proposed SMS and CCM shop main facilities are –

Facilities Nos , Capacity

Torpedo ladle car receiving For receiving hot metal from BFs by 350 t
station Torpedo ladle car
De-Sulphurisation unit 1x150t
BOF converter system 1x150t
Ladle Furnace 1x150t
RH-OB unit 1x150t
Slab Caster 1x1 strand slab Caster [ Design- slab
thickness : 220 - 250 mm; and width : 950
– 1850 mm; length : 6 – 10 m]

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1.7.3 Production planning (potential) cast slab/ crude steel will be as given below:

BACKGROUND
Heat size 150 t (nominal); 165 t (max.).
Tap to tap time 40-50 min approx.
No. of heats per day 24 (nominal)
No. of working days /year 320
Slab Thickness 220 mm (Machine Designed up to 250
mm)
Slab width 950 to 1850 mm
Yield (liquid to cast) 98.5 %
Annual production (potential) 1.15 Mtpa cast slab

1.8 PACKAGES IMPLEMENTATION

1.8.1 The project is proposed to be executed through following packages:
Packages Package No. Brief of Work
Enabling Package-I Enabling Works – Dismantling and
Package Relocation of Facilities
Package-II A Area Survey & Soil Investigation for
Enabling Packages
Package-II B Underground Mapping for Enabling
Packages
Package-II C Area Survey & Soil Investigation for Main
Package
Package-II D Underground Mapping for Main Package
Package-III A Installation of New Building - ED(W)
Package-III B Installation of New Building - RCL
Package-IV Rerouting of Power Supply
Package-V Rerouting of Utilities Facilities
Installation Package-VI Enhancing the Steel Making Capacity in
Of New RSP
Facilities Package-VII Calcined Lime and Dolo Plant for New
SMS
Package-VIII New Rail track connection
1.8.2 Package-II A: Area Survey & Soil Investigation and Package II B: Underground
Mapping has RSPs under consideration for tender out.

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1.8.3 The project is envisaged to be implemented in a period of 57 months from

the date of Stage-II approval. Pre-ordering activities are envisaged to be
completed within 6 months from the date of Stage-I approval. Seven days (7)
of shutdown is required for construction of new lime and dolo conveyer line
interconnection with the existing SMS-I lime and dolo conveyer.
BACKGROUND

1.9 Estimated capital cost net of input tax credit (ITC) is Rs 2896.70 Crore at an
IRR and NPV of 12.80 % and Rs 370.09 Crore respectively.
1.10 The project is technically feasible and financially viable. Hence, it is
recommended for implementation.
1.11 The co-operation and assistance received from RSP in preparation of this
report is gratefully acknowledged.

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2. BACKGROUND

2.1 EXISTING FACILITIES AND PRODUCTION

BACKGROUND
2.1.1 Rourkela Steel Plant (RSP), a unit of Steel Authority of India Limited (SAIL),
has two Steel Melting Shops (SMS). Both the Steel Melting Shops (SMS) have
BOFs, secondary steel making facilities and slab casters. Both the shops
follow BF-BOF-Slab CC route to produce cast slabs. The slabs are the inputs
for old and new Hot Strip Mills (HSM). Final products at RSP include HR coils,
CR coils, Plates and Pipes.

2.1.2 Major technological facilities in SMS for steel making and casting at RSP are
as given below:

Facilities SMS-I SMS-II

HM De-Sulphurization unit 6 x 80t BF ladle 2 x 150 t
Primary steel making facilities 2 x 66 t BOF 3 x 150 t BOF
(nos. x heat size)
Secondary steel making 1 x 66 t VOR, 1 x 150 t ARS,
facilities (nos. x heat size) 1 x 66 t VAR, 3 x 150 t LF
1 x 66 t LF 1 x 150 t RH-OB
Continuous Casting Facilities 1 x 1-strand slab 3 x 1-strand slab
caster casters

2.1.3 Present Rated Capacities Of The Various Finishing Mills at RSP are Given
Below:

Sl. Mill Installed capacity

(slab throughput)
1 New plate mill 1.00 Mtpa
2 Old plate mill 0.53 Mtpa
3 New Hot Strip Mill (HSM #2) 3.00 Mtpa
4 Old Hot strip mill (HSM #1) After commissioning of HSM #2,
HSM#1 will be closed
Total capacity 4.53 Mtpa

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2.1.4 To Feed The Mills as Stated Above Crude Steel Production /Capacity of
RSP Will Be As Follows:

Sl. Description Crude Steel Capacity

BACKGROUND

1 SMS-I (after closure of the shop) Nil

2 Existing production from SMS-II 3.3 Mtpa
3 Capacity of SMS-II after the 3.7 Mtpa
installation of CCM # 4
Net crude steel capacity 3.7 Mtpa (Slabs)

2.1.5 Hence, balance requirement of slab for feed to the existing mills shall be 0.83
Mtpa (4.53 Mtpa - 3.7 Mtpa= 0.83 Mtpa). Thus, it is necessary to install
additional shop facilities in from of a new SMS and CCM shop to produce
0.83 Mtpa slabs.
2.1.6 The average consumption of HM is 1.020 t for the production of 1 ton of
crude steel (slab). Hot metal production and consumption figures, with the
closure of SMS-I, are given below:

Sl. Hot Metal Capacity Balance HM Available

1 As per MEP (Modernisation and 4.50 Mtpa
expansion plan)
2 As per production potential 4.65 Mtpa
3 Hot metal requirement for SMS-II 3.77 Mtpa
4 Hot metal available for Proposed 0.88 Mtpa
SMS and CCM Shop
5 Total hot metal requirement 4.65 Mtpa
(SMS-II and Proposed SMS)

The HM production from the existing blast furnaces can be enhanced in

future by adopting prepared burden practice such as a mixture of sinter and
pallets. Thus with the installation of pellet plant in future, the HM capacity
from the existing BFs will be enhanced. The proposed SMS and CC shop has
potential to take up the enhanced hot metal from BFs, though, downstream
facilities like mills etc. needs to be augmented/ upgraded to take up the
enhanced output of SMS and CC shop.
2.1.7 The production potential of RSP after the completion of ongoing
modernisation is as follows:
Hot metal : 4.5 Mtpa (Net)
Pig Iron : 0.542 Mtpa

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SMS-I (crude) : 0.5 Mtpa

SMS-II (crude) : 3.7 Mtpa (revamping of Caster#1&2)
Total (crude) : 4.2 Mtpa (CC Slabs)

BACKGROUND
Saleable Steel : 3.99 Mtpa (including semis)
2.1.8 Grades of Steel
Following main grades of steel are produced in RSP:
“Boiler Quality, Extra Deep Drawing (EDD), Structural steel, steels for SWPP /
ERW PP / Tin plates / Galvanised sheets, Chequered plates, commercial
quality of steel, CRNO, API-5Lx-70 (up-to), SAILMA, HSLA, micro alloyed high
tensile strength steel” .
2.1.9 Existing Production
Production performance, for the last three years, of both the SMSs in terms
of steel slabs is given below:
Year SMS-I (Mtpa) SMS-II (Mtpa) Total(Mpta)
2017-18 0.34 2.88 3.22
2018-19 0.37 3.28 3.65
2019-20 0.35 3.15 3.50
Avg. of last 3 years 0.35 3.10 3.46

2.1.10 Constraints and Analysis

[Link] Present hot metal capacity of RSP with three Blast Furnaces is 4.65 Mtpa.
After installation of proposed 4th slab caster in SMS-II the total crude steel
capacity (SMS-I + SMS-II) will be 4.2 Mtpa. After commissioning of new HSM,
the mills will require 4.5 Mtpa of slabs. Thus, there will be an imbalance
among hot metal production, crude steel production and slab requirement of
Mills.
[Link] Performance of SMS-I has decreased with times and operating conditions
have also deteriorated. Further, because of inherent design limitation of the
equipment, the cost of production at SMS-1 is high. The recent modifications
in GCP system are not able to meet stringent environment norms. Thus, the
SMS-1 will have to be taken out of production due to above technical,
techno-economic and environmental reasons. Following constraints will be
faced on closing the SMS-I:
· Shortage of 0.5 Mtpa of slabs for feeding to the mills. In such case,
this quantity of slabs will have to be purchased by RSP to fully utilised
the mills.

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· Pig iron production will increase (up to the capacity of existing pig
casting machines) due to closing down of SMS-I operation.
[Link] In SMS-II, the old De-sulphurization facility is defunct. There is another offline
De-sulphurization facility in operation. Because of the logistics of BOF shop,
BACKGROUND

feeding/ lifting of hot metal to the De-S station interrupt hot metal charging
operation in the converter bay. This often results in idle time of converters.
Hence, with single De-S unit, it is difficult to cast low 'S' grades of steel
continuously in single sequence particularly in the high-speed caster (3rd
Caster). Thus, lack of capability for mass production of extra low 'S' steel at
RSP is a big bottleneck.
[Link] Presently CRNO heats are being made at SMS-1, which will be closed down
in future. In SMS-II, RH-OB unit is located at one end of the secondary steel
making bay. The shop logistics, particularly the overhead crane movement
while handling heats at RH-OB, is a constraint in achieving its rated capacity
of treatment of 1.0 Mtpa of liquid steel. Further longer treatment time to
produce CRNO grades steels and complex shop logistic are affecting the
productivity of the SMS-II severely.

[Link] Special grade steels having low ‘S’ and low dissolved gasses require both De-
S treatment of HM and vacuum treatment of liquid steel at RH-OB. In such
cases, the overall processing time is very high in SMS-II thus affecting the
productivity. In case of special steels like DMR301, DMR249, and API X-70,
the average duration from the start of De-S to end of casting heats is very
high.

2.1.11 This proposal is based on the following consideration/ assumptions

· HM production potential of BFs- 4.65 Mtpa
· SMS-I closing down after installation of proposed SMS.
· SMS-II, crude steel production will be 3.7Mtpa with the installation of
4th slab caster at SMS-II.
· The proposed SMS shop is required to bridge the gap of imbalance
· Pig Casting Machine closing down.
· Supply of HM to proposed shop by Torpedo ladle car.
· Power and Utilities available as per requirement of proposed SMS
and CCM shop.
· Environmental clearances as required will be taken up by RSP for
installation of proposed SMS and CCM shop before project
implementation.

2.1.12 Need and objective

[Link] Need

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Keeping in view the above constraints, following debottlenecking measure

are being proposed:
a. Enhancement of steel-making capacity through installation of a new steel
melting shop (Proposed SMS and CCM Shop) of suitable capacity to take

BACKGROUND
care of the capacity imbalance among hot metal, crude steel and slab
requirement at mills.
b. Closure of operation at SMS-I after stabilizing production at the new SMS
Shop.
c. Enhancement of capability to produce long sequence casting of special
steels including CRNO grades at the new SMS and CCM shop. The logistic
would facilitate desulphurization of 100% of hot metal without affecting
the charging schedule of Converters and also the sequential feeding of
degassed/ decarburized steel to the casters for special grades.
d. Presently the demand of special quality degassed steel such as higher
grade of API grade is increasing. Moreover over the order for defense
grade steel is also increasing. Such steel needs degassing and hence the
steel should be treated in RH-OB. At SMS-II, the capacity of producing
degassed steel has come to a saturation (around 0.8 Mtpa), hence to
capture the emerging market of degassed steel it is essential to have a
separate shop having degassing facility.
[Link] Objective
Main objective of the proposal is to enhance the steel making facility for
removing imbalance among hot metal capacity, crude steel capacity and slab
requirement. In addition, special grade steel requiring De-S treatment &
Vacuum treatment can be produced with improved logistics resulting in
shortened processing time.
2.1.13 On request of RSP , a “Technical Note (TN)” on proposal of enhancing the
steel making capacity in RSP was submitted by CET in February’ 2020 (
Document no. CET/05/RN/SMS-III/TN/ST/01/R=1).
2.1.14 Subsequently, RSP requested CET vide letter no. AMR-
M&SC/Consultancy/19.02.2020, Note sheet no. SMS-1/2077 dated 18-
02-2020 to prepare feasibility report (FR) & technical specifications (TS) for
enhancing the steel-making capacity in RSP. A copy of the above is placed at
Annexure 2.1.14-1.
2.1.15 After examining the scope of work and understanding the complexity of the
job, CET accepted the assignment vide letter no. CET- 17(3)/018/18/137
dated 21/03/2018. A copy of this is placed at Annexure 2.1.15-1.
Accordingly, this FR has been prepared.

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3. SELECTION OF ALTERNATIVES
3.1 As the requirement of RSP is specific to utilise the excess HM available from
its existing BFs and after closing SMS-I, the only alternative for RSP is to
process the HM from BFs through the conventional, proven & popular HM-
BOF-LF-CCM route only. Thus no other alternatives have been considered.
3.2 In the year 2018, CET had submitted a FR for setting up a SMS-III outside the
plant boundary of RSP. The SMS-III was a part of the expansion proposal
under SAIL Vision 2030 to produce 5.0 Mtpa crude steel. The SMS-III was
envisaged to be installed in two phases. In the 1st phase the balance hot
metal available from the existing BFs was envisaged to be converted into 1.1
Mtpa of CS. In the 2nd phase additional steel making facilities were envisaged
to be set up in the same shop to produce 3.9 Mtpa crude steel.
3.3 RSP has apprehension to acquire land outside the plant boundary and hence
the they suggested to put the 1st phase plant inside the plant boundary.

PROJECT DESCRIPTION
3.4 A due diligence was carried out to find a suitable location for setting up a
new SMS within plant boundary. After lot of deliberation between CET and
RSP, a site beside SMS-I, have been selected for installation new SMS. Thus
no alternative has been envisaged for preparing this proposal.
3.5 The proposed site for installing a new SMS near existing SMS-I will have the
following advantages:
a) The proposed site is having good railway connection for receipt of
scrap, Hot Metal. It has also good railway connection for despatch of
slabs to rolling mill.
b) Power and various utilities are readily available in the proposed site
which are prerequisites for the new SMS.
3.6 However, the proposed site will have disadvantage due to the fact that the
SMS cannot be expanded in future due to space limitation. Even after the
closing and dismantling of existing SMS-I additional steelmaking and casting
facilities such as thin slab casting and direct rolling cannot be installed due to
space & logistics constraint.

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4. PROJECT DESCRIPTION
General
The present proposal is for conversion of excess HM into 0.83 Mtpa crude
steel with future provision in the design of the shop to enhance the
steelmaking capacity. Following Primary and secondary steel making
facilities are envisaged are to produce the desired crude steel:
a. De-sulphurisation unit
b. BOF converter
c. Ladle Furnace
d. RH-OB
e. Slab caster

In addition to the above main facilities auxiliary facilities are also required.
Thus a site has to be selected to accommodate the main and auxiliary

PROJECT DESCRIPTION
facilities.

Selection of Site at RSP

The proposed site for installation of new SMS and CCS shop selected at
Open-Hearth Furnace area of SMS-I. Associated facilities of proposed SMS
and CCM shop will be installed at existing Steel Foundry & Grey Iron Foundry
area.
The proposed project site selected is presently occupied by various
installations/ facilities. Installations (over ground and underground) of
electrical, utilities, mechanical, civil and structural building, rail tracks are
present in the proposed site.
The proposal of installation of new SMS and CC Shop requires clearing /
vacating the area; where existing facilities are interfering to the proposed
installations. Some of the existing facilities are required to be rerouted to
avoid stoppage of SMS-I production.

The project is envisaged to be completed through mainly Enabling works

packages and New facilities installation packages. Due to different nature
of work; the enabling packages are subdivided in to no’s of packages for ease
of execution. The details of package distribution are as follows:

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Table 4-1
Packages Package No. Package Name
Enabling Package-I Enabling Works – Dismantling and
Package Relocation of Facilities
Package-II A Area Survey & Soil Investigation for Enabling
Packages
Package-II B Underground Mapping for Enabling
Packages
Package-II C Area Survey & Soil Investigation for Main
Package
Package-II D Underground Mapping for Main Package
Package-III A Installation of New Building - ED(W)
Package-III B Installation of New Building - RCL
Package-IV Rerouting of Power Supply
Package-V Rerouting of Utilities Facilities
PROJECT DESCRIPTION

Installation Package-VI Enhancing the Steel Making Capacity in RSP

Of New Package-VII Calcined Lime and Dolo Plant for New SMS
Facilities Package-VIII New Rail Track Connection

The brief descriptions of various packages are as described below : -

ENABLING PACKAGES: -
1) Package-I : Enabling Works – Dismantling and Relocation of
Facilities
a) The location of the proposed new Steel Melting Shop complex along
with its associated facilities has been envisaged to be located
adjacent to existing SMS-I Converter shop as well as adjacent to
Continuous Caster Machine Shop of SMS-I, on the North-eastern side
areas towards Foundry Shop complex.
b) The proposed location is in a totally deep-Brown-field area where
there exist a number of operating/ production units, Rail tracks,
Utility Pipe lines, various buildings of major importance.
c) Almost all these existing facilities just cannot be dismantled without
prior installation of alternate arrangement / rerouting / relocation
work.
d) Dismantling of existing units/installations/facilities and Prior Re-
routing / relocation / Alternative arrangement of these facilities have
been envisaged under Package No. I , considering following
modalities:

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· To facilitate continuity of regular production from SMS-I shop

during site execution work for installation of new SMS.
· Alternative arrangement for existing production units.
· Relocation of Building complex with facilities which are directly
or indirectly linked with plant production and also to meet
technological & administrative requirement of Rourkela Steel
Plant.
e) Following are the list of major existing units / facilities which need
complete dismantling and disposal for creating space for installation
of new SMS shop & associated facilities:
1. Dismantling of Pig Casting Machine-I (PCM-I) Shop complex
2. Dismantling of Part of SMS-I Shop Building

PROJECT DESCRIPTION
- Part of the shop building of approx. 175 m length is required
to be dismantled.
- Dismantling will cover the redundant area where Open Hearth
Furnaces were earlier installed and phased out.
3. Dismantling of Rail tracks for feeding scrap to SMS-I shop floor at
+7.5 M level through wagons
- This need alternate route for continuity of production
- Alternate route for scrap feeding through trucks & dumpers
on road ramp has been considered, which will be constructed
prior to dismantling of existing tracks.
4. Dismantling of Rail tracks for feeding Hot metal to SMS-I.
- Hot metal feeding track to Mixer #1 will be dismantled.
- Hot Metal feeding tracks to Mixer-3 will only be operational
for continuing operation of SMS-I
5. Dismantling of Conveyor gallery for Calcined Lime/ dolomite, for
feeding SMS-I shop
- Needs alternate route for lime/dolomite feeding conveyor for
continuity of production
- New conveyor system has been considered for installation
through diverted route prior to dismantling of existing
lime/dolomite conveyor.
6. Dismantling of Road / Ramp for access to SMS-I Shop floor at
+7.5 M level

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- Need alternative access road/ramp.

- New Ramp has been considered prior to dismantling.
7. Dismantling of Yard Utility Pipe Lines
- Mixed Gas Fuel line, Steam Line, Nitrogen line feeding to SMS-
I, LDBP shop and Oxygen Lines for feeding Blast Furnaces # 1
& 4.
- New Utility pipe lines will be installed through alternate route,
under Package No.V, prior to start of dismantling of existing
lines.
8. Dismantling of Rail Tracks for dispatch of Cast slabs of SMS-I to
Mills
- New rail track for alternate route has been envisaged, which
will be constructed before dismantling of existing slab
PROJECT DESCRIPTION

despatch track.
9. Dismantling of Mould Yard shop building [Along with Mould &
Segment repair facilities of SMS-I Caster Shop and Slab cutting /
Scarfing facilities]
- Relocation of Mould & Segment Repair facility has been
considered.
- Slab cutting / scarfing activities will be relocated by RSP
departmentally.
10. Dismantling of Electrical Substation : T-Off substation (33 kV)
- This substation feeds Power to Transformer of VAD (Vacuum
Arc De-gassing) Substation of SMS-I and also feed power to
NSP Transformer in Sintering Plant-I
- Alternative power feeding arrangement for VAD & NSP at SP-I
will be installed (under separate [Link]. IV), before
dismantling. Dismantling will be under [Link].I.
11. Dismantling of Field breaker substation : In SMS-I shop
- This substation feeds Power to Field Breaker stations (415 V) of
Hot metal & Pit Side cranes of SMS-I
- Alternate arrangement of power feeding arrangement will be
installed, under [Link]. IV, prior to dismantling. Dismantling
will be under Pkg.I
12. Dismantling of Foundry Shop Complex : Grey Iron Foundry &
Steel Foundry

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- Complete dismantling has been envisaged. No relocation work

has been considered.
13. Dismantling of ED (Works) Building complex
- New building will be constructed under Pkg. No. IIIA, before
dismantling. Dismantling will be under Pkg. No. I
14. Dismantling of Research, Control & Lab (RCL) Building
- New building will be constructed under Pkg. No. III B, before
dismantling. Dismantling will be under Pkg. No.I
15. Dismantling of Stripper Yard building along with rail tracks in the
area
- Complete dismantling. No relocation
16. Dismantling of SMS-I Office building complex

PROJECT DESCRIPTION
- New building will be constructed before dismantling.
17. Dismantling of Marammat Bhawan, Crane Uddyan / Crane
maintenance office building
- Construction of new buildings have been considered, before
dismantling
18. Dismantling of LU-OP, Stock control/ Stock verification office
building, CISF Building (near Foundry), Canteen buildings
- New buildings for relocation are considered.
19. Dismantling of Office building complex of Foundry shop, RCM
shed (near Foundry) & Various temporary stores/ sheds, PCBs etc.
in the area
- Complete dismantling. Relocation is not considered.
20. Dismantling of Part of Repair Shop Mechanical (RSM) [Adjacent
to Power Distribution / SLCC building].
2) Package-II A: Area Survey and Soil Investigation for Enabling Packages
Area Survey and Soil Investigation has been envisaged within the battery
limit of proposed SMS and CC Shop and its periphery. It also covers the
areas where all linked associated facilities will be installed. Rout survey
from MSDS-VII to new MSDS-VIII for installation of new transmission
line/cable is also included. The surface and sub-soil information will be
obtained through this package.
The package is prerequisite to enable other packages to create space
for proposed SMS and CC shop. The report obtained through this

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package will be provided to bidders for better planning, engineering and

execution of Enabling Packages I, III A, III B, IV and V.

3) Package-II B: Underground Mapping for Enabling Packages

Underground mapping has envisaged within the battery limit of proposed
SMS and CC Shop and its periphery. It also covers the areas where all
linked associated facilities will be installed.
The package is prerequisite to enable other packages to create space
for proposed SMS and CC shop. This package execution will avoid
interference of underground facilities in the proposed site of SMS and
CCM shop and its associated facilities. The report obtained through this
package will be provided to bidders for better planning, engineering and
execution of Enabling Packages I, III A, III B, IV and V.

4) Package-II C: Area Survey and Soil Investigation for Main Packages

PROJECT DESCRIPTION

Area Survey and Soil Investigation has been envisaged within the battery
limit of proposed SMS and CC Shop and its periphery. It also covers the
areas where all linked associated facilities will be installed. The surface
and sub-soil information will be obtained through this package.
The package is prerequisite for installation of proposed SMS and CC
shop. This package will be executed at the end of Package-I completion.
The report obtained through this package will be provided to bidders for
better planning, engineering and execution of Enabling Packages VI and
VII.
5) Package-II D: Underground Mapping for Main Packages
Underground mapping has envisaged within the battery limit of proposed
SMS and CC Shop and its periphery. It also covers the areas where all
linked associated facilities will be installed.
The package is prerequisite for installation of proposed SMS and CC
shop. This package will be executed at the end of Package-I completion.
This package execution will avoid interference of underground facilities in
the proposed site of SMS and CCM shop and its associated facilities. The
report obtained through this package will be provided to bidders for
better planning, engineering and execution of Enabling Packages VI and
VII.

6) Package-III A: Installation of New Building - ED(W)

To make space for the proposed SMS and CCM shop, existing ED works
building is required to be shifted from the present location. It is
considered that an area of about 90m X 85m is available in the close
vicinity of plant networks (road, sewage and water supply) without any
significant over-ground & underground hindrances.

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The proposed building is envisaged to be a three storied (G+2) RCC

framed construction with brick cladding walls including all serviceability
requirements such as finishes, water supply & sanitation, electrical works,
fire-fighting & detection works etc.

7) Package-III B: Installation of New Building – RCL

To make space for the proposed SMS and CC shop, existing R&C Lab
building is required to be shifted from the present location. It is
considered that an area of about 125m X 50m is available in the close
vicinity of plant networks (road, sewage and water supply) without any
significant over-ground & underground hindrances. This will be taken up
as one of the first activities in the project and only after all facilities of this
building are completed and becomes operational, the existing building
can be taken up for dismantling to make space for proposed SMS and CC
shop.

PROJECT DESCRIPTION
The proposed building is envisaged to be a three storied (G+2) RCC
framed construction with brick cladding walls including all serviceability
requirements such as finishes, water supply & sanitation, electrical works,
fire-fighting & detection works etc.

8) Package-IV: Rerouting of Power Supply

Various electrical equipment/ facilities/ cables of SMS –I interfering with
the proposed SMS and CCM shop site. Therefore, diversion/ relocation of
existing Power Distribution facilities / cables are envisaged to be rerouted.
Major installation/ relocation/ diversion are
i) T-Off substation relocation
ii) Field breaker substation relocation
iii) Diversion of Existing Cables and HT/ LT Power and Control Cables
iv) Rerouting of telecommunication cables.

9) Package-V: Rerouting of Utilities Facilities

Utilities service lines are interfering with the proposed SMS and CCM site.
These pipes are envisaged to be rerouted to avoid the stoppage of SMS-I
production. Gas pipe lines such as mixed gas, steam line, oxygen line,
nitrogen line and make up water ring main, make up water tec. service
lines considered to be rerouted.

INSTALLATION OF NEW FACILITIES:

1) Package-VI: Enhancing the Steel Making Capacity in RSP
The packages envisaged to install a complete new SMS and CC shop. It
covers installation of new shop building, primary and secondary steel
making units along with associated facilities.

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Primary and secondary steel making facilities envisaged are as follows:

a. De-sulphurisation
b. BOF converter
c. Ladle Furnace
d. RH-OB
e. Slab caster

For the above facilities installations; necessary associated facilities cover

mechanical equipment’s, utilities, electrics, instrumentation and
automation, refractories, civil and structural etc. are also been envisaged
in this proposal.

2) Package-VII: Calcined Lime and Dolo Plant for New SMS

For catering input flux requirement to new SMS, it is proposed to install a
new calcined lime and dolo plant consisting of two new shaft kilns of
PROJECT DESCRIPTION

capacity 300 tpd (for lime) & 150 tpd (for dolo) each including all
associated facilities in the vicinity of existing LDBP area of RSP. Transport
of above items/materials via conveyer up to proposed location of SMS
has also been envisaged.
3) Package-VIII: New Rail Track Connection
The rail track connection to Proposed SMS and CCM Shop with the
existing plant network has been envisaged under this package. It has
been envisaged to appoint an expert agency for consultancy and
execution of work under this package
The scope of works under this package for an expert agency will be:

a) Study of the entire system and preparation of Detailed Project report.

b) Preparation of tender specification and tender evaluation.
c) Carrying out Basic and Detail engineering.
d) Supervision and execution of work.
e) Trial and commissioning of new rail tracks.

Package wise details scope of works envisaged are described below in respective
disciplines.

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4.1 LOCATION AND SHOP LAYOUT

4.1.1 Location of RSP is Shown Below

PROJECT DESCRIPTION

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4.1.2 The proposed site for installation of new SMS and CCS shop at Open-Hearth
Furnace area of SMS-I. Associated facilities of proposed SMS and CCM shop
will be installed at existing Steel Foundry & Grey Iron Foundry area. Location
of proposed SMS and CCM shop and its associated facilities are shown in the
Drg No. CET RN 4706 CE0 00 004 R=0 (Enhancing the Steel Making
Capacity of RSP-Location of Proposed Facilities)

Layout of Shop and Location of Proposed Facilities

Layout of New BOF and CCM Shop

The Basic Oxygen Furnace (BOF) and Continuous casting machine (CCM),
shop building comprises of following bays:
• Slag Handling Bay
• Hot Metal (HM) Receipts cum Scrap Bay
• HM Receipts cum Charging Bay
PROJECT DESCRIPTION

• Converter Bay
• Launder Bay
• Ladle& Tundish Preparation Bay
• Secondary Refining cum Turret bay
• Secondary Refining cum Turret bay
• Casting Machine Bay
• Mould and Roller Segment Repair Bay
• Slab Storage cum Despatch Bay (2 no’s)

BOF and CCM shop lay out Drg no. CET RN 4706 ST2 00 001 R=0 Sheet 1
of 2 (Layout of BOF and CCM Shop ) and Cross Sectional Drg No. CET RN
4706 ST2 00 001 R=0 Sheet 2 of 2 (Layout of BOF and CCM Shop- Cross
Section A-A and B-B ) shows the details of shop building and the facilities
envisaged in this project.

Layout of Utilities and Associated Facilities

The associated facilities’ mainly Utilities (water, gas etc.) , Propene Plant and
associated electrical installations are shown in Drg. No. CET RN 4706 UT1
00 004, R=0 ( Utility System Layout)

The proposed BOF and CCM Shop dimensional parameters of the various
bays and the number and approximate capacity of the cranes installed
therein are given in below table Table- 4.1.2-1.

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Table- 4.1.2-1
Bay Dimension Crane
Length, Width, Capacity No.
m m
Slag handling bay AB 210.0 36.0 120+50t EOT Crane 2
Hot Metal (HM) CD 383.0 27.5 280+80/20t EOT 1
receipts cum scrap bay Crane
20 + 20 t EOT 2
Magnet crane
HM receipts cum DE 383.0 26.5 280+80/20t EOT 2
charging bay Crane
60+60t Semi-portal 1
crane

PROJECT DESCRIPTION
Converter bay – lance E’’ E’ 183 15.5 50/10t EOT Crane 1
Handling bay
Converter bay – Ferro EF 383 23.0 20/10t EOT Crane 1
alloy charging bay (183
+200)
Launder bay FG 383.0 11.0 - -
Ladle& Tundish GH 383.0 27.0 120+25/10t EOT 2
preparation bay Crane (Ladle
handling)
120/10 t EOT Crane 1
(Tundish handling)
Secondary refining cum HI 383 30.0 280+80/20t EOT 2
Turret bay Crane
120/25t 1
Casting machine bay IJ 383 27.0 120/25t 2
Mould and roller JK 171.0 33.0 120/25t 2
segment repair bay
Slab storage cum KL 171.0 36.0 70t on tongue – total 2
despatch bay lifting capacity 100t
EOT Crane
Slab storage cum LM 171.0 35.5 70t on tongue – total 2
despatch bay lifting capacity 100t
EOT Crane

Crane technical details are mentioned in Mechanical section of the FR.

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List of main activities in the various bays of the BOF and CCM Shop:-
Sl. Bay Main Activity
No. nomenclature
1. Slag handling - Transfer of slag pots to slag bay by self-
bay propelled slag transfer cars
- Dumping of liquid slag into pits
- Cooling of slag and its removal to final dump
yard
2 Hot Metal - Receipt of hot metal from blast furnaces via
(HM) receipts Torpedo lade car
cum scrap bay - Pouring of hot metal in to HM ladle at
reladling pit
- Sampling and temperature measurement
PROJECT DESCRIPTION

- Hot metal transfer to adjacent bay by inter

connected self-propelled transfer car.
- Receipt of scrap in open-type railway wagons/
dumpers and also by road
- Unloading of scrap from wagons / dumpers
and storing into scrap pits
- Loading of scrap into scrap boxes
- Transfer of scrap boxes on transfer car into
charging bay
3 HM receipts - Receipt of hot metal from blast furnaces via
cum charging Torpedo lade car
bay - Pouring of hot metal in to HM ladle at
reladling pit
- Hot metal desulphurisation- HM treatment
- Charging of hot metal into converters
- Charging of scrap into converters
- Sampling and temperature measurement of
steel (container laboratory)
4 Converter bay - Oxygen blowing and lance hoisting
- Charging of bulk materials into converters
- Charging of ferro-alloys, deoxidizers and lime
into steel casting ladles
- BOF gas collection, cooling and cleaning
Repair of oxygen lances
- Gas stirring during tapping
- Relining of converter and repair of tap holes
5 Ladle & - Cooling of ladle before debricking

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Tundish - Debricking of ladle

preparation - Relining of ladles (HM+ Steel ladle)
bay - Slide gate repair and maintenance
- Preheating of running ladle
- Repairing and maintenance of ladle
- Tundish deskuling
- Tundisc cooling
- Tundish new relining
- Tundish slide gate maintenance
- Tundish preheating
6 Secondary - Receiving of hot metal via transfer car
refining cum - Processing of heat metal
Turret bay - Processed heat transfer to turret of slab caster
7 Casting - Casting machine main control room

PROJECT DESCRIPTION
machine bay - Preheating of tundish
- Casting machine mould preparation for hot
slab casting
- Casting machine primary cooling
- Hot slab rolled through the various segment
- Changing/ replace of mould and segment
- Return of empty tundish after casting
8 Mould and - Mould and roller segment repair and
roller segment maintenance
repair bay - Checking of mould and segment
- Ready segment sends to adjacent bay
9 Slab storage - Hot rolled slab receiving
cum despatch - Piling and air-cooling
bay - Inspection of rolled slab
- Scarfing of rolled slab
- Despatch of air-cooled slabs to mills via rail

Description of Shop Layout

Slag Handling Bay (A-B)
Slag from the converters are slagged-off into slag pots of 18 m3 capacity and
are placed on self-propelled transfer cars operating underneath the
converters.
HM treatment at Desulphurisation unit will generate slag and it will be
transfer to the slag bay by self-propelled slag pot transfer car.

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Slag remaining in the steel ladles after casting operation is tipped into slag
pots. The slag pots are transfer to slag handling bay my means of self-
propelled transfer car.
The slag pots received from the above processing unit are transferred to slag
bay for dumping. Slag pots are of self-supporting design. Slag pot coating
facility has also being envisaged in this bay.
The bay is served by two slag pot-handling cranes of capacity 120 + 50 t.
Remote control facilities will be there in each crane. One crane will be
provided with grab buckets and the other one without grab bucket.
HM Receipt cum Scrap Bay (C-D)
Hot metal from blast furnace to BOF shop is brought through torpedo ladle
car. Capacity of torpedo ladle car envisaged as 350 t, so that hot metal for
two heats is available from one torpedo ladle. The hot metal from torpedo is
poured in 165 t hot metal charging ladle placed on transfer car is having
PROJECT DESCRIPTION

weighing device. The transfer car will be travel in pit and feed the
Desulphurisation unit.
A scrap bay has been envisaged near to the charging bay of BOF shop to
provide for a buffer stock of prepared scrap required for charging into
converters. The scrap is stored in pits provided in the scrap bay. Self-
propelled transfer cars are used for transfer of scrap boxes from the scrap
bay to the charging bay of the BOF shop. Weigh scales are provided on the
transfer car track for weighing of the loaded scrap chutes.
The bay will be served by three (3) no’s of crane. Two (2) combined
magnet/grab cranes of capacity 20+20 t and one (1) no. HM ladle handling
crane of capacity 280 t + 80t/20t. The scrap handing cranes will be utilised
for unloading of scrap from incoming railway wagons and trucks into the
storage pits and subsequent loading into scrap charging chutes/ boxes. The
HM handling crane will handle the HM Ladle.
Main control room of BOF converter is also be located in this bay.
HM Receipt cum Charging bay (D-E)
Hot metal from blast furnace to BOF shop is brought through torpedo ladle
car. The hot metal from torpedo is poured in 165 t hot metal charging ladle
placed on transfer car is having weighing device. The transfer car will be
travel in pit.
Openings are provided in the working platform of the charging bay to
facilitate receipt of steel casting ladles from casters in case of aborted heats.

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The bay will be served by total three no’s cranes (2 +1), Two (2) no. HM ladle
charging crane of capacity 280 t + 80t/20t and one (1) no. scrap charging
crane of capacity 60t + 60t (semi portal).
Converter Bay (E- G)
One (1) basic oxygen furnace is installed in the converter bay with oxygen
lance installations, part of converter gas cooling and cleaning installations,
bulk material storage and charging system, ferro-alloys storage and charging
facilities, lance repair and testing facility, etc. are located in this bay.
A working platform at a level of about +9.500 m is provided covering the
converter and charging bays of the BOF shop.
Platforms at various levels have been envisaged in the bays to have access to
various equipment and installations provided in these bays, including access
staircases and/or ladders to link up these platforms.

PROJECT DESCRIPTION
One numbers of 50/10 t EOT crane are provided in this bay for handling and
transportation of oxygen lances, converter and lance equipment, etc.
One additional crane of 20/10 t capacity has been envisaged for receipt of
the ferro-alloys bottom dischargers, brought by road transport,
One no. of tap hole repair cum debricking machine are provided on
converter platform.
Ladle and Tundish Preparation Bay G·H
A ladle preparation bay is provided for cooling, debricking, relining and
drying of steel and hot metal ladles, assembly, fixing and testing of slide
gates , porous plug, etc. Equipment for such facilities debricking machine,
ladle relining pits, ladle coolers , ladle driers and on-line ladle heaters, etc.
Tundish preparation has also envisaged to be done in this bay. The facilities
are tundish tilter , cooling, relining of tundish, tundish preheating etc.
Jib crane, wall cranes and mortar mixer is also provided in this bay in ladle
and tundish preparation area.
Self-propelled transfer cars and slag pot are provided for cross transfer of
empty ladles and slag pot between the bays.
A self-propelled transfer car for inter bay transfer of tundish also provided for
transferring of ready tundishes and receiving of empty tundishes.
By steel ladle/ HM/ slag pot transfer car, it is possible to return the full ladle
heat from CCP to BOF and pouring back into the converters by hot metal
crane.
The bay is served by three EOT cranes of capacity of 120+ 25 t/ 10t -2 (two)
nos for steel ladle handling and 120/10t - 1 (one) no. for tundish handling.

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Secondary Refining cum Turret bay (H-I)

In this bay secondary refining units like ladle furnace and RH-OB will be
envisaged to be installed. Auxiliaries of above facilities will be accommodated
in this bay like FAFA system, electrical room control room, equipment of etc.
BOF converter tapped liquid steel will be received in this bay and via EOT
overhead crane liquid steel will be transferred to the secondary refining unit
for further processing . The processed steel will be shifted to slab caster
turret with the help of EOT crane.
The bay is served by 3 (three) EOT cranes of capacity 280 + 80 t/ 10t - 2 (two)
nos for liquid steel ladle handling and 1x 120/25t – 1 (one) no. for facilitate
ladle furnace and RH-OB.
Casting Machine Bay (I-J)
This bay is having main caster equipment’s like mould, mould cover
PROJECT DESCRIPTION

segments, rollers, primary cooling, machine cooling system, main control

room, and tundish preheating stations etc.
Liquid steel poured in to the mould from steel ladle and subsequently cast in
to slab.
The bay is served by 2 (two) EOT cranes of capacity 120/ 25t for casting
machine equipment handling.
Mould and Roller Segment Maintenance Bay (J-K)
Slab caster mould and roller segment repair and maintenance work has
envisaged to be carried out in this bay.
The bay is also having gas cutting machine, emergency Hand Torch Cutters,
Crop and Sample Removal System , dummy Bar Head Storage Stand, dummy
bar receiver roller tables, deburring & Marking etc.
The bay is served by 2 (two) EOT cranes of capacity 120/ 25t for casting
machine equipment handling.
Slab Storage cum Despatch bay ( K-L & L-M)
Cast slab lifted with the help of EOT crane and are piled in floor for air
cooling . after air cooling the cast slab are despatch to mills .
Inter bay transfer car has also provided between the bays for transport of
slab from one bay to another.
Both the bays is served by 2 (two) EOT cranes each of capacity 70t tongs
crane ( 100t lifting with tongs) for slab handling.

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4.1.3 Process Description, Production Plan and Main Production Units of

Proposed SMS and CCM Shop
[Link] Process Description:
The proposed shop envisaged process flow as De-Sulphurisation - BOF-
Ladle furnace - RH-OB - Slab Caster or De-Sulphurisation - BOF- Ladle
furnace - Slab Caster

Hot Metal (HM) will be delivered to the proposed SMS-BOF shop via torpedo
ladle cars. Re-Iadling into the hot metal charging ladles takes place in the hot
metal re-Iadling pit having transfer car holding the empty HM ladle. Hot
metal poured in the empty HM ladle and after pouring desired quantity of
HM, transfer car moves with in the crane approach. The HM ladle picked up
EOT crane and transfer the HM ladle to De-sulphurisation unit transfer car.

Prior to treatment, the weighed hot metal transfer ladle is placed on the

PROJECT DESCRIPTION
tilting combi type ladle transfer car (ladle + slag pot), which is then driven
inside and placed at the treatment position of De-sulphurisation unit. The hot
metal will be desulphurised by the deep injection of a combination of
desulphurisation agents namely Mg and Lime. The station will be equipped
with deslagging and fume extraction facilities.

In scrap yard, scarp loaded via EOT magnet crane in scrap chute. Self-
propelled transfer car carries scrape chute and travel to the adjacent
converter charging bay. The scrap chute is picked up by semi portal crane
and scrap is charged in to the converter.

HM and Scrap charged in to the BOF converter. In-addition to that flux, iron
ore and ferro alloy also charged in to the converter as per the process
sequence. Flux, iron ore and ferro alloy are store in separate overhead
bunkers.

The converter will be operated with a top lance for oxygen blowing and with
bottom stirring of inert gases. The typical advantage of such combined
blowing technique will be the close approach to the equilibrium of
metallurgical reactions and the resulting smooth blowing process and
benefits of material yield.

The liquid steel will be tapped slag free from the BOF converter, in order to
eliminate the negative influence of the furnace slag (FeO, MnO) during
further processing and casting of the steel.

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After tapping from BOF converter, the steel ladle will be transported to the
twin track ladle furnace (LF) by a self-propelled steel transfer car. With the
help of EOT crane steel ladle full of steel transfer to ladle furnace transfer car.
This car takes the ladle to the treatment position below one of the LF roofs.
Secondary treatment can start immediately.

Once the ladle has been treated in the ladle furnace, the ladle car will be
moved to the ladle pick up position; stirring will be disconnected and the
ladle will be picked up by overhead EOT crane and forwarded directly to
RH-OB unit or the ladle turret of the Continuous Casting Machine (CCM)
depending on processing demands.

One of the main objectives of the ladle furnace, from a logistic and
productivity point of view, is to act as a buffer in between BOF operation and
the subsequent processing unit.
PROJECT DESCRIPTION

The treated steel at Ladle Furnace is further treated at RH-OB unit. RH-OB
degasser process involves a partial mass treatment of steel in the RH-OB
degassing vessel kept under vacuum. The circulation is affected by means of
argon blowing through tuyeres in the snorkel which acts as lift gas. During
degassing, deoxidizers and alloys are added into the chamber while the steel
is circulated. There is facility for Oxygen blowing from top to achieve lower
Carbon levels and also for chemical heating of the bath.

Liquid steel is delivered in a ladle from the steel melting shop to the casting
machine. The bay EOT crane handles the ladle and puts it onto the fork-arm
of the ladle turret. A weighing device in the ladle turret indicates the actual
weight of liquid steel in the ladle.
The continuous casting machine converts liquid steel into semi-products in
the form of slabs which are directly rollable on finishing mills.
The use of this process results in improved yield, energy consumption and
product quality.
Continuous casting involves the following sequence of operations:
· Delivery of liquid steel to the casting strands;
· Formation of the cast section in a water-cooled mould;
· Further heat removal from the casting strands by water sprays, starting
beneath the mould and continuing over the required length;
· Continuous withdrawal and straightening of the casting strands;
· Cutting and discharge of the slab.

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[Link] Production Plan (Potential):

Production of Liquid Steel:-

Heat size 150 t (nominal); 165 t (max.)

No. of converter 1(one)

BOF converter Tap to tap time 40-50 min

No. of heats per day 24

No. of working days /year 320

Annual production (potential) 1.15 Mtpa of liquid steel

Production of cast slabs has been calculated as given below :-

PROJECT DESCRIPTION
No. of heats per day 24

No. of Slab Caster 1 x 1 strand slab caster

No. of heats per sequence 10 (Flying tundish)

Slab Thickness 220 mm

Slab width 950 to 1850 mm

Average casting speed 1.50 m/min

No. of heats cast per day (avg.) 24 heats / day

No. of working days / caster/year 320

Yield (liquid to cast) 98.5 %

Yearly production from one caster : 1.135 Mtpa

(24x150x320x0.985)

Note: BOF and CC Shop have designed to take care the present imbalance
among the HM , crude steel production and slab requirement of various
mills. The present requirement of production is 0.83 Mtpa crude steel meets
the downstream mills requirement. The above calculations are based on
potential of proposed shop.

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[Link] Material Flow Chart

The Base and Proposed material flow chart of RSP is shown at Annexure-
[Link]-1 and Annexure-[Link]-2

[Link] Main Production Units:

The primary production unit envisaged are as follows:
Heat Size: 150t (nominal)

A Desulphurisation unit 1x 150t

BOF Converter 1 x 150t
B
Ladle furnace -Twin track 1x 150 t
C
D RH-OB unit 1x 150 t

E Slab caster 1x 1 strand

PROJECT DESCRIPTION

A. Desulphurisation unit (Co-injection based process)

Technical Features of Desulphurisation station:

Item / Parameter Description

The same system should be capable enough to operate under mono-

injection

Number of treatment stations 1(one)

i) Lime
Reagents
ii) Mg-based compound

Injection time ( Tenderer to indicate) Vary between 12 to 14 min

Allowable temperature drop during

25 °C (max)
entire operation

Capacity of storage silo for Lime 7-10 days’ storage of reagent

Capacity of storage silo for Mg 7-10 days’ storage of reagent

Capacity of HM treatment ladle 150t (nominal);165 t (maximum)

Conveying medium of reagents Dry Nitrogen

Deslagging operation By tilting of HM ladle into the slag

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Item / Parameter Description

pot by slag skimmer

HM treatment ladle should be

Placement of HM treatment ladle placed on a tiltable type ladle
transfer car with weighing facility

Lifting and tilting mechanism of car By hydraulic power pack system

Slag pot will be placed on the

Slag pot
same Hot Metal ladle treatment car

Should be such that fumes

generated during injection and
Desulphurisation enclosure
slag raking do not come in work

PROJECT DESCRIPTION
zone area

B. BASIC OXYGEN FURNACE (BOF)

Operating and design features:
One top blown basic oxygen furnace of capacity 165 m3 has been envisaged.
The converter shall be designed with provision for adoption of combined
blowing/ inert gas stirring process.

Production/ operational potential parameters of new BOF is given below:

Average tap-to-tap time, min 40-50

Relining/ repair time 168 hrs

Average lining life > 8,000 heats

365
BOF shop operating days/yr
Availability of BOF converter, days/year 320

Oxygen blowing time 15 -16 min

Yearly production from one BOF ( minimum) 1.15 Mtpa

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Technical Features of the BOF are indicated below:

Item / Parameter Description

1 (One) no.
No. of BOF converters
150 t (nominal); 165 t (max.)
Heat size
165 m³
Working volume with new lining
Magnesia-carbon bricks
Wear lining
Converter bottom Integral bottom type with provision for
practicing combined blowing (inert gas
stirring) process

Converter Relining Top

PROJECT DESCRIPTION

Temperature and sample Sub lance system

measurement

Oxygen blowing rate 36,000 Nm3/h (max), at 10-12 kg/cm2

Tap to tap time 40 - 50 minutes

Gas collection system Suppressed combustion system

Gas recovery Gas cleaning system and gas holder

Secondary emission control Dog-house for secondary emission

C. Technical Features of Ladle furnace -Twin track

Item / Parameter Description

No. of LF units 1 (One) No.

Heats size 150 t (nominal); 165 t (max.)

Type AC, 3-electrodes

Transformer rating 3 phase, 50 Hz, 33 kV

Heating rate 3oC - 5 oC per minute

Roof type Water cooled roof

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Item / Parameter Description

Ladle positioning method Ladle transfer car (2 nos.) on two parallel

tracks for twin LF

Electrode lowering / lifting Hydraulic system

Roof lifting / lowering Hydraulic system

Inert gas purging -Auto coupler Through porous plugs

Alloy addition system Ferro-alloy and Flux feeding arrangement

(FAFA) and wire feeding device

Gas cleaning system Gas collecting through ladle hood, duct &
ID fan and cleaning through bag filters

PROJECT DESCRIPTION
Control system PLC based

D. Technical features of RH-OB Degasser

Item / Parameter Description

No. of RH – degasser One (1)

Heat size, liquid steel 150 t (nominal); 165 t (maximum)

Type Single station type with refractory lined

vacuum vessel, -Equipped with two
refractory lined nozzles (snorkels) to the
bottom of vessel -Lifting and lowering of
vessel by hydraulic system (Alternately by
winch system)

Inert gas purging Inert gas stirring facility from up-leg of

snorkel

Steel recirculation rate, -Average >120 t/min

-Maximum

Vacuum vessel heating By water cooled O2 injection lance-cum-

gas burner

Steel transfer By self-propelled transfer car

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Alloy addition Ferro-alloys and micro-alloy Charging

system including pollution control
measures

Vacuum facility -Stages By steam ejector

Lifting / lowering of Ladle Hydraulic system

E. Production/ operational potential of cast slabs has been calculated as

given below:

No. of heats per day 24

No. of heats per sequence 10 (Flying tundish)

PROJECT DESCRIPTION

Slab Thickness 220 mm

Slab width 950 to 1850 mm

Average casting speed 1.50 m/min

No. of heats cast per day (avg.) 24 heats / day

No. of working days / 320

caster/year

Yield (liquid to cast) 98.5 %

Yearly production from one 1.13 Mtpa

caster : (24x150x320x0.985)

Technical features of Slab Caster:

Item / Parameter Description

No. of slab caster & strand 1 Single-strand

Heat size (liquid steel) 150 t (nominal); 165 t (maximum)

Tundish Capacity 38 t (approx.), Flying Tundish practice

Tundish practice Hot tundish practice

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Item / Parameter Description

Mould Vertical mould

Machine radius As per design; multi-point unbending

Width adjustment Remote Adjustable Mould for on-line

width changing

Slab thickness 220 mm

Slab width 950 – 1850 mm

Slab Length 7500 – 10500 mm

Casting time / heat 40 – 50 minutes

PROJECT DESCRIPTION
Machine preparation time 50-60 minutes; bottom fed dummy bar

Caster yield 98.5%

Stream protection Refractory shroud between ladle to

tundish and SEN between tundish to
mould.

Dummy bar Chain link type

Mould level control Automatic mould Level control

Mould Oscillation Hydraulic Mould Oscillator suitable to

Quick Change practice

Secondary cooling Multi zones, high-pressure automatically

controlled air mist cooling system,
dynamic control of cooling water

Withdrawal and straightening Multi point straightening, hydraulic

unit pinching, modular design

Slab cutting Gas cutting machine

Slab marking Slab marking machine; Aluminium spray

type

Control PLC based system

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Item / Parameter Description

Process control Computerised process control

Other features - AMLC system,

- Mould monitoring system
- Break-out prediction system,
- Process Control software / models,
- Cut length optimization system
- Soft Reduction system,
- Slag detection system,
- Slab marking system
PROJECT DESCRIPTION

4.1.4 Laboratory Facilities of Proposed SMS And CCM Shop – A new Laboratory
room envisaged to be suitably located inside the SMS and CCM Shop
building. The laboratory room is connected via pneumatic sample transport
system (PST) from all the processing unit of the shop .
Following are the main equipment envisaged in the room:
a) Optical emission spectroscope – 1 set
b) Gas analyser (Oxygen, Nitrogen & Hydrogen) – 1 set
c) Facilities for sample preparation (polishing, drilling & cutting) – 1set each
d) Top pan electronic weighing m/c (capacity – 220 gms) – 1nos
e) Pneumatic sample conveying / transport system from Desulphurisation
unit operating platform, BOF converter operating platform, ladle furnace
operating platform, RH-OB operating platform and slab caster operating
platform up to the laboratory – 5 set
f) Furniture for lab. Room : Chair-8, Table-4, Steel almirahs-3 & Cupboard-2
nos.
The room shall be divided in to two parts. One for the main equipment
installation and other portion shall be for sample preparation equipment
installation and sample receiving system. The main equipment room shall be
suitably Air conditioned. Space provision for future installation (1set similar
type equipment) in the laboratory room has also been envisaged.

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4.1.5 CALCINED LIME AND DOLO PLANT FOR NEW SMS

[Link] New SMS is proposed to process available HM of 8,76,000 tpa (2738tpd). To
cater the new Proposed SMS and CCM Shop, requirement of input flux
materials such as calcined lime and calcined dolo has been calculated as
follows:

[Link]. Flux Material Requirement Requirement Size (mm)

(tpa) (tpd)

1 Calcined Lime 87331 273 10-70 (avg-

40)
2 Calcined Dolo 33982 106

3 Miscellaneous - Lime 320 1

[Link] To meet the production target from new Proposed SMS and CCM Shop, it is

PROJECT DESCRIPTION
proposed to install a new calcined lime and dolo plant consisting of two new
shaft kilns of capacity 300 tpd (for lime) & 150 tpd (for dolo) each including
all associated facilities in the vicinity of existing LDBP area of RSP. Transport
of above items/materials via conveyer up to proposed location of SMS has
also been envisaged.
[Link] Existing LDBP is presently having one twin shaft kiln of 150 tpd capacity to
meet flux requirement for existing SMS-I. Other 7 nos. of kilns of the shop
have already been phased out. This shop is also having refractory brick
making facility, which is in operation.
[Link] The main advantage of choosing proposed location as LDBP shop is
utilisation of existing infrastructural facilities like raw material receiving
facilities with high line bunkers.
[Link] The approximate total requirement of limestone and raw dolomite for
production of lime & dolo flux for Proposed SMS and CCM Shop will be as
under:

Sl. Required Raw Approx. Approx.

No. Materials Requirement (tpa) Requirement (tpd)

1. Limestone of 25 - 55mm 1,76,000 550

size

2. Raw Dolomite of 25 – 55 76,000 238

mm size

Quality of feed limestone & dolomite will be SMS grade and produced flux
will be SMS grade. Source of limestone and raw dolomite will be same as
existing one i.e. Jaisalmer / Dubai / Oman for limestone and Bela /
Bardgaman for raw dolomite.

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[Link] Technical Parameters

A. Quality of Feed Limestone/ Raw Dolomite
The typical quality of feed lime stone/ raw dolomite to new shaft kilns is as
follows:

Sl. no. Properties Unit Limestone Raw Dolomite

1. Chemical Analysis
SiO2, max % 1.5 2
CaO, min % 53 30
MgO, max % 2-3 20
Fe2O3, max % 1 -

2. LOI, min % 43 43
PROJECT DESCRIPTION

3. Feed size mm 25-55 25-55

B. Quality of Produced Calcined Lime/ Dolo

The typical quality of produced calcined lime/ dolo from the new shaft kilns
will be as follows:

Sl. no. Properties Unit Calcined Lime Calcined Dolo

1. Chemical Analysis
CaO, min % 85 52

2. LOI, max % 5 6

3. Reactivity with 4 (N) HCl, cc 350 250

min

4. Size produced mm 0-50 0-50

5. Fine generation, max % 10 15

C. Other Parameters
For installing “300 tpd Lime Shaft Kiln & 150 tpd Dolo Shaft Kiln” following
other design parameters will be considered:

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Sl. No. Description Unit Lime Shaft Kiln Dolo Shaft Kiln

1. Capacity of new shaft tpd 300 150

kiln

2. Nos of kiln nos. 1 1

o
3. Temperature C 1050 - 1150 1050 - 1150
(burning zone)

4. Purpose of kiln - Calcination of Calcination of

Limestone Raw Dolomite

5. Type of kiln - Vertical, twin Vertical, twin

shaft, parallel shaft, parallel

PROJECT DESCRIPTION
flow regenerative flow regenerative

6. Shape of shaft - Circular Circular

(preferred)/ To (preferred)/ To
be decided by be decided by
technology technology
provider provider

7. Method of charging - Skip Skip

to shaft Kiln
o
8. Average temperature C 80 80
of discharged
product, max.
o
9. Fume temperature C 120 - 130 120 - 130
o
10. Skin temperature C 80 80
above ambient
(burning zone), Max

11. Fuel consumption kcal/ 860 860

(CV of mixed gas kg
ranges from 3600 –
4000 kcal/ Nm3)

12. Working schedule of Day 320 320

the kiln on 3-shift per s/
day and 8-hours per year

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Sl. No. Description Unit Lime Shaft Kiln Dolo Shaft Kiln
shift basis, Min.

D. Process description of new 300 tpd Lime Shaft Kiln & 150 tpd Dolo
Shaft Kiln
Lime stone/ Raw dolomite of size (+) 25mm to (-) 55mm will be received by
existing railway wagon from OBBP to existing high rise bunkers (HRB) of
LDBP and it will be stored in HRB # 3, 4 & 5 or to be decided by RSP (HRB #
3 & 4 for limestone and HRB # 5 for raw dolomite) of capacity 1000 tons
each.
From HRB # 3, 4 & 5, limestone and raw dolomite will be transported (after
suitable modification at discharge of HRBs) through suitable belt conveying
PROJECT DESCRIPTION

system to raw material screening, storage and feed unit. In raw material
screening, storage and feed unit, it is envisaged to install 2-nos. single deck
screen of 25mm size (1-for limestone & other for raw dolomite) with 4-feed
bunkers (2x300 tons for limestone & 2x300 tons for raw dolomite) and 2-
safety bunkers for undersize/ reject raw materials (1x100 ton for limestone &
1x100 ton for raw dolomite). There will be provision of dispatch of undersize/
reject limestone/ raw dolomite by road.
From the feed bunkers, the materials will be fed to weigh hopper through
belt conveyor for feeding the measured quantity of material to the kilns
through skip hoist. 2-twin shaft kilns (1x300 tpd for lime & 1x150 tpd for
dolo) is envisaged to meet demand of flux for Proposed SMS and CCM Shop.
The kilns will be fired with mixed gas fuel to generate heat of calcination
temperature of 1050oC-1150oC.
Produced lime/ dolo will be stored in the hopper placed below the kilns and
will be discharged by vibratory feeder to the high rise belt conveyors. There
will be 3 nos. of high rise belt conveyors (2W+1S) below the kilns to convey
lime/ dolo from the kiln’s hopper to flux screening, storage & dispatch unit.
Flux storage, screening & dispatch unit will have screening facility for (+)/ (-)
10mm lime/ dolo. There will be 2-screens (1-for lime & other for dolo). There
will be 3 bunkers of 150 ton capacity (each) for storage of produced (+)
10mm lime/ dolo from kiln. Out of 3-bunkers, 2-bunkers will be used for
storage of (+) 10mm lime and 1-bunker will be used for storage of (+) 10mm
dolo. Also, there will be 2-bunkers of 100 tons capacity (each) for storage of
produced (-) 10mm lime/ dolo. Out of 2-bunkers, 1-bunkers will be used for
storage of (-) 10mm lime and 1-bunker will be used for storage of (-) 10mm

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dolo. (+) 10mm lime/ dolo will be conveyed to Proposed SMS and CCM Shop
through 2-nos. belt conveyers.
There will be provision for loading of lime/ dolo fines of (-) 10mm from 2-
bunkers on Cement Tank Carrier and finally dispatched to other consumers
like sinter plant, etc.
Also, there will be provision for storage and dispatch of reject lime/ dolo by
road. Reject lime/ dolo will be stored in 2-bunkers (1x150 ton bunker for lime
& 1x150 ton bunker for dolo)
The waste gas which is coming out from kilns will be cleaned in waste gas
cleaning system to vent out the clean gas to the atmosphere. The dust load
at clean gas let out to atmosphere will be < 50mg/Nm3 at normal
temperature.
The dedusting system will be provided at all transferring points of materials

PROJECT DESCRIPTION
for raw material screening, storage & feed unit and flux screening, storage &
dispatch unit to keep dust free atmosphere in this calcination plant.
The process flow diagram (typical) showing flow of material for production of
lime and dolo flux is shown in Drg. No.: CET RN 4706 RE0 00 001 R=0.
E. Existing facilities
a) Existing rail and wagon will be utilized for receiving limestone/ raw
dolomite from OBBP to existing high rise bunkers of LDBP. The capacity
of the HRBs is 1000 tons each. HRBs are located at elevation of ~18m
level.
b) Nearby space of existing 2-rotary kilns in LDBP area will be utilized for
installation of proposed 2-new shaft kilns (1x300 tpd for lime & 1x150
tpd for dolo) with various auxiliary units like booster house, MCC room,
substation etc.
c) To establish various units under this calcination plant, Jaw crusher lying
near to HRB area will be dismantled completely and relocated if desired
by RSP.
F. Technological Layout & Proposed Location:
The following typical drawing showing the technological layout & proposed
location for installation of 2-new shaft kilns along with upstream and
downstream major units in vicinity of existing LDBP is enclosed
Drg No. CET RN 4706 RE0 00 002 R=0, Proposed Location for Lime and
Dolo Plant for Proposed SMS and CCM Shop (Typical).

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4.2 ENABLING WORKS – DISMANTLING & RELOCATION OF FACILITIES

4.2.1 The location of the proposed new Steel Melting Shop complex along with its
associated facilities has been envisaged adjacent to existing SMS-I Converter
shop as well as adjacent to Continuous Caster Machine Shop of SMS-I, on
the North-eastern side areas towards Foundry Shop complex.
4.2.2 The proposed location is in a totally deep-Brown-field area where there exist
a number of operating/ production units, Rail tracks, Utility Pipe lines,
various buildings of major importance.
4.2.3 All these existing facilities can not be dismantled without prior installation of
alternate arrangement / rerouting / relocation work.
4.2.4 Re-routing / relocation / Alternative arrangement of these facilities are
required to be installed prior to dismantling, to fulfil the following
requirements:
PROJECT DESCRIPTION

· To facilitate continuity of regular production from SMS-I shop during

site execution work for installation of new SMS.
· Alternative arrangement for existing production units
· Building complex with facilities which are directly or indirectly linked
with plant production and also to meet technological & administrative
requirement of Rourkela Steel Plant.
4.2.5 Following are the list of major existing units / facilities which need complete
dismantling and disposal for creating space for installation of new SMS shop
& associated facilities:
1) Dismantling of Pig Casting Machine-I (PCM-I) shop complex
2) Dismantling of Part of SMS-I Shop building
- Part of the shop building of approx. 175 m length is required to be
dismantled.
- Dismantling will cover the redundant area where Open Hearth
Furnaces were earlier installed and phased out.
3) Dismantling of Rail tracks for feeding scrap to SMS-I shop floor at
+7.5 M level through wagons
- This need alternate route for continuity of production
- Alternate route for scrap feeding through trucks & dumpers on
road ramp has been considered, which will be constructed prior to
dismantling of existing tracks.
4) Dismantling of Railtracks for feeding Hot metal to SMS-I.
- Hot metal feeding track to Mixer #1 will be dismantled.

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- Hot Metal feeding tracks to Mixer-3 will only be operational for

continuing operation of SMS-I
5) Dismantling of Conveyor gallery for Calcined Lime/ dolomite, for
feeding SMS-I shop.
- Needs alternate route for lime/dolomite feeding conveyor for
continuity of production
- New conveyor system has been considered for installation through
diverted route prior to dismantling of existing lime/dolomite
conveyor.
6) Dismantling of Road / Ramp for access to SMS-I Shop floor at +7.5 M
level
- Need alternative access road/ramp.

PROJECT DESCRIPTION
- New Ramp has been considered prior to dismantling.
7) Dismantling of Yard Utility Pipe Lines:
- Mixed Gas Fuel line, Steam Line, Nitrogen line feeding to SMS-I,
LDBP shop and Oxygen Lines for feeding Blast Furnaces # 1 & 4.
- New Utility pipe lines will be installed through alternate route, prior
to start of dismantling of existing lines.
8) Dismantling of Rail Tracks for dispatch of Cast slabs of SMS-I to Mills.
- New rail track for alternate route has been envisaged, which will be
constructed before dismantling of existing slab despatch track.
9) Dismantling of Mould Yard shop building [Along with Mould &
Segment repair facilities of SMS-I Caster Shop and Slab cutting /
Scarfing facilities]
- Relocation of Mould & Segment Repair facility has been
considered.
- Slab cutting / scrafing activities will be relocated by RSP
departmentally.
10) Dismantling of Electrical Substation : T-Off substation (33 kV)
- This substation feeds Power to Transformer of VAD (Vacuum Arc
De-gassing) Substation of SMS-I and also feed power to NSP
Transformer in Sintering Plant-I
- Alternative power feeding arrangement for VAD & NSP at SP-I will
be installed before dismantling
11) Dismantling of Field breaker substation : In SMS-I shop

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- This substation feeds Power to Field Breaker stations (415 V) of Hot

metal & Pit Side cranes of SMS-I
- Alternate arrangement of power feeding arrangement will be
installed prior to dismantling.
12) Dismantling of Foundry Shop Complex : Grey Iron Foundry & Steel
Foundry
- Complete dismantling has been envisaged. No relocation work has
been considered.
13) Dismantling of ED (Works) Building complex
- New building will be constructed before dismantling
14) Dismantling of Research, Control & Lab (RCL) Building
- New building will be constructed before dismantling
PROJECT DESCRIPTION

15) Dismantling of Stripper Yard building alongwith railtracks in the area.

- Complete dismantling. No relocation
16) Dismantling of SMS-I Office building complex
- New building will be constructed before dismantling.
17) Dismantling of Marammat Bhawan, Crane Uddyan / Crane
maintenance office building
- Construction of new buildings have been considered, before
dismantling
18) Dismantling of LU-OP, Stock control/ Stock verification office building,
CISF Building (near Foundry), Canteen buildings
- New buildings for relocation is considered.
19) Dismantling of Office building complex of Foundry shop, RCM shed
(near Foundry) & Various temporary stores/ sheds, PCBs etc. in the
area.
- Complete dismantling. Relocation is not considered.
20) Dismantling of Part of Repair Shop Mechanical (RSM) . [Adjacent to
Power Distribution / SLCC building]
4.2.6 The scope of work, envisaged to be executed under Package No.I – Enabling
Works, shall generally include follows:
· Total works of Dismantling & disposal of existing facilities with a view
to create necessary space for proposed SMS

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· Relocation / re-routing of certain units to facilitate continuity of

Operation of SMS-I during installation of new SMS.

4.2.7 Scope of Work : Dismantling & Disposal - area wise.

[Link] Dismantling of Pig Casting Machine-I (PCM-I) shop complex
a) To install the proposed SMS, it is necessary to dismantling the PCM-I
shop.
b) In PCM-I shop building; relining activities of Hot Metal Ladle (80 Ton
capacity fleet) are also carried out. There is one underground pit which
is used for refractory relining work of 3 (three) nos. HM Ladles.
It is necessary to relocate Ladle Relining facility before dismantling of
PCM-I.

PROJECT DESCRIPTION
c) Under Enabling Pkg. I of this FR, it has been considered for Relocation
of B.F Ladle (80 Ton capacity) Relining facility. The relining facility will
be relocated in the existing covered shed of B.F Ladle Repair Shop.
d) Brief on PCM-I Shop
· PCM-I was installed and commissioned in Jan’1959.
· The shop handles 80 T capacity hot metal ladles.
· There are two machines. Each machine has two strands of chains
fitted with small steel mould, rotating on sprockets. Hot metal is
poured into the lime coated moulds & cast as solid pigs.
· EOT Cranes
There are total 5 (five) nos. of EOT Cranes in PCM-I shop complex:
List of EOT Cranes:
Sl. Location Capacity Quantity Span Top level
No (In Ton) (Nos.) (Meter) of Crane
Girder
Rail top
1 PCM-I Shop 130 T / 2 18 +11 M
32 T

2 PCM-I Shop 8T 1 7.5 +8 M

Annex Bay

3 Junction 7.5 T 1 6 +10.5 M

House of Pig
Conveyor

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Sl. Location Capacity Quantity Span Top level

No (In Ton) (Nos.) (Meter) of Crane
Girder
Rail top
delivery
(Head end)

4 Pig Yard 10 T 1 20 +10 M

Open Gantry
(Magnet
Crane)

· PCM-I Shop building is of Structural Steel construction with CGS

sheeting in both roof and side cladding work.
Crane Girders are at +11.0 M (Max.) level: Top of crane rail.
Height of the shop building is approx. 20 M.
PROJECT DESCRIPTION

· Covered Shop floor area is estimated to be approx. 2980 SqM.

· There is 1 (one) open gantry of 20M wide x 110M length, used
for storage of pigs. 10Ton capacity Magnet crane is used for
loading pigs in wagons. Height of Gantry is 10M.
[Link] Dismantling of Part of SMS-I Shop
a) It is required to dismantle part of SMS-I shop for creating space for
new SMS.
b) SMS-I shop proper is structural building covering shop plinth area of
approximately 39,625 SqM.
This SMS-I shop was originally equipped with the following Steelmaking
Technological facilities:
Sl. Description Quantity Location Present Status

1. Open Hearth 4 Nos. BC bay : Not in position

Furnaces (80 Between Col All 4 nos Open
Ton capacity) axis # 24-42. Hearth Fces. have
Covering been phased out
approx. 135 and dismantle.
Meter length.

2. LD Converters 3 Nos. CD bay: Not in position.

(50 Ton Heat Between Col All 3 nos. phased
size) axis # 06 – 14. out and
dismantled.

3. LD / BOF 2 Nos. CD bay: In operation

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Sl. Description Quantity Location Present Status

Converters (66 Between Col
ton Heat size) axis # 02 - 06
Pit side AB bay Ingot casting
4.
facilities for route was stopped
Ingot Teeming in late ‘90s after
installation of
Continuous
casting shop at
separate place.

5. Secondary 2 Nos. AB bay: In operation

Steel Making Between Col
Facilities (VAR, axis # 7X – 22x
VOR)

PROJECT DESCRIPTION
c) In course of time all the 4 nos. Open Hearth Furnaces and 3 Nos. LD
converters (50 ton heat size) were phased out and dismantled.
Ingot casting route was also stopped in late ‘90s after installation of
Continuous casting shop in Aug’1996.
d) In view of phasing out of old technological facilities, in phases, a
considerable part of SMS-I shop building at one end have become
redundant.
e) The redundant part of SMS-I shop building of approx. 175 M length,
from Col. axis no 25 to 48, towards Main road “A”, has been envisaged
to be dismantled for creating space for new SMS.
This strategy will not affect the present Technological facilities which are in
operation for production in SMS-I.
However, there will be logistic issues in 4 (four) areas which need alternate
arrangement before dismantling:
1) Scrap feeding rail tracks need to be dismantled.
2) Existing ramp/road for access to SMS-I shop floor at +7.5 Meter level
will also be dismantled.
3) Existing Lime/dolomite feeding conveyor gallery from LDBP will be
dismantled.
4) Presently the activities of Slag dumping from steel ladles are done in
AB & BC bay which need to be shifted towards axis 24 in the same
bay.

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f) To overcome the above logistic issues, alternative schemes for 3

(three) facilities have been envisaged in the FR which will be installed
prior to dismantling of existing facilities.
1) One new ramp is envisaged from the existing road, between
Caster shop-I and Mould preparation building, up to SMS-I shop
floor at +7.5 M level.
Scrap will be transported to SMS-I shop floor by trucks, dumpers
by road through this new ramp.
2) The above new Ramp will be used as road access to SMS-I shop
floor. This will be connected to existing plant road network via
side road of Caster Shop-I.
3) One new conveyor gallery through a diverted route nearby, has
been envisaged for feeding calcined lime/ dolomite to SMS-I.
PROJECT DESCRIPTION

g) Heavy Steel casting section, under Foundry Deptt., located at Pit Side,
AB bay of SMS-I.
This facility in AB bay will be completely dismantled. Relocation of this
section is not considered in FR.
h) Brief on SMS-I Shop dismantling.
1) The whole SMS-I shop building is of Structural Steel construction with
CGS roof sheeting & side cladding work.
· Total Shop floor area is estimated to be approx. 39,625 SqM.
· SMS-I shop building consists of total 6 bays. Details of various
bays and cranes installed are given below:
Name of Bay Dimension Bay EOT Crane Roof Height
Sl
Bay Width Length Crane Capacity Qnty.
(M) (M) rail top
1 AB bay 27.4 ~525 M +19 M 100t/ 32t 2 Nos. ~36 M
(Ingot Monitor:
130t/ 32t 1 No.
Teeming)
+41.65 M

40t / 8t 1 No.
Semi-
portal
Crane

2 BC bay: 23.25 ~435M +19 M 120t/ 32t 1 No. ~36 M

(Hot Metal Monitor:
100t/ 32t 1 No.

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Name of Bay Dimension Bay EOT Crane Roof Height

Sl
Bay Width Length Crane Capacity Qnty.
(M) (M) rail top
Handling) +41.65 M
12t / 5t 1 No.

3 CE bay 23 CE bay +19 M 130t/ 32t 1 No. ~ 40M

~300M

CD bay
~416M

4 DE bay 14.38 ~295M +16 M 12t / 5t 2 Nos. ~28 M

(Scrap
Handling)

5 EF bay 7.75 ~200M ~25 M

PROJECT DESCRIPTION
6 FG bay : 20.5 ~195M 50t / 12t 2 Nos. ~20 M
(Slag Pot
Handling)

2) Part of the SMS-I shop building of 175 meter length will be

dismantled along with all existing redundant equipment & facilities.
3) The extent of dismantling will be from column axis no. 25 up to the
end at axis no. 48, towards Main road “A”. Existing building columns
at axis no.25 will be retained.
4) Total shop area which will be dismantled is estimated to be
approximately 10,800 SqM.
5) Following jobs are necessary to be completed, before dismantling
work is taken up
i) Erection and commissioning of New diverted Lime/dolo
conveyor system.
ii) Construction of new ramp from Mould preparation Building
side.
iii) Erection of new bracing system in existing building columns
iv) Erection of new buffer-stops in cranes rails for all EOT cranes at
axis # 25.
6) After dismantling, new Gable end of structural steel construction, will
be constructed at [Link] #25
7) Total shop area of SMS-I envisaged to be dismantled is estimated to
be approximately 10,800 SqM.

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[Link] Dismantling of Scrap feeding railtrack to SMS-I shop floor

a) Present system of scrap feeding
· Metal Scraps are transported to SMS-I shop floor in scrap boxes
through rail wagons from scrap yard.
· Scrap yard is at ground level, located at around 800 Meter distance
from SMS-I shop. SMS-Shop floor is an elevated platform which is
at 7.5Meter height from ground level. Scrap feeding railtrcks are
laid in gradient from scrap yard location at ground level, to reach
SMS-I Converter shop floor, which is at 7.5 meter height from
ground level.
· Enroute to SMS-I, scrap feeding rail tracks run through 2 (two) nos.
rail bridges, namely 1) Bridge “H” constructed over Main road “A”
and 2) Bridge “N” constructed over the road near SMS-I shop.
PROJECT DESCRIPTION

b) It is required to dismantle existing scrap feeding rail track system

including its elevated embankment and 2 (two) nos. rail bridges “H”
and “N”.
c) In absence of present system of scrap feeding rail tracks, it will not be
possible to operate SMS-I shop.
d) For continuity of SMS-I Converter operations, it will be needed for
installation of alternate route of scrap feeding before dismantling of
existing scrap feeding rail tracks.
e) Alternative route for scrap feeding has been considered in the FR.
f) Brief on proposal of Alternative route for scrap feeding
i) Construction of one Ramp has been considered for
transportation of scrap, by road, through trucks/ dumpers.
ii) SMS-I shop floor will be connected with existing plant road
network through the ramp..
iii) In addition to scrap feeding, the ramp will be used for vehicular
movement fulfilling operational requirement of SMS-I Shop.
iv) Location:
The proposed Ramp will be constructed from ground level
starting from the location near Mould Yard column no. A-4, run
straight across mould yard, Pit side (AB bay) on gradient and
reach SMS-I shop floor at +7.5 M level up to end of BC bay end
near column no. C-24.

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Ramp will be connected to existing plant road network via side road of
Caster Shop.
v) Sizing of Ramp
· Width : 9 M
· Length : Approx. 100 M
· Graidient: 1 in 12 [ 1 M vertical in 10 M Horizontal
distance]
vi) Ramp will be of structural frame work construction with Deck slab
of Reinforced cement con (R.C.C) construction.
vii) Ramp construction will be executed under Enabling [Link].I.
[Link] Dismantling of Railtracks for feeding Hot metal to SMS-I.
a) In SMS-I, there are two Mixers (1100 ton capacity each) in operation,

PROJECT DESCRIPTION
for Hot metal received from Blast furnaces through open ladles.
- Mixer #1 is located at one end of SMS-I shop, in CE Bay, between
column axis 24 & 28
- Mixer #3 is located at the other end of SMS-I shop, in CE Bay,
between column axis 3X & 7X.
b) Location of Hot Metal feeding track to Mixer-1 falls in the area of
proposed SMS facilities.
- Hot metal feeding track to Mixer-I will be dismantled. This will
result in stoppage of operation of Mixer-1
c) Hot Metal feeding tracks to Mixer-3 will be operational for continuing
operation of SMS-I, during execution of work for new SMS.
[Link] Dismantling of Conveyor gallery for Calcined Lime & dolomite, for feeding
SMS-I shop.
a) The existing Conveyor Gallery, which used for despatch of calcined
lime and dolomite from LDBP shop despatch Junction House to SMS-I
shop, falls under the area of proposed new SMS complex.
It is required to dismantle the gallery
b) For continuity of SMS-I operation, a new conveyor gallery will be
installed through a diverted route for despatch of lime & dolomite
material to SMS-I shop.
c) Execution of new conveyor gallery and thereafter dismantling of
existing conveyor have been envisaged under Enabling Package No.I.

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d) For installation of new conveyor, shut-down of existing Lime/dolo

conveyor system will be required for interfacing work of new system
with old one.
Duration of shut-down is estimated to be around 7 days.
e) Brief on new diverted conveyor gallery
i) The New covered gallery will be of Structural steel construction.
Estimated total length of new Conveyor system will be approx. 175
meter.
ii) New 4 (four) Nos. Junction Houses will be required for diverted
conveyor gallery.
iii) Electric hoists for maintenance of drive arrangements and Chain pulley
blocks for maintenance of tail pulley arrangement along with monorail
beams will be provided in each Junction house.
PROJECT DESCRIPTION

iii) Modification will be required in the existing conveyor # 0 with

installation of new drive arrangement. Existing conveyor#7, in SMS-I
shop will be reused after modification work viz. shortening its length
by shifting of existing tail pulley in new Junction house in SMS-I shop.
iv) Schematic General Arrangement of rerouted Lime/dolo conveyor
system is shown in Drawing [Link] RN 4706 ME0 00 001.
[Link] Dismantling of Road / Ramp for access to SMS-I Shop floor at +7.5 M level
a) A new Ramp has been envisaged to be constructed from Mould
preparation building side for feeding scrap by trucks/ dumpers directly
to SMS-I shop floor at +7.5 M level.
This ramp will be used for vehicular movement to meet the need of
fulfilling operational requirement of SMS-I Shop.
b) The ramp will be constructed before dismantling of existing road/ ramp
access SMS-I shop floor.
[Link] Dismantling of Yard Utility Pipe Lines
a) Various Utility lines viz. Fuel gas, Oxygen, Steam, Nitrogen are running
in the area of proposed new SMS location. These utility lines are feeding
to SMS-I shop, Lime Dolomite & Brick Plant (LDBP) of SMS-I, PCM-I.
b) List of Utility Lines in the area between B.F Highline and SMS-I Shop
Building is given hereunder:

Sl. Description Present Status Remarks

1 Mixed Gas Line NB In operation. Needs rerouting

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800 Feeds to SMS-I, LDBP before dismantling

and PCM-I shop.

2 Mixed Gas Line NB Not in operation - No need for rerouting

700 Defunct

3 B.F Gas Line NB 800 Defunct No need for rerouting

along with Flare
Stack

4 Steam Line NB 300 In operation. Needs rerouting

(Pressure at 17 Bar) Feeds to SMS-I before dismantling

5 Steam Line NB 200 In operation (For Needs rerouting

(Pressure at 17 Bar) Purging) before dismantling

PROJECT DESCRIPTION
6 Oxygen lines NB 50 In operation. Needs rerouting
& NB 25 before dismantling
Feeding to [Link] in
MT area [ # 1, 4]

7 Nitrogen line NB In operation. Needs rerouting

100 (LP) before dismantling

a) For continuity of SMS-I operation and in other areas, utility lines will
be re-routed prior to start of dismantling work.
b) Execution work of Rerouting of Utility lines have been planned in the
FR, under Package No.V.
c) The existing overhead Utility lines feeding to Foundry Shop complex
viz. Mixed gas fuel line, Oxygen etc. will be completely dismantled.
d) Dismantling of existing Utility lines falling in the area of new SMS, will
be executed under Enabling package No.I
The work of rerouting work under [Link].V is to be completed before
start of dismantling work under [Link].I.
[Link] Dismantling of Rail Tracks for dispatch of Cast slabs of SMS-I to Mills.
a) Slabs from CCM-I shop is evacuated through Zone-IV main line. The
railtracks for slab movement are running through the area envisaged
for new SMS facilities.
These rail tracks are required to be dismantled for installation of proposed
new SMS

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b) It is therefore needed to lay rail track connection of CCM-I in an

alternate route for slab dispatch to the Mills for continuity of SMS-I
operation, during installation work of new SMS.
c) Study on alternate track
Two alternatives have been identified
· Option – I : Slab movement through existing railtracks via
Zone-VI
· Option – II : Connection of CCM-I outer track by laying new
track via existing Central Store, with Zone-IV track.
d) Discussion on Option-I : Slab Movement via Zone-VI
· Regular movement of Slab wagons through Zone-VI is not
possible because of the reason that all steel dispatch of RSP is
done via this Zone-VI only.
PROJECT DESCRIPTION

· If movement of slab from CCM-I is done via Zone-VI, there will

have adverse affect on steel dispatch activities of all the mills
e) Option-II : Connection of CCM-I with Zone-IV track by new tracks via
existing Central Store
· New track connection can be done with Zone-IV. This will need
to occupy some part of Central Stores area adjacent to CCM-I
shop for laying new track for connection with Zone-IV.
· However one stores building (34m wide x 64m long) needs to be
dismantled and relocated in central store complex. The end part
of central store boundary wall, adjacent to CCM-I is to be shifted.
· This track can be used as independent track for Slab movement
from CCM-I shop upto Zone-IV main tracks in a shortest route.
f) In view of the advantages of Option-II, connection of CCM-I with
Zone-IV through existing Central Store area has been considered in
the FR.
g) All the enabling jobs viz. relocation of stores shed (34m x 64m),
shifting of boundary wall will be executed under Enabling package
([Link]. I).
Laying of rail track will be executed under Rail track package ([Link].
VIII).
[Link] Dismantling of Mould preparation yard building of SMS-I
a) This building was earlier used for Ingot Mould preparation activities.
After installation of Continuous casting facilities in late 90’s, ingot

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casting route was totally stopped at RSP. Since then, activities of

Mould stripping in Stripper yard and Mould preparation in the bay
were also stopped.
b) One overhead Bridge is in operation for Steel Ladle Transfer car which
runs between SMS-I pit side (AB bay) and Caster shop LF bay. This
overhead bridge runs through Mould yard between shop column axis
No. 3 & 4. This facility was installed in 2005-06.
It has been considered to retain overhead steel ladle transfer bridge.
c) Presently, following 2 (two) activities are carried out in the Old Mould
preparation bay:
i) Mould and Segment repair Facilities of Caster-I of SMS-I.
· This additional facilities for segment repair was installed in the
vacant area of Mould preparation building in the year 2007-08.

PROJECT DESCRIPTION
· Area : 25m wide x 40m length.
· Major activities of Mould & segment repair are carried out in
Caster shop itself which was originally installed by the supplier
M/s HEC+SMS.
ii) Slab cutting & sizing for Plate mill and slab scarfing
d) Before start of dismantling of Mould yard building, the above two
activities are to be shifted to other areas.
i) Shifting of Mould & Segment repair stands have been considered in
the FR, under enabling [Link]. I.
The facilities will be shifted to the end of the building between shop
column axis no. 0 – 4.
ii) The activities of slab cutting & scarfing will be shifted to other area(s)
by RSP departmentally.
e) Existing Mould preparation building is structural building of 28 M wide
x 300 M length.
· Crane Girders top level : + 13 M (Top of crane rail)
· Covered area : 28 m Wide x 260 m Length.
· Open gantry : 28 m x 40 m Length.
· There are two nos. EOT Cranes [# 251, #253]
- Dogging crane : Capacity 20 Ton x 25 M span
- Travelling Crab : Capacity 10 Ton.
f) Dismantling

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The part of the building from shop column axis # 0 to axis # 4 [40 m
length] along with 20ton capacity crane, will be retained.
Rest part of Mould preparation building beyond #4 along with 10ton
capacity crane will be completely dismantled.
g) New Gable end construction
Gable end will be constructed at column axis no. 4, with structural
framework and CGS sheeting
[Link] Dismantling of Electrical Substation : T-Off substation (33 kV)
a) This substation feeds Power to Transformer of VAD (Vacuum Arc De-
gassing) Substation of SMS-I and also feed power to NSP Transformer
in Sintering Plant-I.
b) Alternative power feeding arrangement for VAD & NSP at SP-I will be
installed before dismantling of existing T-Off substation.
PROJECT DESCRIPTION

c) Alternative Power feeding arrangement will be executed under

Package : Rerouting of power supply ([Link])
Dismantling work will be executed under Enabling package (Pkg.I)
[Link] Dismantling of Field breaker substation : In SMS-I shop
a) This substation feeds Power to Field Breaker stations (415 V) of Hot
metal & Pit Side cranes of SMS-I.
b) Alternate arrangement of power feeding arrangement will be installed
prior to dismantling.
c) Alternative Power feeding arrangement work will be executed under
Package : Rerouting of power supply ([Link])
Dismantling work will be executed under Enabling package (Pkg.I)
[Link] Dismantling of Foundry Shop Complex : Grey Iron Foundry & Steel Foundry
a) It is required to completely dismantle existing Foundry shop complex
including its all service buildings, facilities in and around of the shop.
b) The whole Foundry Shop building is of Structural Steel construction with
CGS roof sheeting & side cladding work.
· Total Shop floor area of Foundry shop building is estimated to be
approx. 22150 SqM.
· Height of Building : Approx. 19 M. (max.)
· Foundry Shop building consists of total 7 bays :
- Grey Iron Foundry : 5 bays - AB, BC, CD, DE, EF bay

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- Steel Foundry: 2 bays - GH, HI bays.

· Top level of Crane Girders are at +9.0 M level (Top of rail).
c) No relocation work of Foundry shop has been considered in this FR.
d) Brief on Foundry shop complex
The primary activities of present Foundry Shop is to make castings of
certain spares which are used in various units of Rourkela Steel Plant.
Following are generally manufactured in Foundry:
1) Ferrous castings like Door frame, Flash plate, Wharf plate, Sinter
breakers, Grate bars, Hammer heads.
2) Slag pots for Blast Furnaces and Steel Melting Shop-II.
3) Steel Casting, Cast Iron and Non-ferrous castings of other certain
spares as needed by various units of RSP.

PROJECT DESCRIPTION
4) Salvaging of copper wired from the rejected electrical cables &
fittings and converting them into ingots.
5) Conversion of Aluminium ingots into nuggets for use in Steel
Melting Shops at RSP.
6) Making of ternary alloys of zinc, aluminum and lead for use in
galvanizing line of CRM
e) EOT Cranes
There are total 9 (nine) nos. of EOT Cranes in Foundry complex
In GIF : 6 nos. ; In Steel Foundry: 3 Nos.
List of EOT Cranes:
Sl. Location Capacity Quantity Crane Span Top level of
No (In Ton) (Nos.) (Meter) Crane rail
1 CD Bay 25 T / 8 T 1 27.5 +9 M

2 CD Bay 40T / 8T 2 27.5 +9 M

3 CD Bay 60 T / 12 T 1 27.5 +9 M

4 DF Bay 25 T / 8 T 1 29 +9 M

5 DE Bay 5T 1 7.5 +8 M

6 GH Bay 10 T 3 22 +9 M

f) Various units of Foundries and List of Equipment’s

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1) Engineering Casting (EC) section:

Moulds are prepared for cast iron castings like door frame, flash
plate, wharf plate for Coke Ovens and steel castings for various units
of the plant.
Equipment:
1 (one) Continuous sand drying and mixing plant. Capacity : 5 Ton /
Hr.
2) Steel Foundry:
The list of equipment are as follows:
i) Electric Arc Furnace: 1 (one) No.
Capacity: 5 Ton
ii) Sand Mixer: 1 No.
PROJECT DESCRIPTION

iii) Sand Dryer: 2 Nos.

iv) Annealing Furnace: 1 No. For Heat treatment of Castings.
v) Fettling equipment like swing grinder and gas cutting facilities
3) Non-Ferrous Foundry:
List of Equipment’s are as follows:
i) Bale-out Pit Fces: 3 (thee) Nos.
Holding Capacity: 300 Kgs of Brass / Bronze
ii) Tilting Fce. (Hydraulically operated)
Holding Capacity: 500 Kgs of Brass / Bronze
iii) One hand operated crane 3 Ton capacity
4) Pattern Shop
Patter Shop building will remain. Dismantling of Pattern Shop unit
has not been considered.
5) Heavy Steel Casting section
i) This casting section is presently installed in a separate area in
SMS-Shop : At the end part AB bay (Pit Side).
ii) For manufacturing of heavy spares (i.e. spares in excess of 5Tons
in weight), sand moulds are prepared in Heavy Steel Casting
section.
The molten metal for the purpose of casting is obtained from
the Steel Melting Shop.

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iii) Various products include Steel Slag pots, PMD Tyre for Sinter
Plants, Trunnion Ring for LD Converter, Intermediate pieces,
Dump boxes for SMS, Breast Roll carrier for Plate Mill.
[Link] Dismantling of ED (Works) Building complex
a) It will be required to completely dismantle and dispose the ED(Works)
Building complex for new SMS shop.
b) Construction of New building has been considered in the FR as a
measure of relocation of ED(Works) building complex.
c) The Construction work of Relocated New ED(Works) building, has
been planned to be executed under Package [Link]-A.
d) Dismantling & disposal work will be executed under Enabling Package
No. I.

PROJECT DESCRIPTION
e) Dismantling work under Pkg.I will start only after completion of New
Building under Package No. III-A and after shifting of personnel to
new building complex.
f) Brief about existing ED(W) Building Complex
i) ED(W) building complex is of civil construction with Roof of R.C.C
(Reinforced Cement Concrete) construction and walls are of
brickwork construction.
ii) Constructed in 3 (three) floors.
· Ground floor : Plinth Area 2725 SqM [ ~ 29,330 SqFt]
· First floor : Plinth Area 2725 SqM [ ~ 29,330 SqFt]
· Second floor : Plinth Area 1115 SqM [ ~ 12,000 SqFt]
iii) ED(W) Building Complex houses the offices of the Senior level
executives of Rourkela Steel Plant including their secretariats,
Technical Advisors (TA), Secretarial Staffs, Working executives &
Non-executives, Conference Halls, Panel discussion rooms, Store
rooms, Record Rooms, Offices, pantry rooms, washrooms,
supporting and service staffs & facilities.
The Senior level executives (E-9 & E-8 grades) are:
1) Executive Director (Works)
2) Chief General Manager I/c (Maint.)
3) Chief General Manager & I/c (Services)
4) Chief General Manager & I/c (Steel)
5) Chief General Manager (PPC)

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6) Chief General Manager (Electrical)

7) Chief General Manager (Safety & Fire)
8) Chief General Manager (Mechanical)
9) Chief General Manager (Utility & Environment)
In addition, full-fledged offices of the following Departments are also
housed in the complex:
1) Production, Planning & Control (PPC) Department
2) Plant Control
3) AMR Deptt.
4) Personnel & Administration (Works) Deptt.
5) PCS
PROJECT DESCRIPTION

6) MSS
[Link] Dismantling of Research, Control & Laboratory (RCL) Building complex
a) It will be required to completely dismantle and dispose the RCL
Building complex for new SMS shop.
b) Construction of New building has been considered in the FR as a
measure of relocation of RCL building complex.
c) The Construction work of Relocated New RCL, has been planned to be
executed under Package [Link]-B.
d) Dismantling & disposal work of existing RCL building will be executed
under Enabling Package No. I.
e) Dismantling work under Pkg.I will start only after completion of New
Building under Package No. III-A and after shifting of personnel &
equipment to new building complex.
f) Brief about existing RCL Building Complex
i) RCL building complex is of civil construction with Roof of R.C.C
(Reinforced Cement Concrete) construction and walls are of
brickwork construction
ii) Constructed in 3 (three) floors.
· Basement floor : Plinth Area 1860 SqM [ ~ 20,020 SqFt]
· Ground floor : Plinth Area 2275 SqM [ ~ 24,485 SqFt]
· First floor : Plinth Area 2275 SqM [ ~ 24,485 SqFt]

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iii) RCL Building Complex houses various laboratory facilities including

the office of Chief General Manager (Quality) and executives & non-
executive personnel of RCL Department.
iv) The list of Laboratory facilities, which are presently installed in the
existing RCL building.
· Refractory Laboratory – 3 Nos.
· Heat Treatment Laboratory
· Coal & Coke Laboratory – 2 nos.
· Pulverizer, Micum Test & sample preparation Room
· Sample Receipt & Storing facilities
· Metallography Lab
· Non-Destructive Testing (NDT)

PROJECT DESCRIPTION
· CCM-I Laboratory
· Iron & Steel # 2 Laboratory
· Water & Oil testing Laboratory
[Link] Dismantling of Stripper Yard building alongwith railtracks in the area.
a) The Stripper Yard building have been defunct after stoppage of ingot
casting route at RSP.
b) Stripper yard were originally equipped with 40 Ton capacity Stripping
cranes and travelling crab 10 Ton capacity
c) Stripper Yard building along with EOT cranes and railtracks will be
completely dismantled.
[Link] Dismantling of other existing Buildings
Details of existing buildings which will be dismantled and relocation of
certain buildings have been considered in Enabling Pkg.I, are as follows:

Sl Existing Building Floor area No. of Remarks

(Approx.) Storey

1. SMS-I Office Building 1000 SqM Single Relocation

considered

2. Marammat Bhawan 12.4 m x 34.5 m 3- Storey -do-

3. Crane Uddyan building 18m x 12m 2- Storey -do-

4. Crane maintenance office 250 SqM Single -do-

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Sl Existing Building Floor area No. of Remarks

(Approx.) Storey
building

5. LU-OP, Stock control/ Stock 245 SqM 3-Storey -do-

verification office building.

6. CISF Building (near Foundry) 12m x 9 m Single -do-

7. Canteen Buildings – 3 Nos. Relocation

(Near SMS-I, RCL & RCM considered.
shed)

8. Office building complex of No Relocation

Foundry shop, RCM shed
near Foundry, Temporary
PROJECT DESCRIPTION

sheds, PCBs in the area.

[Link] Dismantling of Part of Repair Shop Mechanical (RSM) [adjacent to Power

Distribution Building / SLCC building]
a) It is required to dismantle part of the covered shed of Repair Shop
Mechanical, located adjacent to PDB / SLCC building. Scale Pit &
Pump House facilities of new SMS has been planned to be located in
this vicinity.
b) Approximately 25 length of the RSM bay towards main road will be
dismantled, keeping rail track of Dividing line in position.
c) Before dismantling buffer-stops will be installed in crane rail for EOT
crane (32t/5t).
d) After dismantling gable end in structural framework will be
constructed by the side of railtrack.
e) The overhead existing utility lines running in the area will be rerouted
before dismantling.

The equipment and facilities envisaged in are described separately as

Enabling works and Installation of new facilities in respective discipline in this
chapter below.

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4.3 MECHANICAL
4.3.1 Mechanical - Enabling Works – Dismantling and Relocation of Facilities
[Link] Proposed Facilities
i) Installation of new drive arrangement for conveyor#0 at the new
junction house after necessary modification in the existing conveyor#0
gallery.
ii) Shifting of existing tail pulley arrangement of conveyor#7 in the new
junction house after necessary modification in the existing conveyor#7
gallery.
iii) Installation of new conveyors along with new technological structure
and conveyor gallery as per new layout.
iv) Installation of new junction houses.
v) Provision of electric hoist along with monorail for maintenance of
drive arrangement at new junction houses

PROJECT DESCRIPTION
vi) Provision of chain pulley block along with monorail for maintenance of
tail pullet arrangement at new junction houses
vii) A shutdown of 7 days will be required during interfacing jobs at
conveyor -1 and conveyor-7.
[Link] Dismantling
i) Complete dismantling of existing bunker and conveyor #5.
ii) Length of the existing conveyor#0 and Conveyor #7 will be reduced as
per the new arrangement.

4.3.2 Mechanical - Installation of New Facilities

Mechanical work envisages provision of the following:
[Link] The torpedo ladle car (TLC) will be used to transfer HM from BF’s to Torpedo
ladle receiving station in Proposed SMS and CCM Shop. New torpedo ladle
cars along with its accessories like upper car, under carriage drive
arrangements etc. have been considered for transfer of HM. The technical
parameters envisaged for the Torpedo ladle are as follows:

Sl. No. Parameter Value

1. Capacity of TLC 350t

2. Quantity 3 nos.

3. Negotiating curve radius (Min.) 100m

4. Speed on track

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Sl. No. Parameter Value

With hot metal 10 km/hr

Without hot metal 20 km/hr

5. Track gauge 1676mm

6. Tilting angle +1200 (normal)

+ 3600 (maximum)

7. Tilting Speed 0.2 rpm (maximum)

0.02 rpm (creep)

[Link] Torpedo Ladle Receiving Station

PROJECT DESCRIPTION

Self-Propelled Ladle Transfer Car for Re-ladling

HM charging ladle will be placed on the ladle transfer car (1 no. in each re-
lading pits) in re-lading pits with the help of shop cranes in HM receipt bay
as per attached layout. The ladle transfer car will carry the hot metal ladle in
the re-ladling pit for pouring hot metal from torpedo ladle and then will
bring back the ladle for lifting by shop crane and placing on self-propelled
ladle-cum-slag pot transfer car of de-sulphurization unit. The ladle car will be
driven by electric motors. The movement of car will be controlled from the
adjacent control pulpit. The ladle transfer car will have high temperature
withstanding capacity.
[Link] Hot Metal De-Sulphurization
Hot metal de-sulphurization unit (1x150t) will be installed for pre- treatment
of hot metal. The indicative mechanical equipment & facilities for hot metal
de-sulphurization unit is as mentioned below:
[Link].1 Reagent Unloading and Storage Facilities
Reagent will be stored in two storage silos. One silo will be dedicated to lime
and other silo to magnesium powder. Both the reagents will be supplied to
the silo building in tankers. Filling station will consist of a valve and hose
system. The reagent will be pneumatically transferred from the tanker to the
silo. The silo will be equipped with a fluidising cone at its lower discharge
end. Reagent will be fluidised before being gravity fed from the silo to the
transport dispenser.
Lime Reagent Silo

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One no. silo will be provided and will have a capacity of 120m 3. It will mainly
consist of the following:
· Storage silo body
· Fluidising cone
· Fluidising liner
· Displaced air filter unit
· Rupture disc unit
· Silo level probe
· On-silo valves
· Vent filters
Magnesium Reagent Silo

PROJECT DESCRIPTION
One no. silo will be provided and will have a capacity of 30m3. It will mainly
consist of the following
· Storage silo body
· Fluidising cone
· Fluidising liner
· Displaced air filter unit
· Rupture disc unit
· Silo level probe
· On-silo valves
· Vent filters
Valve Racks
All process valves and instruments will be provided mounted on steel
support frames. Pipings will be provided for the transport of reagents from
the tankers to the silos.
Lime and Magnesium Transport Dispenser
One no. each lime and magnesium transport dispenser will be provided and
will have a capacity of 1m3 and 0.5m3 respectively. It will mainly consist of the
following
· Fill pipe between silo and transport dispenser complete with valves
· Transport dispenser
· Fluidising cone

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· Fluidising liner
· On-equipment valves & instrumentation
· Weighing system and load cells
· Transport dispenser valve rack complete with valves and
instrumentation
· Reagent transport pipings with reinforced bends
[Link].2 Injection Dispenser
One no. each lime and magnesium injection dispenser will be provided and
will have a capacity of 1.5m3 and 0.5m3 respectively. It will mainly consist of
the following:
· Injection dispenser complete with support frame
· Weighing system and load cells
PROJECT DESCRIPTION

· Fluidising cone
· Fluidising liner
· Fill pipe
· Actuated fill valve
· Vent line
· On-equipment valves & instrumentation
· Material flow control valves
· Valve racks complete with valves and instrumentation
· Mass flow controller
· Piping between dispenser & lance unit, including shot blast hose
[Link].3 Lance System
The injection lance unit will consist of a vertical mast, fabricated from steel.
There will be three lances, two for injection (one working and one standby)
and the third for temperature measurement/ sampling. The system will
primarily consist of
· Support structures – 1set
· Carriages – 3 sets
· Sprockets – 3 sets
· Duplex chain – 3 sets
· Drive units – 3 sets

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· Hose/ cable drag chain – 3 sets

· Limit switches – 3 sets
· Lubrication piping and manifold for lubrication of critical components
from central location using manual grease gun
[Link].4 Lance Changing Device and Storage Unit
A lance storage rack will be provided with six available slots for old and new
lances. A 2t jib hoist will be provided to carry out lance exchange. The jib
hoist will raise new lances from floor level and place them in the storage rack.
It will also remove old lances and lower them to floor level for removal. The
jib will be provided with off centre lifting device so that new lances can be
lifted vertically and presented to the connecting flange clamped in the lance
carriage.
[Link].5 Ladle-Cum-Slag Pot Transfer Car with Tilting Device

PROJECT DESCRIPTION
The ladle transfer car will be used for moving the hot metal ladle into the de-
sulphurizing position and tilting for raking. The movement of this car will be
controlled from the control pulpit. A carrier frame of slag pot will be
integrated into the transfer car to collect slag being removed from the hot
metal charging ladle during raking. The car will primarily consist of
· Car frame with buffers
· Slag pot handling frame
· Idler and driven wheel assemblies including bearing blocks
· Travel mechanism
· Emergency pull out hook with pulley and steel rope
· Hinged titling frame
· Hydraulic system
· Cable reeling drum
· Lubrication piping and manifold
· The tracks of ladle cum slag pot transfer car will extend from de
sulphurization to slag handling bay
[Link].6 Slag Raking Machine
The slag raking machine will be mounted on a fixed platform. The machine
will consist of hydraulically actuated telescopic boom, on the end of which
will be a replaceable raking machine blade. All the motions of boom will be
carried out by hydraulic cylinders. An electric hoist of 0.5t capacity with
monorail will be provided to take the weight of raking machine blade and

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knock out the connecting wedge. The same hoist will be used to pick up a
new raking machine blade, position and reconnect it. Control of the machine
during de-slagging will be either local or remote from the air conditioned
control room using closed circuit cameras.
[Link].7 Following handling facilities has been envisaged:
· 2t electric hoists for magnesium bag handling
· 1t electric hoist for hydraulic room
· 0.5t electric hoist for raking machine blade
· 2t jib hoist for lance exchange
[Link].8 Following facilities will be provided
· HM ladle stand (vertical) – 2 nos.
· HM ladle heater (vertical) with stand – 1 no.
PROJECT DESCRIPTION

· Bucket for muck & debris – 2 nos.

[Link] BOF Converter
[Link].1 BOF Converter (1x150t) heat size will broadly consist of following equipment/
system :
1) BOF Proper – 1 set
· Vessel Shell
· Trunnion ring
· Vessel Suspension system
· Trunnion bearing and pedestals
· Slag shields for radiation protection
· Rotary joints
· Sample & temperature measurement system
2) BOF Vessel Tilting Drive System & Brake – 1set
· Tilt drive system
· Pneumatic emergency drive system
3) Vessel Relining facility with one no. 3t forklift for transportation of
refractory – 1 set
4) Bottom Stirring Equipment
It will consist of a set of porous plugs, hoses and pipework, valve station,
control instruments and auxiliary equipment. Through the porous plugs,
nitrogen or argon can be blown in at the bottom of the vessel

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5) Oxygen blowing lance system with carriage, handling system &

maintenance facilities (complete set) – 1 set , including
· Oxygen lance, (body & tips), for blowing lance and spare lance set
· Additional blowing lance tip
· Lance carriage system complete with lance trolley
· Lance guide system with accessories
· Lance hoist system – lance lowering and lifting system with
emergency pneumatic lance lifting device
· Lance cooling water system (pump, heat exchangers, valves, pipes,
hoses, make up water system – complete set)
· Valve station for Oxygen complete system including Oxygen pipes,
hoses, valves etc.

PROJECT DESCRIPTION
· Lance guide car (lance handling/ changing system- automatic)
· Quick release coupling for Oxygen and water system
· Slag splashing facilities with valve station
· Bath height measurement system
· Lance clamping/ de-skulling system with maintenance de-skulling
platform
6) Lance De-skulling & Re-Tipping Facilities – 1 set , Including
· Lance tilting device
· Tube bearing with columns(fixed & movable) roller trestle
· Traverse for lifting lances – lifting attachment for horizontal
transportation including belt sling
· Lance exchange device for handling of lance from vertical to
horizontal position & vice-versa
· Lance storage rack
· Gas cutting facility for cutting of skull
· Muck boxes with wheels for collection & transportation of skull
· Hack saw machine
· Angle grinding machine
· Hydraulic pressure test device
· Tip welding device
· Lance tip cutting device

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· Spare lance stands

7) Sublance System
It will measure the carbon content, bath temperature, soluble oxygen, bath
level; secure a steel sample in the upright position of the converter. The
system will have sublance assembly (comprising of sublance with tip, travel
carriage, cooling water & nitrogen hoses, guide column, centering tong,
lance hoist, sublance measurement system), robot system, water cooled
fume hood gate including nitrogen sealing & control unit, safety fences,
storage rack for lances & hoses, sublance repair equipment, utility system,
electrics and automation.
8) Slag detection & stopper system in BOF – 1 set each , including
· Slag detection system (Infrared type)
· Slag stopper system (pneumatic type) comprising of housing with
PROJECT DESCRIPTION

heat shields & accessories, rotary joint, piping & flexible hoses, slag
protector for slag stopper, pneumatic control panel, pressure
reducing station for nitrogen, buffer tank, storage tank etc.
9) Tap hole maintenance machine/ facilities along with maintenance platform
– 1 set
10) On line inert gas purging system in ladle, complete set – 1 set , including
· Hoses/ pipes
· Inert gas valve station/ piping etc.
· Hose reeling drum system
· Arrangement for hose supports
· Instrumentation system
11) Scrap handling equipment & facilities comprising of
· Scrap storage pit for return scrap, pig iron and DRI
· 3 nos. scrap boxes (1 in the scrap yard,1 in the charging bay and 1
spare) suitable for handling with semi portal crane and overhead
crane
· 1 no. scrap box transfer car with emergency pulling device consisting
of a deflection roller & rope
· Track system for scrap box transfer car
· Rail weighing bridge
· Traverse for scrap box
· parking stand for storage of traverse

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12) Flux charging system with belt conveyors, bins, vibratory feeders, gates,
chutes and other facilities will be provided. The flux charging will be
designed for uniform feeding of flux to the convertor. The system will
primarily comprise of:
· Belt conveyor from bottom of silo of calcined lime and calcined dolo
at lime plant to top of bins
· Reversible shuttle belt conveyor for filling the high level bins
· 12 nos. high level storage bins consisting of level detector & bin
vibrators

Material Number Useful volume Total volume (m3)

of bins of bin (m3)

Burnt lime 2 150 300

PROJECT DESCRIPTION
Calcined dolo 1 70 70

Iron ore 1 70 70

Raw dolomite 1 30 30

DRI 1 150 150

Pig iron 1 30 30

Coke 2 30 60

Bauxite 1 30 30

Spare 1 30 30

Spare 1 30 30

Total 12

The high level storage bins will also include the two way chute,
charging chute and emergency discharge chute & rejection container
· Stopper gates, vibratory feeders below high level storage bins
· 6 nos. weighing bins (2 x 10 m³, 4 x 9 m³)
· vibratory feeders below weighing bins
· 2 nos. charging bins (2x 10m3)
· Gate and Chute system at required places

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· Material handling equipment along with steel structure necessary for

support, different platforms
13) Ferro-alloy charging system with belt conveyors, bins, vibratory feeders,
gates, chutes and other facilities will be provided. The system will primarily
comprise of:
· 4 nos. self discharging buckets of 2m3
· 10 nos. high level storage bins as follows:

Material Number of Useful volume Total volume (m3)

bins of bin (m3)

Pet coke 1 16 16

FeSi 75 1 16 16
PROJECT DESCRIPTION

FeMn 75 1 16 16

SiMn 70 1 16 16

Fe Mn MC 1 16 16

Lime 2 16 32

Al 1 16 16

Spare 2 16 32

Total 10

· vibratory feeders below high level storage bins

· 5 nos. weighing bins (5 x 3 m³)
· Belt conveyors for transport of alloys to charging bins
· 1 no. charging bins (1 x 10m3)
· Gate and Chute system at required places
· Material handling equipment along with steel structure necessary for
support, different platforms
· For manual alloy feeding system weighing scale (2t) at platform, 5t
electric hoist for handling ferroalloys and 3t capacity forklift has
been considered.
[Link] Steel/ teeming Ladle

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Ladle capacity 150/ 165 t

Ladle Shell Temperature 250 °C

max.

Free Board Min. 500 (as per technological supplier)

Steel flow control Slide gate nozzle

Ar-rinsing By porous plug fitted in bottom (2 Nos.)

No of Steel/ teeming Ladle 9 nos.

Each of the above ladles will be complete with

· Ladle shell, reinforcing rings, trunnions, supporting legs

PROJECT DESCRIPTION
· Tilting lug
· Tilting shackle
· Slide gate connecting plate
· Porous plug etc.
· Auto coupler provision for bottom stirring in steel/ teeming ladle
[Link] Steel/ teeming Ladle – slab caster area

Ladle capacity 150/ 165 t

Ladle Shell Temperature max. 250 °C

No of Steel/ teeming Ladle 2 nos.

Each of the above ladle will be without porous plug and slide gate
[Link] 1 no. self-propelled Steel ladle transfer car with weighing facility for transfer
of Steel ladle from BOF converter to turret bay for heat weight 150t along
with tracks
[Link] 1 no. self-propelled Slag pot transfer car for transfer of slag pot from BOF
converter to slag handling bay along with tracks
[Link] Converter Relining
Following equipment & facilities will be provided:
· Converter lining break out machine
· Converter relining equipment including relining car with hoist &
modular scaffold

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· Converter cooling fan

· Mortar mixer
· Tools for relining
· Stone cutting saw
· Brick cutting machine
· Converter gunning machine
· Fresh air fan
· Tap hole drilling/ resleeving facility
[Link] Repair of Liquid Steel Handling Equipment & Ladle Preparation Bay
· On-line ladle heater(vertical) on transfer car track at converter - 1
no.
PROJECT DESCRIPTION

· Steel Teeming ladle cooler (vertical type) – 2 nos.

· Ladle (Steel Teeming and HM) break-out stand (horizontal type) – 2
nos.
· HM/ Steel Teeming ladle relining platform for 3 ladles – 1 no.
· Mortar mixer
· Tools for relining
· Brick cutting saw
· Ladle gunning machine
· Ladle relining pedestal
· Steel Teeming ladle heater with stand (vertical type) – 2nos.
· Steel Teeming ladle stand (vertical type) – 4 nos.
· Steel Teeming ladle maintenance platform including stand for two
ladles - 1 set
· Repair post for repair & maintenance of ladles (steel & HM) – 1 set
· Slide gate repair stand for 2 ladles – 1 set
· Sand filling tube
· Ladle shell temperature measurement
· Temperature and sampling measurement (manual)
· Hot metal ladle stand with maintenance platform – 1 no.
· Hot metal ladle drier (vertical) with stand – 1set
· Hot metal ladle stand (vertical) – 1 no.

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· Ladle break-out machine (common for HM and steel)

· Buckets for muck & debris – 4nos.
[Link] Slag Bay
The slag from the BOF Converter and De-sulphurisation unit will be
transported in slag pots placed on the rail bound slag transfer cars to the
slag handling area. The slag pots will be handled by overhead cranes for
dumping into the slag pits. After that the slag pots will be lime coated for re-
use and transferred back.
The slag bay will consist of following equipment/ system:
· 10 nos. of Slag pots of 18m3
· Lime coating unit – 1 set
· It will consist of silo for lime fines with supporting structure,

PROJECT DESCRIPTION
pneumatic filling system, level indicator etc. and spray gun with
compressed air hose & material hose.
· Slag cooling facility for cooling of slag by spray water
· Slag dumping pits
· Dozer – 1 no.
· 35t dumper – 1 no.
· Backhoe loader (0.5 m3) – 1 no.
· Pay Loader (0.5 m3) – 1 no.
[Link] HM Ladle - Ladle shell with pouring spout, reinforcing bands, fist bottom
supporting legs, trunnions with wearing bushes, tilting lug, tilting shackle etc.
has been envisaged. The details are as follows:

Ladle capacity 165t

Ladle shell temperature 2500C

max.

Free Board Min. 500 (as per technological supplier)

No. of HM Ladle 4 nos.

[Link] Handling facilities

· Lance handling crane - 10t, crane rail height - +19.5 m approx
· Wall Crane- 3t at Ladle relining platform
· Jib crane – 1t for repair and maintenance of Ladle

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· Jib crane – 1t at Ladle slide gate repair stand – 2 nos.

· Electric/ manual hoists will also be provided for BOF tilting drive,
Oxygen valve station, hydraulic room etc.
[Link] 1 no. 5t capacity passenger lift and 1 no. 5t capacity freight lift at BOF will be
provided. It will cover each floor of the shop building
4.3.3 EQUIPMENT DESCRIPTION OF BOF
[Link] BOF Converter Shell
The BOF shell will comprise of a cast mouth welded to a conical top section, a
cylindrical centre section and spherical bottom welded to the bottom edge of
the cylindrical shell. The tap-hole socket will be welded on the conical top
section. Brick retaining rings will be provided on convenient locations to
facilitate BOF relining.
A part of the platform in front of the BOF will be made detachable to have
PROJECT DESCRIPTION

approach for changing of the vessel.

The BOF shell and trunnion ring will be designed keeping all provisions
required for the combined blowing (Bottom blowing) system.
Design of BOF will have suitable clearance between BOF shell and trunnion
ring for adequate circulation of air and hence cooling of shell.
The Converter will also have inert gas blowing system from the bottom of the
vessel.
Trunnion Ring
The trunnion ring will be of box section design of welded low-alloy steel
plate construction. The forged trunnion will be securely welded into the
trunnion ring. Design of BOF will provide a larger clearance between BOF
shell and trunnion ring for adequate circulation of air and hence cooling of
shell.
BOF Suspension
The BOF will be fixed in the trunnion ring by means of a suitable support
system.
Trunnion Bearing and Pedestals
i) The trunnion shaft will be supported by bearing assemblies. The
bearing will be double-row spherical type. The bearing will be
designed to take all static and dynamic loads during BOF operation.
ii) The bearing assembly located at the drive end of the BOF will be fixed
bearing support while the non-drive end will be sliding bearing

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support. The sliding support will allow thermal expansion of the

trunnion ring that may occur during operation of BOF.
iii) The bearings will be provided with oil lubrication system.
iv) The drive side bearing will be split type.
v) The bearings will be mounted on supporting pedestals of welded steel
plate construction which will be anchored on concrete foundation
vi) The pedestals will be supplied with a set of regulating shims to be
placed on shop foundations with the aim to regulate, if necessary,
supporting bearing assemblies.
vii) On-line condition monitoring system for BOF trunnion shaft bearings
will be provided.
Slag Shields

PROJECT DESCRIPTION
i) The upper part of the trunnion ring and vessel fixing parts in the
trunnion ring will be protected from splashing and spitting of molten
steel and slag by protective shields.
ii) Protective elements will be fabricated from rolled steel in the form of
cone shells and will be welded to supporting brackets. The pedestals
from the BOF side will be protected with refractory material.
iii) Stationary slag shields will be also provided below the BOF for
deflecting sloppy slag to the slag pot during blowing.
Tilt Drive
i) The BOF will be tilted with the help of electro mechanical drive. Brake
with emergency release mechanism will be provided. The drive system
will incorporate pneumatic motor which will be used for emergency
tilting back of BOF to vertical, in case of power failure. Drive system
will have suitable access for maintenance purposes.
ii) The drive will be designed taking into account all the dynamic loads
arising in the course of starting and braking, BOF loading, skull
removal and BOF relining.
iii) New oil lubrication system for bearings of output shaft of tilting drive
gear boxes and bull gears proper will be provided. There will be one
system for trunnion shaft bearing and one system for output shaft of
tilting drive gear boxes and bull gears.
Oxygen Lance System

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BOF will be equipped with an Oxygen lance system consisting of two Oxygen
lances (one working and one standby). The lance system will have the
following features:
i) Exchange of the operating lance with the stand-by lance, if required.
ii) Installation / dismantling of Oxygen lance into/ from the lance
Carriage.
iii) Use of the blowing lance for preheating the newly relined BOFs.
iv) Oxygen supply to the BOFs will be through two identical water-
cooled Oxygen lances. One of the lances will be in the blowing
position and the other will be in the standby position.
v) BOF will be provided with four lances – one operating, one stand-by
and 2 nos. as spares. The tube for supply of oxygen will be made of
stainless steel. Other tubes will be of carbon steel. The lance casing will
PROJECT DESCRIPTION

be fabricated from seamless pipes and will be of straight cylindrical

design.
vi) Lance tip will be fabricated from malleable, high conductivity copper
without any oxygen content. The construction of the lance as
assembled with hose and suspending bracket will be such that it will
provide safety of operation and ensure vertical alignment along centre
line of the BOF.
Carriage with Guide
i) One movable lance carriage will be provided. The guide frames will be
mounted on the platform, one for working lance and second one for
the standby. The carriage will be installed on rail tracks.
ii) The rigid lance guides will consist of two guide rails interconnected
with each other by welded structure and will serve for guiding the
running rollers and the guide rollers for the lance carrier. Top of the
guide will be equipped with 2 limit switches interacting with carriages.
Lance Carrier
i) Two lance carriers will be provided for BOF. The lance carrier will be
equipped with 4 pairs of mutually perpendicular rollers, rolling over
the guide ensuring that the lances will be always in the centre-line of
the BOF. The carrier will be manufactured from steel plates and has
got upper cantilever featuring vertical slot for lance trunnions and a
bottom cantilever featuring screw type lock. The carrier will be
equipped with special device providing its fall within the guides in
case of wire rope breakage.

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ii) Rigid guides consist of 2 shafts guiding rollers of the lance carriage.
Top of the guide will be equipped with 4 limit switches interacting
with carriers. Suitable interlocks will also be provided.
Lance hoist mechanism
i) Two identical lance hoists, one for each lance, will be provided for the
vertical movement of the lance within the lance guide frame.
ii) The lance hoist mechanism will be complete with drive motor, flexible
couplings to electro-magnetic brakes, a gear reducer, coupling,
bearing, rope drum, rope and kinematic block. In addition to the main
motor one auxiliary motor will be provided for emergency lifting of
the lance from BOF. The pneumatic drive consists of cylindrical
reducing gear with pneumatic drive and pneumatic motors.
iii) The mechanisms for lifting and lowering lances consist of a differential

PROJECT DESCRIPTION
reducing gear & provided with wheels.
iv) Wire ropes will be fixed to the suspension of the carriage with pulleys
and will be wound on the drum. Additional safety ropes will be
provided to the carriage body. The drum installation will be equipped
with devices for tripping the drive in case of wire rope breaker or
slackening.
[Link] Ladle Furnace
Ladle furnace (with twin arcing station) 1x150t will be installed for secondary
refining of liquid steel. All the associated facilities will be provided for ladle
furnace
[Link].1 One twin track swivelling arcing system type ladle furnace will broadly consist
of following equipment/ system:
i) Self-propelled ladle transfer cars equipped with weighing system
along with tracks & pits, twin tracks - 2 sets
ii) Water cooled ladle roof complete with supporting system – 2 sets + 2
sets(spare)
iii) Roof lifting arrangement – 2 sets
iv) Swivelling Arc Heating System consisting Electrode Masts and Arms &
Electrode Holder and Clamp System for both station - 1 set
v) Electrode nippling and storage stand/ station – 1 set along with 1 no.
jib crane at suitable location
vi) Ferro Alloy Feeding Arrangement (FAFA) – 1 set
For addition of alloy following storage bins have been considered:

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Sl. No. Items No. of Useful volume of bin (m3)

bins

1. CaO 3 3 x 16

2. CaF2 1 1 x 12

3. Coke 1 1 x 16

4. FeMn (HC) 1 1 x 16

5. FeSi 1 1 x 16

6. SiMn 1 1 x 12

7. MnSi 1 1 x 12
PROJECT DESCRIPTION

8. FeCr 1 1 x 12

9. Spare 2 2 x 12

Total - 12

Weighing bins – 5 nos. (5 x 3m3)

Charging bin – 1 no. (1 X 5m3)
Charging chutes for two treatment station and emergency discharge chute &
container.
vii) Wire feeding system- 2 sets (1 set for each station)
viii) Temperature measurement and sampling Lance- 2 sets (1 set for each
station)
ix) Inert gas injection and stirring system with auto coupler – 2 sets (1 set
for each station)
x) Hydraulic system – 1 set
xi) Centralized grease lubrication system – 1 set
xii) Emergency top lance (off line along the LF treatment track) - 2 sets (1
set for each station)
[Link].2 The Fe-alloys/ additives will be received in 2m3 capacity self-discharging
containers from Fe-alloy storage by road transport. This will be discharged to
the overhead bunkers by the crane in the bay. Six nos. self-discharging
bucket of 2m3 has been envisaged for FAFA system.

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[Link].3 Handling facilities such as electric hoists in hydraulic room, 10t jib crane near
ladle station will be provided.
[Link].4 Laboratory facilities
Facilities for sample preparation (polishing, drilling & cutting) – 1 set each
[Link] RH-OB Degasser Unit
Following mechanical components have been envisaged for RH-OB (1x150t)
degasser unit:
[Link].1 Vessel
The vessel is of a monoblock type with welded snorkels. The vessel is
equipped with sockets for temperature measurements, supports for vessel
support in the lifting cage and at the steel structure relining station as well as
trunnions for vessel transport by the shop crane. Further an alloying socket is
part of vessel. The hot off take connects the vessel with the vacuum pump.

PROJECT DESCRIPTION
The flanges at the hot off take are water cooled. Between the hot off take
and the main part of the vessel one vacuum sealing ring will be installed and
the connection between of both parts will be ensured by the gravity. The hot
off take is equipped with one water cooled TV-camera of pin hole design and
one central socket for path through of the T-COB lance.
[Link].2 Vessel Lifting System
The vacuum vessel is mounted to a lifting frame with three swivel supports.
The vertical lifting is guided by the guide rollers on the frame and by guide
rails mounted to the steel structure. At the upper end of the lifting frame
cable sheaves are mounted. Other cable sheaves are permanently fitted to
the steel structure above. A winch with drive is mounted on a platform at the
side of the guiding steel structure. It consists of two motor driven cable
drums, couplings, brakes and a gearbox. In case of failure of one motor, the
lifting still can be done with the remaining motor at reduced speed. Two
cables are installed which are fixed on one side to the drums. They pass
through the cable sheaves and are fixed to the steel structure above. For
standby position of the lifting cage, swivel supports, which are mounted to
the steel structure, will be moved out in place to provide vessel support. All
vessel movements can be controlled from a central control station or from
the ground floor. Interlocks will be provided for all operation modes.

[Link].3 T-COB Lance System

The T-COB Lance will be installed in a carriage in order to move the lance out
of the maintenance crane stroke in case of off take exchange. The T-COB
lance body will be designed in a mono-block, the different pipes are sealed
by packing. The lance is equipped with a double jacket water-cooling and is
used to blow oxygen, nitrogen or gas depending on the process

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requirements. Flexible hoses with quick exchange joints will feed the utilities
so that lance exchange can be carried out quickly. At the top the tubes are
fitted with sockets for water in- and outlet as well as oxygen or nitrogen. At
the top the lance is equipped with a lifting lug for maintenance using the
crane. The attachment to the lance carriage will be realized by means of a
quick joint. Excellent vacuum decarburization capability will be realized by
means of a special designed center oxygen nozzle in combination of an
advanced vessel design and a strong vacuum pump system ensuring a stable
operation. The top oxygen lance will be sealed by a stuffing box to secure a
high oxygen efficiency, air tightness, as well as operation safety.
The multifunctional lance system comprises the following main functions:
i) Oxygen Blowing for Decarburisation
ii) Oxygen Blowing for Chemical Heating
iii) Quick skull removing with oxygen jet
PROJECT DESCRIPTION

iv) Vessel heating by Gas/Oxygen Supply under atmosphere

v) Temperature holding between treatments
vi) Skull removal by using the burner function under atmosphere
vii) Lance storage for two lances will be provided
[Link].4 Vacuum Pump System
The vacuum system is used for evacuation of the RH Vessel to allow the
vacuum treatment of liquid steel.
The vacuum pump is designed for:
i) Light treatment
ii) Hydrogen removal
iii) Natural decarburization without oxygen blowing
iv) Forced decarburization treatment with oxygen blowing
v) Chemical heating
The vacuum pump is designed as a system with steam ejector vacuum pump
[Link].5 Temperature Measuring and Sampling Equipment
This equipment will be capable to perform automatically the following
functions:
i) Temperature measuring
ii) Free Oxygen measuring
iii) Sampling

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iv) Slag breaking

The equipment will be located on the platform near to the control room and
consists of a frame construction with four vertical guide rails mounted onto a
tilting arm. Four carriages are running in these guide rails. Each carriage can
be moved independently vertically by a hoist with gear motor, coup ling and
endless chain. Three carriages are dedicated to take metal samples,
temperature/ Oxygen probes or probes to measure the bath temperature
only. The fourth carriage carries a ram for slag breaking. The tilting arm with
the four guide rails and carriages is tilted by a cylinder for slag breaking and
for immersion of the lances into the molten steel. The guide rails for the
samples, temperature/ Oxygen probes and the guide rail for the slag breaker
are arranged in an angle to each other, so that they immerge at the same
point into the steel. The instruments and displays for the temperature/
Oxygen measuring and sampling equipment will be located in the main

PROJECT DESCRIPTION
control panel.
[Link].6 Ferro Alloy Transportation & Addition System
A system of overhead bunkers (12 nos.) has been envisaged for charging of
various Fe-alloys into the RH-OB vessel. The Fe-alloys/ additives will be
received in 2m3 capacity self-discharging containers from Fe-alloy storage by
road transport. This will be discharged to the overhead bunkers by the crane
in the bay. Four nos. self-discharging bucket of 2m3 has been envisaged for
the system.
The various materials stored in each bunker are as follows:

Bunker no. Material Useful volume of No. of bins

bins (m3)

1. Fe Si 10 1

2. Fe Mn (L.C.) 10 1

3. Fe Mn (H.C.) 10 1

4. Fe Si HP 10 1

5. Fe Cr LC 10 1

6. Fe Ni 10 1

7. Si Mn 10 1

8. Al Shots 10 1

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Micro Alloys

9. Fe Mo 5 1

10. Fe Ti 5 1

11. Fe Nb 5 1

12. Fe V 5 1

Total -12

Each bunker will be provided with level switches and manual operated rack &
pinion gate. These bunkers will feed to weighing hoppers (3nos. – 1 x 1m3 +
2 x 2.5m3) through vibrating feeder. These weighing hoppers will feed the
material to horizontal reversible conveyor, which will either feed to a steep
PROJECT DESCRIPTION

inclined belt conveyor or to a container in the shop floor for rejecting the
material as per requirement. The steeped belt conveyor will feed the material
into the vacuum vessel via charging bin & charging chute. Vacuum lock will
be provided for addition of the required material into the vacuum vessel. The
entire Fe-alloy charging system and the process operations will be fully
automated by use of PLC, computer and appropriate process software.
The system is designed for suction of dust coming from the material
handling system of RH-OB degasser unit. The collected gas will be connected
to the dust line of fume extraction system consisting of bag filter & ID fan
and a duct supported with the shop column. This will ensure work zone dust
concentration of not more than 5 mg/Nm3 as per CPCB norm.
[Link].7 Wire feeding system
One no. of 4-wire feeding system for feeding of Aluminium/ CaSi/ CaF cored
wires will be provided. Machine will have two tracks for feeding two wires
simultaneously or individually from two wire strands. Each wire will be driven
by roller pairs independently. The coils will be located in the de-coiling unit,
which will also be provided. The wire feeder will be equipped with its own
control system based on PC. Automatic and manual modes of operation will
be possible. Essential parts of the wire feeding machine are the machine
itself, de-coiling units, wire guides into the machine, coil supports, telescopic
wire guiding system and wire cutting system.
[Link].8 Vessel Maintenance
For vessel maintenance and repair the complete vessel will be transported
into the maintenance area. The following working position in the
maintenance area will be provided:

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i) 1 stand for vessel relining

ii) 1 stand for vessel preheating
iii) 1 stands for cooling, break out, snorkel exchange
iv) 1 stand for off take repair / drying
[Link].9 Snorkel Maintenance Car
One no. of self-propelled snorkel maintenance car along with accessories has
been envisaged. The main platform of the snorkel maintenance car is
equipped with a gunning machine with manipulator for repair of the snorkel
in hot condition. The snorkel maintenance car will be controlled from a local
control box on shop floor. The gunning machine will be controlled from a
local control box on the car. For snorkel deskulling a deskulling box will be
installed on the snorkel maintenance car

PROJECT DESCRIPTION
[Link].10 Self-propelled ladle transfer car along with tracks & pits. The ladle transfer
car will be equipped with a vessel exchange frame - 1 set
[Link].11 Handling Facilities
5t Jib crane at snorkel maintenance platform and electric/manual hoists at
overhead bunker platform, hydraulic room and ejector house has been
envisaged for maintenance purpose
[Link] Continuous Casting Plant
[Link].1 List of major equipment/ facilities (tentative and indicative) envisaged are as
follows:

Sl. No. Description Unit Quantity

1. Ladle Equipment

1.1 Ladle turret Set 1

1.2 Ladle cover(lined with refractory) Nos. 4

1.3 Ladle cover manipulator Nos. 2

1.4 Ladle slide gate operating mechanism Nos. 2

1.5 Ladle weighing system on turret Sets 2

1.6 Ladle slide gate lance (Oxygen lancing Set

2
system near slide gate operator)

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1.7 Ladle Shroud manipulator [ Docking Set

(lifting, lowering) and shroud tube 2
rotation will be hydraulic]

2. Tundish & Associated Facilities

2.1 Tundish car Sets 2

2.2 Tundish at casting station Nos. 2

2.3 Tundish cover (split type) Sets 2 Sets (4 nos.)

(Nos.)

2.4 Tundish Slide gate Sets 2

2.5 Automatic SEN changing device Nos. 2

PROJECT DESCRIPTION

(hydraulically operated)

2.6 Tundish preheating station Sets 2

2.7 SEN preheating device Sets 2

2.8 Exchange SEN preheating device Set 1

2.9 Pulpit - operation of mechanical No. 1

equipment

3. Mould, Bender, Segment

3.1 Mould 220mm No. 1

3.2 Mould cover (fixed part) No. 1

3.3 Mould cover (movable part) Nos. 1

3.4 Mould oscillator Sets 1

(Each set
consisting of
02 nos. i.e. 01
left + 01
right)

3.5 Bender 220mm No. 1

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3.6 Bow segment Nos. 6

3.7 Straightener segment Nos. 2

3.8 Horizontal segment Nos. 7

3.9 Strand guide support structure No. 1

4. Machine supporting structure

4.1 Casting platform with columns Set As per

technological
4.2 Ladle operator platform requirement

4.3 Slide gate connecting platform

PROJECT DESCRIPTION
4.4 Stairs and access platforms

4.5 Guides for segment exchange

4.6 Temperature and sampling platform

5. Break-out prediction system Set As per

technological
requirement

6. Emergency equipment

6.1 Overflow box for tundish/ ladle (below No. 1

the tundish)

6.2 Splash protection system (Includes plate No. 1

design to protect the working
personnel/ mould operator at the mould
from liquid steel splashes)

6.3 Tundish emergency/ slag box including Nos. 2

cover (below tundish car)

6.4 Emergency ladle with slide gate No. 1

mechanism

7. Withdrawal units and straightener segment

7.1 Drive rollers with gear box, coupling & Sets As per
technological

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universal joint and supporting structure requirement

8. Dummy bar system

8.1 Dummy bar transition piece 220mm Set 1

8.2 Dummy bar head (220mm) Sets 2 (Set will be

as per
technological
requirement)

8.3 Dummy bar receiver Set 1

8.4 Dummy bar head storage stand Set 1

9. Cutting & Crop Handling

PROJECT DESCRIPTION

9.1 Automatic torch cutting machine No. 1

9.2 Runway supporting structure Set 1

9.3 Nos. 4
(02 nos.
Emergency torch cutter straight type
+ 02 nos.
bend type)

9.4 Crop & sample removing system Set 1

9.5 Automatic Length measurement system Set As per

technological
requirement

10. Run Out Equipment

10.1 Torch approach roller table Set

10.2 Torch cutting roller table

As per
10.3 Run out roller table
technological
10.4 Weighing roller table with weighing grid requirement

10.5 Discharge roller table & inter bay roller

table

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10.6 Slab cross transfer with storage rack in Set

each bay as per layout

10.7 Roller table auxiliaries (moveable stop & Set As required

fixed stop )

11. De-burring & Marking Equipment

11.1 De-burrer No. 1

11.2 Burr discharging device Set 1

11.3 Slab marking machine No. 1

12. Slab Inspection Equipment

PROJECT DESCRIPTION
12.1 Slab inspection grate Set 1

12.2 Slab scarfing device Set 1

12.3 Slab turnover device Set 1

13. Repair and storage stands near caster

13.1 Mould storage stand for inspection Nos.

01
(220mm thick slab)

13.2 Bender storage stand (220,mm thick Nos.

slab) 01
And/or
Nos.
First guide segment storage stand 01
(220mm thick slab)

13.3 Segment storage stand (for each type of Sets

segments i.e. bow, straightener, 01
horizontal)

13.4 Segment assembly and dismantling No.

01
stand

13.5 Segment assembly, calibration and No.

01
dismantling stand

13.6 Mould water testing stand No. 01

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13.7 Segment water testing stand No. 01

13.8 Mould alignment stand No. 01

13.9 Segment alignment stand No. 01

Storage stand at Casting platform

13.10 Mould storage stand 220mm No. 01

13.11 Bender storage stand (220mm thick Nos.

slab) 01
And/or Nos.
First guide segment storage stand (220 01
mm thick slab)
PROJECT DESCRIPTION

14. Mould & segment repair shop (MSRS)

14.1 Mould alignment stand & templates Set 1

14.2 Mould dismantling stand Set 1

14.3 Ready mould storage stand Sets 4

14.4 Mould water testing stand Set 1

14.5 Bender- Loose side aligning stand Set 1

14.6 Bender- Fixed side aligning stand Set 1

14.7 Bender water testing stand Set 1

14.8 Ready bender storage stand Sets 4

14.9 Segment - Loose side aligning stand Set 1

14.10 Segment - Fixed side aligning stand Set 1

14.11 Segment tilting stand Set 1

14.12 Ready segment storage stand Sets 7

14.13 Bearing washing facility (Ultrasonic Set 1

cleaning facility, having a tank capacity
of minimum 250 liters, will be provided

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for segment roller and roller table

bearings).

14.14 Common hydraulic system for operating Set 1

mould, segment tilting stand and
segment HSA stand

14.15 Special tackles and chain ropes for Set 1

handling mould / bender / segments

14.16 Mould measuring instruments Nos. 2

(i) Digital inclinometer for measuring
narrow face taper

(ii) Manual spirit level taper measuring No. 1

PROJECT DESCRIPTION
instrument

14.17 Strand monitoring system (Digital type) Set 1

(Offline roll gap checker including spray
pattern checker, bearing condition, roll
bearing, roll bending etc.)

14.18 Laser alignment system for mould, Set 1

bender and all the segments

15. Operational Spares

15.1 Tundish Nos. 6

15.2 Tundish cover (split type) Sets (Nos.) 06 (12nos.)

15.3 Tundish stopper rod mechanism Sets 4

15.4 SEN change device Sets 2

15.5 Overflow box No. 4

15.6 Tundish emergency/ slag box No. 1

15.7 Dummy bar chain Sets 2

15.8 Dummy bar transition link Nos. 2

15.9 Dummy bar head (for each section of Sets 2

slab)

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15.10 Crop and sample box Nos. 1

15.11 Burr box (at de-burrer) Nos. 1

15.12 Mould Sets 4

15.13 Mould cover (fixed part) No. 1

15.14 Mould cover (movable part) No. 4

15.15 Mould oscillation system Sets 1

(Each set
consisting of
02 nos. i.e. 01
left + 01
PROJECT DESCRIPTION

right)

15.16 Bender Sets 4

15.17 Bow segment Sets 2

15.18 Straightener segment Sets 2

15.19 Horizontal segment Sets 2

[Link].2 Brief Description of Major Mechanical Equipment / Facilities for CCP

A. Ladle Turret
The steel ladle received from BOF/ ladle furnace/ RH-OB will be placed on
the ladle turret by means of crane. The ladle turret will be butterfly type and
will be designed to support, rotate, lift & lower two full ladles simultaneously.
The turret will be fully hydraulically operated. It will also have facilities for
weighing of ladles, handling ladle cover and ladle slag detection. There will
be also provision of emergency rotation of turret. The ladle weighing system
will be based on strain gauge type load cell and will be able to monitor
individual signal from each load cell.
Ladle Cover
Two nos. of ladle covers will be provided to prevent temperature loss from
steel ladles due to radiation. Covers will be refractory lined.
Ladle Slide Gate Operating Mechanism

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The ladle slide gate operating mechanism will be hydraulic type and will be
located in the casting platform for opening/ closing of ladle slide gate. In the
event that liquid steel does not flow after opening of the slide gate, the ladle
slide gate oxygen lance will be utilized to burn open the ladle nozzle. The
lance will also be used for cleaning of the ladle shroud between ladle
exchanges.
B. Tundish and Associated Facilities
Tundish car transfers the tundish from heating position to the casting
position & positions it above the mould. In combination with a second
tundish car, tundish change will be possible without interrupting the casting
process.
The tundish cars will be operating on the casting platform. It will be provided
with electro mechanical drives for travelling and hydraulic system for lifting
and lowering. It will also be provided with hydraulically operated centering

PROJECT DESCRIPTION
mechanism to facilitate centering of SEN with respect to mould.
It will have both normal and creep speed for proper positioning of tundish
over the mould. Power supply for drive motors and control will be through
cable trolley mechanism with drag chain arrangement. Local control desks
with necessary controls, indication and annunciation will be provided.
Arrangement for tundish weighing (load cell based) will also be provided in
the car and display of tundish weight will be indicated on control desk and
casting platform.
Weighing system will be strain gauge type load cell based and the system
will be able to monitor individual signal from each load cell. Tundish car will
have calibration arrangement with standard weight pieces.
The tundish receives the liquid steel and distributes the steel through one
tundish bottom opening to the mould. Each tundish will have nominal
capacity 40t. There will be provision for hot tundish with dual heating system.
Stopper rod system along with system for emergency closing will be
provided for controlling the flow of liquid metal from tundish to mould. Flow
modifier will be provided.
The submerged entry nozzle quick change mechanism will be provided under
the tundish outlets so that preheated submerged entry nozzles can be
quickly changed during casting without interruption or delay in the process.
Tundish will be made of welded steel plates of heavy section. Each tundish
will be supplied with refractory lined metal covers having suitable openings.
It will also be provided with weighing facility. Ladle to tundish slag detection
system will also be provided. Emergency box for tundish, Overflow box for
tundish and overflow trough for turret will also be provided.

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Ladle Shroud Manipulator

The ladle shroud manipulator will be provided for quick & easy positioning
and connection of the shroud to the ladle. The shroud manipulator applies
an upward force sealing the ladle shroud to the ladle nozzle during the
pouring process. With the shroud manipulator all necessary movements of
the shroud will be performed. The ladle shroud manipulator will be hydraulic
type and it will be mounted on the casting floor. Argon/ Nitrogen shrouding
of ladle shroud joint will be provided.
C. Mould & Mould Assembly
Mould assembly is located below tundish on the oscillating table. It provides
initial solidification to forms slab shell in the adjusted thickness and width.
Straight type mould will be provided. Mould assembly along with foot rollers
will be quick change cartridge type. The mould will be located on the
oscillating tables at the start of the casting machine. The mould assembly will
PROJECT DESCRIPTION

be having water cooling arrangement for the copper plates and complete
with necessary fittings for cooling water arrangement for fixing on to the
mould oscillation table and protection cover to avoid damage due to metal
splash and metal overflow.
Mould will be provided with Automatic Width Change Facility of latest design
to adjust section without stoppage of machine.
Off-line mould width calibration facility will also be provided.
Automatic Mould Level Control (AMLC)
An Automatic Mould Level Control (AMLC) system will be provided. AMLC
will be mounted directly above the mould. AMLC will be used to maintain the
level in the mould constant during casting. AMLC system will be complete
with off line calibrator and spare sensors, sensor cable, cooling air hose etc.
Mould Oscillation System
Hydraulic type mould oscillation system will be provided. Oscillation frame
will be water cooled. Frequency of oscillation will change automatically with
change in casting speed. Quick release coupling will be provided for water
hose connection / disconnection. Off line calibration facilities will be
provided.
Necessary grease lubrication system will be provided. All necessary access
and maintenance platform will be provided.
Strand Guide System
Sets of rollers and their supports, strand guides and various segments along
with drives, Segment exchange arrangements / facilities (quick change with
automatic connections) and all accessories will be provided.

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Strand Guide System will be multi point bending and straightening with soft
reduction. Design of segments will ensure easy access for maintenance &
inspection. Automatic roll gap adjustment facilities will be provided.
Withdrawal Units and Straightener Segment
Withdrawal & straightener units with direct drive will be provided. The
withdrawal & straightener units will have reversible drives with infinitely
variable speed and will be complete with motors, gear boxes, couplings,
brakes, universal joints, supporting structures etc. Withdrawal speed will be
synchronized with the frequency of mould oscillation. Top rolls will be
provided with hydraulic cylinders. The design of frame and housing will be
such that roll changing can be carried out with minimum dis-assembly within
minimum time. The housing frame, rolls and bearing housings will be water
cooled.
D. Dummy Bar System

PROJECT DESCRIPTION
Dummy bar system consisting of dummy bars, dummy bar body, dummy bar
heads, dummy bar disconnecting & storage facility, dummy bar receiver with
platform, storage stand and transport device for dummy bar heads, roll gap
checker (dummy bar head type) etc. will be provided. Suitable handling
facilities for dummy bar will be provided
E. Torch Cutting Machine (TCM)
The cast strands will be delivered from the last segment of the strand guide
to the approach roller table of torch cutting machine. The products will be
cut with the help of oxy-propane flame. A cutting torch for the strand of CCM
will be provided for cutting the products and the operation of the unit will be
fully automatic. The unit will comprise of a machine frame, oxy- Propane
torches with pre-heating burners, a gas distribution system including
necessary hoses, connectors, hose guides, travel and pneumatic clamping
mechanism for the torch cutting machine and the related control and
electrical equipment. The unit will be suitable for cutting the maximum size
of products envisaged to be cast in the CCM. Facilities for sludge granulation
and disposal will be provided. The carriage and the holding arms will be soft
water cooled and provided with necessary heat shields. Emergency torch
cutting facility (2 nos. at 2 different locations) will be provided by the side of
the machine to cut products in case of failure of the GCM torches. De-burring
facilities will also be provided.
The roller tables supporting the products during cutting operation will be of
shifting type / tilting type to protect the rolls from the flame of gas cutting
torches. Each roller will be individually driven and water-cooled. Speed of
strand movement will be synchronized with the speed of casting.

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Sample cutting facility, Manual cutting facility, crop end handling system will
also be provided.
F. Run Out Equipment
Run out equipment will consist of the following:
· Torch approach roller table
· Torch Cutting roller table
· Run out roller table
· Weighing roller table with weighing grid
· Discharge roller table and inter bay roller table
· Slab cross transfer with storage rack in each bay as per layout
· Moveable stop and fixed stop
· De-burrer
· Burr discharging device
· Slab marking machine
PROJECT DESCRIPTION

G. Mould & Segment Repair Shop (MSRS)

A mould & segment repair shop (MSRS) has been envisaged (size 30m x
106m). Following facilities have been envisaged in the MSRS:
Mould and segment preparation/ maintenance facilities:
· Mould assembly storage stand
It will be provided to support the moulds for storage. The stand will be made
of welded steel sections complete with centering pins for moulds and lifting
trunnions.
· Mould alignment stand
· It will be provided to hold the mould in the correct position to
allow their alignment prior to the casting. The stand will be
designed to hold the mould for each casting section.
· Mould measuring instruments
· These will be provided to measure the mould internal dimensions
for all sections and calibration.
· Bender & segment storage stand
· Bender & segment tilting stand
· Bender & Segment loose side frame alignment stand
· Bender & Segment Fixed side frame alignment stand
· Mould and segment cleaning and water test stand area
· Hydraulic compact unit for mould and segment maintenance
· Pump station for mould and segment testing stands
· Portable grease pump unit
· Movable platform

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All storage stands will have elevated platforms for ease of

·
inspection
H. Maintenance equipment
Following maintenance equipment has been considered:

Sl. No. Description Quantity

1. CNC Lathe 2

2. High speed precision lathe 1

3. CNC Milling Machine for machining of both 1

broad & narrow face of mould

4. Vertical Milling Machine 1

PROJECT DESCRIPTION
5. Universal Drilling machine 1

6. Power Saw 1

7. Roll cladding facility including Induction Furnace 1

for heat treatment facilities

8. Submerged Arc welding machine complete with 1

accessories

I. Tundish Preparation Facilities

Description Unit Quantity

Tundish tilting device No. 1

Tundish stand Set 1

Tundish relining stand for 4 tundish Set 1

Tundish cooling device portable Set 2

Tundish drying device

drying stand Sets 1

automatic controlled drying station Sets 1

Tundish skull box and container Set 2

Tundish relining equipment Set 1

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Tundish gunning equipment Set 1

Monolithic tundish lining equipment Set 1

Tundish lifting tackle Sets 2

Tundish SEN charger support stand Set 1

Tundish stopper rod harness stand Set 1

Bucket for muck and debris Nos. 2

J. Ancillary equipment
Standard tools Set 1

Special tools (hydraulic bolt tensioning device Set 1

PROJECT DESCRIPTION

for ladle turret, make shifts for ladle turret,

torque wrench for segment fixation, tie rod
tensioning device for bender and segments

Tools for casting operation Nos. 2

K. Transfer cars
· Self-propelled mould & segment transfer car from tundish
preparation area to casting bay below ground level along with
tracks – 1 set
· Self-propelled tundish transfer car from tundish preparation area
to casting bay below ground level along with tracks – 1 set
· Self-propelled HM Ladle cum steel ladle cum slag pot transfer car
from turret bay to slag bay along with tracks (ladle will be
transferred to ladle preparation bay and slag pot to slag bay) – 1
set
· Self-propelled transfer car to transfer slab from one bay to other
bay along with tracks – 1 set

L. Handling facility
· Double girder EOT crane for mould & segment repair shop – 2 nos.
(50t each)
· 35 t gantry magnet crane at Slab Turn over facility
· Wall Crane- 3t at Tundish relining platform
· Jib crane for and roller assembly/ disassembly and dummy bar
head maintenance

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· Electric hoist/ manual hoist will be provided for electrical rooms,

hydraulic room, steam exhaust room, elevator machine room etc.
· Tractor trailer for shifting of segments – Gross vehicle weight–55t –
1no.
· 1 no. 5t goods cum passenger lift near caster platform will be
provided. It will cover each floor of the shop building

[Link].3 Slab dispatch to Hot Strip Mill

30 nos. boggies of 100 t capacity each will be provided for transportation of
continuous cast slabs from dispatch bay of CCM Shop to new Hot Strip Mill
(HSM). One locomotive (WDS 6ADT) will be provided to haul the boggies.

[Link] Material handling facility

EOT and semi-portal cranes considered for proposed SMS and CCM shop are

PROJECT DESCRIPTION
as follows:
a) AB Bay

Sl. Location Purpose Capacity Qty.

no. (nos.)

1. Slag handling bay Slag pot filled with slag 120t+50t 2

Double girder EOT receiving and with grab &
dumping. Empty ready
crane magnet
slag pot transfer to
Span – 34m various units of SMS.
(tentative)
Crane rail height≈
+16.50m

b) CD bay

1. HM Receipt cum Scrap received via rail/ 20t+20t with 2

scrap bay road, unloading to magnet
scrap pit.
Double girder EOT
Crane Loading scrap to scrap
chutes to make charge
Span – 25m
(tentative) mix for converter
charging.
Crane rail height ≈
+21.50m

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2. HM Receipt cum HM received via 280t+80t/20t 1

scrap bay torpedo car. Empty
Four girder EOT HM ladle placing at pit
Crane and HM metal poured
to empty HM ladle
Span – 25m from torpedo car.
(tentative) Filled HM ladle shifted
Crane rail height ≈ to De- sulphurisation
+21.50m station for further
processing.

c) DE bay

1. HM receipts cum HM received via 280t+80t/20t 2

charging bay torpedo car. Empty
PROJECT DESCRIPTION

Four girder EOT HM ladle placing at pit

and HM metal poured
Crane
to empty HM ladle
Span – 24m from torpedo car.
(tentative) Filled HM ladle shifted
Crane rail height ≈ to BOF/ De-
+27.50m sulphurisation station
for further processing.
The processed HM
ladle at
Desulphurisation unit
transfer to Converter.

2. HM receipts cum Scrap chute filled with 60t+60t 1

Scrap charging scrap charging to BOF
bay converter
Semi portal Crane
Span - 20m
(tentative)
Crane rail height ≈
+20.75m

d) E’E” bay

1. Lance handling Lance handling and 50t/10t 1

Bay converter tilt drive

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Double girder EOT handling

Crane
Span – 14.00m
(tentative)
Crane rail height ≈
+56.60m

e) EF Bay

1. Ferro alloy Filling of Ferro alloys 20t/10t 1

charging bay bunkers Crane
Double girder EOT
crane
Span – 21.00m

PROJECT DESCRIPTION
(tentative)
Crane rail height ≈
+27.46m

f) GH bay

1. Ladle and tundish Ladle 120t + 2

preparation Bay Preparation/Repair 25t/10t
Four girder EOT Maintenance / Relining (Magnet on
Crane 10t hook)
Span – 25m
(tentative)
Crane rail height ≈
+28.00m

2. Ladle and tundish Tundish 120t/10 t 1

preparation Bay Preparation/Repair
Maintenance / Relining (Magnet on
Double girder EOT 10t hook)
Crane
Span – 25m
(tentative)
Crane rail height ≈
+28.00m

g) HI bay

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1. Secondary refining Full liquid steel ladle 280t+80t/20t 2

cum turret Bay shifting from LF and
Four girder EOT RH-OB transfer car to
Crane Slab Caster turret.

Span – 27.00m
(tentative)
Crane rail height ≈
+34.50m

2. Secondary refining Ladle furnace and RH- 120t/25t 1

cum turret Bay OB unit activities
(Ferro alloy charging,
Double girder EOT
Crane roof changing etc.)
PROJECT DESCRIPTION

Span – 27.00m
(tentative)
Crane rail height ≈
+34.50m

h) IJ bay

1. Casting machine Mould and segment 120t/25t 2

bay install/ remove from
Double girder EOT m/c, Empty tundish
return and ready
Crane
tundish supply to
Span – 25.00m caster. LF and RH-OB
(tentative) maintenance activities
Crane rail height ≈
+32.00m

i) JK bay

1. Mould & roller Mould and roller 120t / 25t 2

segment segment maintenance/
maintenance bay repair
Double girder EOT
Crane
Span – 31.00m
(tentative)

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Crane rail height ≈

+32.00m

j) KL bay

1. Slab storage cum Slab storage and 70t on tong. 2

despatch bay despatch via rail Total lifting
Double girder EOT capacity
including
Crane
tong weight
Span – 33.00m 100t.
(tentative)
Crane rail height ≈
+16.00m

PROJECT DESCRIPTION
k) LM bay

1. Slab storage cum Slab storage and 70t on tong. 2

despatch bay despatch via rail Total lifting
capacity
Double girder EOT
including
Crane
tong weight
Span – 33m 100t.
(tentative)
Crane rail height ≈
+16.00m

[Link] Other handling facilities considered for various purposes are as follows:
· Electric hoists of suitable capacity will be provided for crane gear box
maintenance in each bay.
· Water system

Sl. Area Capacity Qty Span Type

(m)
no

1. Main Pump 10t / 5t 2 15 Underslung

House

2. Scale Pit (Scale 5t 1 12 Grab Bucket

Removal)

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3. Scale Pit Pump 5t 1 12 Underslung

House

4. Settling Tank 5t 2 (2 12 Grab Bucket

(Scale Removal) compar
tment)

5. GCP Pumps 5t 1 12 Underslung

House

6. Filter Press 10t / 5t 1 15 Underslung

7. Hood Cooling 5t 1 12 Underslung

Pump House

8. RH-OB 5t 1 12 Electric
PROJECT DESCRIPTION

Condenser Water Hoist in

Pump House Monorail

9. Various Drain 2t 10 - Monorail /

Pumps Manual
Chain Pulley
Blocks

10. Side Stream 2t 10 - Manual

Filtration Pumps hoist in
of Cooling Monorail
Towers

· Propane system

Sl. Area Capacity Qty Type

No

1. Vaporizer shed 1t 1 Manual chain pulley

block

2. Compressor shed 1t 1 Manual chain pulley

block

· Compressed air system

Sl. Area Capacity Qty Span (M) Type

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No

1 Compressor house 15t/5t 1 18 EOT Crane

· BOF Gas System

Sl. Area capacity qty Span Type

no (m)

1 ID Fan 20t/5t 1 18 EOT crane

2 Booster House 10t 1 12 Underslung Crane

· Fume extraction system

Sl. Area capacity qty Span Type

PROJECT DESCRIPTION
no (m)

1 ID Fan 20t/5t 1 12 1

2 ESP Bottom 15 tph 2 25 2

· Conveyors for water system

Capacity-5 tph, Length-50 m, Purpose-To discharge sludge cake from
filter press building to outside for truck dispatch.
· Conveyors for fume extraction system
Capacity-10 tph, Length-50 m, Purpose- To transport fines from ESP
to receiving hopper (Drag Chain / Belt Conveyor) – 1 set
Capacity-15 tph, Length-50 m, Purpose- To transport fines from ESP
to receiving hopper (Drag Chain) quantity- 2 sets
4.3.4 Calcined Lime and Dolo Plant for New SMS
Followings have been considered under mechanical job:
i) Installation of 6 nos. vibro feeders below existing high rise bunkers.
ii) Necessary conveyors along with technological structure & conveyor
gallery for raw material and product as per system requirement.
Cleated conveyors will be provided as per layout requirement.
iii) 1 no. 25mm screen each for limestone and raw dolomite.
iv) 2 nos. 300t silo for storage of +25mm limestone and 2 nos. 300t silo
for storage of +25mm raw dolomite along with motorised rack &
pinion gates and vibro feeders.

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v) 1 nos. 100t silo each for storage of -25mm limestone and -25mm raw
dolomite along with motorised rack & pinion gates.
vi) 1 no. 10mm screen each for calcined lime and calcined dolo.
vii) 2 nos. 150t silo for storage of +10mm calcined lime and 1 no. 150t
silo for storage of +10mm calcined dolo along with motorised rack &
pinion gates and vibro feeders.
viii) 1 nos. 100t silo each for storage of -10mm calcined lime and -10mm
calcined dolo along with motorised rack & pinion gates.
ix) 1 no. 100t dedusting silo each for lime and dolo along with motorised
rack & pinion gates.
x) 1 no. 150t silo each for reject lime and reject dolo along with
motorised rack & pinion gates.
xi) Motorised bin vibrator, rotary airlock valve and truck loader will be
PROJECT DESCRIPTION

provided as per system requirement.

xii) All the silos will be in covered sheds with handling facilities.
xiii) 1 no. goods cum passenger lift of capacity 1.5t in the kiln building
common for both kilns.
xiv) Hydraulics & lubrication system for kiln.

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4.4 UTILITIES
4.4.1 Utilities - Re-routing of Utility Lines
[Link] Re-routing of following water lines & gas lines has been envisaged to
continue the production of SMS-I.
· Mixed gas line DN 800 Size, tapping of this line is near trestle no.A-28
area & feeding to SMS-I shop, LDBP, PCM-I shop. This line will be
rerouted through gable end along A row of proposed SMS and CCM
Shop.
· Steam line of DN300 & DN200 size is going on same trestle along
with mixed gas line. These two steam lines will be rerouted through
gable end along A row of proposed SMS and CCM Shop.
· Oxygen line of DN 50 & DN 25 is feeding to blast furnaces area. These
lines will be rerouted through gable end along A row of proposed

PROJECT DESCRIPTION
SMS and CCM Shop.
· Nitrogen (LP) of DN 100 Size is going on same trestle along with
mixed gas line. This line will be rerouted through gable end along A
row of proposed SMS and CCM Shop.
· DN 960 mm dia. make up water ring main, Starting from valve Pit no.
10 (behind SMS-1 office), the pipeline takes a right turn and passes
through PCM-1, crosses the SMS-1- LDBP road and turns left and runs
outside and parallel to the SMS-1 shop. This line will be rerouted
through gable end parallel to A row. Pipe laying will be done at
approx. -2 m level.
· NB 250 make up water pipeline to CCM-1, starting from foundry side,
crossing the road in front of ED (W) building, passing behind R&C
laboratory building, going up to the water treatment plant of CCM-
[Link] line will be rerouted through gable end of existing CCM-1 Shop.
Pipe laying will be done at approx. -2 m level. Approx. length of
rerouting will be 500m.
[Link] Proposed routing for above mentioned gas lines, steam lines & water lines
are shown in Drgs Nos. CET RN 4706 UT1 00 007 R=0 (“Rerouting of mixed
gas line & steam line at Proposed SMS and CCM Shop”), and CET RN 4706
UT1 00 008, R=0 (“Rerouting of make –up water line”) respectively.

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4.4.2 Utilities – Installation of New Facilities

[Link] Requirement of utilities for proposed SMS and CCM Shop
Oxygen, Nitrogen, Argon, mixed gas, Propane gas, compressed air, steam,
and industrial water are required for the proposed SMS and CCM Shop.
Parameters at which the above utilities are required are indicated below:

Utility Avg. Flow Pressure Source / Battery Limit

(Nm3/h) bar(g)

Oxygen gas (>99.5% 9000 20 From new 1000 tpd oxygen

pure) plant.

Nitrogen gas 6005 20 From new 1000 tpd oxygen

plant.
(>99.9 % pure)
PROJECT DESCRIPTION

Argon gas 1086 18 From new 1000 tpd oxygen

(>99.9 % pure) plant.

Mixed gas 4250 1000mm From 2 locations. One

WC tapping from mixed gas
header at column A-23 &
another from mixed gas
header at Z5/65

Propane gas 360 3 Proposed new propane

plant.

Compressed air 15000 6 to 8 Proposed new compressed

air station

Make up water 150-200 2 Rerouted make up water

from ring main of DN960

Steam 22.5 tph 14 From 60 bar steam header

at CPP-1

Flow and pressure of utilities ie. Mixed gas, BOF Converter gas, steam, high
pressure Nitrogen, Oxygen, Argon, propane/ natural gas, compressed air will
also be provided at EMD energy centre to monitor energy consumption of
New SMS and CCM Shop Necessary hardware and software which may be
required to display the data at energy centre will be provided.
[Link] Tapping points and scheme of utilities for proposed SMS and CCM Shop

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· Oxygen
Requirement will be met by 1000 tpd oxygen plant. A new line shall be laid
for oxygen from new oxygen plant to Proposed SMS and CCM Shop from
the supplier of 1000 tpd oxygen plant. Tapping will be provided from the
nearest header. Necessary pipes, fittings, control valves, isolation valves,
safety valves, instrumentation, platform with railing etc. will be provided
· Nitrogen
Requirement will be met by 1000 tpd oxygen plant. A new line shall be laid
for nitrogen from new oxygen plant to Proposed SMS and CCM Shop from
the supplier of 1000 tpd oxygen plant. Necessary pipes, fittings, control
valves, isolation valves, safety valves, instrumentation, platform with railing
etc. will be provided.
· Argon

PROJECT DESCRIPTION
Requirement will be met by 1000 tpd oxygen plant. A new line shall be laid
for argon from new oxygen plant to Proposed SMS and CCM Shop from
the supplier of 1000 tpd oxygen plant. Necessary pipes, fittings, control
valves, isolation valves, safety valves, instrumentation, platform with railing
etc. will be provided.
· Mixed Gas
Tapping will be provided from existing header at two locations namely A-
23 & Z5/65. Isolation facilities for 100% isolation such as water seal, blank
flange and isolation valve shall be provided for each consumer. Drain pots,
nitrogen/steam purging system, vents etc shall be provided at suitable
locations with access platform and sampling points. Compensators/U
bends shall be provided as per requirement based on flexibility analysis.
· Steam
Tapping will be provided from existing header at CPP-1 by taking tapping
from main steam header of 60 bar. Necessary Pressure Reducing &
Desuperheating Stations (PRDS), isolation valves, steam traps, pipe fittings,
supports etc. will be provided as per requirement. Tapping of DM water for
desuperheating will also be taken from nearest DM water header of plant.
PRDS will have following specification-:
Quantity: 2 nos. (1 W + 1 S)
Range : 15 – 30 tph
Pressure: Upstream: 60 bar (g), Downstream: 14 bar (g)
· Propane

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Tapping will be provided from proposed 3x60 Mt propane plant.

Necessary valves, pipe fittings, supports etc. will be provided.
· Compressed Air
Tapping will be provided from proposed (15000 Nm³/h X 2) compressed
air station. Necessary valves, pipe fittings, supports etc. will be provided.
· Make Up Water
Water Treatment Plant (WTP) will be installed in water complex area.
Tapping will be taken from existing underground DN960 make up ring
main line. 3 no’s of make-up water pump (3x200 m³/h) will be installed.
Necessary valves, pipe fittings, supports etc. will be provided.
· Tapping point for mixed gas & steam is mentioned in drawings no’s.
CET RN 4706 UT1 00 005 R=0 (“Mixed gas tapping & BOF gas
supply points”) & CET RN 4706 UT1 00 006 R=0 (“Steam line
PROJECT DESCRIPTION

tapping from CPP-1”) respectively.

[Link] Quality of makeup water is as under:

Parameter Value In Value In Non-

Monsoon Monsoon

Turbidity (mg/l) 50 (max.) <10

Conductivity (micro mho/cm) 155 (max.) 175

pH 7.6 8.6

Total suspended solids (mg/l) 100 (max.)

Total dissolved solids (mg/l) 95(max.) 110

Total Hardness as CaCO3 (mg/l) 100 (max.)

Calcium Hardness (mg/l) 40 37

Methyl Orange Alkalinity (mg/l) 36 85

Phenolphthalein Alkalinity (mg/l) - 10 (max.)

Sulphate (mg/l) 50(max.) 2.1

Chloride (mg/l) 2.1 2.8

Silica (mg/l) 8.7 5.8

5 (max.) 0.18
Fe (mg/l)

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[Link] Soft water plant

Softening plant of capacity 50m³/h (1w+1s) will be installed to cater the
requirement of soft water. Initial fill pump of capacity 200m³/h (1w+1s),
emergency overhead tank supply pump of capacity 50m³/h (3 nos.) &make
up soft water pump of capacity 50 m³/h (3 nos.) will be installed. Necessary
valves, pipe fittings, supports etc. will be provided.
[Link] Gas cleaning & recovery system
The production of steel in the BOF converter releases fumes rich in Carbon
monoxide laden with a significant amount of dust with high temperature. In
order to utilize the calorific value of the gas and to suppress air pollution,
converter is to be fitted with a Gas Cleaning Plant which will collect and treat
the released fumes called BOF gas, for further utilisation in the steel plant. In

PROJECT DESCRIPTION
the Gas Cleaning Plant (GCP), hot gases will be collected above the converter
mouth using suppressed combustion system, cooled through a hood and
cleaned at a scrubbing installation and either recovered in a gas holder or let
out to the atmosphere after combustion in a flare stack. The Gas Cleaning
Plant will achieve the collection of gas without complete combustion by
means of automatic adjustment of the suction rate to the flow rate of gas
produced by blowing, periodically throughout the entire sequence of
operation. The BOF gas generates during blowing period only
· BOF Gas Cleaning Plant
BOF gas cleaning plant can have two alternatives
- Dry gas cleaning plant: In this system the heat laden BOF gas is
passed through water filled tubes to recovery the sensible
heat . Then the cooled gas is passed through series of ESP to
clean the gas. The main benefit of this process is generation of
superheated steam which can be suitably utilised in the steam
ejectors of RH-OB unit. However this system needs large space
which is not available in the present case. Hence this
technology is not selected.
- Wet gas cleaning plant: The hot and dust laden gases leaving
the BOF converters (called BOF gas) are collected largely un-
burnt with the help of an adjustable (raising & lowering) skirt
ring arranged between the cooling stack & converter mouth.
Skirt and cooling stack will be cooled by soft water to bring
down the temperature of the gases to about 1000 degC. Then
these gases are cooled further and at the same time, cleaned by
a two stage venturi scrubbers. The non-combustion control of

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the system is achieved by controlling the gas pressure in the

hood by means of throat dampers in the secondary venturi of
the two stage scrubbers. Dust content in the gases will be
reduced to less than 50 mg/Nm³ in the present proposal.
· BOF Gas Recovery System
The cleaned BOF gases shall be exported to a gas holder (50,000 m3
volume) or flared through a flare stack by means of a three way valve.
Flaring / export of gas will be carried out depending upon the
operational regime of the plant. The gas recovered in to the holder will
be further cleaned (from 100 mg/Nm3 to less than 5 mg/Nm3) in
Electrostatic Precipitators (ESP). The final cleaned gases will be boosted
by gas boosters before connecting to existing new GMT, old GMT& BF
gas header.
· Proposed schematic Flow Diagram for BOF gas recovery & cleaning
PROJECT DESCRIPTION

system is shown in Drg No. CET RN 4706 UT1 00 009, R=0

(“Schematic flow diagram of BOF gas cleaning & recovery system”)
· Supply points of BOF gas is mentioned in in Drg No. CET RN 4706
UT1 00 009, R=0 (“Schematic flow diagram of BOF gas cleaning &
recovery system ”)
· Supply points of BOF gas is mentioned in Drg No. CET RN 4706 UT1
00 005 R=0 (“Mixed gas tapping & BOF gas supply points”)
· Indirect Gas Cooling System
Indirect cooling of the converter gas will be achieved by passing the
hot gas through a closed loop high pressure Soft water based ducting
consisting of skirt, hood & stack.
In the proposed indirect cooling system, heat removal is achieved by
means of concurrent circulation of pressurized water in the tubes of
the water cooled maintenance skirt, hood & stack. There will be 3 nos.
of circulation water pumps (2 W + 1 S) to provide circulation of
cooling water in the closed loop. The circulating water will be
distributed to the skirt, hood & stack through various branch lines
from the main headers. Hot water from various cooling zones will be
collected in a common return water header. From this header, hot
water will be taken to a set of five fan air cooler consisting of 4
identical cells. Normally all the five cells will be in operation and, if
required, one cell can be isolated for maintenance purpose. The cells in
operation will be automatically started at the beginning of oxygen
blowing and stopped when the air cooler inlet water temperature is
below a fixed set point. The cooling water from each cell will be

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collected in a header, which will be connected to the pump function.

The cooling water will be pumped for further recirculation in the
closed loop.
· Make –up water & Expansion Vessel
An expansion vessel will be installed on the cooling water return line
downstream the air cooler and pressurised with nitrogen.
A make-up water storage tank of adequate capacity will be provided in
the system. The makeup water high pressure pumps ( 1 W + 1 S) will
be installed for injection of Soft water in the closed loop for initial
filling or for compensating the losses. Make up supply will be
automatically carried out through good indication and control from
the expansion tank. Similarly, filling of makeup water storage tank with
Soft water tapped from the existing headers will also be automatically
carried out the makeup water tank level.

PROJECT DESCRIPTION
· Direct gas Cooling & Cleaning System
After indirect cooling of the converter gas to a temperature of about
900 to 1000 degC at the stack exit, the hot gas will be further cooled
down to 60-70 degC in gas cooling & cleaning system. This cooling is
achieved by a direct contact gas cooling system. The contaminated gas
will be cleaned by a wet type cleaning system consisting of two stage
venturi scrubbers.
The hot gas stream leaving the water cooled membrane and stack will
be firstly quenched and saturated by injection of industrial quality of
water at a flow rate in the range of 350-400 m³/h water injection will
be carried out by a number of spray nozzles, equally distributed in the
gas stream. The gas is cooled to approximately 70 degC in the primary
scrubber.
The cooled and partially cleaned gas will enter secondary scrubber at
high speed through adjustable throat of the venturi. On encountering
the water, the gas forms a mist of very fine droplets which capture
dust particles. The water required in the scrubber is about 400 m³/h. at
2 kg/cm² near the throat partition. The outlet of secondary venturi will
be re-circulated to primary venturi, by means of pumps, with
secondary venturi getting the direct supply from the pump house.
The cleaned gases are discharged by an ID fan through a 3-way valve
either to flare stack or to gas holder for recovery. The ID fan will be
provided with fluid coupling to take care of fluctuating loads
· Slurry Treatment Facilities

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Contaminated water from gas cleaning plant will be received in the

slurry launder and transported to Thickeners for dewatering. The clean
water will overflow from thickeners and will be cooled in a cooling
tower. Clean cooled water will be sent back to gas cleaning plant.
Under sludge from thickeners will be collected in slurry tank and will
be sent to filter press for making cakes. Recovered water will be
transported back to thickener. Cake produced in filter press will be
transported through conveyors and collected outside filter press
building for further reutilisation by RSP.
[Link] Water system
The water system envisaged for proposed SMS and CCM Shop will be re-
circulating type for Lance cooling, Hood cooling, machine cooling and spray
cooling.. All major units will have their own water circulation system. Only
make-up water will be supplied to these units from the proposed make up
PROJECT DESCRIPTION

water system. The shops circulating water system will be designed for
minimum/zero water discharge. Recirculation system for new units shall
consist of pumps, filters, heat exchangers, chemical dozing, cooling tower,
pipes, valves, fittings etc.
The recirculating systems are shown in attached process flow diagrams. The
different systems employed are as follows-
· Closed loop recirculation systems for BOF, Caster (mould & machine),
LF, RH-OB and Desulphurisation units. The primary circuit will have
process pumps, heat exchangers and expansion tank. Secondary
system will have cooling tower. All cooling towers will have side stream
filtration. There will be an Emergency Overhead tank to cater to the
emergency requirements of caster & LF.
· Hood cooling system through air cooled fin-fan coolers for BOF gas
hood.
· Air-mist based spray cooling system with scale pit, secondary settling
tank, filters, cooling towers.
· Measuring facility
Measuring facilities will be provided at each taping points to monitor
water consumption of respective shops.
· Operational facility
The water system shall be fully automatic with PLC. However, facility
for local start/stop shall also be provided for each individual drive. The
control scheme shall be such that human intervention will be limited to
filling up of chemicals; lubricants and attending to scheduled/ break

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down maintenance work. Under normal operation all water system

equipment shall work based on process feed backs received from field
instruments.
· All pumps and pipe lines will be provided with corrosion protection
coatings, wherever required.
· Proposed Process Flow Diagram for water systems are shown in Drgs
Nos. CET RN 4706 UT1 00 001, R=0 CET RN 4706 UT1 00 002, R=0,
CET RN 4706 UT1 00 003, R=0.
[Link] Propane Plant
Propane with a CV of around 24000 kcal/Nm3 is required for following
process requirement as a fuel.

Consumers Average Requirement

PROJECT DESCRIPTION
RHOB 200 Nm3/h

Slab caster 160 Nm3/h

Total 360 Nm3/h or around 720 kg/h

To meet the above requirement a 120 Mt capacity Propane plant considering

7 days storage has been envisaged. The propane storage installation will
consist of following major equipment
· Mounded Storage Tanks (3 x 60 Mt)
· Unloading Pump & Compressor
· Vaporiser ((2W+1S) x 360 kg/hr)
· Pressure Reducing Station
· Fire Fighting System including Water Storage Tank
· Pipe work including valves & safety fittings
The location of proposed plant of size ( 75 m x 60 m )has been shown in Dwg
no. CET RN 4706 UT1 00 004, R=0 (“Utility system layout”)

[Link] Compressed Air Station

Compressed Air is required mainly for process requirement of Slab caster.
The same is also needed in RHOB, Ladle Furnace and BOF converter. Based
on the requirement of different units 2 nos. (1W+1S) of Centrifugal air
compressors of 15000 Nm³/h at a pressure of 8 bar (g) has been envisaged
The new air compressor will consist of following major components:

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· Multistage Centrifugal Compressors with motors

· Lubricating Oil System
· Inlet Filter cum Silencer
· Inlet Guide Vane
· After-Cooler
· Air Receiver
· Acoustic Control System
· Instrumentation & Control System
· Electrical System
· Piping & Fittings.
The location of proposed plant of size (50 m x 50 m) has been shown in Dwg
PROJECT DESCRIPTION

no. CET RN 4706 UT1 00 004, R=0 (“Utility system layout”)

[Link] Air conditioning & Ventilation system (ACVS)
· The rooms housing electrical equipment, microprocessor based
equipment / instrument, hydraulic equipment, pump house and
underground areas need to be provided with suitable air-conditioning/
ventilation system, so that a dust free and suitable inside condition as
per requirement can be maintained throughout the year. Same has
been envisaged for smooth and trouble free operation of the
equipment installed there in.
· All control rooms, intelligent MCC rooms, hydraulic rooms and shift-in
charges’ rooms will be provided with chilled water based centralised
air conditioning system to keep ambient at 23±2 deg C at 55±5%RH.
Air Handling Units catering to these rooms will be housed in a
separate AHU room installed by the side of them. Necessary supply
and return ducting network with fire dampers will be provided.
· All HT substations will be provided with air conditioning system to
keep to keep ambient below 35 deg C at 55±5%RH. The above
mentioned chilled water based centralised air conditioning system will
be employed with dedicated AHU room for HT substation.
· Canteen/ Rest rooms will be provided with suitable numbers of desert
water coolers.
· All new electrical switchgear rooms, MCC rooms, hearth main rest
room and tuyere platform area will be provided with washed air
ventilation system. Washed air ventilation system provided in existing
premises such as ground floor of Substation-14 at stock house, stock

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house MCC room will also be replaced with new air washers of
required capacity. Washed air ventilation system will also be provided
for pump houses, however duct distribution will be such as to supply
washed air for man/ material movement area (upto 2 m from ground
level). Further exhaust fans will also be provided in pump house below
roof. Washed air ventilation system will be designed to keep ambient
at 35±2 deg C, wherever possible.
· All other premises such as transformer rooms, CA fan building, pump
houses etc. will be provided with exhaust ventilation system. Exhaust
ventilation system will be designed to permit 3deg C temperature rise
above ambient, except for transformer rooms. Transformer rooms will
be designed to permit 5 deg C temperature rise above ambient.
[Link] Fire Fighting System
Following system has been envisaged for the fire fighting of this project:

PROJECT DESCRIPTION
· Portable fire extinguishers as first aid fire fighting system in new
pumps houses, electrical rooms & MCC rooms as per IS 2190:2010.
· Hydrants system has been envisaged for Proposed SMS and CCM
Shop. A new pump house along with dedicated water tank, electric &
diesel engine driven pumps will be constructed at water complex. The
design of the storage water tank for fire-fighting facility will be as per
TAC guidelines. All the internal and external hydrants will be designed
for minimum pressure of 4 kgf/cm2 and maximum pressure of 7
kgf/cm2.
· Clean agent based fire fighting system for control rooms.
· Foam based fire suppression system for hydraulic rooms.
· Fire sealing in electrical cable network for all floor openings including
conduit openings, cable openings, below electrical panels / equipment
and wall openings.
· Fire Retardant Coating in HT cables and fire sealant.
· Water pipe line for fire fighting and its accessories in all conveyor
galleries.
[Link] Fume Extraction System
· It is proposed to install a centralised ESP based Secondary Emission
Control System as well as area dedusting system for complete SMS.
· The dust generating sources at proposed SMS with approximate fume
volume is as follows-

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Sl. Fume Generation Quality Gas Temp. Gas Volume

No. Activity/Point (°C)
Considered Am3/h
Installe
for system
d
sizing

1 Torpedo re-ladling 2 1 80 388000

station

2 Desulphurisation 1 1 130 177000

units

3 BOF Converter 1 1 150 620000

charging

4 BOF Converter 1 1 100 323000

PROJECT DESCRIPTION

tapping/ blowing

5 BOF Converter MHS 1 1 45 56000

6 Material Handling 1 1 45 27500

Unit of Twin Ladle
furnace

7 Ladle Furnace (Twin 1 1 220 188005

station)

· Dog House shall be provided at BOF. Dog House will consist of fume
collection suction hoods for suction of fumes during various stages of
operation of BOF.
· Suction hoods will be provided in all dust generating sources as
mentioned above. All ducts will be joined and taken to Electro static
Precipitator (ESP) for cleaning.
· The dust laden fumes, after being cleaned in the ESP will be
discharged in to the atmosphere through a stack. Dust, which will be
collected in the hoppers of ESP will be collected in a dust storage silo
from where, it will be transported through road to Sinter Plant for re-
use.
· The ESP will be designed for particulate emission level of 25 mg/Nm3
to comply with latest state PSBs norms.

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· Proposed Process Flow Diagram for fume extraction system is shown

in Drg No. CET RN 4706 UT1 00 0010, R=0 (“FES process flow
diagram”)
[Link] Pollution Control
Pollution Control aspect will be taken into account while formulating the
technical specification as per CPCB norm and all the facilities required for the
purpose of meeting the current and likely Statutory Norms as well as fulfilling
the Corporate Responsibility for Environmental Protection (CREP) shall be
provided. Also, specialist agency will be engaged to conduct Environmental
Impact Assessment (EIA) studies and prepare Environmental Management
Plan (EMP). This EIA & EMP report will address all the elements proposed
under latest guidelines. Based on this, required clearances from State and
Central Regulatory Authorities will be obtained.
Broadly, the pollution control measures are in the following areas:

PROJECT DESCRIPTION
·
· Air Pollution Control
· Water Pollution Control designed for Zero Discharge
· Noise Pollution Control
· Solid Waste Management
· To provide facilities for Environmental and pollution control aspect as
per statutory requirement will be the responsibility of main technology
supplier.
4.4.3 Utilities for Calcined Lime and Dolo Plant for New SMS
[Link] The following utilities/facilities will be provided from the existing facilities at
their respective battery limits to facilitate the smooth functioning of
proposed lime & dolo plant for Proposed SMS and CCM Shop, RSP
§ Mixed gas/coke oven gas supply system.
§ Water Supply system for cooling
§ Nitrogen for purging purpose.
[Link] Mixed Gas/ Coke oven gas supply system
The approximate requirement of mixed gas /coke oven gas at a CV of
around 3600 kcal/Nm3 is indicated below:
Flow : 4400 Nm³/h
Pressure : 1000-1200 mmwc
Tapping will be done from re-routed DN 800 mixed gas line for SMS-I near
[Link] distance from tapping point to new lime & dolo plant
gable end is approx. 150 m. Pipe will be laid suitably along the proposed new

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trestles. U-seal will be provided at tapping point. Vent & purge facility will be
provided at suitable distance.
[Link] Cooling water system
The approximate requirement of water for cooling purpose is indicated
below:
Flow : 5.6 m³/h
Pressure : 2 kg/ cm²
Tapping will be done from re-routed make up water line for SMS-I near D-20.
Approximate distance from tapping point to new lime & dolo plant gable
end is approx. 150 m. Pipe will be laid suitably along with gas trestles.
[Link] Nitrogen
LP nitrogen will be provided for purging in mixed gas header. Tapping will be
PROJECT DESCRIPTION

done from re-routed nitrogen gas line for SMS-I near D-20. Approximate
length of nitrogen gas pipeline is approx. 150m. Pipe will be laid suitably
along with gas trestles.

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4.5 ELECTRICAL SYSTEM

4.5.1 Electrical Enabling Works - Rerouting of Power Supply
[Link] Relocation of existing facilities and dismantling
Various equipment/ facilities/ cables required for running of existing SMS-I
are falling in the proposed SMS and CCM shop site. Therefore, many
diversion/ relocation of existing Power Distribution facilities / cables are
required and being considered.
[Link] Major installation/ relocation/ diversion are mentioned below:
[Link].1 T-Off substation relocation: relocation of existing T-off sub-station has
been considered. T-off is a 33kV sub-station with two incomers from MSDS-V
and CPP-1. There are three outgoing panels from T-OFF- 2 nos. 33kV feeders
for 12.5MVA 33kV/6.6kV Transformers of NSP (Sinter Plant-1) s/s and 1 no.
33kV out going feeder to 12 MVA 33/6.6kV Transformer of VAD s/s. Power

PROJECT DESCRIPTION
supply to NSP/Sinter Plant-1 & VAD substations needs to be maintained.
Relocation of T-Off substation will be done in two parts:

1) New 33 KV GIS Substation at LHF-1 for supplying power to VAD

substation:
New 33 kV GIS substation will be installed in existing LHF-1 substation
room. It will be in door type single bus configuration having one 1600 A
incomer and 3 x 1600A outgoing transformer feeders, bus PT- 1, 33 kV
Relay & Control Panel. Substation Automation System, substation
Auxiliaries, special tool for GIS, Illumination, earthing system etc. have
been considered.
Incoming supply will be tapped from MSDS-2 with new cable. One out
going will feed to LHF-1 furnace transformer through a panel mounted
FOCB (new). Other outlet will feed VAD transformer. New power &
control cables as required and cabling arrangement including cable
trays/GI conduits has been be considered.

Location: New 33 KV GIS Substation GIS will be installed in existing

LHF-1 s/s.
2) Extension in 33 kV GIS at BF-1 for supplying power to NSP s/s (Sinter
plant-1)
It is proposed to add two no 33kV double Bus GIS panels to existing
33kV GIS of BF-1 s/s. These two feeders will be used to feed power with
new cable to NSP transformer-1 & 2

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[Link].2 Field breaker substation relocation (Substitution for both 415 V Field
Breaker stations of Hot metal & Pit Side cranes):
Details of existing Pit side Field Breaker station & Hot Metal Crane Field
breaker station - there are three LT ACBs of 1000 A capacity. These three
ACBs are powered from Transformer # 7 of SMS - I substation. These ACBs
are operating in parallel. The outgoing of all the three ACBs are connected to
2500 A Isolator Chambers. One isolator Chamber is used for A row bus bars
and other is used for B Row bus bars used for Pit side Cranes.
Similarly, the Hot Metal Crane Field breaker station accommodated 2 nos. of
1000 A LT ACBs which are powered from Transformer # 10 of SMS - I
substation. These ACBs operate in parallel. The outgoing of the ACBs are
connected to 2500 A Isolator unit. Hot Metal Bus bars are connected through
these isolators.
Relocation of these two breaker substations will be done by provision of one
no. combined Field breaker Board in a new electrical room. New Board will
PROJECT DESCRIPTION

accommodate the total requirement of the Pit side Cranes and Hot metal
Cranes with new 1000 a L T ACBs and Isolator units. Details are given below:
1) New Field breaker Board having minimum 3x1250A ACB, 2x 2500 A ACB,
3x2500A isolator feeders, bus bar metering etc. substation auxiliaries,
illumination earthing, cable tray etc. have been considered.
2) New power cables connecting to Hot Metal Cranes, Pit side Cranes,
Mould yard Cranes from new Field breaker Board have been considered.
List of cables are:
a) Pit side crane- 3 feeders (5 runs x 3x1/2 Cx240mm2 Al Cable
each)
b) Hot Metal Crane- one feeder (6 runs x 3x1/2 Cx240mm2 Al Cable
each)
c) Lighting feeders for pit side, Hot Metal & Mould yard crane- 4
feeders ( 2 runs x 3x1/2 Cx150 mm2 Al)
d) Emergency lighting feeder to CCM-1- 1 feeder ( 1 run x 3x1/2
Cx150 mm2 Al)
3) Lighting, earthing, etc. has been considered for new electrical room.

Location: It will be suitably located in a new electrical room in the SMS-I area
near existing SMS-I substation
[Link].3 Diversion of Existing Cables
Following important cable links are passing through cable tunnels going
inside the area earmarked for proposed SMS and CCM shop. These cables
will be diverted outside Proposed SMS and CCM Shop area. Existing cable

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will be used as far as possible, however new cable will be considered as per
diverted route. Tentative major cables list are given below:
1) CPP-1 to OXY s/s: 33kV E (4 runs) x3x400 Al XLPE
2) OXY s/s to CRS s/s : 6.6kV UE (2 runs) 3x240 AL XLPE
3) BSM S/S to SMS-1 S/s : 6.6kV UE (1 run) 3x240 AL XLPE
[Link].4 HT/ LT Power and Control Cables
1) 33 kV (UE) grade, XLPE, Aluminium, FRLS outer sheathed, armoured power
cables.
2) 6.6 kV (UE) grade, XLPE, Aluminium, FRLS outer sheathed, armoured
power cables.
3) LT power cables will be 1.1 kV grade, multi-core, heavy duty, XLPE
insulated, extruded PVC inner & FRLS outer sheathed, armoured type
having stranded aluminium and copper conductors.

PROJECT DESCRIPTION
4) 1.1 kV grade PVC/ XLPE multi-core, heavy duty, extruded PVC inner &
FRLS outer sheathed, armoured type LT control cable is considered for all
electrical equipment/ items. All control cables shall be 2.5 [Link] copper.

[Link].5 Methodology for diversion/relocation of existing cables

1) Cable routing, wherever necessary depending upon route survey (to be
done separately) will be considered. Walkable Cable Bridge has been
considered for cable diversion like CPP-1 to OXY s/s etc. Route will be
along the corridor outside the slag handling bay of the proposed
building of Proposed SMS and CCM Shop and then from the proposed
gable end (SMS-I side) to OXY s/s. Existing cable will be kept from CPP-
1 upto Proposed SMS and CCM Shop and afterwards new cable will be
joined till Oxy substation.
2) Trench will be considered for OXY s/s to CRS s/s & BMS S/s to SMS-I
S/S along the proposed gable end (i.e. the space between modified
gable of SMS-I and proposed gable of Proposed SMS and CCM Shop)
for diversion of the cables and will be jointed with the same set of
cables located outside the building to follow existing route further.
3) Cable jointing as required has been considered.
4) All other outgoing power and control cables will be laid on new/
existing cable trays along structures/ overhead walkable cable galleries/
tunnel/ tranches etc. on MS/ GI fabricated & painted cable trays. At
specific locations cables will also be taken through galvanized steel
conduit for additional protection against damage. New cable trays/
conduit will be considered for the proposed facilities.

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Earthing system will be done in accordance with the IS 3043 – 1987

[Link] Electrical works - Installation of ED works’ Building
All power supply arrangement, PDB, internal electrical installation,
illumination system (internal & external) distribution boards, power wiring,
external connection, points & plugs, power supply to equipment, lightening
arrestor, earthing system etc. for the new building have been envisaged. All
illumination is envisaged to be done with LED light fittings
[Link] Electrical- Installation of RCL Building
All power supply arrangement, PDB, internal electrical installation,
illumination system (internal & external) distribution boards, power wiring,
external connection, points & plugs, power supply to equipment, lightening
arrestor, earthing system etc. for the new building have been envisaged. All
illumination is envisaged to be done with LED light fittings
PROJECT DESCRIPTION

[Link] All dismantling work of old cables/substations mentioned above has been
considered in Pkg.-1
4.5.2 Electrical – Installation of New Facilities
[Link] Power Requirement
The estimated power requirement for the proposed SMS and CCM Shop has
been envisaged as:

Maximum demand 65 MVA

Average demand 36 MVA

[Link] Source of Power Supply

A new Main Step down substation, MSDS-VIII has been envisaged to meet
power requirement of new Proposed SMS and CCM Shop. It will be located
at Ingot yard of SMS complex. MSDS-VIII will broadly consist of following
facilities:
· 220 kV double circuit power from MSDS-VII (new HSM) through
overhead transmission lines/ cables (part) to MSDS-VIII
· 220kV GIS
· 33 kV GIS substations
· 220/33 kV , 80 MVA ONAN transformers
[Link] Bulk power will be tapped from existing 220 kV GIS substation at MSDS-VII
(New HSM) by utilising two numbers 220 kV available feeders. MSDS-VII is
feeding power to new HSM, however, load of Proposed SMS and CCM Shop

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was considered during design stage and accordingly two feeders at 220 kV
were earmarked for future Proposed SMS and CCM Shop. Necessary
modifications and facilities required for tapping of power have been
considered in existing 220 kV GIS
[Link] The 220 kV HT power from available feeders at existing 220 kV GIS (MSDS-
VII) will be fed to proposed new 220 kV GIS at MSDS-VIII through
combination of overhead double circuit transmission line and 220 kV cable.
Overhead transmission line is envisaged from MSDS-VII (new HSM area) to
main Plant boundary and 220 kV cable has been envisaged from inside of
boundary to MSDS-VIII (ingot yard). Some part of route may fall outside RSP
boundary hence, finalisation of Route alignment, tower locations, cable
tunnel/ overhead cable gallery etc. will be done based on detailed route
survey. Route survey is a prerequisite for preparation of TS.
New 220 kV GIS at MSDS-VIII will be having two incomers, double bus

PROJECT DESCRIPTION
arrangement and four numbers of outgoing feeders.
The 33kV GIS substation will be having double bus system arrangement with
required nos. of outgoing feeders. Two new 80 MVA, 220/ 33kV ONAN
transformers with all necessary facilities and accessories will be installed. The
33 kV GIS will have two incomers, one bus coupler and 10 outgoing feeders.
The single line diagram (SLD) of power distribution scheme: MSDS-VIII is
shown in drawing no. CET RN 4706 EE1 00 001, R=0 (Sheet no. 1).
[Link] Power Distribution Scheme
[Link].1 Two nos. new 33/6.6 kV HT substations (Converter substation & Caster
substation) comprising of 25MVA, 33 kV/ 6.6 kV transformers, bus ducts &
HT boards have been proposed for meeting HT/LT loads of all technological
units coming under new proposed SMS and CCM shop. Ladle furnace
transformer load will be fed directly from 33 kV GIS Board. These substations
will be located at Proposed SMS and CCM Shop site. Tie feeder (20 MW)
from existing source at HSM 33 KV GIS has been considered.
33 kV cable from the 33 kV GIS/ MSDS-VIII will be taken to proposed 33/ 6.6
kV substations/ Proposed SMS and CCM Shop site through new underground
cable gallery.
Each HT sub-station (Converter substation & Caster substation) will have two
nos. 33/ 6.6kV, 25 MVA transformers to cater to various loads. These two
Converter & caster HT substations will further feed to 6.6 kV HT substations
and 6.6kV/ 415V LT substations of technological units (HMDS, Converter,
RHOB, LF, Caster, utilities, material handling, calcining plant, water system etc)
as required.
[Link].2 Emergency Power (Category-1 Power)

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Emergency power of 10 MVA for Proposed SMS and CCM Shop will be
provided from existing source at CPP-I (to be decided at appropriate level
later) at 6.6kV and connected to new 33/6.6kV HT substation (Caster
substation) with auto-change over system.
[Link].3 6.6 kV HT substations have been considered as per requirement.
6.6 kV/415 V, double ended 2 MVA LT substations have been proposed to
meet all LT loads
[Link].4 HT/ LT & control cables from new Converter substation & Caster substation
to downstream facilities will be laid in new cable galleries proposed inside
Proposed SMS and CCM Shop site.
The single line diagram (SLD) of power distribution scheme is shown in
drawing no. CET RN 4706 EE1 00 001, R=1 (Sheet No. 2).
[Link] Technological unit wise power distribution scheme
PROJECT DESCRIPTION

[Link].1 Torpedo ladle station

Necessary LT power will be tapped LT substation at Converter area. All
required downstream shop electrics will be provided
[Link].2 Hot metal Desulphurisation system
Necessary LT power will be tapped LT substation at Converter area. All
required downstream shop electrics will be provided
[Link].3 BOF Converter unit
Necessary HT power will be tapped from 33/ 6.6 kV Converter substation at
converter zone.
Required nos. of 6.6 kV indoor switchboard will be installed with two
incomers and one bus-coupler. The downstream 6.6 kV/ 433V transformers
will be fed from this 6.6 kV switchboard. Required nos. of double ended 2
MVA 6.6kV/ 433V LT substations has been considered for downstream supply
to the loads of proposed slab caster and auxiliaries.
LT substations will be located in Electrical substation at Converter area.
[Link].4 Ladle Furnace
33 kV power supply for the ladle furnace transformer will be taken from new
33 KV GIS at MSDS-VIII. Incoming 33kV supply will feed one single bus GIS
switchboard which will feed to suitably rated Furnace transformer.
6.6 kV supply for ladle furnace auxiliary system will be taken from new 33/ 6.6
kV Converter substation to 6.6 KV LF Board and will be stepped down to LT
supply through dedicated 6.6 kV/ 433V transformers. HT load will be fed from
above mentioned 6.6 kV switchboard.

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An indoor type power factor (PF) compensation equipment to improve power

factor to minimum 0.9 is considered at 33 kV voltage level. The power factor
equipment comprising of capacitor bank, air cored series reactors, isolator,
surge arrestors, discharge PT, busbar system, neutral CTs etc., will be located
in the power factor compensator room provided for the purpose.
These boards will be located in Electrical substation at LF area.
[Link].5 RHOB
Necessary LT power will be tapped from LT substation at Converter area. All
required downstream shop electrics will be provided.
These boards will be located in Electrical substation at RHOB area.
[Link].6 Slab Caster
Necessary HT power will be tapped from 33 kV/ 6.6 kV Caster substation at

PROJECT DESCRIPTION
water complex.
Required nos. of 6.6 kV indoor switch board will be installed with two
incomers and one bus-coupler. The downstream 6.6 kV/ 433V transformers
will be fed from this 6.6 kV switchboard. Required nos. of double ended 2
MVA 6.6 kV/ 433V LT substations has been considered for downstream
supply to the loads of proposed slab caster and auxiliaries.
HT/ LT substations will be located in Electrical substation at Caster area.
[Link] Lime & Dolomite Plant
Necessary HT power will be tapped from 33/6.6 kV Converter substation at
converter zone.
The downstream 6.6kV/433V transformers will be fed from above 6.6 kV
switch board. Required nos. of double ended 2 MVA 6.6 kV/ 433V LT
substations has been considered for downstream supply to the loads of
proposed Lime & Dolomite plant and auxiliaries.
All necessary shop electrics have been envisaged.
HT/LT substations will be located in Electrical substation at Lime & Dolomite
plant.
[Link] Utility Facilities

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Necessary HT power will be tapped from 33 kV/ 6.6 kV Caster substation at

water complex.
Required nos. of 6.6 kV indoor switch board will be installed with two
incomers and one bus-coupler. The downstream 6.6 kV/ 433V transformers
will be fed from above 6.6 kV switch board. Required nos. of double ended 2
MVA 6.6 kV/ 433V LT substations has been considered for downstream
supply to the loads of proposed utilities and auxiliaries.
HT/LT substations will be located in Electrical substation at respective utility
area.
[Link] Material Handling facilities (Cranes/ Hoists/ Transfer cars etc)
Necessary LT power will be tapped from LT substation of respective zone.
Required nos. of PDBs has been considered for downstream supply to the
loads of proposed loads.
Substations will be located in Electrical substation at respective zone
PROJECT DESCRIPTION

[Link] Design Consideration & Basic Design Parameters

The power distribution network has been designed as a radial system, with
two alternative supply feeders to each load centre. The design of power
distribution system and selection of equipment have to be done based on
the considerations of safety, reliability, ease of operation & maintenance as
well as convenience of future expansion. The equipment will conform to
relevant IS/ IEC specifications and code of practice to meet the operational
requirements and to ensure reliable and trouble free service in the Plant.

The electrical system is proposed to be designed to suit the following basic

design parameters:

Description Technical parameters

HT Power supply 220 kV(+/-)10%, 50 Hz(+/-5%), solidly grounded system

HT Power supply 33 kV(+/-)10%, 50 Hz(+/-5%), solidly grounded system

HT Power supply 6.6 kV(+/-)10%, 50 Hz(+/-5%), resistance grounded

system

Power Supply to Various HT & LT Loads/ Load Centres

Motors rated above 1500 kW 6.6 kV, 3 ph, 50Hz

Motors rated above 160 kW and below 690 V/ 6.6 kV, 3 ph, 50Hz
1500 kW

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Motors rated upto 160 kW 415 V, 3 ph, 50 Hz

Motor rated above 90 kW and up to 160 415 V, 3 ph, 50 Hz

kW fed from direct power control centres
(PCCs)/ VFD

Motor rated up to 90 kW feed from 415 V, 3 ph, 50 Hz

MCCs/ VFD

Illumination and small power 240 V, 1 ph. 50 Hz

Control power supply ac for LT 240 V, 1 ph, 50 Hz through

switchgear, MCC, etc. control transformers

Control power supply dc for HT 110 V DC through Battery bank

PROJECT DESCRIPTION
switchgear

Symmetrical System Maximum Fault

Level

33 kV bus 31.5 kA, 3 s

6.6 kV bus 40 kA, 3 s

415 V bus 50 kA, 1 s

[Link] Major equipment and Facilities at MSDS-VIII

a. Indoor type double bus configuration 220 kV Gas Insulated Substation
(GIS)
b. Two nos. of outdoor 80 MVA, 220 kV/ 33 kV ONAN transformers
c. Switchyard to 220 kV GIS and from GIS to transformer connection will be
through SF6 bus-duct
d. Indoor type double bus configuration 33 kV GIS HT Board for catering to
Proposed SMS and CCM Shop loads.
e. Substation automation system as per IEC [Link] automation
system. SAS will be integrated with the existing Plant SCADA. Necessary
hardware and software have been considered. Necessary number of OPC
gateways will be provided in the SAS for down loading required data to
process automation.
f. Nitrogen injection based fire protection system for above mentioned
transformers
g. On line condition monitoring for above mentioned transformers

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h. Hydrant system for outdoor switchgear equipment protection

i. All protection relays will be numerical type and communicable on IEC
61850 protocol
j. Substation auxiliaries

[Link] 220 kV GIS

The 220 kV GIS will have two incomers, one bus coupler and 4 nos. of
outgoing feeders
[Link] 220 kV/ 33 kV, 80 MVA Transformers
New 80 MVA, 220/ 33kV transformers (2 nos.) with necessary electrics such as
disconnecting switches, SF6 circuit breaker, current transformers, potential
transformers, earthing switches, lighting arrestors, etc., for the protection and
metering purpose has been considered at MSDS-VIII.
Marshalling box for interfacing points for required AI, DI, and DO will be
PROJECT DESCRIPTION

provided at 33kV GIS substation.

[Link] 33 kV GIS
The 33 kV GIS will have two incomers, one bus coupler and 10 nos. of
outgoing feeders.
The 33 kV incoming feeders to the above mentioned 33 kV GIS will be from
new 80 MVA transformers.
33 kV GIS will be of three phase, 50 Hz, double bus bar, indoor gas insulated
switchgear (GIS).
Power factor compensation at 33 KV level.
Tie feeder (20 MW) from existing source at HSM 33 KV GIS has been
considered.
[Link] New GIS sub-station building and all civil works for housing 220 & 33 kV GIS
equipment in MSDS-VIII have been considered. The GIS sub-station will have
two floors. Both the floors will have cable cellars. GIS will be accommodated
in the floor above another cable cellar at 0.00 level. Indoor transformers will
be placed at ground level. Special attention will be given to an optimized
design with small space requirements. An overhead crane will be supplied
and installed in GIS substation for installation and maintenance work of GIS
equipment. The GIS room will have sufficient space for future extension
[Link] Major Equipment and facilities at proposed SMS and CCM Shop Zone
[Link].1 33 kV/ 6.6 kV HT converter Substation
The above substation is proposed to be installed close to the Converter zone
and will be catering power supply to technological units nearer to it as as

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Torpedo ladle, HMDS, Converter, LF, Cranes, transformer cars etc and auxiliaries.
The substation will broadly consist of the following:
a. 2x25MVA, 33 kV/ 6.6 kV HT substation to be fed from 33 kV GIS in MSDS-VII
through cables. New underground cable tunnel from MSDS-VIII to this
substation has been envisaged.
b. Substation automation system
c. Nitrogen injection based fire protection system for above mentioned
transformers
d. On line condition monitoring for above mentioned transformers.
e. Substation auxiliaries
[Link].2 33 kV/ 6.6 kV HT Caster Substation
The above substation is proposed to be installed Water Complex Zone and will

PROJECT DESCRIPTION
be catering power supply to technological units nearer to it as Caster, RHOB,
Water facilities, Calcination plant, Secondary emission control, Cranes, Transfer
cars and associated auxiliaries. The substation will broadly consist of the
following:
a. 2x25MVA, 33 kV/ 6.6 kV HT substation to be fed from 33 kV GIS in MSDS-
VII through cables. Cable laying through cable tunnel upto Proposed SMS
and CCM Shop and through overhead cable bridge from Proposed SMS
and CCM Shop to water complex.
b. Substation automation system
c. Nitrogen injection based fire protection system for above mentioned
transformers
d. On line condition monitoring for above mentioned transformers.
e. Substation auxiliaries
[Link].3 Ladle furnace transformer and associated system
· The Furnace Transformer of suitable rating to achieve the required
rate of heating required by the process has been considered for the
furnace. The furnace transformer will be designed to meet the stresses
generated in the transformer by the high secondary current and will
be provided with special winding, cores and mountings. Transformer
cooling will be OFWF type. The furnace transformer will be located in
the transformer room.
· 33kV switchboard: One set of 33 kV, single bus GIS switchboard is
envisaged for power distribution to furnace transformer circuit and
capacitor bank. This switchboard will be provided at the incoming side
of furnace switch. This will be installed in the HT room of Ladle
furnace.

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· Furnace Switch: A 33 kV, furnace switch will be provided for frequent

switching on and switching off of the ladle furnace.
· Disconnect switch: A 33 kV, 3-pole disconnect switch will be provided
for convenient isolation of ladle furnace circuit. The disconnect switch
will be equipped with key interlock to prevent it being operated unless
the circuit breaker is open.
· Necessary 33 kV, CT's and 33 kV/110V PT's of will be provided for
metering and protection purpose.
· Dedicated battery, battery charger and DCDB has been considered.
Battery will be located in a separate room.
[Link].4 HT Switchgear
The 6.6 kV switchgear will be indoor type sheet metal clad, draw out type
comprising of VCB circuit breakers and will be provided with necessary
protection, control gear, metering and audio-visual alarm annunciation
system. The circuit breaker mechanism will be mechanically and electrically
PROJECT DESCRIPTION

trip free. The circuit breakers will be electrically operated, stored energy type
suitable for operation on 110 V DC control power supply.
[Link].5 415 V Switchgear
The 415 V switchboard will comprise air circuit breakers, draw out design and
multi-tier formation. The switchboard will have two bus sections and a
manual bus coupler breaker. The circuit breakers will be electrically operated
and equipped with microprocessor/ static type direct acting releases for over
load and short circuit as well as earth fault protection. All motor control
centres (MCCs), large drives (below 160 kW) and power distribution boards
(PDBs) will be supplied power from the 415 V switchboards. The 415 V
switchgear will confirm to relevant IS/ IEC specifications.
[Link].6 Power Transformers
The 220/ 33 kV, 80 MVA power transformers will be copper wound, oil
immersed, three phase and OFAF design. The maximum temperature at the
rated output and at principal tap will be 85°C for top oil by thermometer
method and 95°C for winding by resistance method. Core will be made of
low loss CRGO silicon sheet. The winding will be made of electrolytic grade
copper and will be vacuum dried. Inter turn and inter coil insulation will be so
designed that the di-electrical stress is distributed uniformly throughout the
winding under all operating conditions. To ensure reliable and trouble free
operation, the transformers will be designed to withstand short circuit on the
secondary side for duration of 5 seconds without any damage. The 33/ 6.6 kV
transformers will be provided with OLTC and local & remote control cubicles.
The secondary of three 33/ 6.6kV transformers will be connected to 6.6 kV HT
switch board through HT cables/ busduct. All standard accessories such as

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conservator, breather, Buchholz relay, OTI, WTI, oil level gauge, valves,
explosion vent, etc., will be provided for all the oil immersed type
transformers. The transformers will conform to relevant IS/ IEC specifications.
[Link] LT Sub-station
[Link].1 Power Distribution Transformers
LT substations complete with double ended 2000 kVA, 6.6 kV/ 415 V power
distribution transformers, power control centres (PCCs) have been envisaged
for meeting the power requirements of drives, motors, auxiliaries, cooling
system, air compressors, EOT cranes, ACVS equipment, illumination and
welding network, workshop facilities, water facilities, etc. The proposed power
transformers will be dry type (AN), winding insulation class-F and will
conform to IS 2026 – 1977.
[Link].2 6.6 kV HT Disconnecting Switch

PROJECT DESCRIPTION
6.6 kV, load break type HT disconnecting switch at the primary side of 6.6 kV
power transformers will be provided. Further HT stop push buttons will also
be provided in each transformer room for tripping the breakers.
[Link].3 LT Bus Duct
Secondary side of transformers will be connected to the incomers of the
proposed Power Control Centres (PCCs) by non-phase segregated LT
aluminium bus ducts of adequate rating.
[Link].4 Power Control Centres (PCCs)
The 415 V switchboards will comprise air circuit breakers, in draw out design
and multi-tier formation. The switchboard will have two incomers and one
bus coupler breaker. The circuit breakers will be manually operated,
withdrawable, electrical tripping type, equipped with over load and short
circuit as well as earth fault protection, indicating lamps and meters. All
Motor Control Centres (MCCs), large drives starter panel (above 90 kW and
up to 160 kW) and Power Distribution Boards (PDBs) will be supplied power
from the 415 V switchboards. The 415 V switchgears will confirm to IS-8623
and IS 13947.
[Link].5 Power Distribution Board (PDB)
LT PDBs will be set up for feeding power supply to various auxiliaries like EOT
cranes, hoists, exhaust fans, welding network, machine shop, mechanical and
electrical workshops, illumination system, ACVS system, etc.
[Link].6 Converter Transformers
i) 6.6 kV/ 690 V converter transformers to feed motors of 690 V through
VFD controllers

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Main Features:
ii) Two winding/ three winding
iii) Isolation from power supply network
iv) Capable of handling RMS load current drawn by the motor
v) Class H Insulation
vi) OCTC and voltage variation +/- 7.5 % in steps of 2.5%
vii) Dry type up to 2000 KVA and ONAN cooled for more than 2000 kVA
viii) Conforming to IEEE 444, 1973 and IS 2026- 1977
[Link].7 Substation automation system as per IEC 61850 for all new installations of
Proposed SMS and CCM Shop. SAS will be integrated with the existing Plant
SCADA. Necessary hardware and software have been considered. Necessary
number of OPC gateways will be provided in the SAS for down loading
required data to process automation.
[Link] Shop Electrics and Automation
PROJECT DESCRIPTION

The electrical drives, controls and automation equipment, envisaged for

smooth and efficient operation of proposed Proposed SMS and CCM Shop
will be of latest design/ technology. The major equipment envisaged has
been stated below
[Link].1 HT/LT Motors
All motors are AC Squirrel Cage induction motors having class F insulation
with temperature rise limited to class B. Inverter Grade AC Squirrel Cage
induction motor is envisaged for VFD driven applications.
i) Control of LT motors will be done from the Motor Control Centre
(MCC) / Local Control Station. All drives will have local control stations
mounted near the respective drives and will have start/ stop push
buttons near the mechanism.
ii) The squirrel cage induction motors below 160 kW for auxiliaries
system of fixed speed will be fed directly from 415 V level. However,
160 kW & above rating 1500 KW motors like CA fan, ID fan, etc., which
may need speed variation will be fed through converter transformers
(6.6 kV/ 690 V) and 690 V LV VFD drives. VFD motors will be fitted with
accessories such as base plate, pulse encoders, RTDs, space heater,
etc. These motors will be provided with proper air or water cooling
system.
iii) The squirrel cage induction motors equal or below 160 kW will be on
415 V. All motors of rating in the range of 110-160 kW will be of 415 V
variable frequency drives (VFDs).
iv) The squirrel cage induction motors below 110 kW will be direct on
line. However, for mechanisms requiring speed regulation will be with
VFD. Motors having VFD controller will be inverter grade.

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Intermittent duty, reversible, heavy duty squirrel cage induction motors for
crane duty application will be installed in all the drives of the EOT cranes &
transfer cars. All motors will be controlled by VFD and will be inverter grade.
[Link] AC Drives
IGBT based VFD drives with sine coded PWM & vector control have been
envisaged. These drives will be with:
i) High response & control precision
ii) Adaptable to actual supply frequency
iii) Quick fault localization
iv) Regenerative/dynamic braking as per requirement
[Link] Intelligent Motor Control Centres (MCCs)
The intelligent MCCs will be provided for feeding power supply for
controlling the auxiliary drives of fixed-speed mechanisms, drives of utilities

PROJECT DESCRIPTION
& services equipment. Each MCC will have one single incomer with requisite
quantity of out-going feeders. MCCBs, power contactors, thermal overload
relays, auxiliary relays, meters, indicating lamps will be provided in MCC.
Electronic motor protection relay will be considered for motor ratings above
55 KW. The MCC will be equipped with signal modules, microcontrollers and
profibus interface cards.
[Link] Electrics of Miscellaneous Items
It is envisaged that hydraulic power packs, lubrication system, sump pumps,
compressors, air conditioning & ventilation system, equipment for
mechanical & electrical workshop, water facilities system will be supplied with
soft starters, vacuum contactors, etc.
[Link] Sensors/ Field Devices and Measuring Devices
Field devices and sensors like pulse encoders, proximity switches, HMDs, limit
switches, level switches, and load cells, etc., will be provided for feedback,
inter-locking and sequencing.
[Link] Control Desk/ Local Control Stations (LCS)
Control desks, LCB and pulpits have been envisaged for control of process &
support facilities. Pulpit will be structural, aesthetically designed with false
ceiling, false floors, decorative lighting and will have toughened glass front.
The critical pulpits will be air-conditioned. Desks will be floor mounted and
will house HMI PC’s in additions to other controlling devices. LCS’s will be
wall-mounted type and will be used for local control of different mechanisms,
pumps, fans, etc.

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[Link] Uninterrupted Power Supply (UPS)

Uninterrupted Power Supply (UPS) of required rating will be provided in
different unit for supplying power to automation system (CPU), controllers
and in some cases important instrumentation. UPS will be of digital type with
PWM technology based in IGBT. This will be hot redundant type with a
provision to “power change over” through a static switch. The batteries will
be of ‘Ni-Cd’ type along with battery charger. Distribution board for
distributing uninterrupted power supply will be provided
[Link] Cables
[Link].1 HT Power Cables
· 220 kV single core XLPE insulated welded corrugated aluminium-alloy
sheathed with copper conductor conforming to IEC 68040
· 33 kV earthed grade, XLPE insulated armoured aluminium conductor
PROJECT DESCRIPTION

cables
· 6.6 kV unearthed grade, XLPE insulated armoured aluminium
conductor cables.
· HT power cables will conform to IS: 7098.
[Link].2 LT Power Cables & Control Cables
LT power cables for 415 V system will be heavy duty, 1.1 kV grade, XLPE
insulated PVC sheathed aluminum conductor, armoured FRLS cable. The
control cables will be multi strand copper conductor, XLPE insulated and PVC
sheathed with minimum cross section of 2.5 sq. mm for control voltage
circuit and 4.0 sq. mm for power circuit. The LT power and control cable will
confirm to IS-1554-1988.
[Link].3 Special cables
Screened cables, signal cables, coaxial cables, etc are also considered for the
project.
[Link].4 Cabling
Power inside the plant will be distributed through cables to various premises
through Walk able overhead cable galleries/ RCC cable tunnels (of size 2.5mx
2.5m with 600 mm cable tray on both sides of tunnel) and through RCC cable
trenches. GI pipes/ hume pipes will be used at road/ rail crossings. Inside the
substations, shop and covered premises, the cables will be laid in basement
or in concrete trenches (over cable supporting structures/ cable trays) or on
columns and other structures. Power cables will be laid on ladder type trays,
whereas control cable will be laid on perforated cable trays.

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[Link] Illumination
For supply of various illumination loads in the MSDS-VIII, sub-station
buildings, Proposed SMS and CCM Shop shop, provision of main lighting
distribution boards (MLDBs) has been considered. These MLDBs will be
installed in HT/ LT substation rooms and will be fed from the 415 V
switchboards. MLDBs will supply power to the various lighting distribution
boards (LDBs) to be installed in various locations. The LDBs will supply power
to sub-lighting distribution boards (SLDBs). The lighting fixtures will be fed
from SLDBs.
For energy saving, high power factor LED light fittings has been considered.
The internal illumination of low roof buildings will be with LED based light
fittings whereas for shops as well as high roof building will be illuminated
with high bay LED based light fittings. For Shop bay illumination high bay/
medium bay lighting fixtures have been envisaged. Average illumination

PROJECT DESCRIPTION
inside the shop building will be 100-150 lux; however the illumination level in
control rooms will be 300 lux. Illumination in open yard and area illumination
will be provided with LED based light fittings. Pole mounted Solar lighting
has been considered in combination with LED lighting for peripheral &
outdoor lighting.
The average illumination level will be 15 to 30 lux for outdoor illumination.
Illumination will be provided to administrative building & associated facilities.
High mast tower lights will be provided for illumination of MSDS-VIII open
area. The code of practice for illumination system will be as per IS 3646.
[Link] Welding System
For ease of maintenance three phase welding sockets suitably located along
the length of the bay and near other premises have been envisaged. Welding
distribution boards (WDB) will source power to welding receptacles.
[Link] Crane and Crane Trolley Lines/ Electric Hoists
Electrics for all EOT cranes and electric hoists have been envisaged. The drive
motors of the EOT cranes will be provided with VFD controllers and radio
remote controls. Electrics for the hoists will include festoon cables/ cable
drag chain arrangement. Power supply to EOT cranes will be through DSL
system.
[Link] Earthing
An outdoor protective earthing network made of number of electrode
stations interconnected by means of GI strip earth continuity conductor will
be provided around the main shops and auxiliary buildings. A low earth
resistance is envisaged to be obtained by using sufficient number of earth

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electrode. Main earth rings effectively bonded to the outer ring will be
provided inside the electrical control and building structures. All electrical
equipment & machinery will be connected to the main earth rings by two
separate and distinct earth connections in accordance with Indian Electricity
rules and as per IS 3043 - 1987.
A separate electronic earthing system will be provided for electronic
equipment like PLC’s & drives. Provision of special earthing, foundation
earthing will be made as per the specifications of the equipment Suppliers.
[Link] Lightning Protection System
Lightning protection system will be provided for Plant and equipment. The
configuration of the system will be as per IS 2309-1969. The lightning masts/
rings/ down leads will be connected to earthing pits specifically provided for
lightning protection.
4.5.3 Calcined Lime and Dolo Plant for New SMS
PROJECT DESCRIPTION

[Link] Proposed Power Distribution Scheme

One no. new LT substation with new isolators, 2X 2000 KVA dry type
transformer, 415 V LT PMCC switchboard etc. is envisaged for the proposed
facility. Incoming power to the new 2X 2000 KVA transformer will be tapped
from the new 6.6 kV HT switchboard coming up in main package.
Location – New LT substation building in the proposed facility.
[Link] Drive control & regulation system with LT AC squirrel cage induction ,
suitable starters, VFDs etc has been envisaged.
[Link] Adequate capacity of parallel redundant, industrial UPS system has been
considered for the supply to UPS load. UPS system will consist of common
SMF battery bank & ACDB.
[Link] New illumination systems with energy efficient LED light fittings have been
considered for the proposed system. MLDB with two incomers for power
supply to various SLDB is considered.
[Link] Required HT/ LT Power and Control Cables will be considered. Power cables
will be XLPE, Aluminium, FRLS outer sheathed & armoured.
Earthing & lightening protection will be done conforming to IS 2309 - 1989
and IE Rules.

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4.6 PROCESS CONTROL & AUTOMATION

4.6.1 Process Control & Automation- Enabling Works
Rerouting of telecommunication cables (2 Runs of 100 pair), control cables [6
Runs of 19 x 2.5 [Link]] and other instrumentation & telecommunication
cable have considered.
4.6.2 Process Control & Automation- Installation of New Facilities
[Link] General:
Process control & automation system consisting of Control & measurement
system (Level-0), PLC system (Level-1), Level-2 automation system &
Manufacturing Execution System (MES) for Enhancing Steelmaking Capacity
at RSP with associated facilities for smooth operation, planning, scheduling
and tracking is proposed.
Enhancing Steelmaking Capacity at RSP includes following units: Hot Metal

PROJECT DESCRIPTION
De-sulphurisation (HMDS), BOF Converter (BOF), Ladle Furnace (LF), RH-OB
and 1x1 Strand Slab Caster along with associated auxiliaries.
PLC based process control system has been envisaged for monitoring and
control of the complete process including the drive control. Necessary
hardwire interface & communication of Level-II system, for each unit i.e. Hot
Metal De-sulphurisation, BOF Converter, Ladle Furnace, RH-OB and 1x1
Strand Slab Caster with the proposed PLC systems of respective units, MES
system and plant ERP system shall be provided. The proposed Network
interface diagram for Proposed SMS and CCM Shop, RSP is shown in the
Drg. CET RN 4706 CA1 00 006 R-0.
The process will be controlled by the operator from the proposed control
rooms, separate for each unit. The system will be reliable, efficient, less
maintenance oriented, and easy to operate.
Level-2 process automation of proposed Proposed SMS and CCM Shop shall
depend mainly on execution of process model software for all the units
through separate Level-2 systems.
The application software of various models shall be running on the system in
online real time environment. These models shall be executed through
process computer, which shall receive on-line process data from PLC system
(Level-1). The Level-1 system shall get the field data from field instruments
(Level-0). The proposed Level-2 system for each unit shall be interfaced with
the PLC systems of all the units and plant ERP system for exchange of data.
To ensure maximum flexibility, reliability & availability of the automation
system, all the tasks shall be divided on hierarchical basis. The hierarchy
consists of following levels:

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Level-0: Instrumentation system consisting of primary sensing elements,

transmitters, converters, gauges, final control elements etc.
Level-1: Programmable logic controllers (PLCs) complete with HMIs,
engineering stations / programming terminals, operator stations, printers etc.
The tasks to be carried out by Level-1 system are as follows:
· Loop optimization and set point control,
· Sequence and Logic control of drives,
· Data acquisition,
· Report generation and event logging,
· On-line graphical display,
Level-2: The associated software with appropriate hardware like Process
control computer, peripherals shall be associated as part of Level-2
PROJECT DESCRIPTION

Automation for proposed SMS & CCM shop. Further, the proposed level-2
automation systems of all the units of proposed SMS & CCM shop shall have
connectivity with each other through network switch, patch panel, Fiber
Optic/CAT 6 cable etc. There will also be connectivity with Plant ERP system.
The tasks to be carried out by Level-2 system are as follows:
· Execution of Process model software
· Data communication with Level-1 system
· Data logging
· Generation of MIS Reports and Graphics
Modes of Operation
The automation system will have following modes of operation:
· Computer Automatic Mode
· Semi-automatic Mode
· Manual Mode
· Local Mode
Computer Automatic Mode
In this mode of operation, the computer system, Programmable Logic
Controller (PLC) and instrumentation system is fully functional. The set points
of various models running on the process computer system, required for
each process is sent to the Level-1 automation system. PLC will control the
process by controlling the process parameters, drives, interlocks etc.
Semi-Automatic Mode

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This mode of operation will be resorted to, in case of failure of link between
the process computer system and the automation system (Level-1). However,
during this mode both the process computer & the automation system
(Level-1) will be fully operational. The predicted set points of each parameter
for various programmes will be displayed on the HMI of the process
computer and the required status & the value of the parameters is
transmitted to the computer using the key board. Other operations are
identical to those indicated under computer auto mode. In this mode the set
points generated by computer models will be working as advisory mode.
Manual Mode
This mode of operation will be employed in case of failure of the automation
system (Level-1) or communication system bus. It will be effective when a
particular or a group of drives/loops cannot be controlled in the semi-
automatic mode. The operation will be carried out from operator station.

PROJECT DESCRIPTION
Local Mode
It is used mainly for the maintenance purposes. Local stations will be
provided at field i.e. near the equipment for testing of individual equipment
without interlock.
Manufacturing Execution System (MES):
Manufacturing Execution System (MES) will be executed at proposed SMS
and CCM shop to manage manufacturing information like management of
product, resources, scheduling, dispatching, execution of production orders,
collection of production data, production tracking, production performance
analysis etc. and interfacing with Level 4 RSP SAP system over plant wide
network. Data have to be downloaded to MES for order tracking/balance in
MES. There will be integration and exchange of data between proposed SMS
& CCM shop Level-2 (L-2), MES and RSP SAP. MES will integrate all the
functions and services of customer need for sustained maximization of plant
performances and will be interfaced to SAP ERP in higher level & various
units of proposed SMS & CCM shop L-2 optimization at lower level. MES of
proposed SMS & CCM shop will ensure a seamless and transparent flow of
data vertically from the process to the management level and horizontally
from the delivery of raw materials to the finished product of the shop. The
software modules of MES will optimize all horizontal production processes
from receiving of hot metal from Blast Furnace to slab; vertically integrate the
information flow from end to end for better decision making, assured
maintenance and further development over the entire life cycle of the plant.
Hardware of server systems, networking hardware and software like OS,
Application development software, application software modules, distributed
Clients including SAP terminals will be considered for MES. MES will be used

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for production order generation, production schedule management,

production coordination, quality management, production progress tracking
etc. and will also be consisting of the following modules/applications:
i) Maintenance & equipment management module from maintenance
planning using standardized work schedules to the initiation of
maintenance orders based on defined criteria and the collection and
archiving of all incurred costs to fulfill the technological and process
needs of the plant.
ii) Energy management module for recording consumption data,
allocating energy charges, generating energy balances etc. The
module will be configurable and scalable for the different automation
levels and production units.
iii) Electrical energy consumption data will be interfaced with MES
system for energy monitoring.
iv) Hardware of server systems, networking hardware and software like
PROJECT DESCRIPTION

OS, Application development software, application software modules

for MES.
v) Interfacing with SAP ERP system including supply of cables,
installation & commissioning.
vi) During initial startup of the shop & outage of the MES system,
provision is to be made so that SAP, RSP will directly interface with
Level-2 servers of various units of proposed SMS & CCM shop.

Proposed SMS and CCM shop MES will be interfaced with Hot Strip
Mill-2 MES system so that complete tracking of strip upto heat can
be done.
[Link] Proposed System
[Link].1 PLC automation system
Automation system consists of PLC, IMCC, drive system, HMI stations &
microprocessor based SMART sensors and actuators. This level will consist of
all closed loop PID controls, regulatory controls, logic & sequential controls,
dialogue & display for operators, process interface and alarm etc. Monitoring
and control of process parameters as per technological requirement and all
close loop PID functions will be carried out by PLC system.
Suitable human machine interfaces (HMI’s) are being envisaged for smooth
operation.
PLC system will have hot redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O system,
along with necessary system & application software, HMI screen,
programming unit, operator station & peripherals.

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PLC will do supervision of process parameters and sequential logic control,

interlocking and operator interface functions as per process requirement. The
PLC system shall have bus based communication with the new intelligent
MCC (IMCC).
Remote Input/ Output Panels (RIOPs) have been envisaged and the same will
be located at suitable locations in the proximity of process, for all the units
and auxiliary facilities, for catering to the necessary inputs and outputs of the
respective units. From these Remote I/O Panels, cable will be laid to the
respective PLCs of these areas, which are located in the Control room.
[Link] Measurement & Control, Level-1 Automation, Level-2 Automation including
mathematical models for various units of proposed SMS and CCM shop are
listed below:
[Link].1 Hot Metal De-sulphurisation unit

PROJECT DESCRIPTION
A. Measurement & Control
(a) Weighing System
Load cell based hopper weighing system, for measurement of Lime and
Magnesium, shall be provided with indication in the control room.
(b) Pneumatic conveying system of reagents
· Nitrogen flow measurement & control
· Local pressure measurement of pumping system.
(c) Sulphur analysis of Hot metal sample
The system shall be used for sampling and measurement of Sulphur
percentage in the molten metal.
(d) Slag raking machine
The raking machine boom movement will be controlled by proportional
control valves that allow the operator to control the raking machine
blade speed with his joystick to suit the raking requirements
B. Level-1 Automation system
PLC system with Parallel redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O
system with remote I/O sub system, along with necessary system &
application software, HMI screen, programming unit, operator station &
peripherals
C. Level-2 Automation system
Level-II automation system will consist of redundant servers, HMI,
engineering station, Laser printer etc

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The proposed Automation system configuration diagram of Hot metal

De-sulphurisation unit at proposed SMS & CCM shop, RSP is shown in
the Drg. CET RN 4706 CA1 00 001 R-0
D. Level-2 Models
Model for charge calculation and injection time
The process model will calculate the following:
· Magnesium requirement [kg]
· Lime requirement [kg]
· Injection time [min]
· Temperature loss prediction[°C]
E. Servers/ HMI/ Clients/ Network Switches/ software/ peripherals
PROJECT DESCRIPTION

Sl. No. Description Qty.

1. Level-I

a. HMI server with OPC driver 2 nos.

b. HMI client 2 nos.

c. Engineering station 2 nos.

2. Level-II

a. Level-2 Server 2 nos.

b. Level-2 Programming station 1 nos.

c. Level-2 client 3 nos.

3. MES client 1 no.

4. Network switches

a. Layer- 3 Ethernet Managed switch 2 nos.

5. Supply & laying of Fibre optic cable and CAT-6 Lot

UTP cable

6. Software

a. All necessary Software like System software, Lot

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process models and application software along

with media and licenses

b. Network management software lot

7. Peripherals

a. Laser A3/A4 multi-function colour printer 2 nos.

b. Large LED display screen (52”) 1 no.

8. Networking hardware & accessories- LIU, media Lot

convertors, passive components, connectors etc.

[Link].2 BOF Converter

PROJECT DESCRIPTION
A. Measurement & Control
(a) Weighing System
Load cell based hopper weighing system, for hot metal weighing, scrap
weighing, fluxes (lime and dolomite), will be provided with indication in
the control room.
(b) BOF Gas Holder
i) BOF Gas analysis
ii) Booster fan suction pressure measurement
iii) Measurement & control for Booster fan delivery pressure
iv) Gas holder pressure & level measurement
v) Export gas flow & pressure measurement
vi) U-seal level interlocking
vii) BF gas network pressure at the point of mixing
viii) Instrumentation & control for Electro-static precipitator.
(c) Utility gases
Measurements of flow & pressure for all the utility gases, like propane,
methane, Oxygen, Argon, Nitrogen, BOF gas etc.
(d) Sub lance system
The BOF will be equipped with sub lance system to facilitate online
measuring of sample and temperature.
(e) Measurement & control of various process parameters related to
Converter, GCP, Gas holder & Heating systems.
(f) Gas analysers for waste gas analysis.
(g) Digital lance height measurement and recording

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B. Level-1 Automation system

PLC system with Parallel redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O system
with remote I/O sub system, along with necessary system & application
software, HMI screen, programming unit, operator station & peripherals for
the following:
i) Converter
ii) Gas Cleaning plant
iii) Water system
iv) Bulk material handling system
v) Gas recovery plant
C. Level-2 Automation system
Level-II automation system will consist of redundant servers, HMI,
engineering station, Laser printer etc.
PROJECT DESCRIPTION

The proposed Automation system configuration diagram of BOF Converter at

proposed SMS & CCM shop, RSP is shown in the Drg. CET RN 4706 CA1 00
002 R-0
D. Level-2 Models
i) Static model for charge calculation
ii) Blowing pattern model
iii) Dynamic process control model
iv) Alloy addition model
v) Model for carbon temperature curve
vi) Model for extrapolation of the tapping analysis calculation
vii) Model for Steel Bath Level calculation

E. Servers/ HMI/ Clients/ Network Switches/ software/ peripherals

Sl. No. Description Qty.

1. Level-I

a. HMI server with OPC driver 2 nos.

b. HMI client 5 nos.

c. Programming station 2 nos.

2. Level-II

a. Level-2 Server 2 nos.

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b. Level-2 Clients 3 nos.

c. Programming station 1 nos.

3. MES Client 1 no.

4. Network switches

a. Layer- 3 Ethernet Managed Switch 2 nos.

5. Supply & laying of Fibre optic cable and CAT-6 Lot

UTP cable

6. Software

a. All necessary Software like System software, Lot

PROJECT DESCRIPTION
process models and application software along
with media and licenses

b. Network management software lot

7. Peripherals

a. Laser A3/A4 multi-function colour printer 2 nos.

b. Large LED display screen (52”) 1 no.

8. Networking hardware & accessories- LIU, media Lot

convertors, passive components, connectors etc.

[Link].3 Ladle Furnace Unit

A. Measurement & Control
(a) Inert gas (Nitrogen / Argon) Stirring System
i) Pressure measurement (local indication) with low pressure alarm
both at Nitrogen inlet and delivery points.
ii) Nitrogen pressure control through self-actuated type control
valve.
iii) Flow measurement and control with totalizer.
(b) Temperature Measurement and Sampling System
The system shall be used for sampling and measurement of
temperature of the molten metal. The measuring lance shall be suitable
for two-in-one type disposable tip for temperature measurement and

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sampling in single stroke. The system shall be complete with immersion

lance, measuring cable, large display, horn and related electronics.
(c) Weighing System
Load cell based hopper weighing system, shall be provided with
indication in the control room.
B. Level-1 Automation system
PLC system with Parallel redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O
system with remote I/O sub system, along with necessary system &
application software, HMI screen, programming unit, operator station &
peripherals.
C. Level-2 Automation system
Level-II automation system will consist of redundant servers, HMI,
engineering station, Laser printer etc.
PROJECT DESCRIPTION

The proposed Automation system configuration diagram of Ladle

Furnace at proposed SMS & CCM shop, RSP is shown in the Drg. CET
RN 4706 CA1 00 003 R-0.
D. Level-2 Models
i) Ferro alloy addition model
ii) Thermal model
iii) Deoxidation model
iv) Desulphurisation model
v) Temperature correction model

E. Servers/ HMI/ Clients/ Network Switches/ software/ peripherals

Sl. No. Description Qty.

1. Level-I

a. HMI server with OPC driver 2 nos.

b. HMI client 2 nos.

c. Engineering station 2 nos.

2. Level-II

a. Level-2 Server 2 nos.

b. Programming station 1 no.

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c. Level-2 client 3 nos.

3. MES Client 1 no.

4. Network switches

a. Layer- 3 Ethernet Managed Switch 2 nos.

5. Supply & laying of Fibre optic cable and CAT-6 Lot

UTP cable

6. Software

a. All necessary Software like System software, Lot

process models and application software along
with media and licenses

PROJECT DESCRIPTION
b. Network management software lot

7. Peripherals

a. Laser A3/A4 multi-function colour printer 2 nos.

b. Large LED display screen (52”) 1 no.

8. Networking hardware & accessories- LIU, media Lot

convertors, passive components, connectors etc.

[Link].4 RH-OB Unit

A. Measurement & Control
i) Top Oxygen injection cum burner control system.
ii) Lift gas control.
iii) Vacuum pumping station with necessary measurement & control.
iv) Ferro alloy/ micro alloy addition weighing control.
v) Monitoring of vessel refractory temperature.
vi) Monitoring of additives bins level.
vii) Argon/ nitrogen flow control.
viii) Monitoring of Steel bath temperature & dissolved Oxygen in bath.
ix) Monitoring of cooling water flow, pressure and temperature.

B. Level-1 Automation system

PLC system with Parallel redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O system

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with remote I/O sub system, along with necessary system & application
software, HMI screen, programming unit, operator station & peripherals.
C. Level-2 Automation system
Level-II automation system will consist of redundant servers, HMI,
engineering station, Laser printer etc.
ii) The proposed Automation system configuration diagram of RHOB at
proposed SMS & CCM shop, RSP is shown in the Drg. CET RN 4706 CA1 00
004 R-0.
D. Level-2 Models
i) Alloying model
ii) De-oxidation Model
iii) Decarburization model
iv) Temperature correction model
v) Cyclic Metallurgical Model
PROJECT DESCRIPTION

vi) Decarburization
vii) Dehydrogenization and nitrogen model
viii) Cyclic Thermal Model
E. Servers/ HMI/ Clients/ Network Switches/ software/ peripherals

Sl. No. Description Qty.

1. Level-I

a. HMI server with OPC driver 2 nos.

b. HMI client 2 nos.

c. Engineering station 2 nos.

2. Level-II

a. Level-2 Server 2 nos.

b. Programming station 1 no.

c. Level-2 client 3 nos.

3. MES Client 1 no.

4. Network switches

a. Layer- 3 Ethernet Managed Switch 2 nos.

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5. Supply & laying of Fibre optic cable and CAT-6 Lot

UTP cable

6. Software

a. All necessary Software like System software, Lot

process models and application software along
with media and licenses

b. Network management software lot

7. Peripherals

a. Laser A3/A4 multi-function colour printer 2 nos.

b. Large LED display screen (52”) 1 no.

PROJECT DESCRIPTION
8. Networking hardware & accessories- LIU, media Lot
convertors, passive components, connectors etc.

[Link].1 Slab Caster Unit

A. Measurement & Control
(a) Mould
i) Flow measurement and control for mould cooling water (Soft
water)
ii) Inlet and Outlet temperature measurement for mould cooling
water (Soft water)
iii) Pressure measurement of mould cooling water (soft water) with
low pressure alarm
iv) Break Out Prediction System
v) Automatic Mould Level Control System
(b) Secondary cooling circuit
i) Flow measurement & control of secondary cooling water
(Industrial water) in branch line.
ii) Pressure measurement of secondary cooling water (Industrial
water) in main line.
iii) Temperature measurement of secondary cooling water (Industrial
water) in main line.
iv) Mist air pressure control.
v) Mist air flow control.
vi) Differential pressure measurement across Heat exchanger.
(c) Closed circuit machine cooling

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i) Flow measurement of machine cooling water (soft water) in main

supply header.
ii) Local pressure and temperature gauges on up-stream and
downstream of pumps (except drain pit pump), heat exchangers.
iii) Differential pressure measurement across Heat exchanger.
(d) Torch cutting Machine
i) Pressure measurement and control of Propane.
ii) Flow measurement of Propane.
iii) Temperature measurement of Propane.
iv) Pressure measurement and control of Oxygen.
v) Flow measurement of Oxygen.
vi) Temperature measurement of Oxygen.
(e) Weighing System
Load cell based molten hot metal weighing system (for ladle turret weight
measurement, tundish weight measurement in the tundish car) along with
PROJECT DESCRIPTION

Slab weight measurement and Roller table weighing system will be provided
with indication in the control room.
(f) Others
i) Slag detection system in Ladle to Tundish
ii) Dip type temperature measurement in Tundish
iii) Disposable (sample & temperature) tips.
B. Level-1 Automation system
PLC system with Parallel redundant CPU, redundant communication,
redundant Power supply, redundant HMI servers, non-redundant I/O system
with remote I/O sub system, along with necessary system & application
software, HMI screen, programming unit, operator station & peripherals.
C. Level-2 Automation system
Level-II automation system will consist of redundant servers, HMI,
engineering station, Laser printer etc.
The proposed Automation system configuration diagram of Slab caster
at proposed SMS & CCM shop, RSP is shown in the drawing CET RN
4706 CA1 00 005 R-0.
D. Level-2 Models
i) Secondary Cooling Model
ii) Slab cut length optimization
iii) Quality Expert System
In addition to above Models, the following have also been envisaged to have
better control over Caster Process:
i) Break Out Prediction System

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ii) Automatic Mould Level Control

E. Servers/ HMI/ Clients/ Network Switches/ software/ peripherals

Sl. No. Description Qty.

1. Level-I

a. HMI server with OPC driver 2 nos.

b. HMI client 2 nos.

c. Programming station 1 no.

d. Development station 1 no.

2. Level-II

PROJECT DESCRIPTION
a. Level-2 Server 4 nos.

b. Level-2 client 4 nos.

c. Engineering station 1 no.

3. MES client 1 no.

4. Network switches

a. Layer- 3 Ethernet Managed Switch 2 nos.

b. Layer- 2 Ethernet Managed Switch 4 nos.

5. Supply & laying of Fibre optic cable and CAT-6 Lot

UTP cable

6. Software

a. All necessary Software like System software, 1 Set

process models and application software along
with media and licenses

b. Network management software 1 Set

7. Peripherals

a. LaserA3/A4 multi-function colour printer 2 nos.

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b. Large LED display screen (52”) 1 no.

8. Networking hardware & accessories- LIU, media Lot

convertors, passive components, connectors etc.

[Link] Common facilities for proposed SMS & CCM shop Complex
Centralized data centre
Centralized data centre will have facility to host following IT equipment’s::

Sl. No. Description Qty.

1. Historian server 1 no.

2. MES server 2 nos.

PROJECT DESCRIPTION

3. Domain controller 1 no.

4. Antivirus server 1 no.

5. SAN storage 1 no.

6. Web server 1 no.

7. Firewall 2nos.

8. Core switches 2nos.

MES clients shall be installed at various locations in proposed SMS & CCM
shop complex. Data centre shall be installed in the control room of Slab
Caster of the proposed SMS & CCM shop.
[Link].1 Digitalization
i) Remote monitoring facilities for troubleshooting and other required
activities will be provided.
ii) Facilities for App based mobile integration will be provided for MIS
reports & alarms
[Link].2 Water system
Controls
i) Automatic start of hot-standby pumps, in case the working one goes

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down.
ii) Emergency flow in case of power failure.
iii) Soft water generation plant and Zero liquid discharge controls. Hot
redundant PLC shall be provided for soft water generation plant and
Zero liquid discharge (ZLD) along with 02 (two) nos. of HMIs placed at
the control room.
iv) Provision shall be there for automatic filling of sumps, Emergency
Overhead Tank, fire water tank with level sensors.
Measurements (Local as well as transmitters at HMI display)
(a) Pressure
i) Pressure measurement at the discharge header of pumps – 50 nos.
ii) Inlet & outlet of various process connections – 15 nos.

PROJECT DESCRIPTION
(b) Temperature
i) Temperature measurement at inlet & outlet of various heat
exchangers – 24 nos.
ii) Temperature measurement at inlet & outlet of cooling towers – 14
nos.
iii) Inlet & Outlet and distribution channels of fin-fan cooler – 20 nos.
(c) Level
i) Level measurement of underground makeup water sump - 1 no.
ii) Level measurement of underground Soft water sump - 1 no.
iii) Emergency overhead tank for caster mould cooling, caster close
machine cooling, ladle furnace, De-sulphurisation and RHOB - 4 nos.
(compartments)
iv) Emergency overhead tank for BOF converter – 1 no.
v) Over ground fire water storage tank - 1 no.
vi) Over ground cooling tower sumps - 7 nos.
(d) Flow
i) Flow measurement of makeup Water at tapping point.
ii) Flow measurement of supply water at process headers – 15 nos.

[Link].3 Fume Extraction System

i) Measurement of Pressure, Flow and Temperature of extracted fume

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shall be done at the respective extraction points and taken to the

PLC for Fume extraction system placed at the FES control room.
ii) Level measurement at hoppers of ESP – 8 nos.
iii) Temperature (0-150o C), pressure (mm of WC) of the fumes at inlet
& outlet of ESP with indication in control panel
iv) Hot redundant PLC along with HMIs for control of dust disposal
system consisting of operation of Rotary air-lock valves and drag
chain conveyors below ESPs.

[Link].4 Fire detection and Alarm System

Microprocessor based Fire Detection and Alarm System along with Linear
Heat Sensing cables, wherever required, shall be provided for entire Proposed
SMS and CCM Shop complex including, but not limited to the following:
PROJECT DESCRIPTION

Control rooms, PLC rooms, computer server rooms, Transformer rooms, MCC
rooms, Cable Cellars, Cable Vaults, Cable Basements, Cable Tunnels, Hydraulic
Rooms/ Cellars, Oil Cellars, conveyors, water pump house, compressor
houses, electrical rooms, MSDS-VIII complex etc. for all the units coming
under proposed SMS & CCM shop.
For FDA system, HMI based monitoring facility shall be provided in order to
monitor the complete FDA system from centralized location. Necessary
hardware & software shall be considered for all the fire alarm panels
accordingly.
Connectivity to main fire station of RSP will also be provided.
[Link].5 Telecommunication system
Telecommunication System for proposed SMS & CCM shop & associated
areas will be provided as described below:
(a) Selective Loudspeaker Inter Com (SLIC) system: SLIC system (approx.
18 nos.) shall be provided to cover major areas. The locations shall
mainly include the following places of the plant:
· Control rooms
· Working platforms
· Water treatment plant control room
· electrical sub-station buildings
· Shift offices
· Laboratory
(b) Plant Telephone System

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Plant telephone connection including telephone sets (approx.

100nos.) shall be provided in all the units of proposed SMS & CCM
shop area including associated facilities like- pump house etc.
Required cabling from nearest CT box of plant telephone network
shall also be included.
(c) Walkie-talkie communication system
Walkie talkie sets (approx. 30 nos.) complete with Ni-Cd rechargeable
batteries and twin battery chargers will be provided to take care of
the mobile communication requirement among the user/officers of
complete proposed SMS & CCM shop area
[Link].6 Closed circuit Television (CCTV) System
Supply, installation, testing & commissioning of CCTV Hardware, software,
cable & connectors for the entire area of proposed proposed SMS & CCM
shop & associated facilities as required.

PROJECT DESCRIPTION
There will be provision for large display/monitor (min 42”) of CCTV system in
the respective control rooms.
[Link].7 Shop-wise flow measurement for all the utilities like- Mixed gas, LD gas,
steam, high pressure N2, O2, Argon, Propane/Natural gas, compressed air etc.
will be done.
[Link].8 Furniture as Server racks (as required), HMI tables (as required), printer tables
(as required) ergonomically designed chairs- 80nos., document almirahs-
20nos. will be provided.
[Link].9 Supply, routing, laying and termination of communication, control,
instrumentation, screened, compensation and special cables as required.
[Link].10 Minor Civil work as chipping, cutting, making foundation for
panels/modification in rooms and making good all damage thereafter to
facilitate cable laying. The work shall be deemed complete only after
restoration of the surface/ spot to original shape & finish by plastering,
painting etc.
[Link].11 Electronic earthing of all new equipment in accordance with the code of
practice for earthing as in IS: 3043-2018.
[Link].12 Necessary erection material for electrical equipment, PLC, panels, cabling &
earthing equipment.
[Link].13 Special Tool & tackles

Sl. No. Description Qty.

1. Network analyser 1 no.

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2. Multimeters 2 nos.

3. HART calibrator 2 nos.

4. FO cable splicing/jointing kit 1 no.

5. OTDR suitable for both SM & MM 1 no.

6. Tong tester for AC & DC 2 nos.

4.6.3 Calcined Lime and Dolo Plant for New SMS

Process control and automation will be complete with:
a) Field instrumentation for the Lime and Dolo kiln along with bag filter
based de-dusting system:
· Hopper level measurement in bunkers
PROJECT DESCRIPTION

· Differential pressure measurement at inlet and outlet of bag filter

· Temperature measurement in inlet and outlet of bag filter
· Suspended particulate matter (SPM) measurement in stack
b) PLC system has been envisaged for complete process control
including interlocking, sequencing and PID
c) Fire Detection and Alarm System:
Microprocessor based Fire Detection and Alarm system will be
provided in the proposed new Lime & Dolo kiln plant.
Main fire alarm control panel will be located in the manned area of the
building.
Connectivity to main fire station of RSP will also be provided.
d) CCTV:
CCTV system will be provided for Lime & Dolo kiln plant area.
e) Telecommunication System:
Telecommunication will consist of plant telephone system, Selective
Loudspeaker Intercom (SLIC) and Walkie-Talkie system.
Plant telephone facility will be extended from the nearest CT box to
the proposed new Lime & Dolo kiln plant.
Necessary handsets, jelly filled cables, twisted pair cables &
accessories will be provided

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4.7 STRUCTURAL WORK

4.7.1 Enabling Works -Dismantling and Relocation of Facilities

[Link] Scope of work – New Structure
1) Construction of Ramp for transpiration of scrap by trucks/ dumpers to
SMS-I shop floor at +7.5m level. Ramp will be of structural steel
framework and deck with R.C.C slab. Width and length of proposed
ramp is estimated to be 9.5 m and 100m respectively.
2) Construction of new gable end in existing shops:
i) SMS-I shop at axis no. 25, after dismantling of shop building
ii) Mould preparation bay at axis no.4, after dismantling of shop
iii) Repair shop Mechanical Shop building (near PDB/SLCC building)

PROJECT DESCRIPTION
3) New Conveyor gallery (re-routed) for dispatch of calcined Lime/
dolomite to SMS-I shop
i) Covered conveyor galleries along with supporting trestles, working
platforms shall be provided as per technological requirement.
ii) New junction houses with RCC floor supported on structural steel
frame work, handrails, access stairs, ladders, structures for handling
facilities etc. as per technical & technological requirement.
iii) Necessary stairs/ ladders, handrails, working platforms, structural
supports for handling facilities etc.
4.7.2 Rerouting of Power Supply
[Link] Scope of work
1) New structures:
i) Uncovered cable galleries along with supporting trestles, access
stairs, ladders, working & maintenance platform/ walkway etc. as per
technical/ technological requirement.
ii) Miscellaneous structures like platforms, stairs/ ladders, handrails etc.
as per requirement

4.7.3 Rerouting of Utilities Facilities

[Link] Scope of work
1) New structures:
i) Supporting trestles, working platforms, bridges to be provided as per
technical/ technological requirement.
ii) Necessary stairs/ ladders, handrails, structures for handling facilities
etc.
4.7.4 Installation of New Facilities

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Steel structural works envisaged for enhancing the steelmaking capacity in

RSP are as follows:
[Link] New steel structural building for installation of steel making facilities having
the following functional bays.
· Slag handling bay
· Hot metal receipts cum scrap bay
· Hot metal receipts cum charging bay
· Converter bay – lance handling bay
· Converter bay – ferro alloy charging bay
· Launder bay
· Ladle & Tundish preparation bay
· Secondary refining cum Turret bay
· Casting Machine bay
· Mould and Roller Segment repair bay
PROJECT DESCRIPTION

· Slab storage cum despatch bay

· Slab storage cum despatch bay
[Link] Different bays of new steel structural building will have the following facilities
depending upon technological and operational requirement and layout:
1) Runway girders for EOT cranes of specified capacities and crane level
walkway with handrail at different levels.
2) Crane maintenance facilities with hoist supporting structures and
walkways and platforms.
3) Roof of building will not be flatter than 1:10 slope. Roof of building will
be of metal sheet with stiffeners. Access stair to roof and handrails will
be provided on roof edges for cleaning and maintenance purpose.
4) Longitudinal and transverse monitors will be provided on roof for heat
dissipation.
5) Main working platform at converter charging level will be RCC floor over
steel girders, beams and stool columns.
6) Steel structural support for semi portal crane for scrap charging.
7) Working and maintenance platforms at different levels. Grating /
chequered plate with stiffeners will be provided.
8) Openings and cut outs will be provided in floors as per maintenance
and operational requirement.
9) Rooms at different locations and levels. Heat insulation will be provided
as per technological requirement.
10) Support structures for belt conveyors, shuttle conveyors, bunkers, weigh
bins, chutes at different locations and levels.
11) Support structures for utility water and gas lines inside SMS building.
12) Support structures for fume extraction system and associated ducts
inside SMS building.

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13) Platforms and walkways for maintenance of bay light fixtures.

14) Access stairs to different working floors and crane level walkways.
15) Passenger-cum-goods lift as per technological layout.
16) Gable and side wall framing structures for CGS sheeting on gable and
side walls. Bottom of side sheeting will be as per technological
requirement.
17) Louvers will be provided on side walls.
18) Horizontal and vertical bracing will be provided for stability.
19) Rain water gutter and down comers will be provided for roof drainage.
20) Longitudinal and transverse expansion joints will be provided as per
stipulation.
[Link] All necessary steel structural support for equipment and associated facilities,
working platforms, walkways, access stair, handling and maintenance facilities
for installation of the following:

PROJECT DESCRIPTION
1) Hot metal desulphurisation unit
2) Ladle furnace and associated facilities
3) RH-OB Degasser Unit
4) BOF converter
5) Slab caster facilities
[Link] Steel structural frame work for control room building inside SMS building.
Control room flooring will be of RCC and brick cladding will be provided.
Access stair will be provided.
[Link] Steel structural support like monorail for hoists, support for under slung or
grab cranes for maintenance and handling facilities in pump houses, scale pit
areas etc.
[Link] Steel structural support for pipes in tunnels.
[Link] Overhead pipe bridges for road crossing. Pipe bridge will be open on top for
maintenance purpose.
[Link] Structural shed for compressor & pump for unloading of propane tanker.
[Link] Structural shed for vaporizer.
[Link] Structural shed for air compressor house.
[Link] All structural shed will have necessary handling facilities for maintenance.
[Link] Support for BOF gas pipe, launder, mixed gas pipe outside SMS building as
per layout including two and four legged trestles and overhead bridges for
road crossing.
[Link] Support for steam line outside SMS building as per layout including trestles
and overhead bridges for road crossing.

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[Link] Support for ducts outside SMS building as per layout including two and four
legged trestles and overhead bridges for road crossing for fume extraction
system.
[Link] No walkway has been envisaged along pipe lines or on bridges for road
crossings.
[Link] Self-supporting stack for fume extraction system.
[Link] Miscellaneous support for different equipment, platforms, walkways, access
stairs, ladders and handling facilities as will be necessary.
[Link] Covered conveyor galleries including supporting trestles with CGS roof &
side sheeting as per layout.
[Link] Junction houses with RCC working floor. Roof and partial side sheeting,
access stair and handling facilities will be provided as per layout.
[Link] Transmission line towers for 220 kV Double Circuit power line, gantries with
PROJECT DESCRIPTION

tower, support structures for different equipment as per electrical layout

requirement.
[Link] Overhead cable gallery including overhead road crossing as per layout.
Walkway alongside cable trays and roof covering will be provided.
[Link] Painting of all new structures.
4.7.5 Calcined Lime and Dolo Plant for New SMS
[Link] Scope of work
1) Dismantling/ Modification/ strengthening works:
i) Dismantling, modification and strengthening if any in the existing
high-rise bunkers (HRB) structures for Bunker of existing LDBP.
2) New structures:
i) Structural shed over RCC super structure along with bunkers for the
following unit. The shed shall be covered with CGS roof & side
sheeting along with structures for handling facilities. Structural access
stair up to top of bunker structure shall be provided as per technical/
technological requirement.
• Raw materials screening, storage & feed unit.
• Limestone and dolomite storage bunkers.
• Limestone and dolomite reject bunkers.
• Lime and Dolo reject unit.
• Flux screening, storage & feed unit.
• De-dusting bunkers
ii) Structural shed for Lime discharge unit. The shed shall be clad with
CGS sheeting on roof as well as all sides. Structures for handling
facilities, access staircase/ ladder shall be provided as per requirement.

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iii) Lift well of height as per requirement to cater to the kilns. The lift well
shall be supported from Kiln (technological structures) at various
places and properly braced ensuring minimum sway in compatibility
with the lift car rails provided in it. The same shall also be considered
during the design of Kiln structures.
iv) Conveyor galleries & junction houses with CGS roof & side sheeting
along with access stairs, ladders, handrails & structures for handling
facilities etc. for raw materials and flux conveying system as per
technological requirement. The conveyor galleries walkway shall be of
chequered plate floor. Junction houses floor shall be of RCC floor
supported on structural steel framework.
v) Miscellaneous structures like stairs/ ladders, handrails, working
platforms, structural supports for handling facilities etc. as per
requirement.

PROJECT DESCRIPTION
4.7.6 Design Considerations
All steel structures will be designed to meet the technological requirements
with due consideration to the plant and facilities.
Design of steel structures will be as per IS 800:2007.
Steel chimney will be designed as per IS 6533: PART 2: 1989.
Conveyor galleries will be designed as per IS 11592: 2000.
Transmission line towers will be designed as per IS 802: PART 1: SEC 1: 2015
and IS 802: PART 1: SEC 2: 2016. Fabrication and testing of transmission line
towers will be carried out as per IS 802: PART 2: 1978 and IS 802: PART 3:
1978 respectively.
Apart from technological and operational loads, self-weight and
superimposed loads on steel structures will be according to IS 875: 1987.
Structures will be designed for either seismic or wind load as applicable.
Seismic loads will be taken as per IS 1893 Part-1: 2016 & Part4: 2015. Wind
load will be considered as per IS 875(part 3):2015.
All structural steel work will be of welded construction. Due allowance will be
kept for impact, vibration and temperature load and accidental loads.
4.7.7 Technical Specification
[Link] Material for structural steel will be as per IS: 2062-2011. High strength steel
will conform to IS: 2062-2011/SAILMA.
[Link] Rolled steel sections will be as per IS 808: 1989 and parallel flange rolled steel
sections will be as per IS 12778: 2004.
[Link] Rainwater gutters will conform to E 250 Cu.

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[Link] Chequered plates will conform to IS 3502: 2009.

[Link] Skelp plates will conform to IS 10748: 2004.
[Link] All steel gratings, to be used over walkways and stair treads in open areas,
will be galvanized as per IS 4759: 1996.
[Link] Crane rail section will be as per IS 3443: 1980. Fixing plates for crane rail will
be of grade 60Si7 as per IS 3195: 1992.
[Link] Steel tubes will be as per IS 1161: 2014.
[Link] All bolts and nuts will conform to IS: 1363(Part 1)-2019, IS: 1363(Part 2 & 3)-
2018 IS: 1364-2018, IS: 1367-2014. High strength bolt will conform to IS 3757:
1985, IS 4000: 1992.
[Link] CGS sheet will conform to IS 277: 2018. Base material will conform to
structural steel grade 250.
PROJECT DESCRIPTION

[Link] Translucent sheet will be provided as per the provisions of IS 12866: 1989.
[Link] Plain washers will conform to IS 5369: 1975. Tapered washers conforming to
IS 5372: 1975 and IS 5374: 1975 will be used for channels and beams
respectively.
[Link] The welding and the welded work will generally conform to IS 816: 1969 and
IS: 9595- 1996 unless otherwise specified. Electrodes will conform to IS 814:
2004. As much work as possible will be welded in shops and the layout and
sequence of operations will be so arranged as to eliminate distortion and
shrinkage stresses.
[Link] In hot zones areas, like structures around converters, mixers, continuous
caster, furnaces & equipment that are subjected to high temperature will be
given three coats of a single pack heat resistant silicon resin based paint with
leafing aluminium / graphite powders having DFT of 20 microns/coat (total
60 microns).
[Link] Steel structures in no hot zone will be given two coats of air drying phenolic
modified alkyd composition with zinc phosphate as a primer with total dry
film thickness of 80 microns (40 microns/coat). Final paint will be two coats of
air drying high gloss phenolic alkyd modified synthetic enamel paint suitably
pigmented with total dry film thickness 50 microns(25 microns/coat)
[Link] Steel structures exposed to weather, i.e. without cladding, will be given two
coats of single pack air drying phenolic modified alkyd composition with zinc
phosphate as a primer having minimum dry film thickness of 80 microns (40
microns/Coat). Intermediate paint will be one coat of single pack high build
phenolic based paint with micaceous iron oxide (MIO) having minimum dry
film thickness of 75 micron. Final paint will be two coats of single pack air

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drying high gloss phenolic alkyd modified synthetic enamel paint as finishing
coat having minimum dry film thickness of 50 microns (25 microns/Coat).
[Link] Fabrication and erection of steel structures will conform to IS 800: 2007 and
tolerances of fabrication will be as per IS 7215: 1974. Erection tolerances will
be within specified limits and as per IS 12843: 1989.

PROJECT DESCRIPTION

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4.8 CIVIL WORKS

4.8.1 Enabling Works – Dismantling and Relocation of Facilities
[Link] Construction of all civil works including new foundations for the following
1) New Ramp for approach to SMS-I shop floor (Length approx.100M,
Width : 9.5 M). Ramp will be of structural steel frame work with RCC
deck slab. It will be connected to existing plant road network via side
road of Caster Shop of SMS-I..
2) Civil work for Relocated Mould & Segment repair facilities :
a) Construction of foundation for the following:
i) Support Stands for Segment 2-9 : 3 nos.
ii) Turning Stand for Segment 2-9 loose side : 1 no.
iii) Repair & Alignment Stand for Segment 1 : 1 no.
PROJECT DESCRIPTION

iv) Repair & Alignment Stand for Segment 2-9 : 1 no.

v) Support Stand for Lifter Traverse for Segment 1 : 1 no.
vi) Support Stand for Lifter Traverse for Segment 2-9 : 1 no.
vii) Support Stand for Segment 1: 2 nos.
viii) Support Stand for Mould : 1 no.
ix) Mould Assembly & Dismantling Stand : 1 no.
x) Turning Stand for Segment 1 : 1 no.
b) Construction of flooring, new shift room, flooring, finishing
3) Construction of foundations for New Gable end columns in existing
shops as follows:
a) SMS-I shop at axis no. 25, after dismantling of shop building
b) Mould preparation bay at axis no.4, after dismantling of shop
c) Repair shop Mechanical Shop building (near PDB/SLCC
building)
4) Construction of foundations and all civil works for new rerouted
Conveyor gallery for feeding Calcined Lime & dolomite to SMS-I
shop.

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5) Construction of new Buildings (as relocation) as follows:

Sl Relocated Building Floor area No. of Storey

(Approx.)

1. SMS-I Office Building 1000 SqM Single

2. Marammat Bhawan 12.4 m x 34.5 m 3- Storey

3. Crane Uddyan building 18m x 12m 2- Storey

4. Crane maintenance office 250 SqM Single

building

5. LU-OP, Stock control/ Stock 245 SqM 3-Storey

verification office building.

PROJECT DESCRIPTION
6. CISF Building 12m x 9 m Single

7. Canteen Buildings – 3 Nos.

6) All necessary civil works for construction of relocated Stores building

in Central Stores area, shifting of central stores boundary wall adjacent
to CCM-I shop etc. required as enabling works [for new railtrack from
CCM-I shop to Zone-IV track]

4.8.2 Area Survey and Soil Investigation

Area Survey and Soil Investigation has been envisaged within the battery limit
of proposed SMS and CC Shop and its periphery. It also covers the areas
where all linked associated facilities will be installed.
The package is prerequisite for installation of proposed SMS and CC
shop. The surface and sub-soil information will be obtained through this
package. The data obtained will be provided to bidder for better planning
and engineering

4.8.3 Underground Mapping

Underground mapping has envisaged within the battery limit of proposed
SMS and CC Shop and its periphery. It also covers the areas where all linked
associated facilities will be installed.
The package is prerequisite for installation of proposed SMS and CC
shop. This package execution will avoid interference of underground facilities
in the proposed site of SMS and CCM shop and its associated facilities. This

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also helps to protect the unknown facilities, if found, as per requirement. It

also helps to maintain the project schedule

4.8.4 Installation of New Building - RCL / Relocation Of R&C Lab Building

1. To make space for the proposed SMS and CC shop, existing R&C Lab
building is required to be shifted from the present location. It is
considered that an area of about 4100 Sqm. is available in the close
vicinity of plant networks (road, sewage and water supply) without any
significant over-ground & underground hindrances. This will be taken
up as one of the first activities in the project and only after all facilities
of this building are completed and becomes operational, the existing
building can be taken up for dismantling to make space for proposed
SMS and CC shop.
Considering the present practice of local testing facilities, the centralised
testing facilities are minimised and hence only 65 % of the existing floor
PROJECT DESCRIPTION

area of the RCL lab building has been envisaged for the new building.
However details of rooms & its sizing and other facilities/ premises for
the proposed building are to be finalised with RSP during preparation of
TS.
2. The working/ required equipment, furniture & peripherals are envisaged
to be decommissioned, dismantled, packaged, transported and re-
commissioned from existing building to proposed new R&C building
under the strict supervision of RSP
3. The proposed new R&C Lab Building is envisaged to be provided as per
the existing R&C building except for the basement floor of the existing
building, which has been envisaged at ground floor of the proposed
building. However, front car portico and top covered open
spaces/balconies are envisaged at ground floor and each of first &
second floors respectively
4. The plinth level & height of each floor (GF, FF & SF) of proposed
building is envisaged to be 0.3m from FGL and 3.9m respectively.
5. The proposed building is envisaged to be a three storied (G+2) RCC
framed construction with brick cladding walls including all serviceability
requirements such as finishes, water supply & sanitation, electrical
works, fire-fighting & detection works etc. as elaborated below:

a) Plot area = ~4100 Sqm. (Approx.)

b) Plinth Area of ground floor = ~1200 Sqm. (Approx.)
c) Plinth Area of First floor = ~1200 Sqm. (Approx.)
d) Plinth Area of second floor = ~1200 Sqm. (Approx.)
e) Boundary wall of 1.5m height in brick construction with 0.6m high
grill and 2 main gates have been envisaged.

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f) Rain water harvesting system for ground recharge for entire plot
area.
g) Internal all-around bituminous road with WMM sub base and its
interconnection with main plant road within a vicinity of 100m and
illumination.
h) Officer rooms and equipment rooms will be provided with
centralised air conditioning system and ventilation system as per
the requirement along with cooling tower, chiller plant room &
AHUs.
i) Separate ladies & gents toilets and drinking water point at each
floor.
j) Reception lobby at each floor with main staircase along with 2 exit
staircases at each end of the building are envisaged.
k) Conference hall of about 60 Sqm. at 1st Floor with audio-visual &
conferencing facilities.

PROJECT DESCRIPTION
l) All internal electrical installation, illumination system (internal &
external) distribution boards, power wiring, external connection,
points & plugs, power supply to equipment, lightening arrestor,
earthing pits etc. have been envisaged. All illumination is envisaged
to be done with LED light fittings.
m) Microprocessor based Fire Detection and Alarm System will be
provided in all the rooms, corridors & staircases in the proposed
new building. The main fire alarm control panel will be located in
the manned area of ground floor of the building and connectivity to
main fire station of RSP is envisaged.
n) Plant telephone facility shall be extended from nearest CT box to
the proposed new building in all the rooms, conference hall etc.
Necessary handsets, jelly filled cables, twisted pair cables and
accessories are envisaged.
o) LAN system including its connectivity with RSP network is envisaged
for the entire building.
p) CCTV surveillance system for indoor (lobby, corridors, critical
equipment areas) & outdoor (gates, portico & back side corridor).
q) Roof waterproofing treatment is envisaged with 4mm thick mineral
finished APP.
6. At the location of proposed R&C lab building, geodetic survey & soil
investigation is a prerequisite and shall be carried out through separate
package.

4.8.5 Installation of New Building - ED(W)/ Relocation Of ED(W) Building

1. To make space for the proposed Proposed SMS and CCM Shop, existing
ED works building is required to be shifted from the present location. It

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is considered that an area of about 5000 Sqm. is available in the close

vicinity of plant networks (road, sewage and water supply) without any
significant over-ground & underground hindrances. This will be taken
up as one of the first activities in the project and only after all facilities
of this building are completed and becomes operational, the existing
building can be taken up for dismantling to make space for Proposed
SMS and CCM Shop
Considering the present man power, electronic facilities and
computerisation, 65 % of the existing floor area of the ED works
building has been assumed for the new building. However details of
rooms & its sizing and other facilities/ premises for the proposed
building are to be finalised with RSP during preparation of TS.
2. The working/ required equipment, furniture & peripherals are envisaged
to be decommissioned, dismantled, packaged, transported and re-
commissioned from existing building to proposed new ED(W) building
PROJECT DESCRIPTION

under the strict supervision of RSP.

3. The offices of ED(W), CGM electrical, CGM Mechanical, CGM I/c
(Services), CGM I/c (Steel), CGM (Utility & Environment), CGM (Safety &
Fire), GM I/c (Personnel), GM I/c (AMR) along with their supporting
executives and staff are presently are situated in the existing ED works
building. The proposed new building is envisaged to cater the
requirement of the mentioned offices as per the existing building
4. The plinth level & height of each floor (GF, FF & SF) of proposed
building is envisaged to be 0.3m from FGL and 3.9m respectively.
5. The proposed building is envisaged to be a three storied (G+2) RCC
framed construction with brick cladding walls including all serviceability
requirements such as finishes, water supply & sanitation, electrical
works, fire-fighting & detection works etc. as elaborated below:
a) Plot area = ~ 5000 Sqm. (Approx.)
b) Plinth Area of ground floor = ~1775 Sqm. (Approx.)
c) Plinth Area of First floor = ~1775 Sqm. (Approx.)
d) Plinth Area of second floor = ~660 Sqm. (Approx.)
e) Boundary wall of 1.5m height in brick construction with 0.6m high
grill and 2 main gates have been envisaged.
f) Rain water harvesting system for ground recharge for entire plot
area.
g) Internal all-around bituminous road with WMM sub base and its
interconnection with main plant road within a vicinity of 100m and
illumination.
h) Officer rooms and equipment rooms will be provided with
centralised air conditioning system and ventilation system as per

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the requirement along with cooling tower, chiller plant room &
AHUs.
i) Separate ladies & gents toilets and drinking water point at each
floor.
j) Reception lobby at ground floor with main staircase and exit
staircases for the building are envisaged.
k) Two conference halls of about 100 Sqm. each at ground floor and
1st Floor with audio-visual & conferencing facilities.
l) All internal electrical installation, illumination system (internal &
external) distribution boards, power wiring, external connection,
points & plugs, power supply to equipment, lightening arrestor,
earthing pits etc. have been envisaged. All illumination is envisaged
to be done with LED light fittings.
m) Microprocessor based Fire Detection and Alarm System will be
provided in all the rooms, corridors & staircases in the proposed

PROJECT DESCRIPTION
new building. The main fire alarm control panel will be located in
the manned area of ground floor of the building and connectivity to
main fire station of RSP is envisaged.
n) Plant telephone facility shall be extended from nearest CT box to
the proposed new building in all the rooms, conference hall etc.
Necessary handsets, jelly filled cables, twisted pair cables and
accessories are envisaged.
o) LAN system including its connectivity with RSP network is envisaged
for the entire building.
p) CCTV surveillance system for indoor (lobby, corridors, critical
equipment areas) & outdoor (gates, portico & back side corridor).
q) Roof waterproofing treatment is envisaged with 4mm thick mineral
finished APP.
6. Wooden wall panelling with hard wood frame of 50mmX50mm spaced
600mm in both direction for supporting 6mm thick plywood and 1mm
thick laminate in ED(W) & In-charges rooms.

[Link] Considerations for R&C Lab and for ED(W) buildings

1. The plot shall be selected for R&C lab building and ED(W) building of
size 4100 Sqm and 5000 Sqm. (Approx.) respectively, free of over-
ground and underground hindrances and with maximum undulation of
+300mm.
2. Availability of plant service lines & networks such as sewage network,
water supply network, drainage and road are available within 100m
from the plot location. These networks shall have additional capacity for
catering to this building.

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3. Utilities such as compressed air, gases etc., as per equipment

requirements in R&C lab building shall be provided by the employer up
to the user point.
4. Incoming Electric power supplies (2x 630 A 415 V, 3 Phase Feeders for
R&C lab building and 2x 800 A 415 V, 3 Phase Feeders for ED(W)
building) are envisaged to be available within a lead of 100m from the
site.
5. Nearest CT box from the proposed R&C lab and new ED (W) building
will be at a distance of approx. 600 mtrs.
6. The existing furniture of both the buildings are envisaged to be shifted
to proposed buildings. In case, any new furniture is required, it is
envisaged to be supplied by RSP.
7. Supervision during shifting of equipment, furniture & peripherals from
old to proposed buildings.
PROJECT DESCRIPTION

4.8.6 Civil works for Rerouting of Power Supply

The major civil works involved are as follows:
· Construction of underground RCC cable tunnel
· RCC Foundation for cable gallery as per technological & service
requirements.
All the civil works like Earthwork, PCC, RCC, shuttering, Reinforcement,
Pressure Grouting etc. related to rerouting of power supply so to continue
production steel from SMS-I have been considered.
4.8.7 Civil works for Rerouting Of Pipe Lines
The major civil works involved are as follows:
· Construction of RCC foundations and trenches as per requirement.
All the civil works like Earthwork, PCC, RCC, shuttering, Reinforcement,
Pressure Grouting etc. related to rerouting of pipe lines so to continue
production of steel from SMS-I have been considered.

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4.8.8 Civil Works – Installation of New Facilities

[Link] The Civil works will comprise of design and construction of building
structures, shed structures, underground structures, foundations for
equipment’s, its auxiliaries, foundation / civil works for all technological units,
electrical and power distribution system, utility and services facilities,
ventilation and de-dusting system, instrument and control system, water
supply facilities, firefighting and detection system, floors, surface channels,
tunnels, drainage, sewage, storm water disposal system, modification of
boundary walls and new boundary walls etc. and all other work as per
technological system & process requirement. Following are the broad
description of units are detailed out in the subsequent clauses.
[Link].1 The major civil works involved are as follows:
a) BOF Convertor and De-S system:
· All Civil works for buildings, tunnels, trenches, platforms,

PROJECT DESCRIPTION
equipment foundations, converter foundations and other works for
BOF Convertor, De-S system and auxiliary facilities for the system
in totality.
· All Civil works for GCP for BOF Gas including gas cleaning and
cooling system, ID fans, duct supporting foundations, valves etc.
for the complete system.
· Civil works for Torpedo ladle receiving station with refractory lined
RCC pits.
· BOF Convertor control room and PLC room- The proposed room
shall be partitioned with glazed aluminum framing. Air lock room
with new doors, windows, corridors shall be provided.
· Charging level RCC floor supported on structural steel framework
· Scrap handling system, storing, tracks charging system etc.
b) Continuous Caster Machine & Mould and Segment Repair Shop
· Civil works for all buildings, tunnels, trenches, cellars, platforms,
equipment foundations for Slab Caster and Mould & Segment
Repair Shop and its auxiliaries units as per technological, process
and system requirement.
· Foundations for Steel Ladle & Slag pot transfer car tracks, Tundish
Transfer car tracks etc.
· Hard stand for slab storage area
c) Ladle Furnace :

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· Civil works for all buildings, tunnels, trenches, cellars, platforms,

equipment foundations for LF and its auxiliaries units as per
technological, process and system requirement. transformer
· Foundations for steel ladle car tracks for LF.
d) RH-OB :
Civil works for all foundations, platforms, equipment foundations for
RH-OB, ladle transfer car track and its auxiliaries units as per
technological, process and system requirement.
e) Others facilities common to all three units:
· Foundations of all building columns for all bays including piling
work, RCC pile caps, bolts, inserts etc.
· RCC flooring for all bays of these shops and finishes as per
technological, process and system requirement. Ramp shall be
PROJECT DESCRIPTION

provided for motorable access to the shop floor in convertor bay.

· Civil works for electrical substations, switch yard (with trenches,
PCC paving and gravelling), Transformer foundations, oil pits,
control rooms, PLC rooms, computer room, Hydraulic rooms,
electrical and MCC rooms, AC & ventilation rooms cable
trenches/tunnels, cable galleries, cable bridges, transmission
towers etc..
· Civil works for transmission towers, cable tunnel and cable bridge
for incoming Power cable from MSDS VII to MSDS VIII as per
technological and site requirement.
· Civil works for Cable tunnel from the proposed sub-station (MSDS
VIII) to the main shop as well as inside the shop as per
technological requirement.
· Civil works for cooling water system for Oxygen lance cooling
system, CCM, caster spray circuit, De-S system, LF, RH-OB
including pump houses, covered and uncovered sumps and on
ground tanks, RCC cooling towers, RCC emergency overhead tank
with staging, foundation for pipe support structures, pipe bridges
etc., heat exchangers, filters etc. and all auxiliary facilities as per
technological, process and system requirement.
· Civil works for Fume extraction system, Pollution Control System
for Secondary Emission Control, including foundations for ID fans,
Gas holder, Booster, ESPs, Chimney, duct supporting foundations
etc. for the complete system as per technological, process and
system requirement.

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· Necessary trestle foundations for Utility and gas system including

compressor house, compressor foundations and all allied works for
the BOF Convertor and Suppressed combustion system in totality.
· Civil works for Propane System including foundations for shed,
equipment, platform, tank, pipe supporting structures etc., fencing
of the area including gates, mounding for bullets, hard stand etc.
for the complete system and its auxiliaries.
· Civil works for new slag bay with RCC slag pits (refractory lining if
required) including its auxiliary facilities for the system in totality as
per requirement. Hard stand for movement of dumper in front of
the proposed slag bay and connecting the same with the existing
road.
· Necessary trestle foundations shall be provided for new over-
ground and rerouted pipelines. Wherever these pipelines are taken

PROJECT DESCRIPTION
underground, at all major road and railway crossings, RCC culverts
or RCC pipes shall be provided as per requirement.
· RCC Scale pit, scale tunnel including pump houses with handling
facilities etc. as per technological, process and system requirement.
· All approach roads to all new buildings and facilities.
· Construction of rail tracks inside the shop including incoming
torpedo ladles, incoming scraps and slab despatch tracks.
· Rerouting/protection and/ or diversion of faecal water pipelines,
storm water pipelines, drinking water pipeline and industrial water
pipeline if any other than the main shed area but in the area where
new facilities shall be provided by the Successful Bidder of this
package.
· Faecal Sewage water system for the new complex shall be
developed and shall be connected to the existing system.
· New storm water system with trunk lines along with gulley’s shall
be provided catering to the entire developed area in and around
new facilities and same shall be connected with trunk line of
existing system.
· All open drain shall be of RCC construction
· RCC cable trench with pre-cast cover slab/chequered plate cover
all along & PCC encased RCC pipe at the location of road
crossings as per requirement.
· RCC Cable and pipe tunnel with necessary inserts for cable tray
and pipe fixing as required.

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· Dismantling of existing shed, buildings, underground & over

ground service lines or pipelines, tunnels, trenches, roads, etc. in
the area wherever there is fouling with the proposed facilities.
· Tapping of drinking water line from the nearby existing line and
laying the same from the tapping point up to the proposed new
buildings.
· All buildings shall be RCC framed with brick cladding walls
including all finishes, doors, windows, rolling shutter, false ceiling
& flooring, drinking water facility, cable trenches etc. as per
technological/service requirements for all process /production
buildings, offices, welfare & administrative blocks.
· Necessary Heat Resistant Concrete work (Reinforced and / or
plain), will be provided as per technological, process and system
requirement.
PROJECT DESCRIPTION

· All underground cellars, tunnels, pits, sumps, tanks and water

retaining structures will be provide with water proofing treatment.
· Grouting under the base plates & bolts as per the requirement.
Necessary chipping, Grouting under the base plates and pockets
for equipment and technological structures, if any, which forms
part of the equipment.
· Necessary grading and surface dressing shall be done around all
the new facilities as required.
[Link] Calcined Lime and Dolo Plant for New SMS
The Civil works will comprise of design and construction of building
structures and foundations for equipment its auxiliaries related to
technological structures, electrical and power distribution system, utility and
services facilities, ventilation and de-dusting system, instrument and control
system, hard stand floors, roads, drainage, rain water harvesting, etc. as
detailed out in the subsequent clauses.

[Link].1 The major civil works involved are as follows:

a) RCC Foundation systems for Kilns supporting structures including
foundations for equipment & auxiliaries, chimney, staircase, lift
supporting arrangements, floor finishes, hard stand etc. as per
technological & service requirements.
b) RCC Foundation systems for receiving, charging, de-dusting, reject and
storage bunkers for raw materials & finished products as per
technological requirement including all inserts, bolts, floor finish etc. as
per serviceability requirements.

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c) RCC foundation for all indoor & outdoor equipment including inserts,
bolts, trenches with cover slab, drains, fencing with gate etc. as per
technological, service & safety requirements.
d) RCC foundations for structural steel trestle foundations for conveyors,
utility lines and electrical cable gallery as per technological, system and
layout requirements.
e) Construction of 3 storied RCC framed building with brick cladding walls
for Blower, MCCs and control room including equipment foundation, all
finishes, glazed aluminium partitions, false floor, false ceiling cable
trenches, doors, windows, rolling shutter, roof treatment, drinking water
point, separate ladies & gents toilet etc. complete as per technological
& serviceability requirement.
f) Construction of RCC framed building with brick cladding walls for
electrical sub-station building including equipment foundation, all
finishes, glazed aluminium partitions, false floor, false ceiling cable

PROJECT DESCRIPTION
trenches, doors, windows, rolling shutter, roof treatment etc. complete
as per technological & serviceability requirement.
g) Construction of RCC framed building with brick cladding walls for gas
boosting station building including equipment foundation, all finishes,
glazed aluminium partitions, trenches, doors, windows, rolling shutter,
roof treatment etc. complete as per technological & serviceability
requirement.
h) Construction of RCC framed building with brick cladding walls for office
building including all finishes, glazed aluminium partitions, doors,
windows etc. complete as per system & serviceability requirement.
i) Construction of general civil facilities such as bituminous road over
WMM and its interconnection with plant road network, RCC storm water
drainage system with pre-cast cover slab and interconnection with plant
drainage system, rain water harvesting system for ground recharge,
sewage network & its interconnection with plant network / provision of
septic tank & soak pit arrangement and drinking water point network
with in the battery limit as per system, serviceability and layout
requirements.

[Link] Rail track connection to new proposed SMS and CCM Shop
The hot metal from the existing blast furnaces will be transported to
Proposed SMS and CCM Shop through torpedo ladle. Also, the scape to
Proposed SMS and CCM Shop from Scrap Yard and slabs from Proposed SMS
and CCM Shop caster to mills will be transported through railway wagons.
The rail track connection to Proposed SMS and CCM Shop with the existing
plant network has been envisaged under this package to ensure above

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movements. Considering the following constraints in providing rail track

connection to Proposed SMS and CCM Shop, it has been envisaged to
appoint an expert agency for consultancy and execution of work under this
package.
i) The SMS-I is to be kept in operation till the stabilisation of Proposed
SMS and CCM Shop; which will require dismantling, modification
and rerouting of existing rail tracks depending upon their
requirement.
ii) There are numbers of existing rail tracks at the proposed location of
Proposed SMS and CCM Shop; which will require modification and
rerouting depending upon their requirement.
iii) The movement of torpedo ladle from existing blast furnaces will
require modification in the existing rail tracks to facilitate torpedo
movement; as there has not been torpedo movement to SMS-I.
PROJECT DESCRIPTION

The scope of works under this package for an expert agency will be:
a) Study of the entire system and preparation of Detailed Project report.
b) Preparation of tender specification and tender evaluation.
c) Carrying out Basic and Detail engineering.
d) Supervision and execution of work.
e) Trial and commissioning of new rail tracks

[Link] Design Considerations

a) All the RCC designs shall be done conforming to IS: 456-2000.
b) The loadings shall be taken as per the loads provided by the
equipment supplier and IS: 875 (Part-I & II) - 1987.
c) Pile foundations will be provided for Shed for main shop, converter
and major buildings as per requirement. Open foundation for other
facilities.
d) In laying the tracks, norms of Indian Railways, as formulated by RDSO,
with regard to radius of curve, sizes of switches, distance between
tracks, gradients, clearances on the sides and above, etc. will be
followed.
e) Proper drainage system shall be provided along the tracks and yards.
Level crossings with drop gate arrangement shall be provided at rail-
road crossings.
f) RCC road with bituminous top have been envisaged. Thickness of
different layer of road/ pavement shall be adequate for traffic intensity

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and imposed loading. Proper drainage system shall be provided along

the road
[Link] Technical Specification
a. All RCC works including building etc. will be of concrete grade M25C
conforming to IS: 456-2000. Jigs, fixtures will be used to fix all anchor
bolts, inserts etc., wherever required.
b. The design will be based on latest IS codes/British codes/N.B.O
c. Major activities relating to civil engineering work are dismantling, plain
& reinforced concrete work, brickwork, flooring etc. Following
guidelines have been envisaged for the material of construction for
civil engineering works:

· R.C.C : M-25

PROJECT DESCRIPTION
· P.C.C : M 10 B

· Brick work in C.M : 1:6

· Cement plaster for walls : 1:6

· Cement plaster for : 1:4

ceiling

· Anchor pocket grouting : M-25 D M-30 D or anti-shrinkage

compound

· Painting of doors & : Synthetic enamel Paint

windows

· Outside finish for : Anti Algal Weather Proof Exterior

buildings Acrylic Emulsion Paint

· Inside finish for : Whitewash / Colourwash/ Acrylic

buildings Emulsion Paint

· Rail track : 60-kg/ m conforming to IRS T-18

· Density of PSC Sleepers : M+13

· Turnouts : 1 in 8.5

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· Road : 4 and 7 m wide carriage along with 1

m wide berm on both side

[Link] Finishing For Major Areas

Sl. No. Location Details of Finishing Items

1. Shop Floors · Flooring- Minimum 150mm thk. RCC floor

over 250mm thick (min) compacted boulder
soiling for grade floors.
· Floor Finish- Ironite Finish or dry shake floor
hardener finish as per serviceability
requirements.
PROJECT DESCRIPTION

2. Hard Stand · Sub-base- 150mm thick consolidated sand

filling on compacted soil.
· Base- 200mm thick boulder soling blinded
with sand fill/ query dust.
Water bound Macadam (WBM)- 150mm
thick WBM above base.

3. Electrical · Flooring- Minimum 150mm thk. RCC floor

Rooms/ over 250mm thick (min) compacted boulder
Buildings. soiling for grade floors.
· Floor Finish- Di-electric flooring/ PVC tiles/
IPS floor finish as per serviceability
requirements.
· Ceiling- Two coats of low VOC acrylic
emulsion paint over layers of cement based
putty and primer in control rooms, white
washing/colour washing in other rooms.
· Walls – Low VOC acrylic emulsion paint on
the layers of cement based putty and primer
in control rooms, white washing/colour
washing in other rooms.
· False Floor/ Ceiling- as per serviceability
requirement.

4. Control Rooms/ · Flooring- Minimum 150mm thk. RCC floor

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Sl. No. Location Details of Finishing Items

Building over 250mm thick (min) compacted boulder
soiling for grade floors.
· Floor Finish- False floor with wooden panels.
· Ceiling- Gypsum board false floor system
with painting same as on walls.
· Walls – Low VOC acrylic emulsion paint on
the layers of cement based putty and primer.

5. Pump Houses · Flooring- Minimum 150mm thk. RCC floor

over 250mm thick (min) compacted boulder
soiling for grade floors.
· Floor Finish- IPS floor finish as per

PROJECT DESCRIPTION
serviceability requirements.
· Dado- at least 1.5m high IPS dado
· Ceiling & Walls- Three coats of white wash

6. Hydraulic Room · Flooring- Minimum 150mm thk. RCC floor

over 250mm thick (min) compacted boulder
soiling for grade floors.
· Floor Finish- anti-skid ceramic tiles.
· Dado- at least 1.5m high ceramic tile.
· Ceiling & Walls- Three coats of white wash

7. Battery/ UPS · Flooring- Minimum 150mm thk. RCC floor

room over 250mm thick (min) compacted boulder
soiling for grade floors.
· Floor Finish- acid resistant ceramic tiling
work.
· Dado- at least 1.5m high acid resistant
ceramic tile.
· Ceiling & Walls- Two coats of low VOC
acrylic emulsion paint over layers of cement
based putty and primer

8. Shop Floor · Flooring- Minimum 75mm thk. PCC floor

offices & shift over brick on edge soiling.

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Sl. No. Location Details of Finishing Items

room · Floor Finish- 300X300 vitrified tile.
· Skirting- 150 mm High vitrified tile.
· Ceiling & Walls- Two coats of low VOC
acrylic emulsion paint over layers of cement
based putty and primer

9. Toilets at Shop · Flooring- Minimum 75mm thk. PCC floor

Floor over brick on edge soling.
· Floor Finish- 450 x 450 mm coloured Anti-
Skid Ceramic Tiles.
· Dado – 2100 mm High with 200 x 300 mm
coloured ceramic glazed tiles.
PROJECT DESCRIPTION

· Ceiling & Wall – Three coats of white wash.

· - WC – Indian WC, floor mounted with low
height PVC flushing cistern, health faucet
etc.
· Urinals – Flat long back urinals with single
unit mounted flushing cistern with Granite
Stone partitions (700 mm X 600 mm each).
· Wash Basin – 550 mm X 400 mm size of
counter top type with granite top with C.P.
brass towel rail & soap holder.
· Glass Mirror – 500 mm X 400 mm size.

10. Roof Treatment · 4mm thick Atactic Polypropylene modified

plastomeric bitumen based membrane with
(All bldg.
exposed to sky) polyester fiber reinforcement (minimum
50gsm)

ED (Works) and R&C Building

1. Office building · Flooring- 600x600 mm Vitrified Tiles.

· Ceiling- Two coats of low VOC acrylic
emulsion paint over layers of cement based
putty and primer
· Skirting – 150 mm High with Vitrified Tiles.
· Walls – Low VOC acrylic emulsion paint on

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Sl. No. Location Details of Finishing Items

the layers of cement based putty and primer.

2. Equipment · Flooring- 300x300 mm Vitrified Tiles/ IPS/

Rooms PVC tiles/ Acid proof vitrified tiles etc. as per
serviceability requirements.
· Ceiling- Two coats of low VOC acrylic
emulsion paint over layers of cement based
putty and primer
· Skirting/ dado – 150 / 2100 mm High with
Vitrified Tiles/ acid resistant tiles as per
serviceability requirements.
· Walls – Low VOC acrylic emulsion paint on

PROJECT DESCRIPTION
the layers of cement based putty and primer.

3. Ladies & Gents · Flooring- 450 x 450 mm coloured Anti-Skid

Toilets Ceramic Tiles.
· Dado – 2100 mm High with 200 x 300 mm
coloured ceramic glazed tiles.
· Wall – Low VOC acrylic emulsion paint on
the layers of cement based putty and primer.
· Ceiling - Low VOC acrylic emulsion paint on
the layers of cement based putty and primer.
· WC – European WC, floor mounted with low
height PVC flushing cistern, health faucet &
ablution tap.
· Urinals – Flat long back urinals with single
unit mounted flushing cistern with 12 mm
thick frosted glass partitions (700 mm X 600
mm each).
· Wash Basin – 550 mm X 400 mm size of
counter top type with granite top with C.P.
brass towel rail & soap holder.
· Glass Mirror – 500 mm X 400 mm size.
· Hand Drier:- 1 [Link] SS body Hand Drier of
size 200 x 270 x240 mm having rated power
of 2500 Watt.

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Sl. No. Location Details of Finishing Items

4. Staircases · Tread – Kota Stone/ Black granite finish.

· Riser – Kota Stone/ Black granite finish.
· Railing – 1050 High SS railing with 40 mm
dia. SS tube as hand rail.

5. External Walls · Low VOC exterior weather coat paints on the

layers of Cement based putty and exterior
grade primer.

6. Internal Piping · All internal water supply pipelines will be

concealed and shall be with CPVC/ uPVC
pipes.
PROJECT DESCRIPTION

7. Overhead Water · OH PVC Tank:- Rotationally moulded

Tank PVC/HDPE water Tanks of minimum capacity
of 5000L with all fittings complete to be
placed on raised RCC platform at roof

8. Doors Frames & · Door frames of 2nd class Indian teakwood or

shutters equivalent in rooms.
· Flush door with teak veneered ply

9. Door frames · uPVC door frames & shutters in wet areas.

and shutters in
wet area

10. Window frame · Standard powder coated extruded

and shutters Aluminium tubular sections frames
· Factory made Anodised powder coated
shutters with toughened glass glazing.

11. Fittings · Anodized aluminium /stainless steel or

equivalent

12. False ceiling · Gypsum board seamless false ceiling with GI

frame & hanger supports in complete area
including corridors & toilets to cover the
services as per design requirement

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4.9 REFRACTORY WORK

4.9.1 Installation of New Facilities ( Proposed SMS and CCM Shop)
[Link] For the installation of facilities for proposed SMS and CCM Shop, following
table lists the shop-wise equipment / items required under refractory work

[Link]. Description

1. Torpedo Ladle Car (3x350T)

2. Convertor Shop
A. Hot Metal Ladle (4x150 T)
B. De-sulphurisation Unit
C. BOF Convertor (1x150 T)
D. Steel Ladle (10 Nos.)

PROJECT DESCRIPTION
3. Secondary Refining Furnaces
A. Ladle Furnace (1x150 T)
B. RH-OB Unit

4. Continuous Casting Shop

A. Slab Caster (1x150 T)

1. Torpedo Ladle Car:

a) Design & detailed engineering of refractory arrangement for the following
process equipment have been considered:

Sl. No Equipment Description Quantity

1 350T Torpedo ladle car including 3 nos.

splash protection cover and
protection hoods

b) Torpedo ladle car will be lined with ASC (Alumina silicon carbide carbon)
bricks as working lining while fireclay brick and insulation bricks as backup
lining.
c) Minimum 1200 heats life for each torpedo car with maximum two nos. of
major repair has been considered with the latest lining configuration.
2. Convertor Shop

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A. Hot metal ladles:

For transfer of hot metal from torpedo ladle to de-sulphurisation/convertor
vessel, suitably designed HM charging ladle (4 nos.) will be used. The ladles
will be lined with dense high grog Alumina bricks. Heat size of each ladle will
be 150T (nominal) and 165 T (maximum).
Ladle relining pit will be provided for HM charging ladles.
B. De-sulphurisation Unit:
Equipment/areas covered under refractory for this unit are:
· Injection Lance
· Ladle Transfer Car
· Pit below Desulphurization Unit
i) Injection Lance
Injection Lances (1W+1S) will be coated with refractory low cement castable
PROJECT DESCRIPTION

of adequate thickness (approx. 60mm).

Refractory life of injection lance will be ~30 heats.
ii) Ladle Transfer Car and Pit below Desulphurisation Unit
Ladle transfer car (1 no.) and pit below desulphurization unit will be lined
with fireclay bricks IS-8 (1994)-type 2/castable having min. 40% alumina.
C. BOF Convertor Shop:
Complete design & detailed engineering, supply and erection of refractory
arrangement for the following process equipment/areas have been
considered for this project:

[Link]. Equipment/Areas Description Quantity

1. Converter (150 T) with bottom stirring & 1set

protective heat shield

1set
2. Protection refractories for converter
working platforms, dog house, converter
adjacent areas, columns etc.

i) Converter
Refractory will be considered for 150 ton capacity converter with bottom
purging facilities. Minimum refractory lining life has been considered as 6000
heats. The burnt magnesite bricks will be used for permanent lining of
converter shell and magnesia carbon bricks for wear lining. The basic

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ramming mass will be used for filling gap/ cavities. Brick retainer plate will be
used for supporting the lining. The replaceable tap hole sleeve will be of
mag-carbon bricks.
ii) Protection Refractories
Converter working platforms, trade area below converter, columns, etc. will
be lined with fireclay bricks IS-8 (1994)-type 2 and dog house will be lined
with refractory castable for metal / heat protection.

D. Steel Ladles:
Steel ladle design will be suitable for secondary refining in ladle furnace and
RH Degasser with minimum refractory lining life of 100 heats. The composite
lining of Mag-Carbon/ Alumina Mag-Carbon bricks will be used for hot face.
Permanent lining will be with high alumina castable/bricks. Ladle will have

PROJECT DESCRIPTION
provision of attaching slide gate system at the bottom.
3. Secondary Refining Furnaces:
A. Ladle Furnace:
For raising the temperature of steel and composition adjustment, the
electrode electric arching type ladle furnace with water cooled tube hood is
envisaged. The water cooled tube will be protected with suitable refractory
sleeves from radiation / arching heat. Suitable protection refractories for
transfer cars (2 nos), transfer car pits (2 nos) and platform & column areas
have also been considered.
B. RH_OB unit:
i) The RH-OB vessel is designed with following sections for ease of
refractory installation:
· Snorkels
· Legs
· Mono vessel
· Alloy chute
· Gas duct
· Compensator
Three vessels concept has been adapted to aid high productivity. When one
vessel will be in operation the other two will be in heating or repair/ relining/
stand-by.
ii) The lining pattern of different sections of RH vessel is as follows:

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Snorkels
Inner part of snorkels will be suitably lined with direct bonded Mag-Cr brick
and outer part of snorkel will be casting of high alumina low cement steel
fiber reinforced castable with anchor support.
Legs
Legs part will be lined with direct bonded Mag-Cr brick with outside casting
of 96% high alumina castable.
Lower part of vessel
The bottom of the vessel will be lined with direct bonded Mag-Cr brick with
back up lining of Mag-Cr safety brick and insulation board.
The side wall of the lower vessel will be lined with direct bonded Mag-Cr
brick with back up lining of Mag-Cr safety brick followed by fireclay and
insulation board of adequate thickness.
PROJECT DESCRIPTION

Upper part of vessel

Upper part of vessel will be lined with direct bonded Mag-Cr brick with back
up lining of fire clay followed by insulation bricks and insulation board of
adequate thickness.
Alloy Chute
Alloy chute will be lined with direct bonded Mag-Cr brick with back up lining
of fire clay followed by insulation board of adequate thickness.
Gas duct
Gas duct of the vessel will be lined with direct bonded Mag-Cr brick followed
by insulation brick and insulation board of adequate thickness.
Compensator
Compensator part will be lined with direct bonded Mag-Cr bricks followed by
insulation bricks of adequate thickness.
iii) The expected heat life of the vessel components with above lining
pattern are as follows:
Snorkels 100 (min) per snorkel
Vessel Bottom 300
Vessel Top 2000
Gas Duct 3500
iv) After lining of the vessel and snorkels, the same are heated by
propane gas burner in respective heating chambers. The heating
chamber will be kept in the lining / repair bay.

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v) After heating the newly lined snorkels are welded with the vessel leg
and transferred to the operation bay.
vi) The ladle transfer car and the ladle lifting frame will be refractory lined
with IS-8 (1994)-type 2 fireclay bricks. There will be an emergency
refractory lined pit below the RH-OB treatment station running along
the track.
vii) The elbow of the fume extraction system will be refractory lined and
rest portion will be water cooled.
4. Continuous Casting Shop:
A. Slab Caster:
i) All tundishes (8 nos) will be lined with MgO based dry vibro mass/spray
mass as working line along with LMC-70 castable reinforced with anchor
support and ceramic board in safety lining. Tundish will have slide gate
mechanism for casting of steel. Average life of tundish working lining

PROJECT DESCRIPTION
will be 10-heats.
ii) Tundish cover, ladle cover, mould cover , slag pot transfer car will be
lined with 70% alumina low cement castable reinforced with anchor
support.
iii) Overflow/emergency boxes, splash protection wall, slag box will be lined
with basic spray mass along with 60% alumina low cement castable as
backup lining reinforced with anchor support.
[Link] Casting Floor, transport rail bogie will be protected by IS-8 (1994)-type 2
fireclay brick lining.
i) The casting refractory items like slide gate plates for steel ladles &
tundishes, ladle shroud, sub-merged entry nozzles etc. will be used,
commensurate with design and technological parameter specified for
casting machine.
ii) Protective lining on the columns and walls, lining on platforms ,floors etc.
will be provided wherever required in Proposed SMS and CCM Shop.

4.9.2 Calcined Lime and Dolo Plant for New SMS

In order to reduce both thermal losses and high temperature on the
extended walls and to provide structural integrity of the kiln shell, the kiln will
be lined with refractory and insulating material.
The preheating and cooling zones of the kiln will be lined with an abrasion
resistant wear lining backed by insulating firebricks. The wear lining in the
burning zone will be made of high quality Magnesite bricks with insulating
secondary lining. The working lining thickness will be suitable for operating
condition and will be backed by insulation made from fireclay bricks and
ceramic fiber insulation board.

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4.10 ENVIRONMENTAL POLLUTION CONTROL SYSTEM

4.10.1 Pollution control of Enhanced New Steel Melting and CCM Shop
Pollution Control aspect will be taken into account while formulating the
technical specification as per CPCB norm and all the facilities required for the
purpose of meeting the current and likely Statutory Norms as well as fulfilling
the Corporate Responsibility for Environmental Protection (CREP) shall be
provided. Also, specialist agency will be engaged to conduct Environmental
Impact Assessment (EIA) studies and prepare Environmental Management
Plan (EMP). This EIA & EMP report will address all the elements proposed
under latest guidelines. Based on this required clearances from State and
Central Regulatory Authorities will be obtained.
[Link] Air, water and noise pollution is caused during steel making facilities.
a) Air Pollution
The air pollutants in SMS are mainly dust and gases like sulphur
PROJECT DESCRIPTION

dioxide, carbon monoxide, nitrogen oxide etc.

b) Water Pollution
Water pollution from the plant mainly comprises inorganic solids, oil,
grease etc., in suspension, solution and emulsion
c) Noise pollution
The major noise generating areas are BOF oxygen blowing, Ladle
Furnace arcing, ID fans steam exhaust system etc.

[Link].1 Air pollution control measures

Depending upon the quality of emissions from different sources, suitable air
pollution control systems shall be provided. Chimney heights shall be as per
requirement to ensure Ground Level Concentration (GLC) of different
pollutants within permissible limits after considering the background GLC.
Various dust extraction and dust suppression systems envisaged are given
below :

S.N. Location/Shop Facilities

1 Torpedo Ladle pouring Fume extraction system comprising of

station suction hood and duct and will be
connected to the common ESP based dust
cleaning system.

2 Hot metal De-S Fume extraction system comprising of

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S.N. Location/Shop Facilities

suction hood and duct and will be
connected to the common ESP based dust
cleaning system.`

3 BOF - Primary Gas Gas cleaning plant comprising of ventury

cleaning plant scrubber and water treatment &
recirculation system

4 BOF – Secondary gas Fume extraction system comprising of

cleaning plant suction hood and duct and will be
connected to the common ESP based dust
cleaning system.`

PROJECT DESCRIPTION
BOF converter charging, Fume extraction system with dog house
tapping/blowing and common ESP based dust cleaning
system.

5 Twin Ladle Furnace Fume extraction system comprising of

suction hood and duct and will be
connected to the common ESP based dust
cleaning system.

6 Continuous casting Mould fume extraction system , steam

machine exhaust system in secondary cooling area

However, in order to meet the statutory GLC limits for SO2, Nox and other
gaseous pollutants, suitable stack heights shall be provided for proper
dispersion. All stacks shall be provided with port hole and working platform
so that stack monitoring can be done as per norms of local authority.

[Link].2 Water pollution control measures

The pollutants present in the waste water from BOF shall be reduced to
acceptable levels by adoption of the following schemes.
· Re-circulating water in the process whereby discharged volume is
considerably reduced
· Clarifier and sludge pond for removal of suspended solids
· Removal of oil and grease from the contaminated water by means of
oil traps and skimming devices.

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The water system shall be designed on Zero Liquid Discharge concept. The
waste water generated from blow-down & neutralisation pits will be taken to
RO based water treatment plant. Recovered water will be utilised in plant
whereas RO reject water will be used for spray cooling in slag dumping area.
[Link].3 Noise pollution control measures
Various measures proposed to reduce noise pollution include reduction of
noise at source, provision of acoustic lagging for the equipment, silencers,
selection of low noise equipment, and isolation of noisy equipment from
working personnel. In some areas where due to technological process such
as arcing at LF, it is not feasible to bring down the noise level within
acceptable limits, personnel working in these areas shall be provided with
noise reduction aid such as ear muffler and also the duration of exposure of
the personnel shall be limited as per the norms.
[Link] Solid Waste Management
PROJECT DESCRIPTION

a) The various waste materials arising out of the technological processes

would be reutilised to the extent possible or it will be dumped at
suitable place.
b) The sludge collected in the BOF scrubber, dust collected from bag
filters and scale generated from CCM shall be reutilised after
processing.
c) The generated slag from BOF shall be used for land filling/dumped.

4.11 MAN POWER REQUIREMENT

Total manpower requirement for the proposed SMS and CCM shop with its
associated facilities area has been estimated on the basis of 3 - shift
operation. The requirement envisaged is both for operation and
maintenance.
Envisaged duty post of manpower is as under:

Manpower → Executive Skilled/ Semi skilled

Total 45 435

4.12 RISK ASSESSMENT

4.12.1 Risk assessment for the project is attached at Annexure- 4.12.1-1

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE

5.1.1 The complete project is envisaged to be implemented within a period of 57

months from the date of Stage-II approval. Pre-ordering activities are
envisaged to be completed within 6 months from the date of Stage-I
approval.

5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and
post-ordering activities are shown at Annexure – 5.1.2-1 & 5.1.2-2
respectively.

5.2 IMPLEMENTATION STRATEGY

5.2.1 Mode of execution and number of packages:

The project is proposed to be executed through A. Enabling packages and

B. Installation of New Facilities. The enabling packages will be executed
through no. of packages, which will pave the way for implementation of the

PROJECT IMPLEMENTATION
main packages. Classification of packages between enabling and main
package are as follows:

A. Enabling packages :-
Package no. Name of package Mode
Package-I Enabling Works – Dismantling and Turnkey
Relocation of Facilities
Package-II A Area Survey and Soil Investigation for Non Turnkey
enabling packages
Package-II B Underground Mapping for enabling Non Turnkey
packages
Package-II C Area Survey and Soil Investigation for Main Non Turnkey
package
Package-II D Underground Mapping for Main package Non Turnkey
Package-III A Installation of New Building - ED(W) Turnkey
Package-III B Installation of New Building - RCL Turnkey
Package-IV Rerouting of Power Supply Turnkey
Package-V Rerouting of Utilities Facilities Turnkey

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B. Installation of New Facilities/Main Packages :-

Package no. Name of package Mode
Package-VI Enhancing the Steel Making Capacity in Turnkey
RSP
Package-VII Calcined Lime and Dolo Plant for New Turnkey
SMS
Package-VIII New Rail Track Provision Turnkey

5.2.2 Envisaged sequence of packages execution/ implementation to be follows as

stated below:

Sequence Package no. Name of package

No.
1 Package-II A Area Survey and Soil Investigation for enabling
packages
Package-II B Underground Mapping for enabling packages
Package-VIII New Rail Track connection
2 Package-III A Installation of New Building - ED(W)
PROJECT IMPLEMENTATION

Package-III B Installation of New Building - RCL

Package-IV Rerouting of Power Supply
Package-V Rerouting of Utilities Facilities
3 Package-I Enabling Works – Dismantling and Relocation
of Facilities
4 Package-II C Area Survey and Soil Investigation for Main
package
Package-II D Underground Mapping for Main package
Package-VII Calcined Lime and Dolo Plant for New SMS
Package-VI Enhancing the Steel Making Capacity in RSP

The area survey and the soil investigation including underground mapping
i.e. Package II-A and II- B are prerequisite for Packages- I, III A, III B, IV and V.
This data will be provided to other packages. This will be executed before
Stage-I approval of this project. Similarly Package-VIII is prerequisite to
facilitate continue hot metal and slabs transportation of SMS-I, moreover the
input of this package necessary to fixed rail track battery limit of Package VI.
Rail track connection to proposed SMS and CCM shop for hot metal, scrap
and slab transportation will be made through Package -VIII.

Consultant appointed through Package - VIII will prepare two Technical

Specification. The execution of rail tracks connection to proposed SMS and
CCM shop will be suitable match with the Package – VI. However the

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execution of rail track to facilitate continues hot metal and slabs

transportation of SMS-I will be executed parallel to Package- I.

Package II- C and II- D are prerequisite for Packages- VI and VII. This will be
executed at end of Package- I completion and before finalisation of tender
for Packages- VI and VII.

Package IIIA and IIIB will be executed first so that can be ready for
dismantled through Package –I. Package IV and V will be executed parallel
with III A and III B. After this rerouting of utilities pipeline and Power supply,
dismantling job can be started.

Package VII - Installation of calcined lime and Dolo plant along package-VI-
Enhancing the Steel Making Capacity in RSP can be taken up parallel.

5.4 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION

This proposal envisaged total shutdown of SMS-I for 7 days. Though the
production loss has not considered as the shutdown will be synchronised
with capital repair of SMS-I.

PROJECT IMPLEMENTATION
· Utilities (Interconnection of utilities lines):
Shut down of two shifts will be required for interconnection of mixed gas,
steam and BOF gas & oxygen gas lines. For other utilities like water,
nitrogen and argon, one shift shutdown will be sufficient.

· SMS-I, Lime conveyer inter connection to existing lime conveyer – 7 days

shutdown
· Electrical – Interconnection of Cables - two shifts

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6. CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:
6.1.1 The capital cost of the project is estimated as Rs.2896.70 cr. net of input tax
credit (ITC) on GST of Rs.284.76 cr. including IDC of Rs.315.93 cr. FE
component considered in it is Rs.428.39 cr. The summary capital cost
estimate is appended at Annexure - 6.1.1-1. Major cost components are as
follows:

Sl. Description of cost components Total (Rs. Cr.)

No.
1 Technological, Mechanical and utilities equipment 1041.13
2 Electrical equipment including cables 69.39
3 Instrumentation & automation equipment 21.69
4 Building structures 298.47
5 Refractory 20.97
6 Civil work 368.02
7 Erection 203.40
8 Engineering and construction including foreign 181.57
supervision
9 Others including training 3.87
10 Taxes & duties and freight 520.58
11 Contingency 136.45
12 Plant cost (sl no 1 to sl no 11) 2865.54
13 Interest during construction 315.93
14 Capital cost (sl no 12+ sl no 13) 3181.46
15 Input tax credit on GST 284.76
16 Capital cost net of ITC on GST (sl no 14–sl no 15) 2896.70

6.1.2 Capital Cost is estimated based on past orders in SAIL plants for BoF
convertor, twin LF, RH-OB, slab caster, slab car etc. and budgetary offers /
engineering estimates for remaining items. Estimated block cost of some of
the major technological units are as follows:

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Sl. Description of units Estimated block Remarks

No. cost (in Rs. Cr.)
1 1x165t HMDS unit with 60 The unit wise
auxiliaries estimated block cost
2 1 x 165t LD Convertor (BoF) 700 is indicative only to
give a general idea.
3 1 x Twin LF of 165 Ton 170

4 1x165t RH-OB unit with 120

auxiliaries
5 1x Slab Caster 700
6 Calcined Lime and Dolo 100
plant
Base date for the estimate is 3rd quarter 2020. FE parity has been considered
as follows:
Currency Current Forward Currency rate including
currency rate premium rate forward premium
1USD=Rs. 74.78 10.83 85.61

1EURO=Rs. 85.56 12.33 97.89

1POUND=Rs. 94.80 13.85 108.65

6.1.3 Necessary provisions have been made in the estimates as per the details
given below:
1. Taxes and duties:
i) GST @ 18 % on basic cost of equipment, refractory, structures, civil,
erection, engineering & construction (contractor), supervision,
training and freight & insurance.
ii) Custom duty @ 7.5 % & Social Welfare surcharge @ 10 %
iii) Income tax @ 10 % of foreign services to be grossed-up.
2. Freight & insurance charges: @ 2% of basic cost of indigenous
equipment and 9% of basic cost of structures and refractory. Inland
freight & Insurance charges for imported item has been taken @ 3%.
3. Erection & commissioning charges: @ 12% of basic cost of indigenous
equipment & refractory, @ 20 % of basic cost of structures and 6% on CIF
cost of imported equipment.
4. Engineering & construction (E&C): E&C (contractor) @ 5% and E&C
(owner) @ 2.5 % on basic cost of equipment, refractory, structures, civil
work and erection & commissioning charges.
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5. Contingencies: @ 5% on overall basis.

6.2 MODE OF FINANCING:

The total capital requirement of the project is proposed to be provided from
100% debt with an interest @ 10% per annum on loan.
6.3 PHASING OF CAPITAL EXPENDITURE:
With the project duration of 57 months from the date of Stage – II approval,
the phasing of capital expenditure is proposed as indicated below:
Rs. in cr.
Year Plant cost Equity Loan IDC Total incl. IDC
st
1 year 57.31 57.31 2.87 60.18
nd
2 year 143.28 143.28 12.89 156.17
rd
3 year 429.83 429.83 41.55 471.38
th
4 year 859.66 859.66 106.02 965.69
th
5 year (9
1088.90 1088.90 152.59 1241.49
months)
Post Comm. 286.55 286.55 286.55
Capital cost 315.93 3181.46
Input tax credit (ITC) on GST 284.76
Capital cost net of ITC on GST 2896.70

6.4 INTEREST DURING CONSTRUCTION (IDC):

Based on the mode of financing and phasing of capital expenditures
indicated above, the total IDC has been worked out to be Rs.315.93 cr.

6.5 COST-BENEFIT ANALYSIS:

6.5.1 The major assumptions considered for cost-benefit analysis are as follows:
1. The proposed scheme is envisaged to produce 0.859 Mtpa crude steel (CC
slab).
2. The proposed production & utilization of slab vis-à-vis existing production
& utilization of slab along with pig iron (base case) is depicted as follows:
A. Base Case:

Production of Crude Value Utilization of Value

steel & pig iron : (MTPA) Crude steel + (MTPA)
pig iron :
From SMS - I (To be 0 Plate Mill 5,30,000
closed soon hence no (Existing)
production considered
for financial analysis)
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From SMS - II 37,00,000 Plate Mill (New) 10,00,000

Purchased Slab 8,30,000 Hot Strip Mill 30,00,000
(Imported) - (To run
the mills as per their
proposed capacity)
Pig Iron 3,28,000 Pig Iron for sale 3,28,000
Total 48,58,000 Total 48,58,000

II. Proposed Case:

Production of Crude Value Utilization of Value
steel: Crude steel:
From SMS – I (phased out) 0 Plate Mill (Existing) 5,30,000
From SMS - II 37,00,000 Plate Mill (New) 10,00,000
From proposed scheme 8,59,000 Hot Strip Mill 30,00,000
Slab for sale 29,000
Total 45,59,000 Total 45,59,000

3. The various other data considered for calculation of gross margin are as
follows:

Sl. Description of Items Value Remarks

No. (Rs./ton)
1 Purchased (Imported) 36,778 Based on landed cost of
price of slab (landed imported slab as per Platts
cost) report (Import from
Southeast Asia)
2 NSR of own slab 31,509 Based on RSP data
3 NSR of Pig Iron 25,642
4 Works cost of own slab 29,266 As per actual cost sheet of
5 Variable cost of pig 19,670 RSP for SMS-II for the year
iron 2019-20

6.5.2 Based on above, it is envisaged that on installation of proposed scheme

additional slab of 0.859 Mtpa will be produced. Out of that required
imported slab of 0.83 Mtpa will be sourced from own slab and balance
slab of 0.029 Mtpa will be sold in the market. Thus, total benefit envisaged
per annum worked out to Rs.629.99 cr. However, in this process existing
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pig iron production of 0.328 Mtpa will be ceased. Hence, opportunity cost
per annum on account of not making pig iron amount to Rs.195.88 cr.
Thus, gross margin works out to Rs.434.11 cr. per annum. Details of gross
margin calculation are shown as below:
A Annual benefit envisaged if proposed scheme is implemented :
A On account of replacement of Value (tpa) Rate Amount
(i) purchased (imported) slab by (Rs./t) (Rs. Cr.)
own slab :
Purchased (Imported) slab 8,30,000 36,778 3,052.56
Works cost of own slab 8,30,000 29,266 2,429.08

Benefit per annum (A (i)) 623.48

A On account of sale of excess Value (tpa) Rate Amount

(ii) slab: (Rs./t) (Rs. Cr.)
NSR of own slab 29,000 31,509 91.38
Works cost of own slab 29,000 29,266 84.87
Benefit per annum (A (ii)) 6.51

Total annual benefit envisaged (A) 629.99

B Opportunity loss per annum on Value (tpa) Rate Amount

account of not making pig iron : (Rs./t) (Rs. Cr.)
NSR of Pig Iron 3,28,000 25,642 841.06
Variable cost of pig iron 3,28,000 19,670 645.18
Total opportunity loss per 195.88
annum (B)
Gross Margin per annum (A-B) 434.11
6.6 FINANCIAL ANALYSIS:
6.6.1 Cash flow analysis has been carried out for 25 years considering the life of
project of 20 years after its commissioning. Techno-economic indices are
indicated as below:
NPV @ 10% (Post tax): Rs. 370.09 cr.
IRR (Post tax): 12.80 %

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6.6.2 Sensitivity Analysis

[Link] Sensitivity analysis of the proposed scheme has been carried out in respect of
capital cost and gross margin as follows:
Item IRR (Post tax)
Capital Cost (+)10% 11.59%
Gross Margin (-) 10% 11.37%
Combined effect of above 10.22%

[Link] Sensitivity analysis of the proposed scheme has been carried out in respect of
imported price of slab as follows:
Item IRR (Post tax)
Imported price of Slab (-) 5 % 7.96%
[Link] Sensitivity analysis of the proposed scheme has been carried out in respect of
NSR of own slab as follows:
Item IRR (Post tax)
NSR of own Slab (-) 5 % 12.65%
[Link] Sensitivity analysis of the proposed scheme has been carried out in respect of
work cost of own slab as follows:
Item IRR (Post tax)
Work cost of own Slab (+) 5 % 8.40%
[Link] Sensitivity analysis of the proposed scheme has been carried out in respect of
NSR of pig iron as follows:
Item IRR (Post tax)
NSR of pig iron (+) 5 % 11.41%
[Link] Loss of gross margin for the proposed scheme has been estimated in respect
of time over run of implementation schedule of the project as follows:
Delay by 3 months 6 months 1 yr 2 yrs
Expected loss of gross
margin (Rs. Cr.) 108.53 217.05 434.11 868.21
[Link] Since the installed capacity of the proposed facility is about 1.1 Mtpa. Hence,
sensitivity analysis of the proposed scheme has been carried out in case of
extra slab production over and above the envisaged slab quantity of 0.859
Mtpa as follows:
Extra slab production IRR (Post tax)
1,00,000 ton 13.50%
2,00,000 ton 14.19%

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7. RECOMMENDATIONS
For harnessing the full potential of RSP, enhancement of steel making
capacity for production of special grade steel is imperative.
The project is technically feasible and financially viable. Hence, it is
recommended for implementation.

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 INSTALLATION OF NORMALIZING FACILITIES IN NEW
PLATE MILL

ROURKELA STEEL PLANT

ROURKELA

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

FEBRUARY 2020 CET/05/RN/4062/FR/RF/01/R=4

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 Experience that delivers

This document has been prepared for Rourkela Steel Plant by:

Centre for Engineering & Technology

Tathagat Ghosh – HOD Rolling Mills
Ashok Kumar Kar - Task Force Leader
Narendra Kumar Jain- Rolling Mills
Manas Ranjan Mishra - Rolling Mills
Sourav Manna – Refractory
[Link] – Refractory
Naveen Kumar - Mechanical
Arun Jose Mathews – Utility
Ms Ruma Bharti - Electrical
Souryam chaturvedi - Electrical
Kamal Reddy Jambula - Process Control & Automation
Vinit Kumar - Structural
Ms Priyanka Parameswaran - Civil
Garish Kumar - Cost Techno-Economics
[Link] – Rourkela Sub-Centre
Ravindra Kumar Verma - Project Formulation & Co-ordination

Document Identification No. CET/05/RN/4062/FR/RF/01/R=4

REVISION HISTORY

Revision No. Brief Description Revision Date

R4 Deliberations amongst RSP, CMO & CET was held February, 2020
for re-working of techno-economics & assessment
of financial viability. Based on latest input from
CMO and RSP, FR has been revised.
R3 As per suggestions of corporate office cost and January, 2020
techno-economics reviewed taking more number of
references
R2 Shot blasting facilities added in the scope of March, 2017
normalising
R1 Splitting of the assignment and separate installation June, 2015
of shot blasting facilities & reviewing of leveller
capacity
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Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

355
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 Experience that delivers

UPSHOT
Normalized plates have lesser degree of anisotropy in longitudinal and transverse directions
enabling better ductility and impact toughness, which are most suitable for boiler and
pressure vessels as well as for dynamic loading applications. In order to attain the market
share and saleability of heavy & wide plates, installation of normalizing facility in the new
Plate Mill of RSP is a necessity. The capital cost of the Project is estimated at Rs 295.56 crore
(net of input tax credit of Rs 44.90 crore) on base date of 1st quarter, 2020, including IDC of R
.23.75 crore, FE component of Rs 129.83 crore. The gross margin works out to Rs 56.27 crore
and IRR (post tax) 13.77%.

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.4

2 Background 2.1-2.6

3 Selection of Alternatives 3.1

4 Project Description 4.1-4.22

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1-6.3

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES
Annexure No. Description No. of pages
2.6-1 Copy of letter of assignment 1
2.6-2 Copy of letter of acceptance of assignment 1
4.14.1-1 Risk Assessment 1
5.1.2-1 Project implementation schedule 1
(after Stage-I approval)

5.1.2-2 Project implementation schedule 1

(after Stage-II approval)

6.1.1-1 Capital cost estimate summary 1

6.5.1-1 Gross margin calculations 1

6.6.2-1 Summary of financial analysis 1

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DRAWINGS

Sl. No. Drawing No. Description

1 CET RN 4062 RF2 00 001 R=3 Layout of new Plate Mill with
proposed normalizing facilities
(schematic)

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1. SUMMARY
1.1 Rourkela Steel Plant (RSP) produces variety of saleable products which

SUMMARY
include hot rolled coils & sheets, heavy plates, pipes, cold rolled coated &
uncoated coils/ sheets and electrical steel (cold rolled non oriented steel).
Rolling & processing facilities at RSP to produce these products comprise:
Hot Strip Mill, Plate Mill, ERW Pipe Plant, SW Pipe Plant, Cold Rolling Mills
and Silicon Steel Mill. In addition to above, a new Plate Mill of 1.0 Mtpa
capacity has been installed under on-going modernisation programme.
The feed material to the Hot Strip Mill and the Plate Mill are cast slabs
whereas the feed materials to the other mills are hot rolled coils produced
from the Hot Strip Mill.
Plate production in new Plate Mill was started in June 2014 and the mill is
getting stabilized gradually. The mill is being installed in phases. After the
completion of present phase-I implementation, the mill will attain
production capacity of 0.92 Mtpa finished plates. After the phase-II
expansion, the mill production capacity will increase to 1.674 Mtpa of
finished plates. Normalizing facilities were initially envisaged in the phase-
II expansion of the mill. However, due to current market scenario and
good saleability of normalizing plates, RSP has decided to install the
normalizing facilities (comprising shot blasting machine, normalizing
furnace, hot leveller, cooling beds, etc) before taking up the phase-II
expansion of the mill. CET was assigned to undertake the feasibility study
for installation of the normalizing facility in new Plate Mill. The feasibility
report FR(R=0) was submitted by CET in May, 2015. Views/ suggestions
were received from RSP on FR(R=0) regarding splitting the assignment
and separate installation of shot blasting facilities & reviewing of leveller
capacity. FR(R=1) was submitted in June, 2015 incorporating views/
suggestions from RSP. The FR(R=1) was reviewed by committee of
directors and it was suggested to include shot blasting machine in the
proposal for normalising line. The FR(R=1) was reviewed by committee of
directors and it was suggested to include shot blasting machine in the
proposal for normalising line. Based on the suggestion, FR(R=2) was
submitted in March, 2017 including shot blasting machine in the proposal.
Subsequently, it was suggested by corporate office to review the cost and
take reference from non-European suppliers also to contain the cost.
Based on this, FR R=3 was submitted in January, 2020. Further review on
techno-economics carried out between RSP, CMO & CET. Techno-
economics reworked with the latest input from CMO & RSP and FR was
revised.
1.2 Normalized plates have lesser degree of anisotropy in longitudinal and
transverse directions enabling better ductility and impact toughness,

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which are most suitable for boiler and pressure vessels as well as for
dynamic loading applications. Other plates producers like JSPL and Essar
have installed normalizing furnace in their new Plate Mills.
SUMMARY

1.3 The product mix of new Plate Mill, RSP comprises thicker and wider plates,
which are mostly demanded in normalized condition for better strength
and toughness. In today’s competitive market, the NSR of the plates is
required to be negotiated and normalizing is one major attribute on which
the actual realization is dependent. It is envisaged that RSP will miss a
considerable market segment in the absence of normalizing facility in the
new Plate Mill. The product-mix of new Plate Mill RSP comprises special
grade plates, which will enable higher NSR as compared to commercial
grade plates.
1.4 CMO has given concurrence to the product-mix of the new Plate Mill
which considers production of 300,000 tpa of normalized plates. CMO has
indicated that saleability of HT and BQ plates in higher thickness without
normalizing is difficult in the current market scenario. Hence to cater the
various consumer segments, sustain in the market of special quality and
also to meet the demand for thicker plates, installation of normalizing
facilities suitable to normalize the complete thickness range of plates is a
necessity in the new Plate Mill of RSP.
1.5 The envisaged technological parameters of the normalizing facilities are
300,000 tpa capacity, with 6,000 hot hours, 3 shift operation. The product
mix will include IS 2062 grades, boiler & pressure vessel steels and other
special grades. The input material will be hot rolled plates from new Plate
Mill with size range from thickness 6 to 100 mm, width 1500 to 4100 mm,
length 6300 to 15000 mm.
1.6 The normalizing facilities will be located in the existing GH bay of the new
Plate Mill shed in the space earmarked for future installation of this facility
in phase-II proposal. The GH bay of the mill will have space for storage of
input/ output material for normalizing facilities. The normalizing facilities
will comprise charging area, shot blasting, normalizing section, hot plate
leveller and cooling bed area. All equipment will be in GH bay. The
normalizing facilities will have various utilities & support facilities like ECRs
for electrics, oil-lubrication, oil-hydraulic, grease systems, air-conditioning
& ventilation system for various equipment & facilities, instrumentation &
automation system like furnace measurement & control, alarm generation,
CCTV, public address system, FDA etc.
1.7 Mixed gas will be used as fuel. Mixed gas of 3600- 4000 Kcal/Nm3 CV at
1000-1400 mm WC pressure will be tapped from column no P18 of the
new Plate Mill shed. EMD, RSP has indicated availability of mixed gas after
the commissioning of new DN 1500 dedicated MG pipe line of new Plate
Mill. Mixed gas requirement will be around 5800 Nm3/h.

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1.8 The water system envisaged for new normalizing facilities will be of re-
circulating type. The equipment/ facilities will have their own water
circulation system. Only make-up water will be supplied to these units
from the existing make-up water system. Recirculation system for new
equipment/ facilities will comprise pumps, filters, heat exchangers,
chemical dozing, water treatment, cooling tower, pipes, valves, fittings, etc.
1.9 The existing fire fighting facilities available in the area will be extended
and augmented as per requirement.
1.10 Pollution control aspects will be as per CPCB norm and all the facilities
required for the purpose of meeting the current and likely statutory norms
will be provided.
1.11 The estimated maximum power requirement for normalizing facilities is
2050 kW. Required power will be tapped from existing 6.6 kV HT switch
board in ECR#3 of new Plate Mill. Four available feeders will be used for
feeding normal power requirement of the project. Required power will be
tapped from spare feeder in existing emergency PDB in ECR#3 of new
Plate Mill.
1.12 The envisaged steel structural works for the project will include
construction of mixed-gas and nitrogen piping support from battery

SUMMARY
limits, chimney structural, and cross over, etc. The envisaged civil works for
the project will include dismantling of the RCC floor in the location of the
new facilities, foundation for equipment, pit for normalizing furnace and
scale channel, construction of rooms, chimney foundation, etc.
1.13 The proposed mill is envisaged to work in 3 shifts for 6 days in a week. The
estimated manpower requirement for the proposed normalizing facilities
is 56. The estimates exclude executives and administrative manpower
requirement which will be resourced from the existing new Plate Mill.
1.14 Training for acquaintance with the equipment/ facilities of the proposed
normalizing facilities for operation and maintenance has been considered.
It is envisaged to provide foreign training for total 10 persons covering
different disciplines including design & engineering, each for 6 days
totalling to ~60 man-days. It is also envisaged to provide classroom and
on the job training at site for 60 man-days.
1.15 The project will be implemented on turnkey basis through a single
package. All preparatory site activities will be carried out without
hampering the normal operation of the new plate mill. The connection
between the delivery of the proposed cooling bed with existing shearing
line will be carried out during annual capital repairs of the mill. The
interface/ integration activities like sourcing power & utilities at battery
limits will be carried out during weekly shutdowns/ annual capital repairs.
To the extent possible, RSP will facilitate the existing EOT cranes of GH bay

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during project execution. It is envisaged that the project will be

implemented in twenty four months from Stage-II approval.
1.16 The capital cost of the Project is estimated at Rs.295.56 crore (net of Input
SUMMARY

Tax Credit of Rs.44.90 crore) on base date of 1st Quarter, 2020, including
IDC of Rs.23.75 crore, FE component of Rs.129.83 crore which includes
increase in FE component of Rs.8.01 Crore due to Forward Premium. FE
parity has been considered as 1 Euro=INR 84.86 and 1 USD=Rs.76.92
including forward premium of Rs.5.27 and Rs.4.74 respectively for a period
of 30 months. The Capital Cost estimate has been prepared considering
budgetary quotation, engineering estimates and available data. The base
date for the estimate is 1st Quarter of 2020. The gross margin works out to
Rs 56.27 crore and IRR (post tax) 13.77%.
1.17 For attaining the market share and saleability of heavy & wide plates,
installation of normalizing facility in the new Plate Mill of RSP is required.
The project proposal for normalizing facility is technically feasible and
financially viable. Hence recommended for implementation.

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2. BACKGROUND
2.1 GENERAL
Rourkela Steel Plant (RSP) produces variety of saleable products which include
hot rolled coils & sheets, heavy plates, pipes, cold rolled coated & uncoated

BACKGROUND
coils/ sheets and electrical steel (cold rolled non oriented steel). Rolling &
processing facilities at RSP to produce these products consist of the following
complexes:
1) Hot Strip Mill
2) Plate Mill
3) ERW Pipe Plant
4) SW Pipe Plant
5) Cold Rolling Mill
6) Silicon Steel Mill
In addition to above, a new Plate Mill of 1.0 Mtpa capacity has been installed
under on-going modernisation programme. The feed material to the Hot Strip
Mill and the Plate Mill are cast slabs whereas the feed materials to the other
mills are hot rolled coils produced from the Hot Strip Mill.
2.2 Plate production in new plate mill was started in June 2014 and the mill is
getting stabilized gradually. The major technological parameters of the new
plate mill are mentioned below:
Capacity
920,000 tpa plates (after phase-I installation)
1,674,000 tpa plates (after future phase-II expansion)
Input Slab
Thickness 210-300 mm
Width 1,200-2,400 mm
Length 2,500-4,100 mm
Weight 23.2 t (max.)
Finished Plate
Thickness 6-100 mm
Width 1,500-4,100 mm
Length 6,300-15,000 mm

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2.3 PRODUCT MIX

The product mix of the new plate mill is mentioned below:
[Link]. Finished Products Size Annual Production
(Tonnes)
Thickness*Width
BACKGROUND

(mm*mm)
1. IS 2062 E 165, 250, A,B,C 6-40*1500-4100 125,000
with or without Cu.
>40 mm 25,000
2. IS 2062 E 300, 350, 410, 6-40*1500-4100 80,000
450D & E
>40 mm 20,000
3. IS 5986-165, 205, 235 & 6-100*1500-4100 70,000
255
>40 mm 10,000
4. IS 5986-325, 355, 420, 6-16*1500-4100 40,000
490 & 560
>40 mm 10,000
5. ASTM A36 (all grades) & 6-40*1500-4100 90,000
A 283(all grades)
>40 mm 10,000
6. ASTM A529 (all grades) & 6-40*1500-4100 35,000
A633 (all grades)
>40 mm 15,000
7. Boiler & pressure vessel 6-40*1500-4100 75,000
steel
IS2002 (all grades) &
ASTM A285 (all grades)
8. Boiler & pressure vessel 6-40*1500-4100 100,000
steel
ASTM A515 (all grades)
ASTM A156 (all grades),
ASTM
A537 Cl.-I, ASTM A202 (all
grades)
ASTM A 299 (all grades)
9. LLOYDS 360, 410 6-16*1500-4100 7,500
including AR, FG
>16-40*1500- 15,000

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4100
>40 mm 7,500
10. API 5L quality 6-40*1500-4100 85,000

BACKGROUND
(upto X-100)
11. Ship Building (LL Gr A,B) 6-16* 1500-4100 5,000
>16-40*1500- 7,500
4100
>40 mm 17,500
12. Other special quality 6-40*1500-4100 55,000
>40 mm 15,000
Total 920,000
2.4 MILL PERFORMANCE
2.4.1 The performance of the mill in last four years (2016-20) is shown below:
Year Input Finished Yield Available Hot Mill Average
Slabs Plates hours Hours Utilization Rolling
Rate
(tpa) (tpa) (%) (h) (h) (%) tph

2016-17 605,515 540,388 89.24 7,674 5,791 75.46 93.32

2017-18 886,576 802,003 90.46 7,749 6,350
81.95 126.30

2018-19 950,577 857,951 90.26 7,702 6,827 88.64 125.67

2019-20 729,900 657,152 89.24 5,880 5,369 91.31 122.40
(Apr-Dec)
Average 793,142 714,374 89.80 7,251 6,084 84.34 116.92

2.5 MAIN TECHNOLOGICAL UNITS

The new Plate Mill comprises following major technological equipment/
facilities:
1) Walking beam type slab reheating furnace
2) Slab de-scaling box
3) 4-Hi reversing mill
4) Plate cooling system

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5) Hot plate leveller

6) Hot plate marking machine
7) Cooling beds (1 walking beam type and 1 disk type)
8) Primary inspection bed
BACKGROUND

9) Plate turnover device

10) Ultrasonic testing (UST) machine
11) Double side trimming shear
12) Dividing shear
13) Dimension measuring device
14) Surface inspection system
15) Marking machine
16) Cold plate leveller
17) Heavy plate cooling grid
18) Heavy plate inspection bed with Plate Turnover (PTO) device
19) Heavy plate flame cutting machine
20) Plate pilers
21) Roll shop facilities
2.6 PROCESS FLOW OF NEW PLATE MILL
Continuous cast slabs are heated and soaked in walking beam reheating furnace
of capacity 225 tph. The slabs discharged from the furnace are de-scaled in the
primary de-scaler with high pressure water jets. The de-scaled slabs are rolled in
the 4 hi-reversing mill stand. The mill stand is equipped with electro-mechanical
screw-down assembly & hydraulic cylinder (HAGC) for rapid response roll gap
adjustment. The mill is also equipped with quick work roll change equipment.
The mill has entry and exit thickness gauges, profile gauge and other necessary
sensors. After rolling of plates in 4 hi-reversing stand, accelerated/ controlled
cooling of the rolled plates is carried out to achieve desired mechanical
properties. The plates are levelled in the hot leveller after accelerated cooling.
After levelling, plates are cooled either in a disc-type cooling beds (up to 50 mm
thickness plate) or in a walking beam type cooling bed (plates above 50 mm
thickness
The plates up to 50 mm thickness are processed in the shear line equipped with
crop shear, dividing shear, side trimmer depending upon customer requirement.
Plates needing cold levelling are processed in a cold leveller. Thereafter, the

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finished plates are piled in pilers and stored in GH bay of the mill shed for
dispatch.
Heavy plates (>50 mm) after passing through cooling bed are taken to heavy
plate processing area and cut to the desired sizes in flame cutting machine

BACKGROUND
before sending to GH bay through transfer car for dispatch.
2.7 PRESENT ASSIGNMENT
Normalizing facilities were initially envisaged in the phase-II expansion of the
new Plate Mill. However, due to current market scenario and good saleability of
normalizing plates, RSP has decided to install the normalizing facilities
(comprising shot blasting machine, normalizing furnace, hot leveller, cooling
beds, etc) on priority before taking up the phase-II expansion of the mill. CET
was assigned to undertake the feasibility study for installation of the
normalizing facility in new Plate Mill vide letter no. DGM(AMR-
M&SC)/Consultancy/15/38 dated 07.01.2015. The copy of the letter is placed at
Annexure-2.6-1. CET had accepted the assignment vide letter no. CET-
17(5)/4062/15/129 dated 12.03.2015. The copy of the letter is placed at
Annexure-2.6-2. The feasibility report FR(R=0) was submitted by CET in May,
2015. Views/ suggestions were received from RSP on FR(R=0) regarding
separate installation of shot blasting facilities & review of leveller capacity.
FR(R=1) was submitted in June, 2015 incorporating views/ suggestions from
RSP. The FR(R=1) was reviewed by committee of directors and it was suggested
to include shot blasting machine in the proposal for normalising line. Based on
the suggestion, FR(R=2) was submitted in March, 2017 including shot blasting
machine in the proposal. Subsequently, it was suggested by corporate office to
review the cost and take reference from non-European suppliers also to contain
the cost. Based on this, FR R=3 was submitted in January, 2020. Further review
on techno-economics carried out between RSP, CMO & CET. Techno-economics
reworked with the latest input from CMO & RSP and FR was revised..
2.8 MARKET ANALYSIS
2.7.1 Normalized plates have lesser degree of anisotropy in longitudinal and
transverse directions enabling better ductility and impact toughness, which are
most suitable for boiler and pressure vessels as well as for dynamic load
applications. Other plates producers like JSPL, Essar have installed normalizing
facilities in their new Plate Mills.
2.7.2 The product-mix of new Plate Mill, RSP comprises thicker and wider plates,
which are mostly demanded in normalized condition for better strength and
toughness. In today’s competitive market, the NSR of the plates is required to
be negotiated and normalizing is one major attribute on which the actual
realization is dependent. It is envisaged that RSP will miss a considerable market
segment in the absence of normalizing facility in the new Plate Mill.

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2.7.3 CMO has given concurrence to the product-mix of the new Plate Mill which
considers production of 300,000 tpa of normalized plates. CMO has indicated
that saleability of HT and BQ plates in higher thickness without normalizing is
difficult in the current market scenario. Hence to cater the various consumer
segments, sustain in the market of special quality and also to meet the demand
BACKGROUND

for thicker plates, installation of normalizing facilities suitable to normalize the

complete thickness range of plates is a necessity in the new Plate Mill of RSP.
2.8 CET expresses sincere gratitude to RSP Collective, CMO and Plate Mill Officials
of BSP for their assistance and co-operation at every stage of this feasibility
study.

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3. SELECTION OF ALTERNATIVES
3.1 To meet the requirement of normalized plates, a normalizing line consisting of
shot blasting machine, normalizing furnace, hot leveller & cooling bed has been
considered for this project. Details of the project are descried in chapter-4. No
other configuration for the proposed facility has been considered.

SELECTION OF ALTERNATIVES

RSP Page no. 3.1

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4. PROJECT DESCRIPTION
4.1 GENERAL
It is proposed to install normalizing facilities in new Plate Mill of RSP to produce
300,000 tpa of normalized plates. The rolled plates produced in new Plate Mill
will be the input material for the normalizing facilities.
4.2 ENVISAGED TECHNOLOGICAL PARAMETERS
4.2.1 The envisaged technological parameters of the proposed normalizing facilities
are mentioned below:
Capacity of normalizing line: 300000 tpa
Input material (Hot rolled plates)
Length (L) 6300-15000 mm
Width (W) 1500-4100 mm

PROJECT DESCRIPTION
Thickness (T) 6-100 mm
Weight 23.2 t (max.)
Product mix:
Material Size(mm) Annual production
(tpa)
MS-E250A/BR/BO equivalent 32,000

MS- E250C 6,500

HT-E300A/ BR/ BO 3,000

E350BR/ BO equivalent (5-10, 10-20 & 77,000

>20mm)
HT-E350C & above grades 97,000

IS2002-GR 2/3 31,500

IS2041 & above grades 53,000

Total 300,000

Reference plate
Size 10000*2500*36 mm
Material ASTM.A515/516 gr. 60/70 IS 2002
Nominal production 50 tph with reference plate

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4.3 LOCATION/ LAYOUT

4.3.1 The proposed normalizing facilities will be located in the existing GH bay of the
new Plate Mill shed between Column 31 to Column 52. The space was
earmarked for future installation of this facility in the overall layout of the mill.
The technological layout showing the location of normalizing facilities in new
Plate Mill along with its major auxiliaries is shown in drawing no. CET RN 4062
RF2 00 001 (R=3). The GH bay will have space for storage of input/ output
material for normalizing facilities. The normalizing facilities will comprise
charging area, shot blasting, normalizing section, hot plate leveller and cooling
bed area. All equipment will be installed within GH bay of the mill shed.
4.4 PROCESS DESCRIPTION
The plates (both thin <50 mm and thick >50 mm) of the new Plate Mill after
finishing are stored in the GH bay for despatch. The plates requiring normalizing
will be identified and stored in the entry side of the proposed normalizing
PROJECT DESCRIPTION

facilities. The plate will be placed on the plate loading table by existing
overhead crane. After centering, the plate will pass through shot blasting
facilities for removal of scale from the surface of the plate prior to normalizing.
The plate will enter the normalizing furnace where heating and soaking will be
carried out in nitrogen atmosphere as per size and material of the plate. The
plate will be discharged from the normalizing furnace after the stipulated time.
After normalizing furnace, the plates of thickness >25 mm will go to the
proposed cooling bed for cooling. Levelling is not required for these plates.
After cooling, these plates will be lifted by existing crane in the shop and kept in
the GH bay for despatch. Manual marking and painting will be carried out as per
customer requirement.
After normalizing furnace, the plates of thickness <25 mm will pass through
proposed leveller and cooling bed. The cooling bed delivery will be connected
to the existing shearing line of the mill as shown in drawing no. CET RN 4062
RF2 00 001 (R=3). These plates will pass through the existing shearing line.
Edge marking will be done for all the plates. The plates will then go to the pilers
and will be stored in GH bay for despatch.
4.5 MAJOR EQUIPMENT/ FACILITIES
4.5.1 Following major equipment/ facilities (as shown in drawing no. CET RN 4062
RF2 00 001 (R=3)) have been envisaged for the normalizing facilities in new
Plate Mill.
1) Plate loading table

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The plate requiring normalizing will be loaded on the loading table by

means of overhead crane in the GH bay. It will centre the plate, measure its
length and move it forward to the furnace charge table.
2) Centring unit
The loading table will have a centring device, consisting of pair of guides
which move in/ out from both table edges in a synchronized manner. The
guides will locate the plate to the centre of the table and subsequently
retract to home position. The guides will be driven by cylinders powered
by a hydraulic power unit located adjacent to the table.
3) Plate length measurement
The table will have a system of plate detectors to measure the plate length.
Once the plate has been centred, the plate detector will be used for
detecting the head end and tail end as the plate moves. The plate length

PROJECT DESCRIPTION
will then be calculated. The detector will facilitate:
i) Confirmation of the plate length and to prevent plate to plate
collisions in the line during processing.
ii) Reaffirmation of the plate identity for the Level 2 control system.
4) Shot blast unit with charging and discharging table
The shot blast unit will clean the plate of mill scale and provide a cleaner
surface for uniform heating. There will be a shot blast charge table ahead
of it, which will receive plates from the loading table and feed them into
the unit. Similarly there will be a shot blast discharge table which will
receive plates from the unit and move them on to the furnace charge
table.
The shot blasting machine is used for continuous shot blasting of plates.
The plates will travel through the machine on the roller conveyor equipped
with the drive. Cleaning of the plates will take place in the central part of
the machine (shot blasting chamber) with steel abrasive which will impact
on the plate surfaces at a very high speed. The steel abrasives will be
dosed at the storage hopper by the abrasive valve to the abrasive throwing
wheels, which will give the necessary kinetic energy. The mechanised screw
conveyor located at the bottom of the housing of the shot blasting
machine will transport the steel abrasives to the transverse screw and to
the elevator. The elevator will lift the steel abrasives up to the abrasive
separators where steel sand will be screened and refined by compressed
air. The separated good abrasives for reuse will fall in the storage hopper.
Abrasive throwing wheels will be located at top and bottom of the shot
blasting machine for cleaning of both surfaces of the plate.
5) Furnace charging roller table

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This table will receive plates from the shot blast discharge table and feed
to the normalizing furnace. It will have adequate length to carry one plate
at a time. This arrangement will facilitate entry of a plate inside the furnace
regardless of the ongoing process in the shot blasting machine.
6) Normalizing furnace
The normalizing furnace will heat the plate to the appropriate temperature
and holds it at this temperature in an inert (nitrogen) atmosphere. The
furnace will be top and bottom fired heat treatment roller hearth furnace,
heated with recuperative burners installed in radiant tubes. The maximum
furnace temperature will be 980°C. Suitable curtained vestibules will be
installed at the entry & exit of the furnace.
The furnace tracking system will actuate opening of the entry door for
charging of the next plate, after ensuring empty space in the charging
table during the process. The door will be closed after the entry of the
PROJECT DESCRIPTION

plate inside the furnace.

The stay period of the plate in the furnace will depend on the thickness,
width, target temperature and holding time and will be determined by the
PLC system. The movement of the plate inside the furnace will be tracked
by monitoring the speed of the rollers and the stay time in the furnace.
The plate position will be updated at regular intervals by the photocells
installed along the furnace length.
The plates will be moved in continuous mode. The plate will be ready for
placement on the discharge table after the attainment of the target
temperature and holding time as calculated by the L2 computer. The plate
will be moved to the discharge table, if empty or will be oscillated in case it
is occupied. The oscillation process will continue till the discharge table is
free to receive the plate.
Subsequently, the discharge door will open and the plate will leave the
furnace and enter the exit roller table at the required speed determined by
the PLC system.
7) Furnace discharge roller table
The discharge table will receive plates from the furnace. The rolls will have
tires to protect the heat transfer from the hot plate to the roller barrels
during the transportation.
8) Leveller charging roller table
This table will receive plates from the furnace discharge table and feed
them into the leveller. There will be a plate centering device attached to
this roller table for centering of plate before feeding to leveller.

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9) Leveller
Leveller will have compact design with low spring in longitudinal and
transverse direction under load. The leveller will be 4-high type with
levelling rolls and back up roll suitably designed to meet the leveling
requirements of thinner/ thicker gauge plates. The thickness range of the
plates for levelling will be 6 to 25 mm.
The leveller will eliminate shape defect and impart required flatness to the
hot plates. Idle rolls will be installed at the entry and exit of the machine
for smooth transfer of the plates through the leveller.
There will be servo-hydraulic positioning system which will ensure under-
load adjustment and multiple adjusting patterns, viz; height adjustment,
skew adjustment, tilt adjustment, quick roll closing and opening for
overload protection, bending compensation, etc. The equipment will have
cassette design with quick changing facility of roll cassettes.

PROJECT DESCRIPTION
10) Leveller outgoing roller table
This table will receive the plates discharge from the leveler and will
transport them to the unloading table of thicker plates.
11) Cooling bed with charging and discharging facilities
The plates received from the leveller outgoing roller table will be received
by cooling bed incoming roller table. The cooling bed entry transfer device
will lift plates from the roller table and will transfer them onto the cooling
bed. The chains will be mechanically synchronized in for traversing and
lifting motions.
The cooling bed will be walking beam type cooling bed which transfers the
plate with a lifting-shifting-lowering sequence. Two separate drives will be
provided to perform the lifting/lowering and the shifting movement of the
plate. The walking beam type cooling bed will consists of four sections:
two on entry side and two on exit side. Each entry and exit section will be
further divided so as to work independently for the shorter plates or
simultaneously for the longer plates.
The cooling bed exit transfer device will lift the plates from the cooling bed
and transfers them onto the existing roller table of shearing line of the mill.
The cooling bed width will be about 17000 mm so that maximum plate
length can be processed.
12) Oil Hydraulic System
The hydraulic system and equipment will be designed to cater to the
needs of various furnace equipment and systems. The hydraulic system has

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broadly been envisaged for Centring unit, Leveller, Cooling bed with
charging and discharging facilities etc.
13) Lubrication System
Automatic dual line centralized grease lubrication system has been
considered for all equipment. Where ever, it is not possible to provide
centralized lubrication system, portable manual grease lubrication system
will be provided.
14) Material Handling Facilities
Material handling facilities will be provided at all required locations, which
is not in the approach of existing EOT cranes for smooth operation &
Maintenance.
4.6 UTILITY
4.6.1 Water System
PROJECT DESCRIPTION

The water system envisaged for the new normalizing facilities will be of re-
circulating type. The equipment/ facilities will have their own water circulation
system. Only make-up water will be supplied from the existing make-up water
system. Recirculation system for new equipment/ facilities will comprise pumps,
filters, heat exchangers, chemical dozing, water treatment, cooling tower, pipes,
valves, fittings, etc.
[Link] Make-up Water & Cold Water
Make up water of 2.4 Nm3/h (pressure 1-2 kg/cm2) will be tapped at 8 m height
from the shop header of the new Plate Mill. Indirect cooling water/ soft water
(pressure 3-5 kg/cm2) will be tapped from the shop header of the new Plate Mill.
[Link] All pumps and pipe lines will be provided with corrosion protection coatings, as
per requirement. Measuring facilities will be provided at each taping points to
monitor water consumption of each consuming unit.
4.6.2 Nitrogen
Nitrogen will be provided for creating inert medium in the furnace and purging
of gas network. Nitrogen at 2200-2700 mm WC pressure will be tapped from
column no B15 of the new Plate Mill shed. Nitrogen requirement will be around
500 Nm3/h.
4.6.3 Fuel Facilities
Mixed gas (MG) will be used as fuel. Mixed gas of 3600-4000 Kcal/Nm3 CV at
1000-1400 mm WC pressure will be tapped from Column no P18 of the new
Plate Mill shed. As indicated by EMD, RSP, mixed gas will be available after the
commissioning of new DN 1500 dedicated MG pipe line of new Plate Mill. Mixed
gas requirement will be around 5800 Nm3/h.

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4.6.4 Compressed Air Facilities

Compressed air at 5-6 kg/cm2 (g) pressure will be tapped from the existing shop
header of the new Plate Mill. Compressed air requirement will be around 100
Nm3/h in the furnace area.
4.6.5 Air conditioning & Ventilation System (ACVS)
Dedicated air conditioning & ventilation system will be provided for the
proposed normalizing facilities based on their technological requirement.
4.6.6 Fire Fighting System
The existing firefighting facilities of the new Plate Mill will be extended to the
proposed normalizing facilities. However, it will be augmented as per necessity
to meet the following requirement of the prosed facility:
1) Portable fire extinguishers as first aid fire fighting system
2) Water based fire fighting system

PROJECT DESCRIPTION
3) Automatic water spray system
4) Automatic foam injection system
5) Automatic gas flooding system
4.6.7 Pollution Control
Pollution control aspects will be as per CPCB norms. The facilities required for
the purpose of meeting the current and likely statutory norms will be provided.
4.6.8 Underground flu tunnel with insulation connecting from furnace to chimney will
be provided. Chimney will be located outside GH bay near H-row.
4.7 REFRACTORY
4.7.1 The normalizing furnace will have refractory linings as per details furnished
below:
1) Roof
Furnace roof area will be lined by heat resistant light weight ceramic fibre
module with approx. thickness of 300 mm.
2) Side Wall
Side walls of firing zone of furnace will consist of one dense layer of min
60% Al2O3 containing fireclay bricks followed by two layer of insulation
bricks layer and other areas will consist of one dense layer of min 40%
Al2O3 containing fireclay bricks followed by two insulation bricks layers.
3) Bottom
Furnace bottom will consist one layer of min 60% Al2O3 containing high
alumina bricks followed by two insulation bricks layers.
4) Burner

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Burners of furnace will consist of high alumina (95% Al2O3) containing

ultra-low cement castable material.
5) Radiant Tube
Radiant tube material will be heat resistant silicon carbide material.
6) Flue duct
Flue duct of the furnace will consist of min 50% Al2O3 containing castable
material with anchors.
Thickness and quality of refractory materials of different area will ensure
skin temperature of the furnace shell 50°C (max.) above ambient.
4.7.2 The chimney of the normalizing furnace will have refractory linings as
mentioned below:
1) Bottom area of the chimney will be lined with two layers of IS-8 quality fire
bricks.
PROJECT DESCRIPTION

2) Side walls of the chimney will be lined with one layer of IS-8 quality fire
clay bricks followed by one insulation bricks layer.
4.8 ELECTRICAL
4.8.1 Electrical Power Requirement
The estimated electrical load for the proposed normalizing facilities including
provision of power for shot blasting (to be installed thorough a separate
package) is mentioned below:
Type Connected Load (kW) Max. Demand (kW)

Normal power 3000 2050

Emergency Power 160 140
4.8.2 Source of Power
To meet the normal & emergency power requirement, following power
distribution arrangement has been envisaged:
1) Normal Power
Required power will be tapped from existing 6.6 kV HT switch board in
existing ECR#3 of new Plate Mill. Four available feeders (panel no 22, 23/
section-II & panel no 55, 56/ section- III) will be used for feeding the
normal power.
2) Emergency Power
Required power will be tapped from spare feeder in existing emergency
PDB in ECR#3 of new Plate Mill.

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4.8.3 Power System Distribution Arrangement

Two double ended load centre substations with 6.6 kV/ 415V, 2*2000 kVA dry
type transformers & LT switch board are envisaged for feeding total load.
Required nos. of MCCs, PDBs, etc., have been proposed. One dedicated
emergency MCC has been envisaged to meet process emergency power
requirement.
4.8.4 Electrical Equipment & Facilities
Following electrical equipment and facilities have been envisaged for the
proposed facilities:
1) 2*2000 kVA, LT load centre sub-stations
2) Motor control centres, emergency MCC & auxiliary distribution boards
3) AC motors
4) Variable frequency drives for roller tables, combustion air fans of furnaces,

PROJECT DESCRIPTION
shot blasting, leveller, cooling bed, etc
5) Limit switches and other field sensors
6) Control desk, local control stations
7) PLC based automation system
8) Illumination of all new rooms as LT sub-stations room, new electrical room,
VFD cum PLC room, etc.
9) HT and LT power cables, control cables, illumination cables, special signal
cables, cable racks, cable trays, cabling materials and accessories, conduit
fittings etc
10) Earthing & lightning protection of the new electrical & micro-processor
based equipment
4.8.5 Drive Automation & Control
[Link] AC motors will be selected to match the driven equipment as regards power
and duty requirements, speed/ torque characteristics, etc., and will be able to
accelerate smoothly the driven equipment/ machine without undue heating.
Totally enclosed fan cooled ac motors are envisaged to be used for fixed speed
applications. Insulation class will be 'F' with temperature rise limited to class-B.
Inverter duty ac motors (sq. cage) are envisaged for variable speed drives. These
motors will be fitted with accessories such as base plate, pulse tacho, PTC's, etc.
[Link] Powers to the fixed speed drives are envisaged to be provided through motor
control centres/ motor control panels. All drives requiring speed control will be
provided with variable frequency drive. Regenerative/ dynamic braking will be
taken as per application. Active front end variable frequency drive will be
provided for regenerative braking. Converter transformer will be considered as
per requirement.

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4.8.6 Drive PLC Control & Automation

[Link] The automation system will be arranged hierarchically in two levels, each level
carrying out its own special tasks to ensure the optimum operation of the
normalizing furnace.
Level #0: motors, drives, actuators and field instruments
Level #1: basic automation system with HMI based operator control &
monitoring
[Link] Level #0 will include all sensing devices, actuators, transducers mounted on the
equipment and will provide all parameters, operating & control data to Level #1
basic automation system.
[Link] Level #1 basic automation system will be based on PLCs and will cover all
functions and devices needed to device control, adjusting and monitoring of the
line.
[Link] Operator control & process monitoring system will be human-machine interface
between machines and operators. Operator will be able to monitor and control
PROJECT DESCRIPTION

the line from the control room.

[Link] PLC based automation system will be provided for normalizing furnace line to
perform the functions of process control, discrete machine control and roller
tables, furnace rollers, etc.
[Link] Individual PLC unit will be connected via an effective ethernet network. Process
I/O’s will be distributed by means of remote I/O units in order to reduce cabling.
4.8.7 Location of Electrical Equipment
One new ECR comprising transformer rooms, electrical rooms and PLC cum VFD
rooms is proposed at space earmarked as ‘future ECR’ adjacent to the furnace of
the proposed normalizing facilities in the GH bay of new Plate Mill shed.
Another electrical cum control room has been considered at the leveller end in
the space between columns of G row to house panels & drives of proposed
leveller & cooling bed, etc.
VFD cum PLC rooms will have air-conditioned environment while electrical room
will have dry pressurised ventilation system.
4.8.8 Illumination System
Energy efficient illumination system for the proposed new rooms has been
considered.
4.8.9 Cables
Cables for HT will be will be heavy duty, 6.6 kV(UE) grade, XLPE insulated, PVC
inner sheathed, FRLS outer sheathed multi core,ST-2 type aluminium conductor,
armoured cables.

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Cables for LT will be heavy duty, 1.1 kV grade, XLPE insulated, PVC inner
sheathed, FRLS outer sheathed multi core, ST-2 type aluminium/ copper
conductor, armoured cables.
The control cables will be multi strand copper conductor, PVC inner sheathed,
FRLS outer sheathed ST-2 type.
4.8.10 Earthing Protection
Earthing protection in accordance with the provisions of the relevant IEC
recommendations/ IS code of practice IS 3043-1987 and Indian Electricity Rules
has been considered.
4.9 PROCESS CONTROL & AUTOMATION
4.9.1 The envisaged instrumentation and control system for the proposed
normalization facilities is a state of the art system with three different levels of
controls, i.e., Level 0, 1 & 2. This system will also be integrated with plant wide
Level 3 network of RSP (ERP network). The control system will be totally

PROJECT DESCRIPTION
automatic type with provisions for remote manual and local operation also.
Normally, fully automatic operation from Level 2 based system is envisaged. The
Level 2 will interact with Level 3 for production related data and other inputs
and pass on the commands to Level 1 system. Level 2 will also be able to
operate the plant based on operator inputs. However, it will also be possible to
operate the plant from Level 1 system in case of any failure of Level 2 system.
The local operation envisaged is for maintenance purpose only.
4.9.2 The Level 1 control system will comprise PLC based control system with client
server based architecture. There will be two number of PLCs designated for
following functions:
1) One PLC for electrical functions and material tracking
2) Second PLC for burner control process and heating functions
4.9.3 Both the PLCs will be integrated at server level for better coordination and
synchronization of control and tracking functions. The server will be of fault
tolerant grade in hot redundant configuration with Raid 1 features. The CPU will
be Intel Xeon processor of latest version. Integration between Level 1 and Level
2 is envisaged through OPC server software.
4.9.4 The envisaged PLCs will have hot redundancy at CPU, power supply and
communication level. The system will have 20% spare prewired I/Os and 1 no of
spare card of each type as loose supply. It will have data storage and archiving
capacity for minimum 30 days.
4.9.5 Level 2 system will have mathematical model software for heating control. It will
compute plate temperature through tracking along the plate length. The level 2
system software will pick up the plate data with the help of bar code reader or
manual entry as per operator selection and will further process it for deciding
the plate movement inside furnace and compute the required flame
temperature and temperature profile of plate by mathematical model. The

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interpolated temperatures will be cross checked with thermocouple inputs and

spot pyrometers. The final exit temperature will be measured with line scan
pyrometer (top & bottom) and the thermal profile will be displayed in the HMI
along with temperature differential graphics for operator’s view. The final
temperature will be compared with the set points and the outcome will be
utilized by level 2 system to optimize the heating cycle for next plate.
4.9.6 All data including plate dimensions, heating time, steel grade, target
temperature, etc., will be available in the tracking system and in turn will be
passed on to the plant wide ERP or Level 3 system of RSP.
4.9.7 The Level 2 system will also perform following functions:
1) Furnace charging schedule based on operator inputs or data received from
ERP
2) Generation of heating cycle recipe for various grades of plates
3) Plate tracking from charging end to discharge end including graphical
display of thermal profile
PROJECT DESCRIPTION

4) Speed curve
5) Compute thermal model of plate inside furnace (zone wise)
6) Generate set points for fuel air ratio and transfer to Level 1
7) Plate oscillations
8) Process visualization
9) Data archiving and history for a minimum period of 13 months in hard disk
10) Report generation
11) Integration between Level 1 and Level 3 system
4.9.8 Logical signal processing and the coordination of operations and functions will
be done by the material tracking control PLC. The following functions are in
general envisaged in tracking PLC:
1) Taking the plate data from bar code reader/ operator input
2) Movement of charging roller table
3) Movement of centring device
4) Plate length measurement
5) Shot blast/ Brush rolls
6) Open/ close of furnace doors
7) Movement of furnace roller table
8) Movement of discharging roller table
9) Control of auxiliary systems, lubrication system
4.9.9 The furnace process operation, particularly temperature control, settings and
sequences will be controlled by the furnace PLC. The control system will include
PID’s for temperature control, combustion control, furnace pressure control and
excess temperature limit control. The excess temperature limit control will shut
down the corresponding zone, if high temperature limit is exceeded. The
burners will be operated in ON/ OFF mode. The following functions will be
achieved in burner PLC:

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1) Flow control for fuel gas and nitrogen

2) Fuel gas pressure control
3) Combustion air pressure control
4) Oxygen content measurement and evaluation
5) Temperature controls (of each zone)
6) Excess temperature limit control (radiant tube protection)
7) ON/ OFF round robin burner control
8) Waste gas flow and temperature control
9) Furnace pressure control (nitrogen supply)
4.9.10 The new control equipment including PLC’s, HMIs and Level 2 servers are
envisaged to be installed in the respective control rooms.
4.9.11 The Level-0 instruments will basically comprise various field instruments
required for burner control process and heating functions. This will also include
all the measurement and control parameters of furnace and utilities. The special
instruments will comprise line scan pyrometers, spot pyrometers for measuring

PROJECT DESCRIPTION
plate temperature before exit from furnace, portable pyrometers for
measurement of plate temperature, plate length measurement system, plate
thickness measurement system by triangulation laser device (2 nos), plate
detectors, bar code readers, centring devices, etc.
4.9.12 Pneumatic control valves will be operated through control air at 5-6.0 bar
pressure. Compressed air/ nitrogen will be tapped from existing source within
mill premises. Required conditioning and distribution for the proposed facilities
has been considered.
4.9.13 Screened cable, control cable, power supply cable, thermocouple compensating
cable, FO cable, Ethernet cable, profibus cable and any other special cable as
required has been considered. FRLS type cables will be used in and around the
furnace.
4.9.14 Hazardous Gas Detection System
Ambient CO detectors will be provided near firing zone and other hazardous
areas with annunciation and alarm through hooters. For the plant personnel
safety, ten numbers of portable CO detectors will also be provided.
4.9.15 Instrumentation System
1) Thermocouples
There will be thermocouples to measure the following:
i) Furnace temperature control thermocouples, two per module (one
upper and one lower), wired to the PLC
ii) Furnace over-temperature thermocouple, one per module, wired
directly to the PLC
iii) Furnace exhaust gas temperature
2) Plate Detectors
As part of the plate tracking system, there will be plate detectors to sense
the presence of the plate. Detectors will be installed on the charge table,

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all other tables and inside the furnace to locating & update the plate
position in the tracking system.
3) Plate Length and Thickness Measurement System
Two laser meters will be used to measure the plate length at the entry of
normalization furnace. Thickness of the plate will also be measured at this
point with triangulation laser meter. These data will be cross checked with
the data from bar code reader/ operator input and will help in plate
centring as well as deciding the heating transfer recipe.
4) Pressure Monitoring
Pressure switches will be provided to monitor the following:
i) Fuel supply
ii) Nitrogen supply
iii) Instrument air
iv) Combustion air
There will be pressure transmitters to monitor the following:
PROJECT DESCRIPTION

i) Combustion air pressure

ii) Fuel gas pressure
iii) Exhaust system pressure
iv) Furnace pressure
5) Cooling Water Monitoring
Switches will be provided to monitor cooling water flow to all the water-
cooled points of the furnace. This will include:
i) Plate detectors on furnace and tables transporting hot plates
ii) Furnace doors
iii) Pyrometers
iv) CCTVs
6) Limit Switches
Limit switches will be provided to monitor the position of following
devices:
i) Furnace doors
ii) Fuel valves on the gas train and at the burners
iii) Dampers
7) Flow Monitoring
There will be flow meters to measure the following:
i) Fuel gas flow
ii) Nitrogen flow to the furnace
iii) Electromagnetic flow meters on water headers
8) Flue Gas Analyzer
i) There will be an analyzer to measure the levels of CO in the furnace
products of combustion.
ii) CV analyzer has been envisaged for measuring the CV of fuel gas.
This will act as input to the heating model.

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9) Spot Pyrometer
Two spot pyrometers will be provided inside the furnace, before exit area
line for measuring the exit plate temperature. The pyrometers will have a
cooling jacket.
10) Scan Pyrometer
Two scan pyrometers will be provided for measuring and viewing the
thermal profile of plate (top and bottom) along with graphics. The
measured temperature will be displayed both as a graphical image and a
thermal image on the HMI screen. This will display every small difference in
temperature over the surface of the plate. The display will be configured to
show temperature and show deviations from target temperature, etc.
11) Furnace Camera System
Camera will be provided and mounted in the furnace roof to view plates
inside the furnace. Camera will be mounted in a water-cooled housing
which will sit outside the furnace. It will include a sight tube which will

PROJECT DESCRIPTION
extend to the furnace and, at the tip, will have a right angle lens assembly.
The sight tube will be cooled by air/ nitrogen. The system will have auto-
retraction and auto insertion function. The system will directly display
inside view of the furnace on 24’’ monitor in central control room directly.
4.9.16 Fire Detection & Alarm System
Automatic fire detection & alarm system (FDA) will be provided for early
warning in case of smoke or fire in the plant complex so that the same can be
extinguished in time and the whole premises, equipment and lives of personnel
can be saved. FDA system envisaged is intelligent addressable type system. The
proposed FDA will comprise:
1) Control rooms, false floor/ ceiling
2) Electrical rooms/ MCC rooms
3) VFD room
4) Transformer rooms
5) ACVS rooms
6) Battery rooms
7) PLC room, UPS room
8) Cable basement/ gallery/ tunnel/ vaults
Any other fire hazardous area
4.9.17 Closed Circuit Television (CCTV) System
IP Based CCTV system will be provided. The CCTV system will comprise:
1) Required nos. of colour, high resolution and low light sensitive IP cameras
with encoder, lens, shutter, IR filter, motorized pan and tilt head, motorized
zoom lens with remote control arrangement.
2) All cameras will be provided with auto lens cleaning arrangement by
instrument grade clean compressed Air/N2. Cameras will be provided with

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cooling arrangement like water cooling jacket, etc., for high temperature
application as well as considering upper temperature limit of the cameras.
3) Cameras also will be provided for process monitoring from a central
location by installing CCTV system at various locations. This system will
assist in monitoring various areas on a continuous basis from a central
location and for taking timely action in the event of any dysfunction. It is
proposed that the system will consist of required number of analog day/
night dome type cameras/ bullet cameras with motorized pan, tilt and
zoom facilities & one 55” wall/ desk mounted LED display will be located in
the control rooms. The yard area will also have CCTV for surveillance.
4.9.18 Voice Communication system
1) PA system
Loudspeaker intercommunication/ Press to Talk (PTT) system with selective
calling type features have been envisaged for communication amongst
various locations of the proposed facilities. PA system will have eight
PROJECT DESCRIPTION

number of wall hanging sets.

2) VHF Wireless Communication System
Desk top stationary sets (base station one number) and portable hand held
sets (Walkie-talkie 6 nos) have been envisaged for establishing
communication amongst crane and floor/ control room personnel as well
as amongst the maintenance personnel.
3) Telephone System
Telephone connection will be provided from existing EPABX based plant
telephone system. The telephone cable network will be extended to the
proposed normalizing facilities from the nearest available junction box/
marwilling rack. Necessary cabling and ten number of telephone sets have
been envisaged in this project.
4.9.19 Earthing System
A dedicated electronic earthing system to effectively earth all electronic
equipment like PLC, computer, peripherals, etc., has been envisaged. Electrical &
electronic earthing will be separate.
4.9.20 Equipment List for Instrumentation
The instrumentation envisaged for the proposed normalizing facilities will
comprise the following:
[Link]. Description Quantity
1) Two sets of PLC with following: 1 lot
Hot redundant processor, power supply and
communication module
I/O cards with 20% spare pre-wired I/Os and 1 no. spare
card for each type of I/O cards

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[Link]. Description Quantity

Switch fuse terminals and interfacing relays
Panel & chassis etc
Electronic hooter
4 no. of HMIs with 22” colour monitor, keyboard and
mouse
Panel view type 10” display units in various control rooms
for operator’s ease
Hot redundant server with Raid 1 configuration and 22”
monitor
1 no. large video display unit (55”) for mimic display and
other process values

PROJECT DESCRIPTION
1 no. of engineering station with 22” color monitor,
keyboard and mouse
2 no. A3/A4 size black & white laser jet printer
1 no. A3 color printer
SCADA software
Laptop based Programming tool 1 no
Application software& System software along with OPC
server software
2) Level 2 servers fault tolerant grade (Intel Xeon processor) 1 lot
in hot redundant configuration with 22” colour monitor,
keyboard and mouse – 2 nos.
Gateway with firewall for up-linking with Level 3 system of
plant
System software and application software for
mathematical model and MIS functions
3) Field Instruments 1 lot
i) Pressure, flow & DP transmitters
ii) Thermocouples and RTDs
iii) Flow elements
iv) Pressure/ temperature gauges and switches
v) Line scan pyrometers 2 nos. for top and bottom
view
vi) Spot pyrometers 2 nos.

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[Link]. Description Quantity

vii) Portable type radiation pyrometers – 2 nos.
viii) Plate length measurement system with two laser
sensors
ix) Plate thickness measurement system based on laser
triangulation system
x) Plate detectors at various locations
xi) Bar code readers at entry table
xii) Centring devices at entry table
xiii) Flue Gas Analyzer
xiv) CV analyzer
xv) Oxygen analyzer to monitor furnace atmosphere
xvi) Furnace camera system with 24”display in control
room
4) Pneumatic control valves for zone-wise gas and air-flow 1 lot
PROJECT DESCRIPTION

control and furnace pressure control

5) Flame safeguard control system inclusive of control block, 1 lot
flame scanners, zone temperature relay, solenoid valves,
ignitors, On/ Off devices, etc. for each zone
6) Hazardous Gas detection system comprising of 8 fixed 1 lot
detectors and 10 portable detectors
7) Fire Detection & Alarm System for areas as listed 1 lot
8) Closed Circuit Television (CCTV) System for entire plant 1 lot
and furnace along with one 55” display
9) Voice communication system 1 lot
i) PA system for 8 points
ii) VHF wireless communication system for 1 no desk
top and 6 nos. hand sets
iii) Telephone system for 10 points including cabling
and telephone sets
10) UPS in hot parallel redundant configuration with 1 lot
individual battery bank comprising of SMF batteries for 30
minutes backup
11) Panels, local cabinets, Junction boxes, etc. 1 lot
12) Cables, pipes, switches, fuses and other erection 1 lot
hardware, etc

4.10 STRUCTURAL WORK

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4.10.1 The structural steelworks envisaged for the proposed normalizing facilities will
include design, engineering, supply, fabrication, erection, painting, testing and
commissioning of structural steel works for:
1) Self-supported chimney, access ladder, platforms, etc., including stair case
access to sampling point location in chimney as per technological
requirement
2) Brackets from existing side & gable columns to support new utility pipe
lines as per technological requirement. No walk way has been considered.
3) Cross-over above roller table as per technological requirement.
4) Trestles for compensators support and U seal support including access
ladder and platforms for the same as per technological requirement.
4.10.2 Design Considerations
1) All steel structures will be designed with due consideration to the existing
plant and facilities.
2) Apart from technological loads to be supported on steel structures, self-

PROJECT DESCRIPTION
weight and superimposed loads for the design will be according to IS
875:1987. Structures will be designed either for wind or seismic forces as
applicable. Due allowance for impact, vibration & temperature loads will
be kept.
3) Design of steel structures will be as per IS 800:1984.
4) Design of chimney will be as per IS 6533:1989.
4.10.3 Specifications
1) Structural steel conforming to IS 2062: 2011.
2) All steel structures will be of welded construction. The welding procedure
will conform to IS 816:1969 and IS 9595:1996. Electrodes will conform to IS
814: 2004. Fabrication and erection of steel structures will be as per IS 800:
1984.
3) All building structures will be given two coats of single pack air drying
phenolic modified alkyd composition with zinc phosphate as primer coat
having minimum dry film thickness of 80 microns (40 microns/ coat). One
coat of primer will be applied before erection and one coat after erection.
4) Final paint will be done with two coats of single pack air drying high gloss
phenolic alkyd modified synthetic enamel paint suitably pigmented to
achieve even shade and a minimum dry film thickness of 50 microns (25
microns/ coat).
5) Chimney Painting
Inner surface of the chimney up to 3m height from base will be given two
coats of (DFT/ coat=40 microns) a single pack air drying phenolic modified
alkyd composition with zinc phosphate as a primer and three coats of
(DFT/ coat=40 microns) a heavy duty single pack air drying anti-corrosive
black bituminous paint as finishing coat. Rest of the height of the chimney
at the inner side will be given one coat of two pack heavy duty zinc dust

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rich silicate (DFT/ coat = 60 micron) as primer paint and three coats of a
single pack heat resistant silicon resin based paint with leafing aluminium/
graphite powders as finishing coat (DFT/ coat=20 micron).Top two courses
of the chimney at the outer side will be given two coats (DFT/ coat=40
microns) of a two pack air drying epoxy polyamide resin based red oxide
zinc phosphate as primer, one intermediate coat of a single pack high
build phenolic based paint with micacious iron oxide (DFT/ coat =75
micron) and two coats (DFT/ coat=40 microns) of a two pack air drying
epoxy polyamide enamel suitably pigmented as finishing coat. Rest of the
outer surface of the chimney will be painted as per specification
mentioned for general building structures. Intermediate/ finishing paint
will be applied only after completion of erection.
4.11 CIVIL
4.11.1 The broad scope of civil works for normalizing facilities will comprise:
1) Dismantling of the RCC floor in the location of the new facilities for
PROJECT DESCRIPTION

normalizing furnace and other auxiliary facilities.

2) Construction of foundation for the following
i) Roller table for loading
ii) Shot blasting machine entry roller table
iii) Shot blasting machine
iv) Shot blasting machine delivery roller table
v) Plate centering system for charging roller table
vi) Normalizing roller hearth furnace
vii) Normalizing furnace delivery roller table
viii) Plate leveller entry roller table
ix) Leveller
x) Plate leveller delivery roller table
xi) Cooling bed entry roller table
xii) Cooling bed
3) The pit of the normalizing furnace and the scale channel will be made
water proof by pressure grouting.
4) Construction of rooms for entry side and exit side electrical buildings
housing the transformers, panels, UPS, control room, cable trenches with
chequered plates and other facilities. The flooring and finishing will be
done as per the technological requirement.
5) Foundation for compensator trestle supports and any other supports for
taking the gas line from the tapping point to the furnace. Making
foundation for U-Seal supports and U-seal pits.
6) Foundation for structural steel chimney.
7) Construction of RCC flume tunnel.
8) Making good the dismantled flooring and restoring the same as per the
original design.

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4.11.2 Design Considerations

1) All RCC designs will be done conforming to IS: 456-2000. All RCC water
retaining structures will be designed as per IS: 3370 (Part-II) – 2009 and IS:
3370 (Part-IV) – 1967
2) The loadings will be taken as per the loads provided by the equipment
supplier and IS: 875 (Part-I & II) – 1987
3) Soil Condition: The allowable soil bearing capacity of the soil has been
considered same as that of the new plate mill
4.11.3 Specifications of Civil Work
1) All RCC works including building, equipment structures and foundations
etc will be of concrete grade M25C conforming to IS: 456-2000. Jigs,
fixtures will be used to fix all anchor bolts, inserts, etc., wherever required.
2) The design will be based on latest IS codes/ British codes/ N.B.O
3) Major activities relating to civil engineering work will include site clearance,
excavation, dismantling, plain & reinforced concrete work. Following

PROJECT DESCRIPTION
guidelines have been envisaged for the material of construction for civil
engineering works:
R.C.C M-25C
P.C.C M 10 B
Brick work in C.M 1:6
Cement plaster for walls 1:6
Cement plaster for ceiling 1:4
Anchor pocket grouting M-30 D or anti-shrinkage compound
Painting of doors & windows synthetic enamel paint
Outside finish for buildings anti-algal weather proof exterior
Inside finish for buildings whitewash/ colourwash
Flooring RCC M-15C/ PCC (as per design)
Floor finish IPS
4.12 MANPOWER REQUIREMENT
4.12.1 The proposed normalizing facility is envisaged to work in 3 shifts for 6 days in a
week. The estimated manpower requirement for the proposed normalizing
facilities is around 56. The break-up is mentioned below:
Non-executives
Skilled 32(to be out sourced)
Unskilled 24 (to be out sourced)

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Total 56
The estimates exclude executives and administrative manpower which will be
resourced from new Plate Mill.
4.13 TRAINING
4.13.1 Training for acquaintance with the equipment/ facilities of the proposed
normalizing facilities for operation and maintenance has been considered. It is
envisaged to provide foreign training for total 10 persons covering different
disciplines including design & engineering, each for 6 days totalling to ~60
man-days.
4.13.2 It is also proposed to provide classroom and on the job training at site for
operation & maintenance personnel, for equipment, electrical & automation
system, etc., of the normalizing facilities. It is envisaged to provide 60 man-days
on the site training for this purpose.
4.14 RISK ASSESSMENT
4.14.1 Risk assessment for the project is attached at Annexure- 4.14.1-1
PROJECT DESCRIPTION

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE
5.1.1 The project is envisaged to be implemented within a period of 24 months from
the date of Stage-II approval. Pre-ordering activities are envisaged to be
completed within 6 months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1 & Annexure – 5.1.2-2
respectively.
5.2 IMPLEMENTATION STRATEGY
5.2.1 The project is proposed to be executed through single package on turnkey
basis.
5.2.2 All preparatory site activities will be carried out without hampering the normal
operation of the new plate mill.
5.2.3 The connection between the deliveries of the proposed cooling bed with

PROJECT IMPLEMENTATION
existing shearing line will be carried out during annual capital repairs of the mill.
5.2.4 The interface/ integration activities like sourcing power & utilities at battery
limits will be carried out during weekly shutdowns/ annual capital repairs.
5.2.5 Diversion of any known over ground or underground facilities that need
diversion, etc. for execution of the project is not envisaged as the area is already
earmarked for normalising facilities.
5.2.6 RSP will facilitate the existing EOT cranes of GH bay during project execution to
the extent possible.
5.2.4 Statutory Clearance
RSP will take all the required statutory clearances (environment, pollution,
power, right to establish, right to operate, etc.) from the concerned government
agencies prior to processing for obtaining stage-II approval. Specialist agency
will be engaged by RSP to conduct Environmental Impact Assessment (EIA)
studies and prepare Environmental Management Plan (EMP). This EIA & EMP
report will address all the elements proposed under the latest guidelines. Based
on this, required clearances from State and Central Regulatory Authorities will
be obtained.
5.3 DETAILS OF PRE-SHUTDOWN ACTIVITIES WITH DURATION
Installation of Normalising facilities was already planned in the New Plate Mill
and hence, separate space is earmarked for it in GH bay of New Plate Mill. All
preparatory site activities will be carried out separately without hampering the
normal operation of the new plate mill. The interface/ integration activities like
sourcing power & utilities at battery limits will be carried out during weekly
shutdowns/ annual capital repairs.
5.4 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION
Due to the reasons mentioned in 5.3 no separate shut down is envisaged.

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6. CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:
6.1.1 The capital cost of the Project is estimated at Rs.295.56 Crore (net of Input Tax
Credit of Rs.44.90 Crore) on base date of 1st Quarter, 2020, including IDC of
Rs.23.75 Crore, FE component of Rs.129.83 Crore which includes increase in FE
component of Rs.8.01 Crore due to Forward Premium. FE parity has been
considered as 1 Euro=INR 84.86 and 1 USD=Rs.76.92 including forward
premium of Rs.5.27 and Rs.4.74 respectively for a period of 30 months. The
summary capital cost estimate is appended at Annexure-6.1.1-1.
6.1.2 The Capital Cost estimate has been prepared considering budgetary quotation,
engineering estimates and available data. The base date for the estimate is 1 st
Quarter of 2020.
6.1.3 Necessary provisions have been made in the estimates as per the details given
below:
1) For indigenous items:

i) GST @18% on basic cost of equipment, erection and E&C

(Contractor’s) and @ 18% on freight and insurance has also been
considered.

2) For imported components:

i) Ocean freight & insurance: @7% on FOB cost;

ii) CD @ 7.5% on (CIF);
iii) GST @ 18% on (CIF+CD);
iv) Income Tax @ 10% to be grossed up for value of Design &
Engineering and foreign services;

6.1.4 Freight & Insurance charges @ 2% of basic cost of indigenous equipment.

Inland freight & Insurance charges for imported item has been taken @3%.
6.1.5 Erection & commissioning charges have been taken @ 6% on CIF cost of
imported equipment and 12%on indigenous equipment.
6.1.6 Engineering & Construction (E&C): E&C (Contractor) @ 7.5% and E&C (Owner)
@ 2.5 % on basic cost of equipment and erection & commissioning charges
have been considered.
6.1.7 Contingencies: @ 5 % on overall basis has been considered.

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6.2 MODE OF FINANCING:

The total capital requirement of the project is proposed to be provided from
100% debt with an interest @ 10% per annum.
6.3 PHASING OF CAPITAL EXPENDITURE:
With the project duration of 24 months from the date of Stage – II approval, the
phasing of capital expenditure is proposed as indicated below:

Rs. Crore

Year Plant cost Equity Loan IDC Total incl.

IDC

1st year 95.01 95.01 4.75 99.76

2nd year 190.02 190.02 19.00 209.03

Post Comm. 31.67 31.67 31.67

Capital cost 316.71 316.71 23.75 340.46

Input tax credit (ITC) on GST 44.90

Capital cost net of ITC on GST 295.56

CAPITAL COST & FINANCIAL ANALYSIS

6.4 INTEREST DURING CONSTRUCTION (IDC):

Based on the mode of financing and phasing of capital expenditures indicated
above, total IDC has been worked out to Rs.23.75 Crore.
6.5 COST-BENEFIT ANALYSIS:

6.5.1 The proposed project envisages an annual production of normalized plates @

3,00,000tpa. For techno economic purpose the contribution of normalized
plates has been considered. Comparing the above with credit of plate the total
revenue works out to be Rs.64.35 crore. After accounting for the expenditure in
the normalizing process the gross margin works out be Rs.56.27 crore. Details
are enclosed at Annexure-6.5.1-1.

6.6 FINANCIAL ANALYSIS

6.6.1 Financial analysis has been carried out on the basis of cash flow during 22 years.
Life of the project is considered 20 years after its commissioning.

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6.6.2 Techno-economic indices are furnished at Annexure-6.6.2-1. Some of the

important parameters are indicated below:
 IRR (Post Tax) 13.77%,
 NPV@10% (Post Tax) Rs.68.81 crore.

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7. RECOMMENDATIONS
7.1 For attaining the market share and saleability of heavy & wide plates,
installation of normalizing facility in the new Plate Mill of RSP is required. The
project proposal for normalizing facility is technically feasible and financially
viable. Hence recommended for implementation.

RECOMMENDATIONS

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402
 ANNEXURE-2.6-1
COPY OF LETTER OF ASSIGNMENT

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 ANNEXURE-2.6-2
COPY OF LETTER OF ACCEPTANCE OF ASSIGNMENT

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ANNEXURE – 4.14.1-1

RISK ASSESSMENT REGISTER

Sl Issues Risk Probabili Consequ Rpn Current Addln. Respon Implemen Revised Revised Revis
no. ty ence controls actions sibility tation ed
(DxE Probability Conseq
(H/M/L) (H/M/L) ) date uence rpn
(H/M/L)
(H/M/L) (KxL)

A B C D E F G H I J K L M

1 Availability Delay in L (1) M (2) 2 Timely Planned RSP

of Shut- project completion of Shut-down
down completion shut down
(Capital activities
Repair)

2 Environmen Delay in L (1) M (2) 2 Timely RSP

tal clearance planning for
clearance environment
al clearance

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 ANNEXURE – 5.1.2-1

PROJECT IMPLEMENTATION SCHEDULE

(POST STAGE-I APPROVAL ACTIVITY)

Sl. No. Activity Duration in Months

1 2 3 4 5 6

1. Stage I approval of the project

2. Issue of Tender & Receipt of

Offers
3. Evaluation of offers and
submission of TER
4. Opening of Price Bids/ RA, Price
Bid Evaluation
5. Stage II approval

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ANNEXURE – 5.1.2-2
PROJECT IMPLEMENTATION SCHEDULE
(POST STAGE-II APPROVAL ACTIVITY)
Sl. Activity Duration in Months
No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1. Stage-II approval

2. Placement of order &

contract signing

3. Preparation, submission and

approval of BE drawings

4. Preparation, submission and

approval of DE drawings
5. Manufacture & supply of
equipment

6. Civil, structural works

7. Erection/Installation of
equipment
8. Testing & commissioning

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ANNEXURE – 6.1.1-1

ANNEXURE 6.1.1-1
S T E E L A U T H O R I T Y OF I N D I A L I M I T E D Base date: 1st Qtr 2020
Rourkela Steel Plant Figures in Rs. Crore
Installation of normalizing facilities in new Plate Mill

**CAPITAL COST ESTIMATE**SUMMARY

1 USD (With forward premium rate)= 76.92 CD IT GST (Supply & services) Contingn E&C
1 EURO (With forward premium rate)= 84.86 7.5% 11.11% 18% 5% 10%
EQUIPMENT SPARES STRUCTURALS REFRACTORIES CIVIL ERECTION ENGG & CONSTN FRT. & INSURANCE DUTIES & TAXES OTHERS CONTINGENCY CAPITAL COST
[Link] SHOP/FACILITY/PACKAGE Total Incl. Total Incl. Total Incl. Total Incl. Total Total Total Incl. Total Incl. Total Incl. Total Incl. Total Incl. Total Incl.
Cost FC Cost FC Cost FC Cost FC Cost Cost Cost FC Cost FC Cost FC Cost FC Cost FC Cost FC
a b c d e FC g h I j k l m n o p q r s t u v w x
1 Installation of normalizing 183.03 105.12 7.59 5.26 0.66 0.27 3.71 16.44 21.15 5.29 12.96 7.73 55.56 0.25 0.25 15.08 6.18 316.71 129.83
facilities in new Plate Mill
2 Total Plant cost 316.71
3 IDC 23.75
4 CAPITAL COST 340.46 129.83
5 Input tax credit (ITC) 44.90
6 Capital Cost net of ITC 295.56 129.83

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ANNEXURE – 6.5.1-1
ANNEXURE - 6.5.1-1
S T E E L A U T H O R I T Y OF I N D I A L I M I T E D
Rourkela Steel Plant
Installation of normalizing facilities in new Plate Mill
GROSS MARGIN CALCULATIONS
I. TECHNICAL PARAMETERS:
1 Annual production of Normalised Plates t/year 300,000
2 Annual production of Plate t/year 300,000
3 NSR of as rolled normalized plates (NR) 2019-20 Rs./t 37609
4 Envisaged NSR of normalized plates (As per CMO data) Rs./t 40059
5 Present variable cost of as rolled normalized plates (NR) Rs./t 27036
6 Variable cost of black plates for normalizing Rs./t 26508
7 Additional cost for narmalisation Rs./t 834
8 Contribution of Normalised Plates (4-6-7) Rs./t 12717
9 Credit for Plate (3-5) Rs./t 10573
SL. NO. DESCRIPTION UNIT QTY RATE AMOUNT
(Rs./Unit) (Rs. Crore)
II. Benefits
1 Contribution of Normalised Plates t 300,000 12,717 381.52
2 Credit for Plate t 300,000 10,573 -317.18

Sub-Total (Revenue) 64.35

III. Expenditure on normalising process

1 Manpower 0.68
2 Repair & Maintenance 7.39
Total Expenditure 8.07
IV. GROSS MARGIN (II-III) 56.27
Additional cost for narmalisation
Sl. No. Item Unit Qty Rate Total (Rs. Crore)
1 Make up Water m3/t 0.05 10.19 0.02
2 Fuel(Mixed gas) Gcal/t 0.42 1,439.00 18.13
3 Power kWh/t 33.00 6.53 6.47
4 Nitrogen Nm3/t 10.00 1.22 0.37
5 Compressed air Nm3/t 2.00 0.42 0.03
6 Total Cost (Rs. Crore) 25.01
7 Per ton additional cost (Rs./T) 833.59

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ANNEXURE – 6.6.2-1

Annexure 6.6.2-1

S T E E L A U T H O R I T Y OF I N D I A L I M I T E D
DURGAPUR STEEL PLANT
Installation of normalizing facilities in new Plate Mill
FINANCIAL ANALYSIS

Sl. No. Description Unit Value

1 Capital Cost (Net of Cenvat) Rs crore 295.56

2 Gross Margin Rs crore 56.27

3 NPV @ 10% discount rate (Post-tax) [Link] 68.81

4 IRR (Post-Tax) % 13.77%

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415
 Feasibility Report
Installation of New Oxygen Plant
At RSP

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

JULY 2020 CET/05/RN/4390/FR/UT/01/R=0

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 Experience that delivers

This document has been prepared for RSP by:

Centre for Engineering & Technology

[Link], GM &I/c (U&S) – HOD Lead section
ANAND TRIVEDI, DGM (U&S) (Task Force Leader)
MANISH KUMAR, GM (U&S)
RAVINDRA KUMAR VERMA, DGM (PFC)
AKSHYA PANDYA, SM(ELECTRICAL)
SUBIR DAS, GM(C&C)
KAMAL REDDY JAMBULA, AGM(PC&A)
[Link], AGM(RSC)
[Link] RANGA RAO, MANAGER(STRUCTURAL)
MANOJ KUMAR SINGH, DGM (CIVIL)
RAJIB BANERJEE, AGM(I&S)
GARISH KUMAR, AGM(CTE)
SATYENDRA KUMAR GUPTA, MANAGER(STEEL)

Document Identification No. CET/05/RN/4390/FR/UT/01/R=0

REVISION HISTORY

Revision No. Brief Description Revision Date

R3

R2

R1

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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 Experience that delivers

UPSHOT
To cater to the present deficits of oxygen for production of 4.65Mtpa of hot metal and 4.2 Mtpa of
crude steel, a new 1000 tpd oxygen plant on "Lease and O&M basis" has been proposed. This
project will be commissioned in 30 months from the date of stage II approval. The estimated cost
for installation of plant will be borne by O&M operator.

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.2

2 Background 2.1-2.9

3 Selection of Alternatives 3.1-3.3

4 Project Description 4.1-4.2

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1

7 Recommendations 7.1

Annexures

Drawings

ROURKELA STEEL PLANT

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ANNEXURES

AnnexureNo. Description No. of pages

2.13-1 Client Letter 1

2.14-1 Acceptance Letter from CET 1

4.1.3-1 Location of Rourkela 1

4.3.1-1 Risk Assessment Register 1

5.1.2-1 Schedule of Pre-ordering Activities 1

5.1.2-2 Schedule of Post-ordering Activities 1

6.3.2-1 Sensitivity Analysis 1

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DRAWINGS

S. No. Drawing No. Description

1 CET RN 4390 UT2 00 001, R=0 Location of Proposed Oxygen Plant

ROURKELA STEEL PLANT

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1. SUMMARY
1.1 Rourkela Steel Plant (RSP) fulfils its Oxygen, Nitrogen & Argon

SUMMARY
requirement with the help of both captive generation as well as purchase
from Built Own &Operate (BOO) Oxygen Plant. The existing installed
captive oxygen generation capacity is 1060tpd whereas installed capacity
of BOO oxygen plant is 2x700tpd.
1.2 RSP produced 3.84 Mtpa of hot metal and 3.66 Mtpa of crude steel in
2018-19. Corresponding oxygen requirement of approx. 2138 tpd was met
by operation of ASU-I & ASU-III at TOP-II and two units of BOO plant.
1.3 The present expansion plan envisages 4.65 Mtpa of hot metal production
and 4.53 Mtpa of crude steel production. To meet oxygen requirement for
envisaged production, existing oxygen generation capability needs to be
expanded. Further, existing 2x180 tpd captive units are energy intensive.
Hence after shutting down / keeping them in standby mode these 2x 180
tpd units, the oxygen deficit is approx. 923 tpd for 4.2 Mtpa crude steel &
1050 tpd for 4.53 Mtpa crude steel.
1.4 A new oxygen plant of 1000 tpd capacity is planned to meet 4.65 Mtpa of
hot metal and 4.53 Mtpa of crude steel production. The new oxygen plant
will take care of the deficit of oxygen as well as the requirement during
capital repair /shut down activities of the existing units.
1.5 The new 1000 tpd oxygen plant is also proposed to be outsourced in line
with BOO plant. Due to restrictions in captive power supply to outsourced
unit in Odisha, the new plant is proposed to be installed on “Lease and
O&M (LOM) basis”.
1.6 The power supply arrangement to proposed 1000 tpd Oxygen Plant is
being done through separate assignment “Power enabling package for
additional oxygen/nitrogen gas for steel production” (Assignment No.:
05/DE/4622).
1.7 IMPLEMENTATION
1.7.1 Implementation of the project is proposed to be carried out through
different packages as detailed below-
1) Main package for Installation of 1000 tpd on LOM basis
2) Site survey & soil investigation
3) Power supply enabling package

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1.7.2 The implementation schedules of different packages are as follows-

S. Package Implementation Schedule

No.
SUMMARY

Pre-ordering Post ordering

activities activities

1 Main Turnkey Package for 6 Months 30 Months

Installation of 1000 tpd on
LOM basis

2 Site survey & soil 3 Months 3 Months

investigation

3 Power supply enabling 5 Months 18 Months

package

1.8 COST ESTIMATES

1.8.1 The block cost for main package is approx. Rs 425 crore. The cost will be
incurred by LOM supplier.
1.8.2 The cost of power supply enabling package is estimated as Rs 37.85crore
net of input tax credit of Rs. 4.52crore including IDC of Rs 2.68 crore.
1.9 RECOMMENDATION
1.10 The project is technically feasible & required to cater the present deficits
of oxygen for production of 4.65 Mtpa of hot metal and 4.53 Mtpa of
crude steel and hence recommended for implementation.

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2. BACKGROUND
2.1 EXISTING GENERATION CAPABILITY
2.1.1 The existing captive oxygen generation capacity of RSP is 1060 tpd whereas
installed capacity of BOO Oxygen plant is 2x700 tpd.

BACKGROUND
2.1.2 For captive oxygen, RSP had two Tonnage Oxygen Plants (TOPs) namely TOP–I
and TOP–II. The facilities for oxygen generation in TOP-I have been written off.
At present, only TOP-II is used for oxygen generation.
2.1.3 TOP-II is having three Air Separation Units (ASUs) of different capacities. Two
ASUs are of 180 tpd each and third ASU is of 700 tpd. 2x180 tpd units were
installed in the year 1992/94 whereas third unit of 700 tpd was installed in the
year 2010-11.
2.1.4 To meet modernisation & expansion requirement of RSP, one 2 x 700 tpd BOO
oxygen plant was installed and commissioned in 2014. Old units of TOP-II are
currently operating at 170 tpd. Hence, the present total capacity of captive and
BOO oxygen plants taken together comes to 2440 tpd.
2.2 CURRENT OXYGEN BALANCE
2.2.1 Oxygen balance for last three years is given below:
2.2.2 Oxygen Generation:
PRODUCTION (x1000 tpa) Total
Year
CAPTIVE Generation
BOO LOX EVA * TOTAL
GENERATION in tpd**
2018-19 263.7 491.8 4.4 759.9 2172
2017-18 208.2 480.7 3.8 692.7 1980
2016-17 198.7 434.5 8.2 641.4 1833
* LOX EVA = Liquid Oxygen Evaporation
**Considering 350 days of operation for conversion from tpa to tpd

2.2.3 Oxygen Consumption:

CONSUMPTION (x1000 tpa) Total
Year SMS & Loss & Consumption
BF Others TOTAL
CCM Vent in tpd*
2018-19 341.1 294.03 18.9 94.1 748.1 2138
2017-18 297.8 302.7 19.4 72.8 692.7 1980
2016-17 268.3 303.3 20.3 49.5 641.4 1833
*Considering 350 days of operation for conversion from tpa to tpd.

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2.3 PRESENT CONSTRAINTS

2.3.1 The ASU-I & II of TOP-II is in operation since last 27 years and their actual
production capacity has been reduced to 170 tpd. Specific power of these units
is more than 1 kWh/Nm3 of oxygen gas as compared to 0.75 kWh/Nm3 of
oxygen gas achieved in the present 700 tpd captive unit.
BACKGROUND

2.3.2 RSP was also planning to enhance its crude steel production capacity from
current level of 3.5Mtpato 4.2Mtpa.
2.4 In view of above RSP requested CET vide their letter no. AMR-
M&SC/Consultancy/15/193-96 dtd 24.2.2015 to study the oxygen/ nitrogen
balance and accordingly finalize the additional capacity of the plant, if required.
CET studied the oxygen and nitrogen requirements of RSP and submitted their
recommendations for installation of 700 tpd oxygen plant on BOO basis in their
Approach Note vide CET/05/RN/4081/ AN/UT/01/R=0 in September 2015.
2.5 RSP further requested CET vide their letter ref. no. OP/617/70/69/1108 dated
25.08.2017 for preparation of Draft Investment Proposal (DIP). CET issued DIP
for 700 tpd oxygen plant on 24.11.2017.
2.6 The proposed capacity was revised to 750 tpd after inclusion of additional
facilities for enhancement of steel production and revised DIP was issued to RSP
on 04.10.2018.
2.7 RSP further informed vide mail dated 24.10.2018 to include additional 100 tpd
for Sinter Plant. Based on that, oxygen plant capacity was revised to 900 tpd and
revised DIP was issued to RSP on 11.12.2018.
2.8 Subsequent to this, Committee of Directors (COD) meeting was held on
27.02.2019. The COD advised to submit revised proposal for higher capacity
oxygen plant.
2.9 RSP further requested CET for preparing reports on revised capacity of oxygen
plant vide Letter No. AMR-M & SC/Consultancy/18/3193 dated 29.03.2019
along with approved note sheet ref. no. Utilities/617/70/153 dated
[Link] note sheet mentioned that RSP has already initiated action for
bidder‟s conference for Installation of Oxygen Plant on “Lease and O&M basis”.
However earlier documents were provided based on BOO basis which has
limitation of power supply since RSP has no license for power supply to third
party.
2.10 RSP invited Expression of Interest (EOI) for 1200 tpd oxygen plant on Lease and
O&M basis vide ref. letter no. P/Proj/EOI/Oxygen Plant/22 dated 06.04.2019. EOI
were received from following four firms-
1) M/s Inox Air Products Pvt. Ltd., Mumbai
2) M/s Linde India Limited, Kolkata

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3) M/s Praxair India Pvt. Ltd., Bangalore

4) M/s Yingde Gases Group Company Limited, China
2.11 RSP requested CET to revise DIP considering Lease and O&M (LOM) basis and
further study oxygen balance for proposed plant‟s capacity. Based on that,

BACKGROUND
oxygen plant capacity was revised to 1000 tpd considering oxygen enrichment
for three BF operation and revised DIP was issued to RSP on 13.09.2019.
2.12 REQUIREMENT OF OXYGEN, NITROGEN & ARGON
2.12.1 RSP has following three scenarios for hot metal production-
i) 4.65 Mtpa with three BF operation (BF1, BF4 & BF5)
ii) 4.5 Mtpa with three BF operation (BF1, BF4 & BF5)
iii) 4.5 Mtpa with two BF operation (BF1 & BF5)
2.12.2 Oxygen requirement for hot metal production in all three scenarios are as
follows-

Scenario 4.65 Mtpa with 4.5 Mtpa with 4.5 Mtpa with two
three BF three BF BF operations
operations (BF1, operations (BF1, (BF1 & BF5)
BF4 & BF5) BF4 & BF5)

Oxygen BF1 & BF4 : 4% BF1 : 4% BF1: 5%

Enrichment BF5 : 6% BF4 : 3% BF5 : 8%
BF5 : 6%

BF1 requirement 251 tpd 251 tpd 358 tpd

BF4 requirement 214 tpd 135 tpd 0

BF5 requirement 953 tpd 945 tpd 1346 tpd

Miscellaneous cast 69 tpd 66 tpd

72 tpd
house requirement

Total Oxygen 1490 tpd 1400 tpd 1770 tpd

Requirement in
BFs

2.12.3 For sizing of proposed Oxygen Plant, 4.65 Mtpa with three BF operations (BF1,
BF4 & BF5) with 1490 tpd Oxygen Requirement has been considered.

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2.12.4 Oxygen Balance for 4.65Mtpa Hot Metal, 4.2Mtpa Crude steel :
CONSUMPTION
Blast Furnaces (4.65 MT Hot Metal) with 3 BF operations
Unit wise Oxygen Shop wise Oxygen
Units
BACKGROUND

Requirement (tpd) Requirement (tpd)

BF-1, BF4 & BF5 1490

SMS (4.2 Crude Steel)
BOF 1040
CCD/Scarfing 150 1215
RHOB (existing) 25
Sinter Plant (proposed)
100
(Oxygen enrichment in post ignition hood air)

Miscellaneous (General purpose, scrap cutting in Rolling

100
Mills, New PM, LRS, BF Aux, SMS Services etc.)

Sub Total(Overall) 2905

Losses @ 2% 58
2963
GENERATION
Oxygen Generation
Units
(tpd)
ASU-I 170
ASU II 170
ASU III( Gas production in mixed mode) 640
BOO Plant 1400
Generation considering all units in operation 2380
Deficit considering all ASU under operation 563 tpd
Deficit with both existing 180 tpd under shut 923 tpd
down/standby Say 1000 tpd
Following considerations have been made while making above balance:
1) Specific oxygen consumption for BOF, CCD/Scarfing & RHOB in SMS has
been taken as 57 Nm3/t, 8 Nm3/t &1.33 Nm3/t respectively considering the
present situation with 330 working days.
2) Line losses at the rate of 2% of total consumption have been considered
for oxygen.

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3) The Hot Metal production will be 4.65Mtpa and total crude steel produced
will be 4.2Mtpa (0.4 Mtpa from SMS-Iand 3.8 Mtpa from SMS-II )
2.12.5 Nitrogen Balance for 4.65Mtpa Hot Metal, 4.2Mtpa Crude steel :
RSP has high (18 and 30 kg/cm2 (g)) & low pressure network (3000 mmWC) in

BACKGROUND
the plant.
[Link] High and Medium Pressure Nitrogen Balance
As per nitrogen balance for planned production of 4.65Mtpa of Hot Metal(with
3 BF operation) and 4.2 Mtpa of Crude Steel, the total short fall of high &
medium pressure nitrogen is as shown below:
CONSUMPTION
Units Pressure Continuous Intermittent Remarks
requirement 3
Nm /h 3
Nm /h
Coke Ovens
CDCP Medium 4000 6000 For CDCP of
Pressure Battery no.
6&7
CCD &Sulphuric Acid -do- 1000
Plant
Sinter Plant-III
-do- 150
Sub total 5150
Blast Furnaces
BF-1
CDI/ BLT /TRT(Future)/ Medium
4845 6289
Instrumentation & Pressure
Miscellaneous
BF-4
CDI/ BLT /
-do- 4470 6289
Instrumentation &
Miscellaneous
BF-5
CDI/ BLT/TRT/
-do- 6895 9155
Instrumentation &
Miscellaneous
With 0.8 diversity factor on
Sub total 33597
intermittent requirement
SMS
SMS I & II High 17300

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CONSUMPTION
Units Pressure Continuous Intermittent Remarks
requirement Nm /h3 3
Nm /h
Pressure
BACKGROUND

LHF & RHOB -do- 200

Medium
Caster III & IV Pressure 1000
BOF-III -do- 300
Ladle Furnaces -do- 50
BOF I & II -do- 2500
SMS-I hood -do- 3000
Sub Total 24350
Propane Plant/CPP-
I/CCD (Coal chemical
dept.) 500
Power & Blowing Medium
Station Pressure 500
New Plate Mill -do- 300
COB-7 -do- 3500
Sub total 4800
Total 67897
Additional safety
requirement of
Nitrogen in CDI,CDCP
@15% of total 10185
Total consumption 78082
GENERATION
BHEL Comp 6000
ASU-I & ASU II* 20000
ASU III 15000
BOO Plant 20000
Grand Total 61000
DEFICIT -17082
Say 20000
Nm3/h**
*Only pressure boosting is being done through own compressors. LP Nitrogen
is taken from existing BOO Plant.

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Actual Nitrogen consumption in CDI & CDCP is presently much more than their
design norms due to frequent usage of nitrogen in controlling oxygen
percentage in circulating gas.
**Capacity considering maintenance of existing compressors.

BACKGROUND
[Link] Low Pressure Nitrogen Balance
Low pressure Nitrogen available at 3000 mm WC across the plant satisfies the
purging needs and process requirement of rolling mills. The requirement of
nitrogen for low pressure is as follows:
Low Pressure Nitrogen Balance
CONSUMPTION
Consumers Flow Rate Remarks
3
(Nm /hr)
Average
CRM 4000 Cont.
Silicon Steel Mill 2000 Cont.
Hardening Furnace in SPP 750 To provide inert atmosphere
New Plate Mill 1000 To provide inert atmosphere
Misc. (Coal Chemical, HSM, PM etc.) 4000 Intermittent purging requirement
Blast Furnace 5 8000 PCI
SP-III 2000 Intermittent purging requirement
New CCD 250
Total consumption in low pressure 22000
grid
Low pressure nitrogen to TOP I for 6000
further compression
Net Consumption 28000
GENERATION
Nitrogen blower at ASU III 12000
Total capacity for generation 12000
Deficit 16000
Say 20000
Nm3/h

Hence, Nitrogen blower and compressor with standby each of 20000 Nm 3/h
needs to be considered to take care of the requirement up to 4.2 MT stage.
2.12.6 Argon
Argon to the tune of 400 Nm3/h will be provided at 30 bar.

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2.12.7 Oxygen Balance with SMS-III in place of existing SMS-I

[Link] RSP is also exploring the possibility of installation of SMS-III and shutting down
SMS-I. With new SMS-III, the hot metal production will rise to 4.53 Mtpa. The
comparative oxygen balance for 4.2 Mtpa hot metal production with existing
SMS-I and 4.53 Mtpa with new SMS-III is as follows-
BACKGROUND

4.2 Mtpa Crude Steel 4.53 Mtpa Crude Steel

CONSUMPTION
(With existing SMS-I) (With proposed SMS-III)
Units Oxygen Requirement (tpd)
Blast Furnaces 1490 1490
SMS 1215 1340
Sinter Plant(proposed) 100 100
Miscellaneous 100 100
Sub Total(Overall) 2905 3030
Losses @ 2% 58 60
Gross Consumption 2963 3090
GENERATION
Units Oxygen Generation (tpd)
ASU-I & II (2 x 170) 340
ASU III( Gas production in
640
mixed mode)
BOO Plant 1400
Generation considering all
2380
units in operation
DEFICIT
Deficit considering all ASU
583 tpd 710 tpd
under operation
Deficit both existing 170
tpd under shut 923 tpd 1050 tpd
down/standby

[Link] Since the requirement of oxygen also depends on factors such as level of
oxygen enrichment etc., many times the demand is below envisaged level. With
outsourced oxygen generation facility, RSP will be forced to buy minimum
quantity. Also proposal of SMS-III is in study stage. Hence it is recommended to
install 1000 tpd Oxygen Plant only considering 5% divergence factor to meet
4.53 tpd CS production level also. In case there is additional requirement of
oxygen, same can be met by running one captive ASU of 170 tpd.

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[Link] SMS III will have additional requirement of around 6000 Nm 3/h of High Pressure
Nitrogen and 1100 Nm3/h of Argon. Further margin considered in the capacity
of nitrogen compressors are sufficient to take care of additional nitrogen
requirement. Additional requirement of Argon will be also taken care of in
proposed plant

BACKGROUND
2.13 RSP'S COMMUNICATION REGARDING FEASIBILITY REPORT
Committee of Directors (COD) meeting was held on 20.01.2020 to review
proposal of new oxygen plant for RSP. The COD suggested to take required
clearances / No Objection from concerned state government agencies
regarding various aspects. RSP requested CET on 17.04.2020 for preparation of
FR for obtaining Environmental Clearance from Ministry of Environment, Forest
and Climate Change (MoEFCC) and Consent to Establish from State Pollution
Control Board (SPCB), Odisha. The copy of mail is attached as Annexure 2.13-1.
2.14 Accordingly, CET accepted the request and intimated schedule for the
preparation of FR. The acceptance letter is attached as Annexure 2.14-1.
2.15 Likewise, this FR has been prepared. CET gratefully acknowledges the co-
operation and assistance extended by Rourkela Steel Plant in preparation of this
feasibility report.

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3. SELECTION OF ALTERNATIVES
3.1 For meeting the oxygen gap, there are two alternatives of installation of oxygen
plant:
1) Captive Plant
Captive plant will be installed, operated & maintained by RSP. The cost of
installation and other activities will be borne by RSP.

SELECTION OF ALTERNATIVES
2) Outsourced Plant
Outsourced plant will be installed, operated & maintained by oxygen plant
supplier. The cost of installation, operation & maintenance will be borne
by oxygen plant supplier. RSP will provide land for installation. All new
oxygen plants in last 15 years have been outsourced in Built, Own &
Operate (BOO) mode.
3.2 Merits/Demerits

Captive Plant Outsourced Plant

Oxygen is critical  Oxygen plants are capital intensive plants.
Merits
item for For outsourced plants capital is employed
production of by oxygen plant supplier and SAIL has to
steel and with pay Fixed Facility Charge (FFC)and O&M
captive charges for contract period of 15-20 years
installation, the  Oxygen plant supplier have proven
reliability and expertise in plant operation and hence
control is with capital cost of plant as well as O&M
RSP. expenses are lower as compared to captive
plant which results in supply of oxygen &
nitrogen at lower cost.
 RSP is assured of reliable supply of gases as
oxygen plant supplier is well experienced in
the field with several operating plants and
can take care of any emergency situation by
quick mobilization of spares & resources.
Further in case of any exigency supply of
gases to purchaser is ensured by operator
by supply of liquids from their other plants
 Based on recommendation of high level
task force constituted in 2004 SAIL has
gone for outsourced Oxygen plants in BSP,
BSL, DSP & RSP. These plants are working

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since last 10 years and there are no major

issues. Also there is uninterrupted oxygen
supply available from these BOO units.
The oxygen plant  There are some grey areas regarding plant
Demerits
is capital salvage cost &contracting issues after
intensive. In completion of Lease and O&M period.
captive plant, the  A fixed facility charge and minimum off-
capital cost in take cost is to be ensured on continuous
SELECTION OF ALTERNATIVES

borne by SAIL. basis.

 There are limited number of Oxygen plant
suppliers worldwide.
3.3 Looking into above aspect, Alternative-II i.e. outsourced oxygen generation
plant has been selected for this project.
3.4 With BOO plant as outsourced generation facility, the cost of oxygen generation
will be more in Rourkela. Generally, input power for operating BOO plants of
BSP, DSP and BSL is being provided by SAIL. However, regulations at Odisha
restrict supplies of power to own units only. The owner of a BOO plant is the
supplier itself. Due to this, BOO Oxygen plant of RSP purchases power from
Odisha grid. This results in higher cost of input power. Unit cost of power
purchased from WESCO for year 2018-19 was Rs 6.6, whereas units cost of
power generated in SAIL‟s joint venture company NSPCL, Rourkela was Rs 4.78.
3.5 Based on this, it has been proposed to install new Oxygen Plant on “Lease and
O&M basis”. The proposal will require bidder to install 1x1000 tpd Oxygen Plant
at RSP‟s premise and then lease the plant to RSP on long term basis. This will
effectively give ownership of the plant to RSP and help in utilising NSPCL power
for own consumption. RSP will further place long term order for Operation &
Maintenance (O&M) to the same bidder.

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4. PROJECT DESCRIPTION
4.1 GENERAL

4.1.1 A new oxygen plant with one cryogenic Air Separation Unit (ASU) of 1000 tpd
capacity will be installed. This proposal will be done on „Lease and O&M basis at
RSP by a reputed & experienced manufacturer/ supplier of industrial gases.
4.1.2 The Lease and O&M supplier will be paid lease as well as operation
&maintenance charges by RSP. Lease charges will cover the capital expenditure
for setting up the plant as well as other fixed expenses viz. salaries & wages,
insurance etc. Operation & Maintenance charges will cover the cost of O&M.
4.1.3 This will be a green field project and land (150 m x 120 m approx.) for setting up
this plant will be made available by RSP besides the existing 1x700 tpd captive
plant. The map of Rourkela is shown in Annexure 4.1.3-1. The location of
proposed oxygen plant at RSP is shown in attached Drawing No. CET RN UT2

PROJECT DESCRIPTION
00 001, R=0.
4.1.4 The Lease and O&M supplier will be provided power free of cost from new
NSPCL plant by RSP.
4.1.5 Make-up water of around 120m3/h (Max.) is considered for this new facility and
the same will be given on chargeable basis by RSP.
4.1.6 Product piping for the supply of Oxygen, Nitrogen and Argon, from proposed
Lease and O&M plant up to the existing supply headers near the Captive
Oxygen Plant and near proposed SMS-III will be under the scope of O&M
operator.
4.2 MAIN FACILITIES ENVISAGED
4.2.1 The oxygen plant will consist of 2x50% Main Air Compressor (MAC), 2x50%
Booster Air Compressor (BAC) and cryogenic Air Separation Unit (ASU). The
plant will be able to produce oxygen at 30 bar-g. The plant will also utilize
2x50% turbines. Further, the provision for restarting ASU with LIN injection while
replacing/ repairing turbines will be provided. The plant will be able to work at
50% of contracted capacity by the use of any one BAC and MAC. Also the plant
will be capable of running at turn down of 70% of the contract capacity of 1000
tpd.
4.2.2 Back up pumps and vaporizers will be included for Liquid Oxygen (LOX), Liquid
Nitrogen (LIN) and Liquid Argon (LAR) to meet any supplemental demand and
in case of shutdown of ASU. Hot water bath vaporizer system is proposed. Back
up liquid storage will also be provided to meet the demand of gases during
peak requirement/ outages / shut down of Production Facility due to
unforeseen reasons as well as for planned maintenance. Suitable DG power
facility will be provided for operating back-up pumps & vaporizing system.

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4.2.3 The envisaged capacity of LOX, LIN & LAR tank will be 2000 m3, 2000 m3 and
100m3 respectively. The vaporiser for LOX, LIN & LAR will have capacity of
30000 Nm3/h, 30000 Nm3/h & 1500 Nm3/h respectively. Gaseous storage of
1000 m3 and 200 m3 for Oxygen and Nitrogen respectively has been envisaged.
4.2.4 The proposed plant will have additional nitrogen compressor of 20000 Nm3/h
capacity with standby facility and Blower to take care of any additional
requirement or during scheduled maintenance and breakdowns of existing
Nitrogen compressors and Blowers of RSP/ Existing BOO plant.
4.3 RISK ASSESSMENT
4.3.1 Risk assessment for the project is attached at Annexure- 4.3.1-1
4.4 ENVIRONMENT MANAGEMENT
4.4.1 Overview
Oxygen generation though cryogenic means has almost negligible impact for
PROJECT DESCRIPTION

environment. The principles of sustainable development will be adopted while

considering the design of systems.
Factors considered for minimizing environmental impact include the following:
1) Control of Water Pollution
The water system will be deigned on “Zero Liquid discharge” concept. The
blow down water from cooling tower and other sources will be treated and
used inside plant.
2) Control of Noise Pollution
Systems will be designed to control noise pollution. Further, If any noisy
operations have the potential to exceed the noise limits;silencers, specific
barriers, enclosures or other effective means will be provided to reduce the
noise level.
3) Emission Control
No waste stream particulate matter emission is generated in the process.
4) Emission Control during construction
Adequate precaution in terms of water spray etc. will be taken to minimise
air pollution during construction. Necessary clearance from State pollution
Control Board will be taken in this regard.
5) Energy Saving
The oxygen production from this project will be energy efficient and will
help in saving specific power 0.25 kWh/Nm3 of oxygen due to shutdown of
existing 2x180 tpd units.

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE
5.1.1 The project is envisaged to be implemented within a period of 30 months from
the date of Stage-II approval. Pre-ordering activities are envisaged to be
completed within 6 months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1 & 5.1.2-2 respectively.
5.2 IMPLEMENTATION STRATEGY
5.2.1 Mode of execution and number of packages:
The project is proposed to be executed through two turnkey package(s) as
follows:
1) Main Package for Installation of 1x1000 tpd Oxygen Plant at RSP on LOM
basis
2) Soil survey and geo-technical study / Location of underground facilities on
Turnkey basis

PROJECT IMPLEMENTATION
5.2.2 There are no known underground facilities in the proposed area. However, the
area needs to be cleared for construction by RSP before execution of the
project.
5.2.3 Linked Package
[Link] Electrical Power required for the proposed 1x1000 tpd Oxygen Plant will be
approx. 25 MW. This much of power is not available in the existing switchyard
which is feeding the existing 2x180 tpd units.
[Link] In view of the above, additional 132kV/ 33kV power source is required to be
installed for sourcing power to the new 1x1000 tpd plant. This job will be
implemented through a separate project titled a “Power Supply Arrangement
for the proposed 1x1000 tpd Oxygen Plant”. Feasibility Report (FR) & Technical
Specification (TS) for the same has already been prepared by CET and submitted
to RSP.
[Link] The said linked project can be parallelly awarded/ executed. However, suitable
timely action is required to be taken to ensure implementation of the said linked
projects.
5.3 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION

[Link] No shutdown of existing system has been envisaged. However, for joining
oxygen & nitrogen piping to existing grid, necessary shut down will be provided
by RSP.

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6. CAPITAL COST &FINANCIAL ANAYLSIS

6.1 As the oxygen plant is proposed to be installed on by Lease and O&M basis,
hence no capital investment is required to be done by RSP. Therefore no
estimated capital cost has been worked out. However, for installation of
enabling facilities, the cost has been prepared and submitted through another
assignment.
6.2 Since the proposed oxygen plant is to be installed on by Lease and O&M basis,
no financial analysis has been done.
6.3 SENSITIVITY ANALYSIS
6.3.1 Sensitivity analysis has been done to check viability of operation of existing
2x180 tpd units. Since these units are producing 170 tpd only, total generation
from 2x180 tpd units have been taken as 340 tpd.
Two cases have been prepared for sensitivity analysis-
1) Case-I
ASU I,II (340 tpd) & ASU III (700 tpd) + Existing BOO (1400 tpd) +
Proposed BOO (700 tpd)
2) Case-II
ASU III (700 tpd) + Existing BOO (1250 tpd) + Proposed BOO (1000 tpd)
6.3.2 The analysis concludes that annual cost of oxygen production for Case-I is Rs
547.67 crore. By shutting down / keeping these units in standby and producing

CAPITAL COST & FINANCIAL ANALYSIS

oxygen by new plant (Case-II), the annual cost of oxygen production reduces to
Rs 500.18 crore. The analysis is enclosed as Annexure 6.3.2-1.

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7. RECOMMENDATIONS
7.1 The installation of new oxygen plant with a capacity of 1000 tpd is required in
order to cater to the present deficits for production up to 4.65Mtpa of Hot
Metal and proposed 4.53 Mtpa of Crude Steel also. The proposal to set up this
new facility under LOM will ensure product gases (oxygen, nitrogen & argon)
availability and at no additional capital investment. Hence, it is recommended to
install a new Oxygen Plant of 1000 tpd at RSP under LOM.

RECOMMENDATIONS

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ANNEXURE - 2.13-1

Client Letter

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ANNEXURE - 2.14-1

Acceptance Letter from CET

RECOMMENDATIONS

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ANNEXURE - 4.1.3-1

LOCATION OF ROURKELA

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ANNEXURE - 4.3.1-1

RISK ASSESSMENT REGISTER

SL ISSUES RISK PROBABILITY CONSEQUENCE RPN Current Additional Actions Responsibility Implementation Revised Revised Revised
(H/M/L) (H/M/L) (DxE) controls date probability consequence RPN (KxL)
(H/M/L) (H/M/L)

1 Power Supply Delay in L H L3 - RSP - L H L3

All clearances within
Package shall be execution
boundary limits of shall
complete before of power
be completed before
commissioning of supply
erection of power
project package
supply package.

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ANNEXURE – 5.1.2-1

SCHEDULE OF PRE-ORDERING ACTIVITIES AFTER STAGE I APPROVAL

Duration in Months

S. Activity 1 2 3 4 5 6
No

1. Stage I approval of the project

2. Issue of Tender & Receipt of

Offers

3. Evaluation of offers and

submission of TER

4. Opening of Price Bids / RA,

Price Bid Evaluation

5. Stage II approval

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ANNEXURE - 5.1.2-2

SCHEDULE OF POST-ORDERING ACTIVITIES AFTER STAGE II APPROVAL

In Months
Sl. No. Activity 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1
Stage-II approval

Placement of Order &

2
Contract signing

3 Design & Engineering

Civil work including area

4
development

Manufacture and supply

5
of equipment

Erection/ Installation of
6
equipment/ piping

Testing and
7
Commissioning

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ANNEXURE –6.3.2-2

Sensitivity Analysis

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 INSTALLATION OF NATURAL GAS PIPELINE NETWORK

ROURKELA STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

SEPT 2019 CET/05/RN/4606/FR/UT/01 R=0

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 Experience that delivers

This document has been prepared for ROURKELA STEEL PLANT by:

Centre for Engineering & Technology

T K Mishra – HOD Lead section

Arun Jose Mathews (Task Force Leader)
Ajay Kumar, U&S
Narendra Kumar Jain, Rolling Mills
H Brahme, PC&A
Akshya Pandya, Electrical
Manoj Kumar Singh, Civil
S Mukherjee, Structural
A K Thakur, CTEB
R Behera, RSC
Ravindra Kumar Verma, PFC

Document Identification No. CET/05/RN/4606/FR/UT/01 R=0

REVISION HISTORY

Revision No. Brief Description Revision Date

R3

R2

R1

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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 Experience that delivers

UPSHOT
RSP is expected to get natural gas for its operation by June 2020. This natural gas can be
utilized to replace the unclean fuels presently used at RSP (by product gases & petro-
fuels). Availability of natural gas can also improve product quality at SPP. This project is
aimed to install a new natural gas pipe network from GAIL T.O.P. to various consumers in
RSP for their present and future requirements.
The project will be commissioned in fifteen (15) months from the date of stage II approval
and at an estimated capital cost of Rs.19.58 crore net of input tax credit of Rs. 2.14 crore
including IDC of Rs.1.00 crore.

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NETWORK
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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1

2 Background 2.1-2.2

3 Selection of Alternatives 3.1

4 Project Description 4.1-4.5

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1-6.2

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure No. Description No. of pages

2.6-1 Copy of client letter 4

2.7-1 Copy of assignment acceptance letter 1

2.8-1 Copies of MOMs

4.6-1 Risk Assessment Register 1

5.1.2-1 &
Implementation schedule 2
5.1.2-2

6.1.1-1 Summary capital cost estimate 1

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DRAWINGS

Sl. No. Drawing No. Description

CET RN 4606 UT0 00 001 R=0 Layout for new natural gas pipe
1
(2 sheets) network

PFD for Pressure reducing and

2 CET RN 4606 UT0 00 002 R=0
mixing station

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1. SUMMARY
1.1. Presently RSP employs byproduct fuel gases such as Blast Furnace gas (BFG),

SUMMARY
Coke oven gas (COG), Mixed gas (MG) and petro-fuels such as Light Diesel
Oil (LDO), Furnace Oil (FO), Liquefied Petroleum Gas (LPG), to meet its internal
fuel requirement.
1.2. RSP is expected to receive natural gas from its tapping point on GAIL cross
country gas pipeline (inside RSP premises) by June 2020.
1.3. In this connection, RSP requested CET to study the gas balance and suitability
of using natural gas in various consumers and it was accepted as assignment
on 26.04.2019.
1.4. After site studies and discussions with RSP, this report put forwards the
proposal to install a new natural gas pipeline network at RSP to cater to the
requirement for clean gas at various consumers. With the establishment of
new pipeline network for providing natural gas, and improve product quality
of furnaces in SPP and the use of unclean gas requirement can be reduced to
exigency conditions.
1.5. This project will be commissioned in fifteen (15) months from the date of
stage II approval.
1.6. The capital cost for the project is estimated to be Rs.19.58 crore net of input
tax credit of Rs. 2.14 crore including IDC of Rs.1.00 crore.

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2. BACKGROUND
2.1. Rourkela Steel Plant (RSP), an integrated steel plant of Steel Authority of India
Limited (SAIL), is located in Sundargarh district of Odisha state.

BACKGROUND
2.2. The major equipment/ facilities at RSP utilize mainly BFG, COG, Mixed Gas,
LDO/HSD and FO; as fuel. Most of these fuels are of less calorific value, burn less
cleanly and are not environment friendly.
2.3. The major equipment/ facilities at RSP utilize mainly by-product gases (BFG, COG,
Mixed Gas) and petro-fuels (LDO/HSD and FO). All by-product gases are consumed.
2.4. Replacement of LDO/HSD/FO with natural gas is the trend of industry subject to its
availability.
2.5. For certain processes having high product quality requirement, cleaner fuel is
beneficial than the by-product gases.
2.6. Gas Authority of India Ltd. (GAIL) has been authorized to lay 2539 km Jagdishpur-
Haldia-Bokaro–Dhamra Natural Gas pipeline (JHBDPL) project for developing
natural gas infrastructure in eastern India integrated with the execution of six city
gas distribution ventures - en-route the said pipeline, traversing through the states
of Uttar Pradesh, Bihar, Jharkhand, Odisha and West Bengal; and the same is in the
advance stage of implementation. JHBDPL is expected to be operational in 2019-20.
2.7. In line with its strategy of utilizing cleaner fuel gas, SAIL/RSP is in processes of
signing a term-sheet with GAIL for supply of RLNG at Rourkela Steel Plant (RSP).

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2.8. In this connection, RSP had requested CET to conduct a study on suitability of using
natural gas in PBS, Calcination plant-II, SPP and Ammonia cracking unit of Silicon
Steel Mill (SSM) of RSP vide letter AMR/M&SC/Consultancy/17/22-26 dated
04.01.2018. RSP had also indicated that CET may study suitability of using natural

BACKGROUND
gas in any other unit of RSP in consultation with the concerned department. In line
with this, an approach note vide CET/05/RN/4545/AN/UT/01 R=0 January 2019 for
the installation of a natural gas network was issued to RSP. In continuation with this
Approach Note, RSP requested CET to prepare a Feasibility Report (FR) and
Technical Specifications (TS) vide their letter AMR-M&SC/Consultancy/18/2582
dated 12.03.2019 for the distribution of natural gas pipeline network and necessary
modification inside shop at RSP. (Copy of letter is attached as Annexure 2.6-1)
2.9. The aforesaid letter from RSP was accepted as present assignment by CET vide
acceptance letter No. CET-17(3)/018/19/181 dated 26.04.2019. This letter is
enclosed as Annexure-2.7-1.
2.10. Further a site study was conducted on the scope of work involved. It was decided to
limit the scope of this study to the installation of a new natural gas pipe network for
all consumers considered in aforesaid AN. Copies of the MOMs made during site
study and discussion are attached as Annexure-2.8-1
2.11. The co-operation & assistance received from RSP in the preparation of this report is
gratefully acknowledged.

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3. SELECTION OF ALTERNATIVES
3.1. This project involves creation of an entirely new gas network for natural gas for the
entire plant having consumers like NHSM, NPM, PM, NH3 plant & SSM, CPP-1, CP-II,
SPP, PBS and BFs.
3.2. Hence no alternatives have been considered

SELECTION OF ALTERNATIVES

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4. PROJECT DESCRIPTION
4.1 UTILITY

4.1.1 The project involves the installation of a new pipeline from T.O.P of GAIL to the
various consumers. The proposed network for natural gas will consist of new
pipeline for a length of 11000 m of various sizes.

4.1.2 The proposed pipeline will be designed for a maximum flow rate of 30000Nm3/h
of Natural gas at a pressure of 8 kg/cm2.

4.1.3 Gas balance for FO/ LDO and Mixed Gas for conversion to Natural gas
Furnace Oil+ 3
Sl. No. Parameter Mixed Gas (Nm /h)
LDO (L/h)

Potential Present

PROJECT DESCRIPTION
1 Present Generation 0.00 108722.22 93947.11
2 Present Consumption 2229.00 100936.34 93774.62
Present Net Balance -2229.00 7785.88 172.49
Future
Requirement(New HSM,
3 Furnace in SPP,BOF, -43822.41 -
New Normalizing
furnace)
Future balance of MG
-2229.00 -36036.53 -
and FO
Natural gas
requirement to meet 2622.35 15262.53
3
shortfall of MG(Nm /h)
Total requirement
3 17884.88
(Nm /h) of natural gas
4.1.4 The various consumers along with natural gas requirement are as follows:
Sl no Consumer of NG Quantity of NG required
a. NH3 cracking plan and Silicon 1000 Nm3/hr
Steel Mill
b. SPP – New furnaces 1100 Nm3/hr
c. CP-II FO fired Kilns (#5 and #6) 2500 Nm3/hr
d. PBS for BF-5 9000-10000 Nm3/hr

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(for 4-6 hrs during BF-5 start up)

e. CPP-I 2000 Nm3/hr
f. New HSM 4000 Nm3/hr
g. New Plate Mill 1000 Nm3/hr
h. Old Plate Mill 500 Nm3/hr

4.1.5 In addition to the above consumers, the following consumers will also be
provided with tapping points from the proposed natural gas network for the
future use.
Sl. No. Consumer of NG Quantity of NG required (future use)
a. BF-1 5000 Nm3/hr
b. BF-5 5000 Nm3/hr

4.1.6 The proposed site for Take Over Point (T.O.P.) of natural gas from GAIL has been

PROJECT DESCRIPTION
identified near utilities area of New HSM (East of slab yard). The tapping for the
proposed natural gas will be from the battery limit of GAIL. Since the flow and
energy parameters are in the scope of GAIL as per the GSA, no additional flow
and energy measurement equipment are considered.

4.1.7 The new pipeline for natural gas will be laid over existing/ new trestles as per site
conditions. All consumer locations will be provided with isolation valves with
access platform. The layout of the new natural gas network is indicated as
attached layout drawing CET RN 4606 UT0 00 001 R=0 (2 sheets).

4.1.8 For NHSM, NPM and PM, a new PRMS will be considered for admitting natural
gas to the existing mixed gas lines. For this a space of 8x5 m is considered near
the following locations:
 For PM: near existing chimney & trestle B53 (near to existing tapping
point of propane)
 For NPM: near to existing U seal on mixed gas line
 For NHSM: near to U seal on new mixed gas line & trestle TR46

4.1.9 Nitrogen at 4-7kg/cm2 will be tapped for purging natural gas line at all isolation
valves

4.1.10 Compressed air will be tapped from consumers at 3.5kg/cm2 for operation of
control valves at PRMS.

4.1.11 Remote operation of flow across each PRMS will be provided. The tentative PFD
is provided in drawing CET RN 4606 UT0 00 002 R=0

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4.2 ELECTRICAL

4.2.1 Power Distribution Scheme

Power from existing LT panels in Old plate mill, new HSM & new plate mill areas
will be used to feed proposed UPS in suitable locations. Further power
distribution will be done accordingly through UPSDBs.
4.2.2 The following major electrical equipment have been considered:
[Link] Standalone portable type UPS system
Standalone portable type of minimum 1 MVA rating with inbuilt battery bank installed
inside wall mounted lockable cabinet
[Link] LT and Control Cables
1. LT Power Cable
1.1kV grade aluminium conductor, XLPE insulated, PVC sheathed, armoured,
FRLS PVC outer sheathed power cables is considered.

PROJECT DESCRIPTION
2. Control Cables
1.1 kV/ 650 V grade stranded 1.5 [Link] multi-core copper conductor, XLPE
insulated, PVC sheathed, armoured, FRLS PVC outer sheathed control cables
have been envisaged for all electrical equipment/ items.
[Link] Earthing & Lightning Protection
Earth strips from the proposed equipment will be connected to the existing
earth grid at two points.
Earthing system will be in accordance with the code of practice for earthing in IS:
3043-1987 & relevant OISD standards and will also comply with the relevant
clause of Indian electricity rules - 1956.
All proposed structural supports for pipeline will be connected to nearest
lightning protection earth grid by galvanized steel strip strips. Surge arrestors
will be provided at those joints where metallic continuity of the pipeline is not
maintained. Lightning protection will be provided at suitable places as per
requirement as per relevant IS & OISD standards.
4.3 PC&A
4.3.1 The following equipment/ items are envisaged under Process Control &
Automation :
i) Single Loop Controller (SLC) based control with one number SLC in each
gas mixing station at new HSM, New plate mill and plate mill.
ii) Field instruments to measure process parameters at different locations.

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iii) One number Instrument panel in each control room of gas mixing
station at New HSM, New Plate mill and Plate mill. Instrument panel will
have SLC, Paperless recorder and Digital indicators.
4.3.2 List of measurement and control:
 Pressure measurement in natural gas line for New HSM, New Plate Mill
and Plate mill.
 Orifice and Flow transmitter in natural gas line for New HSM, New Plate
Mill and Plate mill.
 RTD and Temperature transmitter in natural gas line for New HSM, New
Plate Mill and Plate mill.
 Flow Control valve in natural gas line for New HSM, New Plate Mill and
Plate mill.
 Flow Control as per the requirement and measurement from flow

PROJECT DESCRIPTION
transmitter.
4.4 STRUCTURAL
4.4.1 The scope of structural steelworks envisaged are as follows:
[Link] Supply, fabrication, erection, painting, testing and commissioning of all
structural steel works for the following as per technological/ technical
requirement:
1. New Structures:
 New pipe supporting trestles, bridge from T.O.P of natural gas near new
Hot Strip Mill to new Hot Strip Mill along with maintenance/ working
platforms along with stairs, ladders & handrail etc.
 New pipe supporting trestles, bridges along with necessary maintenance/
working platforms, staircase/ ladder etc. will be provided for supporting
pipes along following stretches as per the layout & sizes as indicated in
drawing no CET RN 4606 UT0 00 001 R=0
 From NHSM to the trestle no. Z2/ 50 along the route through
intermediate trestle no. Z5/ 96, Z5/ 1 and Z3/ 1.
 From SMS-II to T.O.P for CP-II.
 From trestle no. Z2/ 37 to PBS.
 From trestle no. B/ 71 to B/ 6 through tapping point for old plate mill and
SPP.
2. Part dismantling, modification/ strengthening of existing structures:
 Part dismantling, modification/ strengthening of existing trestles, bridges
etc. for pipes along following stretches as per the layout & sizes as
indicated in drawing no CET RN 4606 UT0 00 001 R=0

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 From trestle no. Z2/ 50 to SMS-II.

 From trestle no. Z2/ 50 to BF-1.
 From trestle no. Z5/ 96 to new plate mill.
 From trestle no. B-6 to Silicon steel mill.
 Structural bridge between trestles Z5/ 96 and B71.
3. Miscellaneous structures for platforms, access staircase/ ladders, pipe
supports, handling facilities etc. as per requirements.
4.4.2 Design Considerations
[Link] All steel structures will be designed to meet the technological requirement with
due consideration to the existing plant and facilities.
[Link] Design of steel structures will be as per IS 800: 2007. Apart from technological
loads to be supported on steel structures, self-weight and superimposed loads
for the design will be according to IS 875 (Part 1, 2, 4 & 5): 1987 and IS 875 (Part

PROJECT DESCRIPTION
3): 2015.
[Link] Structural steel will conform to IS 2062: 2011.
[Link] Chequered plates will be as per IS 3502: 2009.
[Link] In general, steel structures will be of welded construction. The welding
procedure will conform to IS 816: 1969 and IS 9595: 1996.
[Link] All new structures will be given two coats of single pack air drying phenolic
modified alkyd composition with zinc phosphate as a primer (DFT/coat 40
micron), and two coats of single pack air drying high gloss phenolic alkyd
modified synthetic enamel paint as finishing coat (DFT/ coat=25 micron).
One coat of primer will be applied immediately after fabrication and another
coat after erection. One intermediate coat of a single pack high built phenolic
based paint with micacious iron oxide (DFT=75 micron) will be applied on
open structures.
[Link] All existing modified structures will be given single coat (DFT=150 micron) of
a two pack high build surface tolerant epoxy mastic coating and two coats of
two pack epoxy high build coating as finishing coat (DFT/ coat=100 micron).

4.5 CIVIL

4.5.1 The following civil works are envisaged for this assignment

1) Dismantling of RCC and PCC as per site requirement.

2) Earth work in excavation and backfilling.
3) Boulder soling & PCC work under the foundations.

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4) RCC foundations for structural steel trestles have been considered for
natural gas (NG) pipelines, pipe support Bridge, etc. as per technological
requirement.

4.5.2 Design Philosophy & Guideline

i) Geodetic survey and Underground mapping works of the area will be
carried out through a separate package. The report of this investigation
will be made available to the bidder during tendering of main package.

ii) The net bearing capacity has been considered as 5 t/m2 in virgin strata at
1.5 m depth below the existing ground level.

iii) Grade of RCC for all foundation and superstructures will be not less than
M-25 with provision of 2 coats of bitumen paint on concrete faces in
contact with soil.

PROJECT DESCRIPTION
iv) All RCC structures will be designed as per IS: 456-2000.

4.5.3 Major activities relating to civil works are will earthwork, plain & reinforced
concrete work, flooring, plastering and finishing etc. Following criteria will be
adopted in the design of civil engineering works:
 R.C.C :M-25C
 PCC :M-10B
 Grouting :M-30D below structural steel bases.
 Boulder soling :500mm thick compacted bolder soling with
moorum blinding will be provided below
RCC trestle foundations.
4.6 RISK ASSESSMENT
Risk assessment for the project is attached at Annexure- 4.6-1

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE
5.1.1 The project is envisaged to be implemented within a period of fifteen (15)
months from the date of Stage-II approval. Pre-ordering activities are envisaged
to be completed within four (04) months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1 & 5.1.2-2 respectively.

5.2 IMPLEMENTATION STRATEGY

5.2.1 Mode of execution and number of packages:
The project is proposed to be executed through two (02) package(s) as follows:
1. Over ground survey & underground mapping – on Turnkey basis and
through LTE mode as per empanelment
2. Installation of natural gas pipe network (Package-II) – on Turnkey basis
5.2.2 Pre-requisites/ clearances, special handling eqpt., diversion of any known over
ground or underground facilities that need diversion, etc. for execution of the

PROJECT IMPLEMENTATION
project:
a) Environmental clearance for project execution.

5.3 DETAILS OF PRE-SHUTDOWN ACTIVITIES WITH DURATION

Installation of natural gas pipeline network including valves and trestles

5.4 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION

Shutdown of the existing mixed gas line is to be provided for interconnection of
natural gas line with the mixed gas line at the following consumer locations. The
duration the shutdown needed is also indicated as follows.
Sl. No. Location Duration of shutdown
1 New Plate Mill Full day
2 New Hot Stripping Mill Full day
3 Plate Mill Full day

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6. CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:
6.1.1 The capital cost for the project is estimated to be Rs.19.58 crore net of input tax
credit of Rs. 2.14 crore including IDC of Rs.1.00 crore. The summary capital cost
estimate is appended at Annexure-6.1.1-1.
6.1.2 The Capital Cost estimate has been prepared considering budgetary quotation,
engineering estimates and available data. The base date for the estimate is 3 rd
Quarter of 2019.
6.1.3 Necessary statutory provisions towards taxes & duties have been made in the
estimates as per the details given below:
i) GST @ 18 % on basic cost of equipment, structures, civil, erection,
engineering & construction (contractor).
ii) GST @ 18 % on freight & insurance.
6.1.4 Freight & insurance charge for equipment @ 2% of basic cost and for structure @
9% of basic cost has been considered.
6.1.5 Erection & commissioning charges has been taken @ 12% on basic cost of
equipment, @ 20% of basic cost of structure.
6.1.6 Engineering & Construction (E&C): E&C (Contractor) @ 5% and E&C (Owner) @
2.5 % on basic cost of equipment, structures, civil work and erection &

CAPITAL COST & FINANCIAL ANALYSIS

commissioning charges. Additional provision of Rs.0.34 crore has been kept
towards consultancy charges.
6.1.7 Contingencies: @ 5 % on overall basis has been considered.
6.2 MODE OF FINANCING:
The total capital requirement of the project is proposed to be provided from
100% debt with an interest @ 10% per annum.
6.3 PHASING OF CAPITAL EXPENDITURE:
With the project duration of 16 months from the date of Stage – II approval, the
phasing of capital expenditure is proposed as indicated below:
Rs. cr.

Year Plant Equity Loan IDC Total incl.

cost IDC
st
1 year 10.36 10.36 0.52 10.88
nd
2 year (4 Months) 8.29 8.29 0.48 8.77
Post Comm. 2.07 2.07 2.07

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Capital cost 20.71 20.71 1.00 21.72

Input tax credit (ITC) on GST 2.14
Capital cost net of ITC on GST 19.58

6.4 INTEREST DURING CONSTRUCTION (IDC):

Based on the mode of financing and phasing of capital expenditures indicated
above, total IDC has been worked out to Rs.1.00 cr.
6.5 COST-BENEFIT ANALYSIS:
6.5.1 This being a technical necessity, hence no techno-economics has been worked
out.

CAPITAL COST & FINANCIAL ANALYSIS

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7. RECOMMENDATIONS
7.1 The scheme is a technical necessity which will reduce use of expensive petro-fuels
at RSP and improve product quality in SPP.

7.2 The scheme is technically feasible hence recommended for implementation.

RECOMMENDATIONS

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ANNEXURE – 4.6-1

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ANNEXURE – 4.6-1

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ANNEXURE – 4.6-1

RISK ASSESSMENT REGISTER

SL ISSUES RISK PROBABILITY CONSEQUENCE RPN Current Additional Actions Responsibility Implementation Revised Revised Revised
(H/M/L) (H/M/L) (DxE) controls date probability consequence RPN (KxL)
(H/M/L) (H/M/L)

1 Underground Delay in M M L3 Undergr RSP & - - - -

a)
facilities completion ound contractor
mappin
g TS is
provide
d

2 Shutdown of Delay in L L L2 RSP to RSP & - - - -

b)
existing MG commissioni plan Contractor
line ng shutdo
wn

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 ANNEXURE – 5.1.2-1

SCHEDULE OF PRE-ORDERING ACTIVITIES AFTER STAGE I APPROVAL

(Duration in Months)

SL. Activity
1 2 3 4 5
No.
1. Stage I approval of the project

2. Issue of Tender & Receipt of Offers

Evaluation of offers and submission

3.
of TER
Opening of Price Bids / RA, Price Bid
4.
Evaluation
5. Stage II approval

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ANNEXURE - 5.1.2-2

SCHEDULE OF POST-ORDERING ACTIVITIES AFTER STAGE II APPROVAL

(Duration in Months)

Time →
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Activity ↓
Stage –II approval of the project

Placement of order and signing of contract

Preparation, submission & approval of

Basic & detail engineering drawings

Supply of equipment (utility, PC&A &

electrical)

fabrication

Erection of pipeline, Civil works including bldgs.,

foundation etc.

Testing & commissioning **

** Shut down of full day is to be provided for interconnection at NPM, PM, NHSM. No shutdowns are required for installation of
network.

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ANNEXURE -6.1.1-1
ANNEXURE 6.1.1-1
S T E E L A U T H O R I T Y OF I N D I A L I M I T E D Base date: 3rd Qtr 2019
ROURKELA STEEL PLANT Figures in Rs. Crore
Installation of natural gas network at RSP

**CAPITAL COST ESTIMATE**SUMMARY

GST (Supply & services) Contingn E&C

18% 5% 7.5%
EQUIPMENT SPARES STRUCTURALS REFRACTORIES CIVIL ERECTION ENGG & CONSTN FRT. & INSURANCE DUTIES & TAXES OTHERS CONTINGENCY CAPITAL COST
[Link] SHOP/FACILITY/PACKAGE Total Incl. Total Incl. Total Incl. Total Incl. Total Total Total Incl. Total Incl. Total Incl. Total Incl. Total Incl. Total Incl.
Cost FC Cost FC Cost FC Cost FC Cost Cost Cost FC Cost FC Cost FC Cost FC Cost FC Cost FC
a b c d e FC g h I j k l m n o p q r s t u v w x
1 Installation of natural gas 0.65 8.94 3.12 1.87 1.43 0.82 2.90 0.99 20.71
network at RSP
2 Total Plant cost 20.71
3 IDC 1.00
4 CAPITAL COST 21.72
5 Input tax credit (ITC) 2.14
6 Capital Cost net of ITC 19.58

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 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

480

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

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PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

482
 Feasibility Report
INSTALLATION OF 4TH HOT BLAST STOVE IN BF#5

ROURKELA STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

OCTOBER,2020 CET/05/RN/4753/FR/ME/01/R=0
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This document has been prepared for RSP by:

Centre for Engineering & Technology

SHRISH K. DAS -HOD MECHANICAL
SHRAWAN PRADHAN, MECHANICAL (TASK FORCE LEADER)
VIVEK BHARTI, MECHANICAL
RAJIB BANERJEE, IRON & SINTER
SURENDRA PRASAD, REFRACTORY
T. C. JOSHI, REFTRACTORY
SOURAV MANNA, REFRACTORY
RAVINDRA KUMAR VERMA, PFC
AKSHYA PANDYA, ELECTRICAL
NILESH SINHA, PROCESS CONTROL & AUTOMATION
RAGHUNATH ROY, STRUCTURAL
[Link] PARAMESWARAN, CIVIL
GARISH KUMAR, COST & TECHNO-ECONOMICS
M. K. YADAV, UTILITIES & SERVICES
A. K. MALLICK, ROURKELA SUB CENTRE

Document Identification No. CET/03/RN/4753/FR/ME/01/R=0

REVISION HISTORY

Revision No. Brief Description Revision Date

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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UPSHOT
Blast Furnace (BF) #5 of Rourkela Steel Plant was installed under the Modernisation &
Expansion (MODEX) of SAIL on 13th August, 2013. The blast furnace is having inner volume
of 4060 m³ and working volume of 3470 m³. Existing hot blast system consists of 3 nos. of
internal combustion type hot blast stoves having mushroom dome and ceramic burner.

Stoves of this BF are running continuously since commissioning and are showing hot spots
on the dome shell. The stoves are fast approaching mid-term repair. If repair of these
stoves is carried out one at a time, the furnace will have to be operated with 2 stoves
during the repair period. This will result into lower operating hot blast temperature,
decrease in productivity, increase in coke rate and stopping of coal dust injection which
will adversely impact overall economics of hot metal production through the furnace.

In order to avoid the above situation and as per present trends among reputed
steelmakers operating large blast furnaces worldwide, it is proposed to install 4th stove in
BF#5. The blast furnace BF#5 is already provided with space and utility provisions for the
installation of 4th stove. After installation of 4th stove, it will be ensured that the furnace will
always operate with 3 stoves, both during installation of 4th stove and repair of existing
stoves, without adversely impacting the operating HBT, coke rate and productivity of the
furnace. Blast Furnace shutdown of 10 days is considered for extension of hot blast
main for connection with new 4th stove.

Capital cost of the Project is estimated at Rs.56.23 Crore (net of Input Tax Credit of Rs.8.48
Crore) on base date of 4th Quarter, 2020, including IDC of Rs.3.73 Crore.

As per cost benefit study, a net financial loss of Rs 430.96 Crores on account of less
production and higher coke rate may have to be incurred if 4 th stove is not installed and
the plant operates with 2 stoves during repair of the existing stoves.

The project is envisaged to be implemented in 17 months from stage II approval. BF#5

shutdowns of approx. 10 days has been considered for interconnection of old & new
facilities.

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CONTENTS - CHAPTERS

Chapter No. Description Page No.

1 Summary 1.1-1.3

2 Background 2.1-2.3

3 Selection of Alternatives 3.1-3.2

4 Project Description 4.1-4.24

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1-6.4

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure Description No.

No. of
pages

2.7-1 Notesheet no. PL(I&S)-/20-21 dated 02/07/2020 & letter ref. 2

no. AMR-M&SC/Consultancy/20/6283 dated 10/07/2020
assigning CET to prepare feasibility report for “Installation of 4 th
hot blast stove at BF#5, RSP”.

2.8-1 Assignment acceptance letter no. CET-17(3)/018/20/374 dated 1

22.07.2020

2.9-1 List of assumptions made for preparation of this FR 1

4.2.4 – 1 A typical Stove Operation Sequence for Staggered – Parallel 1

Mode of Operation

4.9.1-1 Hot Blast Stove Foundation; Details of Anchor Bolts 1

4.9.1-2 Hot Blast Stove Foundation; Foundation Plan & GA - Plan & 1
Section of Foundation Marked F2

4.9.1-3 Hot Blast Stove Foundation; RC Detail – Plans for Foundation 1

Marked F2

4.9.1-4 Hot Blast Stove Foundation; RC Details – Section & Details for 1
Foundation Marked F2

4.10.1-1 Risk Assessment Register 1

5.1.2-1 Schedule of Pre-Ordering Activities after Stage-I Approval 1

5.1.2-2 Schedule of Post-Ordering Activities after Stage-I Approval 1

6.1.1-1 Capital cost estimate summary 1

6.4-1 Present Operating Parameters of BF#5, RSP 1

6.4-2 Change in Operating Parameters due to 2 Stove Operation 1

6.4-3 Calculation of Financial Loss due to 2 Stove Operation during 1

Mid-Term Repair

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DRAWINGS

Sl. No. Drawing No. Description

RSP-ROURKELA/DC- HOT BLAST STOVES GENERAL

1
TPL/07/H1/50/BE/0071 LAYOUT

RSP-ROURKELA/DC- HOT BLAST STOVES GENERAL

2
TPL/07/H1/50/BE/0072 LAYOUT-WG SIDE

RSP-ROURKELA/DC- HOT BLAST STOVES GENERAL

3
TPL/07/H1/50/BE/0073 LAYOUT-HBM SIDE

RSP-ROURKELA/DC- HOT BLAST STOVES GENERAL

4
TPL/07/H1/50/BE/0074 LAYOUT-SECTIONAL VIEW

RSP–ROURKELA/DC-
5 PFD OF HOT BLAST SYSTEM
TPL/07/H1/60/BE/0031

RSP–ROURKELA/DC- PFD OF HOT BLAST SYSTEM-

6
TPL/07/H1/60/BE/0032 STREAM TABLE

RSP-ROURKELA/DC- GENERAL ARRANGEMENT - COLD

7
TPL/07/H1/01/BE/0133 BLAST MAIN SECTION A-A & D-D

RSP-ROURKELA/DC- WASTE GAS MAIN GENERAL

8
TPL/07/H1/45/BE/1351 ARRANGEMENT 2

RSP-ROURKELA/DC- GENERAL ARRANGEMENT - HOT

9
TPL/07/H1/01/BE/0182 BLAST MAIN

RSP-ROURKELA/DC- GENERAL ARRANGEMENT – WASTE

10
TPL/07/H1/01/BE/0323 GAS MAIN PART 2

RSP-ROURKELA/DC- GENERAL ARRANGEMENT – HOT

11
TPL/07/H1/01/BE/1021 BLAST STOVE

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1 SUMMARY
1.1 Blast Furnace (BF) #5 of Rourkela Steel Plant was installed under the

SUMMARY
Modernisation & Expansion (MODEX) of SAIL on 13th August, 2013. The
blast furnace is having inner volume of 4060 m³ and working volume of
3470 m³. BF#5 being the largest operating furnace in RSP is critical for
overall production and gas balance of the plant.
1.2 BF#5 was blown in on August 13, 2013. The BF is equipped with 3 nos. of
hot blast stoves, supplied by M/s Danieli Corus BV. While designing the
BF#5 Complex, space provision was kept for installation of 4th stove at a
future date. These stoves were designed to supply hot blast to BF#5 at a
Hot Blast Temperature (HBT) of 1250°C (3 stove operation) with a
campaign life of 20 years. The stove design is state of the art with all
modern features such as ceramic burner, mushroom dome, waste heat
recovery system etc.
1.3 Since the commissioning of BF#5, the stoves had been delivering a
consistent HBT of 1250°C during their initial periods of operation. The
furnace has already surpassed the production levels of 17 million tons.
1.4 Of late, it has been observed that hot spots are appearing in the dome
area of stove#2 from the dome thermocouple region leading to
temperature rise in the region. Similar phenomenon is also appearing in
the other two stoves. The stoves have been provided with mist cooling to
reduce shell temperature in the dome region.
1.5 The stoves are in continuous operation since commissioning and to
maintain the design hot blast temperature in BF#5, mid-term repair of the
existing 3 stoves are necessary. For the mid-term repair, each stove needs
to be cooled, inspected, repaired and heated up. Approximately 6 months
of shut down time is required for each stove to carry out these activities.
1.6 During these 6 months, 2 stove operation of the furnace is required to be
carried out. Hot blast temperature of BF#5 will reduce during 2 stove
operation of the furnace. This will in turn increase the coke rate of the
furnace, disable CDI and decrease the productivity.
1.7 As RSP is highly dependent on BF#5 blast furnace, two stoves operation
may lead to lesser production of the entire plant and adversely impact the
gas balance of the plant.
1.8 In order to eliminate the above situation at RSP, it is proposed to install 4th
stove, so that after installation of the same, while the work of mid-term
repair of stoves are undertaken one at a time, the furnace operates with 3
stoves, without adversely affecting the HBT. As a result the productivity
and coke rate of the furnace will not get adversely impacted.

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1.9 The 4th hot blast stove in BF#5 RSP will be of internal combustion type
with all latest design features as in the existing stove system. All major
levels and dimensions of the stove system will be designed as per existing
SUMMARY

system. The new stove will be installed in the designated place kept in the
General Layout. Extension of hot blast main will be done to accommodate
the 4th stove in the system.
1.10 The stove will be designed based on the design parameters of existing
stove system as given in the following table:

Maximum Dome temperature 1450° C

Hot blast temperature 1250°C (after mixing)

Blast volume 6600 Nm3/Min. (enriched dry blast) +

60 g/Nm3 moisture

Cold Blast Pressure 4.6 kg/cm2 (g)

Cold blast temperature 150 - 180° C

Cold blast moisture (maximum) 60 g/Nm3

Cold blast oxygen enrichment 4 - 6%

Mixed Gas Flow 158400 Nm3/hr

Mixed Gas Temperature 180° C

Air for Combustion 151000 Nm3/hr

Combustion Air Temperature 180° C

Waste Gas 281000 Nm3/hr

Waste Gas Temperature 400° C

1.11 The project is envisaged to be implemented within a period of 18 months

from the date of Stage-II approval. Pre-ordering activities are envisaged to
be completed within 6 months from the date of Stage-I approval.
1.12 It is proposed to implement the job through a single turnkey package.

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1.13 The existing manpower will be utilised for operation and maintenance of
the 4th stove. No additional manpower is envisaged.
1.14 Capital cost of the Project is estimated at Rs.56.23 Crore (net of Input Tax
Credit of Rs.8.48 Crore) on base date of 4th Quarter, 2020, including IDC of
Rs.3.73 Crore.
1.15 Cost benefit analysis of the project is carried out based on estimation of
losses in the scenario of non-installation of 4th stove. In that scenario, mid-
term repair of existing stoves will be carried out one by one. During this
time 2 stove operation will be resorted to. BF#5 will operate with lower
HBT resulting in reduced productivity, increased coke rate and non-
usability of CDI.
1.16 Lower HBT is expected to bring down the hot metal production from 7035
tpd (based on year 2019-20) to 6571 tpd. Lower HBT will also increase the
coke rate from 384 kg/tHM to 509 kg/thm due to combined effect of
higher coke rate and non-usability of CDI. This will lead to additional coke
requirement of 645 tpd.
1.17 As per CET experience, every stove will require approximately 180 days of
shutdown for cooling, inspection, repair and heating up. Two stove
operation during this period (repair of single stoves) will amount to loss of
Rs 153.93 Crores. Monthly loss during repair of three stoves will be around
Rs 25.66 Crores. Total Financial Loss on account of two stove operation
during repair of all 3 stoves will be Rs 461.80 Crores.
1.18 Considering shutdown requirement of 10 days for extension of hot blast
main for installation of 4th stove there will be financial loss of Rs 30.84
Crores on account of production loss.
1.19 As per cost benefit study, a net financial loss of Rs 430.96 Crores on
account of less production and higher coke rate may have to be incurred if
4th stove is not installed and the plant operates with 2 stoves during repair
of the existing stoves.
1.20 With the installation of 4th stove, while the work of repair of existing stoves
is undertaken one after another, the furnace will operate always with 3
stoves, without adversely affecting the HBT. As a result the productivity
and techno economics of the furnace will not get adversely affected. This
is imperative to maintain stable production and gas balance of ROURKELA
steel plant (during stove repair) which is dependent on single blast
furnace.
1.21 The project is technically feasible, hence recommended for consideration.

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2 BACKGROUND
2.1 Blast Furnace (BF) #5 of Rourkela Steel Plant was installed under the
Modernisation & Expansion (MODEX) of SAIL on 13th August, 2013. The blast
furnace is having inner volume of 4060 m3 and working volume of 3470 m3.

BACKGROUND
BF#5 being the largest operating furnace in RSP is critical for overall production
and gas balance of the plant.
2.2 BF#5 was blown in on August 13, 2013. The BF is equipped with 3 nos. of hot
blast stoves, supplied by M/s Danieli Corus BV. While designing the BF#5
Complex, space provision was kept for installation of 4th stove at a future date.
These stoves were designed to supply hot blast to BF#5 at a Hot Blast
Temperature (HBT) of 1250 0C (3 stove operation) with a campaign life of 20
years. The stove design is state of the art with all modern features such as
ceramic burner, mushroom dome, waste heat recovery system etc.
2.3 DESIGN OPERATING PARAMETERS OF EXISTING HOT BLAST STOVES

Nos. of operating stoves 3

Operating mode Standard operation: 2 ON GAS /1

ONBLAST, cyclic

Maximum Dome temperature 1450° C

Hot blast temperature 1250°C (after mixing)

Blast volume 6600 Nm3/Min. (enriched dry blast) + 60

g/Nm3 moisture

Cold Blast Pressure 4.6 kg/cm2 (g)

Cold blast temperature 150 - 180° C

Cold blast moisture (maximum) 60 g/Nm3

Cold blast oxygen enrichment 4 - 6%

Mixed Gas Flow 158400 Nm3/hr

Mixed Gas Temperature 180° C

Air for Combustion 151000 Nm3/hr

Combustion Air Temperature 180° C

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Waste Gas 281000 Nm3/hr

Waste Gas Temperature 400° C

2.4 POOR CONDITION OF STOVE SYSTEM

BACKGROUND

2.4.1 Hot Spots in the Shell

Since the commissioning of BF#5, the stoves had been delivering a consistent
HBT of 1200°C during their initial periods of operation. The hot spots started
appearing from the dome thermocouple region and gradually spread to other
parts of the dome.
2.4.2 Low Hot Blast Temperature
In order to avoid further increase of shell temperature of the stoves, dome
temperature and corresponding hot blast temperature were lowered. The
average monthly hot blast temperature is 1180°C and average monthly dome
temperature is 1330°C.

The table given below shows the monthly hot metal production during the year
2019-20:

Sl. No. Month (2019) Hot Metal CDI Injection

Production (ton) (kg./ ton)

1. August 2019 146337 76

2. September 2019 206177 114

3. October 2019 212056 134

4. November 2019 229895 134

5. December 2019 230558 141

6. January 2020 239369 137

7. February 2020 229704 127

8. March 2020 234593 109

9. April 2020 167235 82

10. May 2020 164470 84

11. June 2020 199019 115

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Sl. No. Month (2019) Hot Metal CDI Injection

Production (ton) (kg./ ton)

12. July 2020 239578 134

BACKGROUND
13. August 2020 244381 126

2.5 APPROACHING MID TERM REPAIR SCHEDULE

The stoves are in continuous operation since commissioning and to maintain
the design hot blast temperature in BF#5, mid-term repair of the existing 3
stoves are necessary. For the mid-term repair, each stove needs to be cooled,
inspected, repaired and heated up. Approximately 6 months of shut down time
is required for each stove to carry out these activities. In absence of 4th stove,
during these 6 months, 2 stove operation of the furnace is required to be
carried out. Hot blast temperature of the blast furnace will be required to be
reduced during 2 stove operation of the furnace. This will in turn increase the
coke rate of the furnace, disable CDI and decrease the productivity.

2.6 In order to eliminate the above situation at RSP, it is proposed to install 4th
stove, so that after installation of the same, while the work of mid-term repair of
stoves are undertaken one at a time, the furnace operates with 3 stoves, without
adversely affecting the HBT. As a result the productivity and coke rate of the
furnace will not get adversely impacted.
2.7 RSP, vide Notesheet no. PL(I&S)-/20-21 dated 02/07/2020 & letter ref. no. AMR-
M&SC/Consultancy/20/6283 dated 10/07/2020 assigned CET to prepare
feasibility report for “Installation of 4th hot blast stove at BF#5, RSP”. A copy of
the Notesheet is placed at Annexure 2.7-1.
2.8 Subsequently, a series of correspondences and deliberations took place
between RSP and CET over the issue of requirement of 4th Stove. Finally, the
assignment was accepted and the acceptance was conveyed to RSP vide letter
no. CET - 17(3)/018/20/374 dated 22.08.2020. A copy of the acceptance letter is
placed at Annexure 2.8-1.
2.9 Due to worldwide pandemic situation due to outbreak of COVID19 and
subsequent lockdown and travel restrictions, site visit could not be carried out
for feasibility study. In this situation, this FR has been prepared based on verbal
communications made over telephone and electronic communication over
email with concerned personnel of RSP and RSC. Due to this unprecedented
situation, the feasibility report is based on certain assumptions, which are listed
in Annexure 2.9-1.
2.10 CET gratefully acknowledges the co-operation and assistance extended by
Rourkela Steel Plant in preparation of this Feasibility Report.
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3 SELECTION OF ALTERNATIVES
3.1 3 nos. of hot blast stoves of BF#5, RSP are operating continuously since August
2013 and fast approaching their mid-term repair schedule. Already hot spots
have started appearing in various areas of stove dome. The deteriorating health
of stoves makes their mid-term repair imminent.
3.2 During mid-term repair, each stove will be taken down, cooled, repaired and
heated up. Approximately 6 months’ time will be required for these activities in

SELECTION OF ALTERNATIVES
each stove. During this period extending to approx.18 months, 2 stove
operations will be resorted to for running BF#5. This will lead to lower hot blast
temperature and corresponding higher coke rate and lower productivity in the
furnace. As RSP is heavily dependent on BF-5, the situation will lead to lower
production of plant and adversely impact gas balance of the plant.
3.3 In recent time, there are some examples of adding a 4th hot blast stove in a 3
hot blast stove system in India and outside India.
3.4 Outside India, in Arcelor Mittal South Africa, Vanderbijlpark works, BF#D (2530
m3), a new fourth stove of an internal combustion type was added to three
existing external combustion stoves. This project was then followed by the
systematic rebuilding of two of the three existing Stoves and ultimately
replacing of the Hot Blast Main as part of the blast furnace rebuild. When the
project is finally completed in 2007 during the blast furnace rebuild, the stove
arrangement has been modified from three aging and non-performing external
stoves to three new and modern internal stoves.
3.5 At SSAB Lulea BF#2(2845 m3), a range of stove work was carried out
commencing with a hot burner replacement on an existing stove, then
installation of a new 4th stove and finally a partial rebuild of two of the
remaining external chambered stoves. This is a case where the fourth stove
ensured three stoves were always available during rebuilding the existing stoves.
At the same time the new stove will significantly reduce the waste gas velocities
in the combustion chambers of the existing stoves during heating cycle, when
operating in a four stove cyclic mode at the future increased blast duty.
3.6 Presently, large and high productive BFs with 3 stove operation in India are also
going for installation of 4th stove. In India, 4th hot blast stoves have been
installed in both BF#3 and BF#4 (both large BFs with 4019 m3 useful volume) of
JSW, Toranagallu.
3.7 In Tata Steel Kalinganagar, after 8 years of operation, 4 th stove in BF #1 (4330
m3) is now under construction. These are external combustion chamber stoves.
3.8 RINL, Vizag, BF#1 and 2, originally designed with 4 Russian designed stoves
operation but later shifted to 3 stove operation after up gradation, again started
4 stove operations due to poor health of one of the stoves.

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3.9 In all the above cases, the need for inclusion of 4th stove arose when either
major upgradation of stoves were due or when a particular stoves(s) had poor
health and required immediate repair without adversely impacting the hot metal
production from the furnace and the coke rate.
3.10 In line with the above global trend, installation of 4th stove in BF#5 is proposed
to avoid 2 stove operations during mid-term repair of existing three stoves.
Space provision and utility tapping points for installation of a 4th hot blast stove
is already kept in the design of the stove system in BF#5, RSP. The smooth
SELECTION OF ALTERNATIVES

operation of the furnace can be guaranteed with the fourth stove acting as a
backup while repairing the existing stoves, one at a time.
3.11 Hence, in view of requirement of RSP and present global trend of installation of
4th stove in large and high productive BFs, no other alternative is considered for
this assignment and installation of 4th hot blast stove is proposed.

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4 PROJECT DESCRIPTION
4.1 GENERAL
4.1.1 The existing hot blast stove system in BF#5 is state of the art, internal
combustion type, ceramic burner, mushroom dome design with all modern
technologies. The stove system is designed for 3 stove operation as well as 2
stove operation in case a stove is out of stream. Provision for installation of a 4 th
hot blast stove is kept in the design of stove system.
4.2 PROCESS & TECHNOLOGY
4.2.1 The 4th hot blast stove will be of internal combustion type with all latest design
features as per the existing stove system. All major levels and dimensions of the
stove system will be same as existing system. The new stove will be installed in
the designated place kept as shown in the General Layout and Cross Section
drawings (Drawing No. RSP–ROURKELA/DC-TPL/07/H1/50/BE/0071 Rev=C,

PROJECT DESCRIPTION
0072 Rev=C, 0073 Rev=C and 0074 Rev=C). The existing arrangement of
stove shell is as shown in General Arrangement drawing (Drawing No. RSP–
ROURKELA/DC-TPL/07/H1/50/BE/1021 Rev=1). Extension of hot blast main
will be done to accommodate the 4th stove in the system. The hot blast system
will be modified for 4-stove operation. Provision has been kept in the existing
stove system for connection of proposed 4th stove with existing cold blast
system, combustion air system, mixed gas system and waste gas system.
4.2.2 The stove will be designed based on the design parameters of existing stove
system as given in the following table:

Maximum Dome temperature 1450° C

Hot blast temperature 1250°C (after mixing)

Blast volume 6600 Nm3/Min. (enriched dry blast) + 60

g/Nm3 moisture

Cold Blast Pressure 4.6 kg/cm2 (g)

Cold blast temperature 150 - 180° C

Cold blast moisture (maximum) 60 g/Nm3

Cold blast oxygen enrichment 4 - 6%

Mixed Gas Flow 158400 Nm3/hr

Mixed Gas Temperature 180° C

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Air for Combustion 151000 Nm3/hr

Combustion Air Temperature 180° C

Waste Gas 281000 Nm3/hr

Waste Gas Temperature 400° C

4.2.3 Process flow diagram of existing stove system attached as drawing no. RSP–
ROURKELA/DC-TPL/07/H1/60/BE/0031, Rev=4 and RSP–ROURKELA/DC-
TPL/07/H1/60/BE/0032, Rev=4. The new 4th hot blast stove system will be
designed keeping all flow parameters same as existing stoves.
4.2.4 After installation of 4th stove, existing 3 stoves will be taken down one by one,
cooled, inspected, repaired and heated up by RSP. Once all 4 stoves are ready
for operation, staggered – parallel mode of operation will be adopted. A typical
PROJECT DESCRIPTION

stove operation sequence for staggered – parallel mode of operation is

attached as Annexure – 4.2.4 – 1. However, in Auto Mode, stoves are selected
for switchover based on dome and waste gas temperature.

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4.3 MECHANICAL
4.3.1 General
New mushroom dome design type stove No. 4 for BF#5 of RSP has been
envisaged along with connections to existing hot blast main, cold blast main,
combustion system i.e. gas main, air main and waste gas main. The new stove
No. 4 will be installed in the space earmarked for future provision of 4th stove.
Hydraulic & lubrication requirement for the new system will be catered by
existing power packs. New valve stands, valves, pipeline and fittings will be
provided for hydraulic and lubrication requirement for stove valves of 4th stove.

4.3.2 Dismantling
The expansion joint HBEJ-04 (existing expansion joint in between 3rd stove &
dished end of HBM) and part of the Hot Blast Main from HBEJ-04 till dished end

PROJECT DESCRIPTION
has been considered for dismantling.
4.3.3 Refractory Supporting Structure
The main consideration in designing the refractory supporting system will be
avoidance of deformation under load and temperature. For this reason, material
of these items will be alloy grey cast iron as this has the advantage of little
deformation under load at higher waste gas temperature and no introduction of
residual stresses during the manufacturing process. Material of checker
supporting system envisaged will be GG 30 as per DIN 1691 suitable for
maximum operating temperature of 400°C and incidental peak of 450°C.
4.3.4 Hot Blast Main
The new hot blast stove no. 4 envisaged will be provided with extended hot
blast main (HBM) & hot blast outlet branch, dished end cover, reinforcement
rings for HBM, tie beams, tie rods, thrust collar and saddle supports. The
extended length of HBM will be 16.45m (approx.). New hot blast outlet (HBO)
branch will be provided to install new hot blast valve with new expansion joint.
The extended HBM will have the same size (ID steel 2600mm) as the existing
HBM and the extended length will be provided with new expansion joints. Tie
rods with thrust collar will also be provided in the extended HBM. The material
of construction of extended hot blast main (HBM) will conform to 16Mo3 (ASTM
A516, Gr. 70) alloy steel.
4.3.5 Cold Blast Branch and Pressurizing Line
A new cold blast branch (ID steel 1600mm) will be connected to the existing
Cold Blast main (CBM). Tapping of cold blast from existing cold blast main will
be provided for this connection. The branch line will be provided with a cold
blast shut off valve and an expansion joint. New pressurizing line (DN 400mm)
with pressurising valve will also be provided which will be tapped from the

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existing pressurising main near Stove no. 4. Cold blast branch and pressurizing
lines will be fabricated from ultrasonically tested steel plates conforming to
ASTM A516, Gr. 60, (P235GH) or IS 2002:2009, Gr.2 or better material.
4.3.6 Combustion System
[Link] Mixed Gas System

A new mixed gas branch line (ID steel 1800mm) for the new stove will be
connected to the existing Mixed Gas Main (MGM) of dia. 2300mm for Stove no.
4. Tapping of mixed gas from existing mixed gas main will be provided for this
connection. The branch line will be provided with isolation valve, control valve,
shut-off valve, purging & venting facilities, insulation, venturie and expansion
joint. New mixed gas branch line will be fabricated from ultrasonically tested
steel plates conforming to ASTM A516, Gr. 60, (P235GH) or IS 2002:2009 or
better material.
[Link] Combustion Air System
PROJECT DESCRIPTION

A new combustion air branch line (ID steel 1800mm) for the new stove will be
connected to the existing Combustion Air Main (CAM) of dia. 2300mm for stove
no. 4. Tapping of combustion air from existing combustion air main will be
provided for this connection. The branch line will be provided with a shut-off
valve, control valve, insulation, venturie and expansion joint. New combustion
air branch line will be fabricated from ultrasonically tested steel plates
conforming to ASTM A516, Gr. 60, (P235GH) or IS 2002:2009 or better material.
[Link] Gas Bleeder System

A gas bleeder system will be provided in order to release the trapped gas into
the atmosphere.
4.3.7 Waste Gas System
Two new waste gas branch lines of ID steel 2500mm for the new 4th stove will
be connected to the existing Waste Gas Main (WGM) of dia. 3900mm for Stove
no. 4. New tapping for waste gas will be provided in the Waste Gas main. The
branch will be provided with a shut-off valve, expansion joint and supports. New
waste gas branch line will be fabricated from ultrasonically tested steel plates
conforming to ASTM A516, Gr. 60, (P235GH) or IS 2002:2009 or better material.
4.3.8 Expansion Joints
Different expansion joints have been envisaged in the extended Hot Blast Main,
hot blast outlet branch, cold blast branch, mixed gas branch, combustion air
branch and waste gas branch lines of stove no. 4 to take care of movements due
to thermal expansion and thrust from internal pressure. These expansion joints
will be designed to take care of axial movement and/ or lateral movement

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because of ambient condition, heated-up condition and pressurised condition,

wherever required.
The material of convolution and the end rings of expansion joints in the
extended HBM and hot blast outlet branch will be NiCrMo 42.21.3 (2.4858) or
Incoloy 825 or equivalent. For Cold Blast Line, Mixed Gas Line, Combustion Air
Line and Waste Gas Lines, material of convolution of expansion joints will be
X2CrNiMo 17-12-2 (1.4404) or stainless steel SA240 Gr.316Ti or equivalent.
Following expansion joints are envisaged for the proposed new stove:
i) HBEJ-05A of size 2600 NB: This expansion joint will be installed on the
HBM in between Stove no. 3 & 4 to take care of axial and angular
movements.
ii) HBEJ-04A of size 2600 NB: This expansion joint will be installed on HBM
after Stove no. 4 before the dished end to take care of axial, lateral

PROJECT DESCRIPTION
angular movements
iii) HBEJ-03A of size 2600 NB: This expansion joint will be installed on the
HBO branch to take care of axial, lateral and angular movements.
iv) CBEJ-03A of size 1600 NB: This expansion joint will be provided in the
new Cold blast branch line to take care of axial, lateral and angular
movements.
v) MGEJ-03A of size 1800 NB: This expansion joint will be provided in the
new mixed gas branch line to take care of axial, lateral and angular
movements.
vi) MGEJ-06A of size 2300 NB: This expansion joint will be provided in the
existing mixed gas header to take care of axial, lateral and angular
movements.
vii) CAEJ-03A of 1800 NB: This expansion joint will be provided in the new
Combustion Air branch line to take care of axial, lateral and angular
movements.
viii) CAEJ-06A of 2300 NB: This expansion joint will be provided in the new
Combustion Air header to take care of axial, lateral and angular
movements.
ix) WGEJ-05A & WGEJ-06A each of size 2500 NB (ID Steel): These expansion
joints will be provided in the two new Waste Gas branch lines to take
care of axial, lateral and angular movements.
4.3.9 Stove Valves
Following new valves have been envisaged.

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Sl. Type of Valve Actuation Quantity

No.

1. Hot Blast Shut-off Valve of ID steel, Hydraulic 1 no.

2600mm / ID refractory 1648mm

2. Cold Blast Shut-off Valve of ID steel Hydraulic 1 no.

1600mm

3. Pressurising Valve of size ND 400mm Hydraulic 1 no.

4. Goggle Valve for Air Line Manual 1 No.

5. Combustion Air Shut-off Valve of ID Hydraulic 1 no.

steel 1800mm
PROJECT DESCRIPTION

6. Goggle Valve for Mixed Gas Line, ID Electric slide 1 no.

steel 1700mm & Hydraulic
clamp

7. Mixed Gas Shut-off Valve of ID steel Hydraulic 1 no.

1800mm

8. Mixed Gas Safety Shut-off (Isolation Hydraulic 1 no.

Valve) of ID steel 1800mm

9. Mixed Gas Vent Valve of size ND Mechanical 1 no.

200mm linkage with
MGSV

10. Mixed Gas Bleeder Valve ND 150 mm Manual 2 nos.

11. Nitrogen Gas Shut-off valve of size Mechanical 1 no.

DN 25mm linkage with
MGSV

12. Waste Gas Shut-off Valve of ID steel Hydraulic 2 nos.

2200mm

13. De-pressurising Valve of size ND Hydraulic 2 no.

400mm

Existing hydraulic system and grease lubrication systems have been envisaged
for operation of hydraulically operated stove valves. New hydraulic & lubrication
piping and valve stands will be provided for operation of these hydraulically

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operated valves. Besides above, new control valves of required sizes will also be
provided in gas line and air line.
4.3.10 Handling Facility
The electric hoists and maintenance trolley available for handling of the existing
stove valves of BF#5 will be used to handle the valves of the new Stove no. 4. If
required existing rail and monorail of the existing maintenance trolley and
electric hoists will be extended to suit the requirement of new 4th Stove.
The existing handling facilities are as follows:
i) A 32t maintenance trolley to handle Hot Blast Shut-off Valve
ii) A 10t hoist to handle Cold Blast Shut-off & Waste Gas Shut-off Valve
iii) A 5t hoist to handle Mixed Gas Isolation Valve
iv) A 5t hoist to handle Combustion Air Shut-off and Mixed Gas Shut-off

PROJECT DESCRIPTION
Valves
v) A 5t hoist to handle Combustion Air Control and Mixed Gas Control
Valves
vi) A 20t hoist to handle Mixed Gas Goggle Valve

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4.4 UTILITIES & SERVICES

4.4.1 It is assumed that the existing utility system of Blast Furnace (BF-5) Stoves have
been designed with the provision for 4th stove. Hence, it is assumed that
tapping and supply/ return header extension of existing utilities like, instrument
air, soft water, combustion air (CA), mixed fuel gas, fuel gas for initial heating
have been considered in existing design. Also, existing oxygen enrichment
facilities and steam humidification will be used.
4.4.2 The following jobs have been envisaged for installation of 4th stove of BF#5,
RSP;
1. Tapping of soft water supply from branch connection provided for 4 th
stove in existing DN 200 supply header after isolation valve and
connecting return soft water (SW) pipe to return water branch pipe
provided for 4th stove in existing DN 200 return water header before
isolation valve of close loop circuit of existing stoves. Installation of supply
PROJECT DESCRIPTION

and return distribution piping with valves, hoses, fitting, supports etc. for
hot blast valve of 4th stove similar to other existing stove. Control valve
system in the return water lines from valve will also be provided.
Connection of safety valve discharge (supply & return side) of 4th stove to
existing DN100 header.
2. Taping of Coke Oven gas line from existing initial heat up header DN300
and installation of new facilities for initial heating up of 4th stove similar to
other existing stove of BF#5.
3. Tapping of Coke Oven gas, compressed air and nitrogen line from existing
header and provision of distribution piping with valves, fitting and
supports for pilot burner system of 4th stove similar to other stoves.
4. Tapping of Instrument air from existing header and provision of
distribution piping with valves and fitting to pneumatic actuated valves of
4th stove similar to other existing stove.
5. Tapping of compressed air and nitrogen gas line from existing header and
provision of distribution piping with valves, fitting and supports for
pyrometer cooling of 4th stove similar to other stoves.
6. Instrument air is selected normally for pyrometer cooling. If cooling air
pressure is low than nitrogen gas to be supplied for cooling purpose.
7. Tapping and extension of nitrogen gas line for purging and provision of
distribution piping with valves and fitting to 4th stove fuel gas lines similar
to other existing stove.
8. Blanking and de-blanking, supports of gas lines and other utility lines have
been considered.
9. Initial heating of stove as per heat up schedule.
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10. Header for following facilities are already provided up to the area of 4 th
stove installation hence, following work will be considered (details as
mentioned in FR cl. 4.3)
a) Tapping of combustion air (CA) header from existing CA fan common
discharge header outlet to 4th stove as per technological
requirement.
b) Tapping of fuel gas header from existing gas header to 4th stove as
per technological requirement.
11. Required instrumentation will be provided for flow, pressure and
temperature measurement in all the utilities similar to other existing stove
of BF-5 and as detailed in FR cl. 4.7.
4.4.3 Battery Limit

Incoming

PROJECT DESCRIPTION
Cold Soft water for From existing water header branch line DN200
cooling stove valves after isolation valve pressure: 5 – 6 kg/cm2 (g)
near stove 3 within a distance of 100m from
proposed site.

Nitrogen for purging From existing nitrogen header DN100,

2
purpose pressure: 4 - 5 Kg/cm (g) near stove 3 within a
distance of 100m from proposed site.

Nitrogen for From existing nitrogen header DN50, pressure:

instrument purpose 6 - 7 Kg/cm2 (g) near stove 3 within a distance
of 50m from proposed site.

Compressed air for From existing compressed air line DN25,

instrument purpose pressure: 5 - 6 Kg/cm2 (g) near stove 3 within a
distance of 50m from proposed site.

Branch BF Gas/ Mixed From existing BF gas/ mixed gas header after
gas branch line DN1800 (pressure: 1000-1400
mmWC) within a distance of 30m from
proposed site.

Coke Oven gas for From existing stoves initial heating header
initial heating DN300, pressure: 1600 mmWC within a
distance of 30m from proposed site.

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Combustion air From existing combustion air header after

branch line DN1800 (pressure: 1500mmWC)
within a distance of 20m from proposed site.

Out going

SW hot water from To existing hot water return header branch line
valves cooling DN200 up to isolation valve within a distance
of 30m from proposed site.

Water discharge of To the existing DN100 header within a distance

safety valve of 30m from proposed site.

Flue gases To the existing Flue gas header within 30m

PROJECT DESCRIPTION

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4.5 REFRACTORY
4.5.1 Hot Blast Stove
[Link] Existing hot blast system consists of 3nos of stove having following major
dimensions and features;
· Internal Diameter Steel : 10200 mm
· Total height of stove : 48500 mm
· Elevation of hot blast outlet : +17950 mm
· Type of stove : Internal combustion
· Type of Dome : Mushroom
· Type of burner : Vertical ceramic (bottom fired)
· Shape of combustion chamber : Eye shape
· Type of checker : Hexagonal with 7 holes
[Link] New hot blast stoves (4th Stove) will have internal combustion type with

PROJECT DESCRIPTION
mushroom dome and ceramic burner for operating HBT of 1250°C (after mixing)
and dome temperature 1450°C. Suitable refractory brickwork lining will be done
to achieve the HBT of 1250°C (after mixing).
Stove cross section will consist of a checker chamber with an eye shaped
combustion chamber. In the combustion chamber vertical ceramic burner will be
installed. The stove shell will be provided with necessary openings connecting to
hot blast main, cold blast main, combustion system i.e. gas and air main, waste
gas system, peep hole, ignition flame, thermo-couple connections, etc. It will
also be provided with manholes for erection and maintenance purpose.

The salient features of the new stoves will be as under:-

· Internal combustion type

· Bottom fired
· Vertical ceramic burner
· Eye shape combustion chamber
· Hexagonal checkers
· Mushroom dome
· Use of silica bricks for dome and upper part of stove
· Use of gunning castable on stove and dome shell
[Link] Refractory Brickwork
The salient features of the proposed refractory brickwork are enumerated
below.

1. Checker Work:

It is proposed to use newly design hexagonal type checkers. The checkers

will be installed together with a matching design checker support system.
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2. Checker Chamber Wall:

The dense wall will be suitably split up in three qualities in high alumina
and silica. The checker chamber wall will consist of a dense layer of
suitable thickness with back up of one/ two layers of insulation refractory
of suitable thickness in addition to a layer of gunning castable along the
inside of the stove shell . The upper dense bricks will be of silica quality.
The quality of insulation layers will be selected in such a way that the steel
shell temperature does not exceed 120°C for the above operating
temperature parameters. To take care of the differential expansion of the
adjacent layers sliding joint construction will be provided.

3. Partition Wall:

The partition wall will consist of two dense layers, one on checker chamber
PROJECT DESCRIPTION

side and the other facing combustion chamber. In between the two dense
layers two insulation layers will be introduced for proper temperature
gradient across the wall to avoid bending tendency of the walls. The upper
dense wall will be in silica quality. The steel alloy sheet will be installed
over the dense layer on checker side. To have better stability and free
expansion, the wall will be designed in panels with tongue and groove
brick construction in the dense layer. To take care of the differential
expansion of the adjacent layer sliding joint construction will be provided.

4. Combustion Chamber Wall:

The combustion chamber wall consists of insulation brickwork followed by

one layer of dense bricks. Adjacent to dense layer, two layers of insulation
refractory will be provided. The inner most layer will be one layer of dense
bricks of suitable thickness. The upper wall will be provided in silica quality
in dense wall. The quality of insulation layers will be selected in such a way
that the steel shell temperature does not exceed 120°C for the above
operating temperature parameters.

5. Dome:

The dome will be mushroom design. Refractory for mushroom dome will
be designed for 1450°C. The dome will consist of one dense layer of silica
bricks of suitable thickness followed with two/ three insulation layers, and
gunning refractory material.

6. Ceramic Burner:

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The ceramic burner consists of gas and air slots made up with different
shapes of refractory bricks/ castable. Refractories used in construction
have special shapes to provide the desired gas and air duct work to obtain
equal distribution of gas and air at the top of the burner. It provides good
and stable combustion for any air/gas ratio. Due to vertical flame in the
combustion chamber, a uniform temperature distribution both across
length and cross-section of the combustion chamber is achieved, which
minimizes thermal stress in the stove refractory construction.

4.5.2 Extended Portion of Hot Blast Main

Existing hot blast main is having following major dimensions

· ID hot blast main : 2600 mm

· ID refractory : 1648 mm

PROJECT DESCRIPTION
Extended portion of hot blast main will also have ID hot blast main and ID
refractory same as existing. The refractory lining of extended hot blast main will
consists of a high alumina hot face layer suitable for maximum hot blast
temperatures of 1250°C (after mixing). The high alumina layer will be backed up
with two insulation brick layers in addition to a layer of gunning castable along
the inside surface of the shell.

4.5.3 Connection of Waste Gas Outlets to the Existing Waste Gas Main
Existing waste gas header is having following major dimensions

· ID shell : 4200 mm
· ID refractory : 3900 mm
Waste gas outlet of the 4th stove will be connected with existing waste gas
header. Waste gas outlets will be lined with dense gunning castable followed by
one layer insulating gunning castable along the inside surface of the shell with
proper anchoring.

4.5.4 Refractory quantity

Gross refractory quantity required for proposed 4th stove, extended hot blast
main and waste gas outlets has been derived based on existing design. It is
approximate 4580 tons. Quality wise break up of refractory material is as under
follow.

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Gross Quantity
Sl. No. Type of refractory material Unit (approx.)

1 Dense bricks Ton 1335

2 Checker bricks Ton 2030

3 Insulation bricks Ton 405

4 Castable and Mortar Ton 730

5 Ceramic Burner Ton 65

Total Ton 4565

PROJECT DESCRIPTION

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4.6 ELECTRICAL
4.6.1 Power Requirement
The tentative power requirement of the proposed system is as under:
Voltage level Connected Load Max Demand
0.415 kV 35 kW(approx.) 20 kW(approx.)

4.6.2 Power Distribution Scheme

LT power supply will be tapped from outgoing terminals of spare feeder of
existing LT panel in MAIN ECR building to feed proposed PMCC panel through
415 V isolator.
This PMCC panel will feed proposed loads through required no. of MCCB/
MPCB feeders in proposed substation.

PROJECT DESCRIPTION
4.6.3 The following major electrical equipment have been considered:
[Link] 415 V Isolator

One no. 100A, 415V isolator will be provided to isolate proposed PMCC panel
during maintenance. This panel will be floor mounted, sheet steel clad in
construction.

[Link] PMCC panel

One no. of single front, sheet steel metal clad PMCC panel will supply LT power
to proposed facilities. It will have 2 nos. incomer MCCBs, one no. bus coupler
MCCB & required nos. of MPCB/ MCCB outgoing feeders.
Location: PMCC panel will be located in Main ECR MCC Room in ground floor.

[Link] Drive Motors

All LT motors will be IE2 class, TEFC squirrel cage induction motor suitable for
415 V, 3 phase, 50 Hz supply. Crane & hoist drive motors will be S4 duty.
Motors being fed from VFD will be inverter duty motors.

[Link] Control desk

Control desk with pushbuttons, indication lamps & selector switches is

envisaged at existing control room. It will be floor mounted, vertically standing
type & will match with existing control philosophy.
Location: Control desk will be located in Main ECR RIO room in second floor

[Link] Local Control Stations

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Local Control stations with Emergency stop & start pushbutton & LED
indications have been considered. LCS will be provided with selector switch
matching with operational philosophy.

[Link] LT and Control Cables

1.1kV grade aluminium conductor, XLPE insulated, PVC sheathed, armoured,

FRLS PVC outer sheathed power cables is considered.
1.1 kV grade stranded multi-core copper conductor, XLPE insulated, PVC
sheathed, armoured, FRLS PVC outer sheathed control cables have been
envisaged.
[Link] Illumination System

Illumination for proposed facilities including lighting board, sub lighting

distribution boards, lighting fixtures, switches, sockets, lighting wires,
emergency lighting etc. is considered.
PROJECT DESCRIPTION

LDB panel will feed SLDB panels across the proposed facility. LED luminaires will
be provided for illumination.

[Link] Earthing

Earth strips from the proposed equipment/ items will be connected to the new
earth pits through earth grid. New earth grid will be joined to the existing earth
grid at two points.
Earthing system will be in accordance with the code of practice for earthing in
IS: 3043-1987 and will also comply with the relevant clause of Indian electricity
rules - 1956.

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4.7 PROCESS CONTROL & AUTOMATION

The process control and automation system is envisaged to provide complete
control and monitoring of the proposed 4th stove of BF#5. The process will be
controlled by the operator from the existing control room housing existing
Level-1 HMIs etc. The system will be reliable, efficient, less maintenance
oriented, and easy to operate.

4.7.1 Level of Automation

The proposed system will be based on microprocessor based SMART sensors
and actuators, with hierarchical control philosophy consisting of field sensors,
field instruments and electrics etc. at level-0, Remote IO Panel (RIOP) of the
existing ABB PLC system at level-1 for integrated control of the process. The
system may be detailed out as below:

PROJECT DESCRIPTION
· New RIOP with communication cards, power supply cards, input/ output
(AI/ AO/ DI/ DO/ T/C/ RTD) cards for integrated control of the complete
process including process parameter monitoring, PID control, and
sequential & interlocking functions of the complete system pertaining to
4th stove of BF#5. Common RIOP has been envisaged for both the
instrumentation and electrical IOs. Separate relay-panel will be provided for
the concerned RIOP. The system will be reliable, efficient, and easy to
operate, less maintenance oriented, transparent to operator, and with self-
diagnostic features.
· Inputs/ outputs from the 4th stove of BF#5 will be terminated in the new
RIOP to be housed in main the ECR RIO room (2nd floor,13 meters) and
relay-panel for the same will be housed in the main ECR MCC room
(ground floor, 0 meter).
· The new RIOP will have PROFIBUS communication with the existing ABB
make PLC system.
· One (01) no. of operator station and four (04) nos. of communication cards,
two each for the new RIOP and for the existing ABB make PLC system, have
been envisaged.
· Necessary modifications in the existing PLC and HMI software including
development of new HMI page(s) have been envisaged.
· All the stoves including the proposed 4th stove will be capable of operating
in staggered-parallel as well as cyclic modes.

4.7.2 Basic functions of Automation

[Link] Automation of Level-0

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The functions of level-0 automation system will be:

· To send all data coming from the field like pressure, temperature, flow etc.
to the PLC based data acquisition and control system.
· To actuate pneumatic and electrohydraulic control valves etc. based on the
output received from PLC.
Level 0 instrumentation system will comprise venturies, Resistance Temperature
Detectors (RTDs), thermocouples, pressure and differential pressure
transmitters, differential pressure type flow indicating transmitters, pressure
switch, pneumatic control valves along with actuators, pyrometers etc.

[Link] Automation of Level-1

Control & automation system of level-1 will monitor operational conditions of

the concerned 4th stove of BF#5, analyse the information and control the
process as well as other technological parameters. The new RIOP and existing
PROJECT DESCRIPTION

ABB PLC system will be used for integrated control of the complete system
including process parameter measurements, PID control, and sequential &
interlocking functions.
The basic functions of the complete system will be:
· Supervision of process variable: Monitoring and control of process
parameters as per technological requirement.
· Graphical display of process information.
· Diagnostic and alarm generation.
· Events and report generation.

[Link] Communication of level-1 system with electrics:

Hardwired communication has been envisaged between MCC and new PLC
RIOP.

4.7.3 Measurement & Control

The various measurements and controls (at a minimum) envisaged in the
process have been given below:-

[Link] List of measurements and controls (at a minimum):

· Dome temperature measurements for 4th stove (Pyrometer and T/C).

· All measurements and controls required for pyrometer cooling and
purging.
· Pressure measurement of combustion air to 4th stove.
· Temperature measurement of combustion air to 4th stove.
· Flow measurement of combustion air to 4th stove.
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· Pressure measurement of gas to 4th stove.

· Temperature measurement of gas to 4th stove.
· Flow measurement of gas to 4th stove.
· Air-gas ratio control.
· Differential pressure measurement across hot blast valve.
· Differential pressure measurement across chimney valve.
· Temperature measurement and high temperature alarm between GSV and
GSSV.
· Temperature measurement and high temperature alarm between CACV
and CASV.
· Waste gas pressure and temperature measurements.
· Combustion chamber temperature measurement.
· Cold blast flow measurement with pressure and temperature

PROJECT DESCRIPTION
compensation.
· Silica interface temperature measurement.
· Silica brick temperature monitoring.
· Checker temperature measurement.
· Combustion chamber temperature measurement.
· All necessary measurements and controls for the process of initial heating.
· Pressure measurement for each cooling water inlet line to hot blast valve
(HBV).
· Pressure, flow, and temperature measurements for each water outlet line
from hot blast valve.
· CO and O2 analyser for waste gas line.
· Differential pressure measurement across tapping line for pyrometer and
waste gas line.
· Pressure measurements before and after N2 SOPRV (Self-Operated Pressure
Regulating Valve).
· Pressure measurements of compressed air to pilot burner.
· Pressure measurements of fuel gas to pilot burner.
· Flame detector for pilot burner.

[Link] Alarms

Visual alarms have been envisaged to alert the operator in case of abnormal
process conditions. Visual alarms will be provided in the operator console.

[Link] Safety Interlocks

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Suitable interlocks have been envisaged for the safety of the process and the
equipment.

[Link] Suitable electronic/ RF earthing provisions for new instruments, new RIO system
etc. have been envisaged. New electronic earth pits will be provided. Also,
necessary earthing cables, earth strips along with all necessary hardware for
earthing the proposed system have been envisaged.
PROJECT DESCRIPTION

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4.8 STRUCTURAL WORK

Structural steel works envisaged for installation of 4th hot blast stove in BF#5,
RSP are as listed below. The structural work will not be limited to these but will
be guided by technical/ technological/ mechanical aspects for the total scope of
work.

4.8.1 New stove shell (mushroom dome) including base plate and anchorage at the
proposed location considering all levels and dimensions of the stove system will
be same as existing system i.e. HBM, CA, BF gas main, cold blast main and waste
gas main.
4.8.2 New structural platforms at top of new stove dome with access stair.
4.8.3 Working/ maintenance platforms including access and handling facility at
different levels for valves, manholes & thermocouples. All platform levels will be
same as existing levels of stove no 1 to 3.

PROJECT DESCRIPTION
4.8.4 New structural supporting arrangement from existing structures to new stove
for mixed gas and combustion air down leg from main header.
4.8.5 Venturi maintenance platforms for air & gas lines as per requirement.
4.8.6 New supporting structure and platform required if any for cold blast main and
WG main from main header to new stove.
4.8.7 New girders from existing columns for supporting the extension of HBM.
4.8.8 New ladder, staircase to be provided as per requirement.
4.8.9 Any other miscellaneous structures, dismantling, strengthening/ modification as
per technological/ mechanical requirement.
4.8.10 Any other work interface with the existing facilities/structures.
4.8.11 Painting of all new and existing modified structures after suitable surface
preparation.
4.8.12 Any other works not specifically mentioned above but are required for the
completion of the work will be included in the scope of work.
4.8.13 Design Considerations
[Link] All steel structures will be designed to meet the technological requirement with
due consideration to the existing plant and facilities.
[Link] Design of steel structures will be as per IS 800 (2007).
[Link] Design of stove shell will be as per technological supplier’s design.
[Link] Apart from technological loads to be supported on steel structures, self-weight
and superimposed loads for the design will be according to IS: 875 (1987).
Structures will be analysed either for wind or seismic as applicable. Wind load
on structures will be considered as per IS: 875-2015 whereas seismic loads will
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be taken as per IS: 1893(latest revision).Due allowance for impact, vibration,

temperature.
[Link] Material for stove shell will be as per 16Mo3, as per EN 10028-2.
[Link] Material for building structures will be as per IS 2062: 2011.
[Link] Steel structures will be of welded construction. The welding procedure will
conform to IS: 816-1969 and IS: 9595-1996. Electrodes will conform to IS: 814 -
2004.
[Link] Chequered plates will conform to IS: 3502-1994. Steel tubes will conform to IS:
1161-1998.
[Link] Fabrication and erection of steel structures will conform to IS: 800-2007 and
tolerances of fabrication will be as per IS: 7215-1974. Tolerances of erection of
steel structures will be as per IS: 12843-1989. All the structures will be duly
inspected and made defect free before erection.
PROJECT DESCRIPTION

[Link] Painting
1. Building Structure

All structures will be given two coats of single pack air drying phenolic
modified alkyd composition with zinc phosphate as a primer having
minimum dry film thickness of 80 microns (40 microns/ Coat). One coat of
primer will be applied before erection and one coat after erection.
Intermediate paint will be one coat of single pack high build phenolic
based paint with micaceous iron oxide (MIO) having minimum dry film
thickness of 75 micron for trestles/ other outdoor structures
Final paint will be two coats of single pack air drying high gloss phenolic
alkyd modified synthetic enamel paint as finishing coat having minimum
dry film thickness of 50 microns (25 microns/ Coat).

2. Stove Shell

One coat (DFT 20 micron) of heat resistant finished paint (F-9 as per IPSS:
1-07-064-03) on outside surface of shell segment after fabrication and two
coats of heat resistant finished paint (F-9 as per IPSS: 1-07-064-03) after
erection will be applied.
One coat of epoxy primer (P-5 as per IPSS: 1-07-064-03) of DFT 40 micron
(min.) thickness on the inside face of shell segment after fabrication and
one coat (P-5 as per IPSS: 1-07-064-03) of DFT 40 micron (min) after
erection will be applied.
Surface preparation for the above will be St-2 standard as per IPSS: 1-07-
064-03.

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4.9 CIVIL WORK

This part of the Feasibility Report deals with the design philosophy, construction
materials and other aspects related to civil works.

4.9.1 The Civil Work will include the following:-

[Link] The foundation for the proposed 4th stove has already been constructed along
with bolts and the same has been encased with lean concrete. The existing
foundation will be used for the new stove. However, any modification if required
will be done. The drawings of the existing foundation in the proposed location
are enclosed as Annexure 4.9.1-1, Annexure 4.9.1-2, Annexure 4.9.1-3 &
Annexure 4.9.1-4.
Necessary dismantling of the lean concrete will be done to expose the bolt upto
the mother concrete level.

PROJECT DESCRIPTION
[Link] Grouting with non-shrink ready mix cementitious grout of grade not less M40 at
the underside of stove base plate.
[Link] Construction of RCC foundations for pipeline supporting structures, if required.
[Link] Necessary modification of existing/ damaged bolts, if required.
[Link] Repair of any damaged existing concrete foundation if any.
[Link] General
1. Necessary surveying work including transferring and fixing of the reference
lines and bench marks for setting up of layout and construction works.
2. Site clearance of the location proposed for installation of the new stove
area as required will be done
4.9.2 Major activities relating to civil works are earthwork, plain & reinforced concrete
work, flooring, plastering and finishing etc. Following criteria will be adopted in
the design of civil engineering works:-

Grouting Grouting with non-shrink ready mix cementitious grout of

grade not less M40 at the underside of stove base plate

R.C.C M-25C in general

P.C.C M-10B for mudmat, For mass filling concrete 1:4:8 (cements
and aggregates)

Anchor pocket Non-shrinking compound (Shrinkomp-30 of M/s. ACC or

grouting equivalent) / M-30 D

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4.10 RISK ASSESSMENT

4.10.1 Risk assessment for the project is attached at Annexure- 4.10.1-1.
PROJECT DESCRIPTION

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5 IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE
5.1.1 The project is envisaged to be implemented within a period of 17 months from
the date of Stage-II approval. Pre-ordering activities are envisaged to be
completed within 6months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities, are shown at Annexure – 5.1.2-1 & 5.1.2-2 respectively.
5.2 IMPLEMENTATION STRATEGY
5.2.1 Mode of execution and number of packages:
The project is proposed to be executed through a single turnkey package.

5.2.2 Pre-requisites/ clearances, special handling eqpt. diversion of any known over
ground or underground facilities that need diversion, etc. for execution of the
project:
a) Clearance for BF shutdown for 10 days for extension of hot blast main and

PROJECT IMPLEMENTATION
final connection of gas and combustion airline, cold blast main, waste gas
main, hot blast main.
5.3 DETAILS OF PRE-SHUTDOWN ACTIVITIES WITH DURATION
a) Placement of order and contract finalisation – 1 month
b) Design & Engineering for 4th stove – 10 months
c) Manufacture and supply of equipment and refractories – 9 months
d) Fabrication and supply of technological and building structure – 9 months
e) Erection of technological and building structures including stove shell,
platforms, walkways etc., required dismantling and Erection of all stove
refractories – 9 months
f) Erection of gas line, airline, cold blast line, all valves, expansion joints,
hydraulic and lubrication piping work, electrics and instrumentation – 5
months
5.4 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION
a) Extension of HBM,
b) Connections of Combustion Air line
c) Connections of Mixed Gas Line
d) Connections of Cold Blast Line
e) Connections of Coke Oven gas line
5.5 Trial, Testing, Heating up and commissioning of 4th stove: 1 month.

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6 CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:
6.1.1 Capital cost of the Project is estimated at Rs.56.23 Crore (net of Input Tax Credit
of Rs.8.48 Crore) on base date of 4th Quarter, 2020, including IDC of Rs.3.73
Crore.
The summary of capital cost estimate of the project is as below:
(Rs. in Crore)

Sl. Indigenous Imported Total

Item
No. Component Component Amount
Plant & equipment including
1 18.53 18.53
technological structures
2 Spares NA NA

3 Building Structures 0.91 0.91

4 Refractories 17.43 17.43

5 Civil Works 0.08 0.08

6 Erection & Commissioning 5.47 5.47

7 Engineering & Construction 4.24 4.24

CAPITAL COST & FINANCIAL ANALYSIS

8 Freight & Insurance 2.70 2.70

9 Taxes & Duties 8.70 8.70

10 Others NA NA

11 Contingencies 2.90 2.90

Charges for engaging
environmental Consultant,
Fee for consent to establish
12 and provision for compliance NA NA
to EC conditions & towards
Enterprise Social
Commitment
13 Total Plant Cost 60.97 60.97

14 IDC 3.73 3.73

15 Capital Cost 64.70 64.70
16 Input tax credit (ITC) -8.48 -8.48
17 Capital Cost net of ITC 56.23 56.23
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6.1.2 Broad break-up of basic cost of “Plant & equipment including technological
structures” of the project is as below:
(Rs. in Crore)
Sl. Indigenous Imported Total
Item
No. Component Component Amount
Mechanical Equipment and
1 16.58 16.58
technological structure
2 U&S 0.53 0.53

4 Automation & Electrical 1.42 1.42

Total “Plant and
5 18.53 18.53
Equipment” Cost

6.1.3 Capital Cost estimate has been prepared considering available past orders data,
budgetary quotations and engineering estimates. However, the major
component of the plant & equipment cost estimate is Budgetary Quotations.
Breakup of basic cost of the project in percentage is depicted in the pie-chart
shown below.
CAPITAL COST & FINANCIAL ANALYSIS

3%
7%
Mechanical Equipment
and technological
structure
U&S

Automation & Electrical

90%

6.1.4 Necessary provisions have been made in the estimates as per the details given
below:
1. For indigenous items:
GST @18% on basic cost of equipment, erection and E&C (Contractor’s),
freight & insurance.

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2. Freight & Insurance charges: @ 2% of basic cost of equipment.

3. Erection & commissioning charges: @ 12% of basic cost of indigenous
equipment.
4. Engineering & construction (E&C): E&C (contractor) @ 7.5% and E&C
(owner) @ 2.5% on basic cost of equipment, civil work and erection &
commissioning charges.
5. Contingencies: @ 5% on overall basis has been considered.
6.2 MODE OF FINANCING:
6.2.1 The total capital requirement of the project is proposed to be provided from
100% debt. An interest rate @ 10% per annum is considered for commercial
borrowing.
6.3 PHASING OF CAPITAL EXPENDITURE & IDC:
6.3.1 With the project duration of 17 months from the date of final approval, phasing
of capital expenditure and IDC is proposed as indicated below:
(Rs. in Crore)
Years Internal Loan IDC Total
Resources
1st Year 36.58 1.83 38.41

CAPITAL COST & FINANCIAL ANALYSIS

2nd Year 18.29 1.91 20.20
(5 months)
Post Comm. 6.10 6.10

Capital Cost 60.97 3.73 64.70

ITC 8.48

CC net of ITC 56.23

6.3.2 Based on the mode of financing and phasing of capital expenditures indicated
above, the total IDC works out to Rs.3.73 Crore.

6.4 COST-BENEFIT ANALYSIS 

Cost benefit analysis of the project is carried out based on estimation of losses
in the scenario of non-installation of 4th stove. Present operating parameters of
BF#5 is attached as Annexure 6.4-1. Mid-term repair of existing stoves will be
carried out one by one. During this time, 2 stove operation will be resorted to if
4th stove is not installed. BF#5 will operate with lower HBT resulting in reduced

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productivity, increased coke rate and non-usability of CDI. Predicted change in

operating parameters of BF#5 due to two stove operation is attached as
Annexure 6.4-2. Lower HBT is expected to bring down the hot metal
production from 7035 tpd (based on year 2019-20) to 6571 tpd. Lower HBT will
also increase the coke rate from 384 kg/tHM to 509 kg/thm due to combined
effect of higher coke rate and non-usability of CDI. This will lead to additional
coke requirement of 645 tpd.
As per RSP experience, every stove will require approximately 180 days of
shutdown for cooling, inspection, repair and heating up. 2 stove operation
during this period will amount to loss of Rs 153.93 Crores. Monthly loss will be
around Rs 25.66 Crores. Total Financial Loss on account of all 3 stoves will be Rs

461.80 Crores. Calculation of financial loss in case of two stove operation is

attached as Annexure 6.4-3. Considering shutdown requirement of 10 days for
extension of hot blast main for installation of 4th stove there will be financial
loss of Rs 30.84 Crores on account of production loss. Hence, net financial loss
for non-installation of 4th stove is calculated as Rs 430.96 Crores.
CAPITAL COST & FINANCIAL ANALYSIS

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7 RECOMMENDATIONS
2.1 With the installation of 4th stove, while the work of repair of existing stoves is
undertaken one after another, the furnace will operate always with 3 stoves,
without adversely affecting the HBT. As a result the productivity and techno
economics of the furnace will not get adversely affected.
2.2 This is imperative for maintaining stable production and gas balance of Rourkela
Steel Plant (during stove repair) which is heavily dependent on BF-5 blast
furnace.
2.3 The project is technically feasible, hence recommended for consideration.

RECOMMENDATIONS

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 INSTALLATION OF HOT METAL GRANULATION UNIT

ROURKELA STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

SEPT 2020 CET/05/RN/4422/FR/IR/01/R=2

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This document has been prepared for Rourkela Steel Plant by:

Centre for Engineering & Technology

Jay Shankar, Iron & Sinter – HOD Lead section
Manish Kumar, Iron & Sinter (Task Force Leader)
Shyam Ji, Iron & Sinter
T C Joshi, Refractory
Surendra Prasad, Refractory
Subhro K Ghosh, Process Control & Automation
Vivek Bharti, Mechanical
K S Chandra, Civil & Structural
S N Roy, Civil & Structural
Anand Trivedi, Utilities & Services
[Link], Utilities & Services
Akshya Pandya, Electrical
Neeraj, Electrical
R Behera, Rourkela Sub Centre
R K Verma, Project Formulation & Co-ordination
P K Mishra, Cost & Techno Economics

Document Identification No. CET/05/RN/4422/FR/IR/01/R=2

REVISION HISTORY

Revision No. Brief Description Revision Date

R2 Comments of RSP on FR, R-1 regarding de-fuming 03.09.2020

system, training needs, handling & lighting facilities
etc. incorporated and cost estimate & techno-
economic analysis updated

R1 Comments of RSP on FR, R-0 for incorporation of 05.07.2018

techno-economic calculation

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report shall be reproduced or transmitted in any
form whatsoever without the written permission from the owner.

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UPSHOT

Hot metal granulation provides a buffer between blast furnace process and steel making
process and facilitates continuous, stable & optimum operation of BFs in case of
downstream disruptions in steel making process. Stable BF process results in achieving
rated techno economic process parameters viz. productivity, coke rate and achieving
maximum campaign lives of the furnace. Granulated hot metal is better alternative to pig
iron as it is easily marketable as the end use includes electric arc furnaces, induction furnaces,
cupolas, basic oxygen furnaces and foundries as a replacement of pig iron, scrap or DRI.

The hot metal granulation system at RSP will be of 300 tph capacity and will include hot
metal handling facilities through torpedo ladle, granulation facilities, water system,
service equipment, handling facilities and associated electrical & automation system.

The project will be commissioned in 18 months from the date of stage II approval.

The estimated capital cost is Rs. 63.35 crore net of ITC of Rs. 7.18 crore including IDC of Rs.
3.52 crore with an IRR 19.87% (post-tax)

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.3

2 Background 2.1-2.3

3 Selection of Alternatives 3.1

4 Project Description 4.1-4.29

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1-6.3

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure No. Description No. of pages

2.9-1 Assignment letter from RSP 1

2.9-2 Assignment acceptance letter from CET 1

2.11-1 Letter for Revision of FR R-1 1

4.1.11-1 Process Flow Diagram 1

4.12.1-1 Risk Assessment Register 1

5.1.2-1 Implementation schedule (After Stage I 1

approval)

5.1.2-2 Implementation schedule (After Stage II 1

approval)

6.1.1-1 Capital cost estimate summary 1

6.5.3-1 Gross margin calculations 1

6.6.2-1 Financial analysis 1

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DRAWINGS

Sl. No. Drawing No. Description

1 CET RN 4422 IR2 00 001, General Layout: Installation of hot metal

R=1 granulation unit

2 CET RN 4422 UT1 01 Flow diagram of water system

001, R=1

3 CET RN 4422 UT1 00 Process Flow Diagram for FES System

002, R=0

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1. SUMMARY

SUMMARY
1.1 Blast Furnace (BF) process is continuous in nature. A stable BF process is
characterized by unhiform chemical, thermal and mechanical regime,
which is pivotal for achieving optimum techno economic process
parameters and maximum campaign lives of the furnace. The BF operation
can be disrupted if the tapped hot metal cannot be processed
downstream in Basic Oxygen Furnace (BOF) / Steel Making Shop (SMS).
The disruptions affect process stabilty and deter operating parameters in
terms of higher coke consumption and lower productivity.

1.2 SMS-1 & SMS-2 of RSP produce about 10000 tpd hot metal on regular
basis. There is capability of producing hot metal of about 12000 tpd. The
mismatch between hot metal production and consumption increases
during scheduled/unscheduled shutdowns of downstream steel making
facilities.

1.3 RSP blast furnaces are provided with two pig casting facilities to process
hot metal in case same can’t be processed downstream in SMS. However,
there are certain limitations in pig casting viz. limited or no acceptance of
pigs in BOF/ EAF steel making, low capacity, slow process, operational
issues in low silicon hot metal casting, weak market etc.

1.4 Hot metal granulation process has emerged in the recent past as a
promising process which acts as a buffer between a BF process and BOF
process and facilitates un-interrupted operation of BFs at higher
productivity levels. The granulation process converts liquid hot metal into
granules (3-50 mm) by rapid solidification/ quenching in water.

1.5 Hot metal granulation process has advantages of being very fast and
capability of handling substantial hot metal quantity. Granules produced
are very easy to handle and melt faster than pig iron due to small size and
large surface area. Granules are easily marketable for use in EAF, induction
furnaces, cupolas, BOF and foundries as a replacement of pig iron, scrap or
DRI.

1.6 Hot metal granulation unit of 300 tph capacity (~4000 tpd) is proposed to
handle excess hot metal from blast furnaces for their optimum techno
economic operation. Also since BF#1 & BF#5 are equipped with hot metal
handling through torpedo ladle, hot metal granulation unit with torpedo
handling has been considered.

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1.7 Hot metal granulation unit will include hot metal handling facilities viz.
runner, runner car, tundish, tundish car, overflow launder etc.,
granulation facilities viz. granulation tank, ejector system, dewatering
SUMMARY

unit, screw classifier etc., water system viz. process pumps, hot & cold
wells, cooling tower etc. service equipment viz. tundish tilter, refractory
dryer, sprayhead changer etc., handling facilities viz. overhead crane,
conveyors etc. and associated electrical & automation system.

1.8 MANPOWER REQUIREMENT

A total of 10 manpower including 4 executives & 6 non executives is

envisaged for operation of proposed hot metal granulation unit.
unit
Manpower required for repair & maintenance work will be sourced from
maintenance pool.

1.9 ENVIRONMENT & POLLUTION CONTROL

Hot metal granulation process is a clean & environment friendly process

with minimal dust & fumes emission. De-fuming system, to collect the hot
metal fumes created during tapping of the hot metal from the torpedo,
will minimise presence of fugitive dust & fumes in the working place.
Closed loop cooling water system with usage of bleed water for existing
slag granulation plant will enable zero discharge from the proposed unit.
Equipment will be designed for keeping noise & vibration under allowable
limits.

1.10 CORPORATE ENVIRONMENT RESPONSIBILITY & ACCREDITED

CONSULTANT

The guidelines of Ministry of Environment Forest and Climate Change

(MoEFCC) for Corporate Environment Responsibility (CER) and engaging
NABET accredited consultant for Environmental Clearance have been
considered for this project.

1.11 IMPLEMENTATION

Project will be implemented through following three packages:

1) Soil investigation, survey (Package-IA) – on Non-turnkey basis and

through LTE mode as per empanelment.

2) Underground survey mapping (Package -1B) - on Non-turnkey basis

and through LTE mode as per empanelment.

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3) Installation of Hot Metal Granulation Unit (Package-II) – on Turnkey

basis

The project is envisaged to be implemented within a period of eighteen

(18) months from the date of Stage-II approval. Pre-ordering activities are
envisaged to be completed within six (6) months from the date of Stage-I
approval.

1.12 CAPITAL COST ESTIMATE

The capital cost of the project is estimated as Rs. 63.35 crore net of ITC of
Rs. 7.18 crore including IDC of Rs. 3.52 crore. FE component considered in
it is Rs.15.28 crore.

The Capital Cost is based on budgetary quotation and available in-house

information. Base date for the estimate is 3rdQuarter 2020. FE parity has

SUMMARY
been taken as 1 SEK=Rs. 8.85 considering forward premium rate.

1.13 FINANCIAL ANALYSIS

Techno-economic indices of the project are indicated below:

Indices Value

IRR (Post Tax) 19.87%

NPV (@10%), Rs. Crore 33.77

1.14 The project is technically feasible and techno-economically viable.

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2. BACKGROUND

2.1 Rourkela Steel Plant (RSP) presently has two blast furnaces (BF) in operation
namely BF#1, & BF#5. BF#1 has recently got reconstructed for upgraded useful

BACKGROUND
volume of 1710 m3 and BF#4 is under capital repair. BF#2 has already been
dismantled and removed. BF#3 has also been put under shutdown and will be
dismantled & disposed of in future.

2.2 SMS-1 & SMS-2 of RSP is processing about 10000 tpd hot metal on regular
basis. There is capability of producing hot metal of about 12000 tpd. The
mismatch between hot metal production and consumption increases during
scheduled/unscheduled shutdowns of downstream steel making facilities.

2.3 RSP has two pig casting facility namely PCM-1 and PCM-2 to process hot metal
in case hot metal cannot be consumed in SMS. However, there are certain
limitations in pig casting machine:

1) Limited or no acceptance of pigs in BOF/ EAF steel making; hence can’t be

considered as replacement for scrap

2) Low capacity of pig casting machines

3) Slow process

4) Operational problem in pig casting with low silicon hot metal

5) Weak market for low silicon content pigs

2.4 Hot metal granulation process has emerged in the recent past as a promising
process which acts as a buffer between a BF process and BOF process and
facilitates un-interrupted operation of BFs at higher productivity levels. The
process was developed at Uddeholm, Sweden and is currently marketed and
sold by M/s UHT – Uvån Hagfors Teknologi AB, Sweden under registered
trademark GRANSHOT®. The granulation process converts liquid hot metal into
granules (3-50 mm) by rapid solidification/ quenching in water.

2.5 Hot metal granulation process is well established and there are many references
worldwide. In India also, following hot metal granulation plants are under
operation/installation:

Plant Capacity Technology supplier

JSW Toranagallu 300 tph M/s UHT Sweden
JSPL Angul 300 tph M/s UHT Sweden

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TATA Steel KPO 300 tph M/s UHT Sweden

ESSAR Hazira 150 tph M/s UHT Sweden
JSW Dolvi 300 tph M/s UHT Sweden
TATA Steel Jamshedpur 300 tph M/s UHT Sweden
BACKGROUND

2.6 Hot metal granulation process has following advantages:

1) Very fast process; takes only 30 seconds for granulation

2) Acts as buffer between BF and BOF

3) Known and consistent chemistry; same as the source hot metal because no
chemical reaction takes place in the process

4) Granules are suitable for use as internal feedstock as coolant in the BOF; or
replacement of virgin scrap in Electric Arc Furnace (EAF)/ Induction Furnace

5) Granules are easy to handle manually and mechanically

6) Granules melt faster than pig iron at lower temperature and faster
dissolution due to small size and large surface area

7) Granules are easily marketable as the end user includes electric arc furnaces,
induction furnaces, cupolas, basic oxygen furnaces and foundries as a
replacement of pig iron, scrap or DRI.

2.7 Due to above advantages, the excess hot metal of about 2000 tpd at RSP can be
processed in hot metal granulation unit for production of granulated pig iron
(GPI) instead of pig casting.

2.8 To take care of the mismatch between hot metal production & consumption
and to enable throttle free operation of blast furnaces for achieving optimum
techno economic process parameters and maximum campaign lives of the
furnace, it is proposed to install hot metal granulation unit to granulate the hot
metal if it cannot be processed downstream in Basic Oxygen Furnace (BOF) /
Steel Making Shop (SMS).

2.9 RSP vide letter no. AMR-M&SC/Consultancy/16/748-53 dt. 28.11.2017 has

assigned CET to prepare feasibility report for ‘Installation of Hot Metal
Granulation Unit’. A copy of the letter is enclosed at Annexure 2.9-1. CET
accepted the assignment vide letter ref no. CET-17(3)/018/17/755 dated
06.12.2017 (enclosed at Annexure 2.9-2). Accordingly, feasibility report (FR,
R=0) was prepared and submitted to RSP on 09.02.2018.

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2.10 Based on RSP’s request for incorporation of techno-economic calculation, the

revised feasibility report (R=1) incorporating techno-economic calculation was
prepared and submitted to RSP on 05.07.2018.

2.11 Subsequently, comments from RSP on FR (R=1) related to de-fuming system,

BACKGROUND
training needs, handling & lighting facilities etc. were received. A copy of the
letter is enclosed at Annexure 2.11-1. The same were discussed and finalized.
Accordingly, this revised feasibility report (R=2) has been prepared
incorporating finalized comments.

2.12 CET gratefully acknowledges the co-operation received from Rourkela Steel
Plant for the preparation of this feasibility report.

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3. SELECTION OF ALTERNATIVES

3.1 Well established and proven hot metal granulation unit has been proposed.
Details are given in Chapter 4. No other alternative has been considered.

For the proposed hot metal granulation unit, hot metal handling through
torpedo ladle has been considered as both BF#1 & BF#5 are equipped with hot
metal handling through torpedo ladle.

SELECTION OF ALTERNATIVES

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4. PROJECT DESCRIPTION
4.1 PROCESS & TECHNOLOGY
4.1.1 The hot metal granulation process converts liquid metal into granules by rapid
solidification in water. The torpedo ladle car arrives to the granulation unit from
the blast furnace. On arrival, the torpedo ladle car is placed in position to a
movable runner that can follow the tilting movement of the torpedo throughout
the granulation. From the runner metal is poured into a tundish, placed on the
granulation tank, and further on to a refractory target (sprayhead) placed in the
centre of the granulation tank. The sprayhead splits the metal steam into
droplets that are distributed evenly over the granulation tank water surface. The
outer layer of granulated metal solidifies partly in-flight before reaching water
surface and further cooling of inner part takes place as the granules sink

PROJECT DESCRIPTION
downwards in the granulation tank.

4.1.2 Liquid metal from the tundish hits the refractory sprayhead, dispersing into
droplets and forming granules. Indicative depiction is shown below:

4.1.3 The granulation rate during the process is controlled by adjusting the torpedo
tilting degree to achieve a certain operational level (metal weight) in the
tundish, in combination with selection of the tundish nozzle outlet diameter.
The metal weight is measured by load cells placed on the tundish.

4.1.4 The solidified granulated product is discharged from the bottom part of the
granulation tank via an air-water ejector system on to a dewatering screen,
where the product is dewatered. The granulated product is thereafter
transported on conveyor belts to the stockpile.

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4.1.5 The cooling water system is carefully balanced in order to handle the large
amount of heat added by the liquid metal during the granulation process. From
a closed-circuit cooling water system, cold water is continuously pumped into
the granulation tank lower section through specially designed nozzles. As the
water passes upwards through the granulation tank, it will exchange heat with
the solidifying metal. The warm water exits the granulation tank in the upper
part via an overflow into a hot well. From the hot well water is further pumped
via cyclone separators to cooling towers, before being returned into the
granulation tank.

4.1.6 Indicative schematic flow of the granulation process and its main components is
shown in figure below. Hot metal entering the granulation unit until exiting at
the dewatering screen takes around 30 seconds.
PROJECT DESCRIPTION

The operator is at all times assisted by the control system to ensure a safe and
stable granulation process.

4.1.7 Indicative schematic arrangement of granulation unit is shown below:

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4.1.8 Functional description of major units of hot metal granulation unit:

Unit Function

PROJECT DESCRIPTION
1. Hot metal handling

Runner The liquid metal is fed from the torpedo into a runner placed on
a runner car which leads the melt into the tundish. The runner is
designed with an impact zone where the melt can collect before
flowing into the tundish. A splash shield is installed around the
runner to minimize metal splash during pouring.

Runner car When the torpedo is in granulation position, the runner car
positions the runner under the torpedo. When the granulation is
finished, the runner is tilted to empty the remaining liquid metal
in the runner. The runner car is equipped with hydraulic cylinders
for tilting and moving it away from the tundish

Tundish and The tundish serves as a buffer between the runner and the
tundish stand granulator, regulating the liquid metal flow and the granulation
rate. It is equipped with a bottom pouring nozzle. The tundish is
placed on a steel stand mounted on the granulation tank.

Tundish car The tundish car is placed on rails. It facilitates a quick change of
the tundish when granulating in a sequence as multiple
tundishes can be placed on the rails, prepared for granulation.
During maintenance, the tundish is lifted by an overhead crane
to the maintenance area.

Nozzle The nozzle preheater heats the tundish nozzle area prior to

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preheater granulation and is fired with gas. The preheater is placed on rails
and is manually positioned underneath the tundish. Two
preheaters are installed, one for the tundish in position and one
for the tundish in the car position.

Stopper rod The stopper rod opens and stops the liquid metal flow out of the
tundish. The rod is lowered directly into the nozzle thereby
blocking the flow. The stopper rod is also used when multiple
batches are granulated in a sequence. The stopper rod is
installed separately from the tundish and is turned into position
during granulation.

Overflow The overflow launder directs the liquid metal into an emergency
launder ladle in case there is an overflow from the tundish.
PROJECT DESCRIPTION

De-fuming De-fuming system collects the hot metal fumes created during
system tapping of the hot metal from the torpedo to the runner.

2. Granulation line

Granulation The liquid metal discharged from the tundish is directed onto the
tank sprayhead in the granulation tank where the metal stream
disperses into droplets and granules are formed. A counter flow
of cold water rapidly cools the granules while sinking through
the granulation tank due to gravity. The water injection nozzles
are optimized for effective cooling. The granulation tank is
prepared with instrument pockets for temperature, pressure and
limit transmitters. All instruments are wired to one junction box
which is connected to the main PLC.

Ejector The ejector discharge system uses hydro and pneumatic ejection
discharge to transport the granules from the granulation tank into the inlet
system box on the dewatering unit. The ejector features an adjustable air
gap for optimized impulse. The ejector bends are equipped with
wear-boxes with leakage indication.

Dewatering At the inlet of the dewatering unit, a lined box is placed to collect
unit and distribute the granules evenly on the dewatering screen. The
inlet box is designed for rapid throughput of the granules. It also
is designed for minimized wear and simplified maintenance. The
dewatering screen is supported by a steel stand. The granules

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are transported on the screen through the dewatering unit where

water is removed mechanically. The surface water content of the
granules is less than 2% after leaving the dewatering unit. The
trough is equipped with built-in water flushing.

Screw classifier Metal fines carried over with the trough from the dewatering unit
are recovered by the screw classifier. The incoming water is
distributed over the surface for dispersion of particles. Fines
generation are typically less than 0.5%. The fines are collected in
a bin and is placed on rails for easy access.

3. Water system

Cold & Hot well Cold The cold well is used for intermediate storage of the
well: process cooling water

PROJECT DESCRIPTION
Hot The hot process water is pumped into the hot well
well: and is cooled in the cooling towers.

Cooling towers The process water is cooled in the cooling towers.

Water piping Piping between units of the cooling water system.

HW process The HW process water pump feeds the cooling towers from hot
water pump well.

CW process The CW process water pump returns the cold water from cold
water pump well to the granulation process.

Ejector water The ejector water pump supplies water to the ejector. Water is
pump circulated back from the hot well to the ejector.

Discharge The discharge pump transports the water in the screw classifier
pump to the hot well.

Sump pump The sump pump is used to remove accumulated water in the
granulation pit.

4. Water treatment

Centrifugal In order to minimize the wear in the cooling towers, carryover

separator particles are separated from the water by a centrifugal separator.
The separated particles settle in the bottom of the unit and are
purged by a timer controlled valve.

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5. Service equipment

Tundish tilter To simplify the desculling process of the tundish and runner, a
tilter is provided.

Ejector service To ease maintenance of the ejector, a service jig is provided.

jig

Pipe support To ease maintenance, a service cart is provided to hold the

cart horizontal ejector pipes during maintenance.

Refractory After the tundish and runner have been relined, the refractory is
dryer for runner dried before the tundish is put into operation.
and tundish

Sprayhead The sprayhead changer simplifies the changing process of the

PROJECT DESCRIPTION

changer sprayhead in the granulation tank.

6. Handling devices

Overhead crane The granulation building has an overhead crane for handling of
tundish, runners, overflow launder, emergency ladle etc.

Misc. handling For handling of equipment in granulation area, pump house,

devices hydraulic room, electrical room etc.

Belt conveyors For transportation of granules from dewatering unit to the

storage area

7. Process control & automation

The granulation plant is fully controlled by the PLC based process control system.
Operators can control the process through HMI screen panels placed in the control
room and relevant information is continuously presented. Warnings and alarms
alert operators to any possible problems, enabling them to run the plant in a safe
and efficient way. In addition, CCTVs give operators a full overview of the
granulation process from tapping to screening at the dewatering unit. Overall
process is provided with required instrumentation viz. flow transmitters, pressure
transmitters, temperature transmitters, level transmitters, level switches, load cells,
conductivity transmitters, limit switches, position transmitters etc. for safe
operation.

8. Electrical

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Transformer, HT panel, MCC, Drives, MLDB etc. for feeding HT & LT loads.

UPS to handle the PLC & process control during power shutdowns.

9. Buildings

Building for main granulation unit; control room; electrical room; pump house etc.

4.1.9 Major parameters of the proposed hot metal granulation unit are as below:

Parameter Value

Capacity 300 tph

2000 tpd average

4000 tpd design

PROJECT DESCRIPTION
Hot metal handling Through torpedo ladle

Make up water Approx. 250 m3/hr

Vaporised water – Approx. 190 m3/hr

Bleed water – Approx. 60 m3/hr

Cooling Water Approx. 4000 m3/hr; Tin < 40 °C, Tout < 65 °C

Electrical power Approx. 2.0 MW (required during granulation)

Fuel Gas (Mixed gas) Approx. 200 Nm3/hr (for preheating & drying)

Compressed air (Ejector) Approx. 1500 Nm3/h, 6 kg/cm2(g)

Oxygen (lancing) Approx. 50 Nm3/hr, 6-8 kg/cm2(g)

Granulation start-up time < 5 min (no preheating required);

requirements ~ 30 min (preheating required)

Yield 99- 99.5%

4.1.10 Properties of Granulated Pig Iron (GPI)

The rapid quenching results in a product with analysis identical to that of the
hot metal. No change in composition takes place during the granulation
process. Hence, the chemistry of the product can therefore be specified by the
ingoing hot metal analysis.

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GPI physical properties

Bulk density ~ 4 t/ m3

Size distribution (main fraction) 3 -50 (5- 25) mm

Granule shape Deformed spherical

Angle of repose > 300

Material handling Inert during handling

Typical GPI photograph is shown below. The granule size and shape allows for
an easy handling of the product. This makes the GPI very suitable for handling
with most raw material handling systems such as conveyor belt, magnet, front-
end loader, bin systems etc.
PROJECT DESCRIPTION

4.1.11 Indicative process flow & tentative layout of the proposed hot metal granulation
unit is shown in Annexure 4.1.11-1 & Drg. No. CET RN 4422 IR2 00 001, R=1
respectively.

4.1.12 GPI will be stored in a stockpile in the storage area. The storage area will be
concrete floored to avoid subsidence of stored GPI and its consequential loss.
From the storage area, GPI will be disposed of through trucks after loading
through pay loaders. Disposal through railway wagons can also be thought of in
future.

4.1.13 Bagging/packaging of the GPI can be thought of in future based on the

response of the customers. For this packaging/bagging unit can be installed at a
suitable location and GPI from the storage area will be suitably transported to
this unit.

4.1.14 Fines collected from screw classifier & cyclonic separator can be utilized like mill
scale in sinter making.

4.2 MECHANICAL

4.2.1 The mechanical equipment for the hot metal granulation unit will comprise of
runners including the splash shield (3 nos.), runner car (1 no.), tundish including

RSP 551no. 4.8>

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lid (4 nos.), tundish car (2 nos.), equipment stand (1 no.), nozzle pre-heater (2
nos.), stopper rod (1 no.), overflow launder (1 no.), reactor (1 no.), ejector
discharge system (1 no.), dewatering system (1 no.), screw classifier (1 no.),
tundish & runner tilter (1 no.), hydraulic system for various equipment,
refractory dryer for runner & tundish (2 nos.), spray head changer (1 no.), belt
conveyor (1 no.), ejector service car (1 no.), pipe support cart (1 no.), screw
classifier settling tank ( 3nos.), overhead cranes, electric hoist and manual hoist
with trolley.

4.2.2 Dewatering Unit

The granulated hot metal from the ejector system will be fed to a Dewatering
Screen to remove moisture. The nominal capacity of dewatering screen will be
300 tph (min.). One no. dewatering Screen, complete with drive arrangement,

PROJECT DESCRIPTION
cordon shaft, exciter, mounting arrangement deck, side skirt plate, springs,
under size chute with liner integral with screen etc. will be provided.

4.2.3 Screw Classifier

One no. screw classifier will be provided for feed from dewatering unit. The
capacity of classifier will be 2 tph. The feed of screw classifier will be in form of
slurry from underflow of the dewatering unit. The screw classifier will be
complete with feeding box/ launder, discharge sprout/ chute, tank, screw lifting
device, drive motor, electrical, instrumentation and control lubrication system
etc.

4.2.4 Handling facilities

[Link] EOT crane (1x 50/10t) will be provided for maintenance of various equipment
inside the main granulation building.

[Link] EOT crane (1x 5t) will be provided for maintenance of various equipment inside
the pump house.

[Link] Electric hoist (3x 3t) will be provided for maintenance of various equipment in
lubrication room and EOT crane.

[Link] All electrically operated cranes and hoist will be provided with radio remote
control for operation.

[Link] Manual hoist (5x 3t) will be provided for maintenance of various equipment of
EOT crane, electrical room and main granulation building.

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4.2.5 Centralized dual line lubrication system will be provided for lubrication of
various equipment.

4.2.6 Hydraulic and lubrication power pack will be provided in a separate suitably
located hydraulic room, which will be provided with 2x3t electric hoist for
maintenance purpose.

4.2.7 One no. electric hoist of capacity 1t & lift 32m will be provided at bag filter top
for maintenance purpose.

4.2.8 One no. Electric hoist of Capacity 2t and Lift 10m approx. will be provided for
maintenance of ID fan for de-dusting bag filter.

4.2.9 Parking shed and maintenance platform will be provided for all electric hoist
located under outdoor conditions.

4.2.10 Spares
PROJECT DESCRIPTION

Operational spares will be provided for the following major equipment:

· Screen deck panel – 80 nos.

· Ejector assembly – One set complete.

4.3 UTILITY

4.3.1 This part deals with the work envisaged, design philosophy, construction
materials and other aspects related to utilities & services such as water,
compressed air, tundish heating system, ACVS & fire fighting facilities along
with associated facilities mentioned below.

4.3.2 Water System

[Link] Water circuit of the system is considered to be the heart of the system as the
granulation process depends upon water quenching of hot metal granules. Flow
diagram of water system is as per attached in Drg. No. CET RN 4422 UT1 01
001, R=1. Location of water system is also shown in attached layout drawing.
The main components of water circuit are:

· Ejector circuit for transporting granulated hot metal & dewatering circuit

· Process water system comprising of hot well, hot water pumps, cyclonic
separators, cooling tower and cold water pumps

· Makeup water circuit

RSP 553no. 4.10>

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[Link] Hot metal granules collected in the bottom of the granulation tank will be
transported to dewatering screen by means of ejectors. Ejectors will receive high
pressure water from 2 nos. ejector water pumps (1W+1S) of capacity 400 m3/h
each at 6 kg/cm2(g) head. Drain water from screen will pass through screw
classifier for removal of fine suspended impurities. Overflow water from classifier
will be pumped to hot well by means of 2 nos. discharge pumps (1W+1S) of
capacity 600 m3/h each.

[Link] Hot water from granulation tank, classifier discharge and drainage will be
collected in a hot well. This water will be sent to cooling tower after being
passed through cyclonic separator through 3 nos. HW process water pumps
(2W+1S) of capacity 2100 m3/h each. 2 nos. cyclonic separators (1W+1S) have
been envisaged for removal of fine iron impurities. Undersludge from cyclonic
separators will be sent back to screw classifier for water recovery by means of 2

PROJECT DESCRIPTION
nos. pumps (1W+1S) of capacity 5 m3/h each.

[Link] Hot water will be cooled in a 3-cell induced draft counter flow cooling tower
(2W+1S) with each cell of capacity 2100 m3/h. Cooling tower will be of RCC
construction and will be designed to cool hot water of 65 degree C to cold
water of 40 degree C. Cooling tower will be designed with COC (Cycle of
concentration) of 4 and blow down of cooling tower will be pumped to SGP of
BF#5 by means of 2 nos. CT blow-down water pumps (1W+1S) of capacity 60
m3/h each. Further, to reduce contamination deposition in cooling tower sump,
a side stream filtration consisting of water pumps (1W+1S) of capacity 200 m3/h
each and cyclonic centrifugal separator of capacity 200 m3/h are also envisaged.

[Link] Cold water from cooling tower will be supplied to granulation tank by means of
three nos. CW process water pumps (2W+1S) of capacity 1900 m 3/h each. The
cold water pumps will be housed in a new cooling water pump house. The
pump house will be equipped with 5 ton double girder Electric Overhead
Travelling (EOT) crane for maintenance.

[Link] Makeup water requirement for this project is approx. 250 m3/h. RSP is working
on a project of recycling of township sewage water after treatment. Tentative
water quality parameters for this recycled water will be TSS-50 ppm, TDS-150-
200 ppm, pH-7-8, Oil & Grease-Nil. This complete recycled water will be used
inside plant at various locations with a suitable piping network which will finally
terminate at Slag Granulation Plant (SGP) of BF#5. 2 nos. of pumps (1W+1S)
have been envisaged in a new structural shed along with maintenance facilities

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near SGP of BF#5. Makeup water will be delivered to cooling tower basin by
means of DN250 pipe. Buried makeup water pipe of DN250 size will be laid
from SGP of BF#5 to proposed location of hot metal granulation cooling system.

[Link] Since the project of recycling of township sewage water is still under
formulation stage, makeup water requirement for this project will be taken from
existing DN500 line, which is passing through roadside near BF#5 administrative
building. Suitable pressure tapping will be made from this pipe. However, after
installation of township recycling water project, this tapping will be used only as
emergency backup.

4.3.3 Compressed Air System

[Link] Compressed air at the rate of 1200-1400 Nm3/h and a pressure of about 6 bar is
required in the ejectors for transporting granulated hot metal to dewatering
PROJECT DESCRIPTION

screen. Compressed air is also required for various instrument and maintenance
activities.

[Link] To meet the compressed air requirement, 2 nos. screw compressors (1W+1S) of
capacity 1500 Nm3/h with discharge pressure of around 7 kg/cm2(g) has been
envisaged. 2 nos. air vessels (one of 2 m3 capacity for process air and one of 1
m3 capacity for instrument air) have also been envisaged. For meeting the
dryness requirement of instrument air, 2 nos. desiccant type air driers (1W+1S)
have also been envisaged.

[Link] Compressors along with air driers will be kept inside pump house and will also
utilize pump house’s 5 t EOT crane for maintenance.

4.3.4 Tundish Heating System

[Link] Following other utilities are required for tundish heating and maintenance
activities-

Mixed Gas - 150-200 Nm3/h

Nitrogen-50-60 Nm3/h (Intermittent- for gas line purging)

Oxygen-50-60 Nm3/h (Intermittent- For maintenance)

Steam-1-2 tph (Intermittent- For gas line cleaning)

Water for condensate seal pot- 0.5-1 m3/h (Continuous- For sealing)

RSP 555no. 4.12>

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 Experience that delivers

[Link] The above mentioned utilities are already in place for existing torpedo ladle
repair shop. Same will be extended in new trestles after taking suitable tapping
near entry of torpedo ladle repair shop.

[Link] Further, tundish heating platform along with mixed gas firing system has been
envisaged. 2 nos. of air blowers (1W+1S) have been envisaged for supplying
combustion air to mixed gas burners.

4.3.5 Fume Extraction System

[Link] It is proposed to install a bag filter based Fume Extraction System (FES) of
60000 m3/h capacity for control of fugitive emission during pouring of hot
metal from torpedo ladle.

[Link] The emission will be extracted by means of suction hood. The dust laden fumes
will be discharged in to the atmosphere through a stack after cleaning in the

PROJECT DESCRIPTION
bag filter. Dust, which will be collected in the hoppers of bag filter will be
collected in a dust storage silo from where, it will be transported through road
to Sinter Plant for re-use.

[Link] The bag filter will be designed for particulate emission level of 25 mg/Nm3 to
comply with latest state PSBs norms.

[Link] Proposed Process Flow Diagram for fume extraction system is shown in Drg No.
CET RN 4422 UT1 00 002, R=0.

4.3.6 Air Conditioning & Ventilation System

For smooth and trouble-free operation of electrical and electronic equipment,

the premises listed below will be provided with air conditioning and ventilation
system.

[Link] Air-conditioning System

Air-conditioning system is envisaged in the premises as mentioned below:

Sl. No. Premises Type of Air-conditioning System

1. Control Room with PLC 2 nos. of 2 TR capacity Split AC

panels

2 VFD and UPS Room 4 nos. of 2 TR capacity Split AC

[Link] Ventilation System

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Ventilation system is envisaged in the premises as given below:

Sl. No. Premises Type of Ventilation System

1 Transformer room with Dry pressurised Ventilation

PDBs and MDBs System by means of centrifugal
fan and supply air ducting
2 HT board and PCC panel network

3 Cable Cellar Push Pull Ventilation System by

axial flow fans

4 Battery room Exhaust ventilation system by

axial flow fans
5 Pump House cum
Compressor room
PROJECT DESCRIPTION

4.3.7 Fire Fighting System

Portable fire fighting arrangement by means of CO2 type, DCP type and
Mechanical Foam type fire extinguishers (9 liter) has been envisaged. The
quantity will be as per TAC norms.

4.4 ELECTRICAL

4.4.1 Power Requirement

The tentative power requirement of the proposed system is as under:

Voltage level Connected Load Max Demand

0.415 kV 1750 kW(approx.) 950 kW(approx.)

6.6 kV 1400 kW(approx.) 950 kW(approx.)

4.4.2 Power Distribution Scheme

One no. 6.6 kV switchboard is envisaged to supply the HT load power

requirements for proposed facilities.

One no. PMCC (Power cum Motor Control Centre) & one PDB (Power
Distribution Board) are envisaged to feed the LT power requirements for
proposed facilities.

Power for 6.6 kV switch board will be tapped from feeder no. 23 & 54 of existing
6.6 kV switch board in LTSS-V.

RSP 557no. 4.14>

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Two nos. 2 MVA (minimum), 6.6 kV/0.433 kV dry type distribution transformers
are considered for feeding PMCC panel at new substation. Incoming power for
distribution transformers will be tapped from feeder nos. 27 & 65 of existing 6.6
kV switch board in LTSS-V. Above PMCC panel will feed to LT motors for
proposed facilities. It will also feed PDB, illumination panels & welding power
supply system.

4.4.3 The following major electrical equipment have been considered:

[Link] 6.6 kV switchboard

One no. 6.6 kV switch board is envisaged to supply the HT load power
requirements for proposed facilities. This switchboard will have two nos.
incomer, one bus coupler & suitable nos. of outgoing VCB feeders of suitable
rating.

PROJECT DESCRIPTION
Location: In switchgear room in proposed substation.

[Link] 6.6 kV Isolator

Two nos. 1250 A, 6.6 kV isolators for each distribution transformer at switchgear
room at new substation room will be provided to isolate transformer primaries
during maintenance. These panels will be floor mounted, sheet steel clad in
construction.

[Link] 6.6 kV/0.433 kV dry type distribution transformers

2 nos., 2 MVA (minimum) 6.6/ 0.433 kV dry type distribution transformers with
all accessories as per latest IS are envisaged.

[Link] PMCC panel

One no. of single front, sheet steel metal clad PMCC panel will supply LT power
to proposed facilities. It will have 2 nos. ACB incomers, one no. ACB bus coupler
& required nos. of ACB/ MCCB outgoing feeders.

Location: PMCC panel will be located be located in switchgear room in

proposed substation.

[Link] PDB

One PDB has been considered for auxiliary power requirements. It will be of
single front, sheet steel metal clad construction. It will have 2 nos. MCCB
incomers, 1 no. MCCB bus coupler & required nos. of MCCB outgoing feeders.

[Link] Crane Electrics

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DSL conductor system along with Insulators, trolley line holders, supporting
brackets & indication lamps is envisaged for crane power supply in each bay.
The down shop lead (DSL) will be MS angle/MS Rail & will have 4 conductors
system. LT power has been envisaged for drag chain system.

[Link] VFD Panel

Standalone VFD panels are considered for feeding power to motors requiring
speed control. The VFD will be IGBT based with sine coded PWM control. VFD
panel will be single front with one MCCB incomer.

[Link] Drive Motors

All HT motors will be CACA/TEFC squirrel cage induction motors suitable for 6.6
kV, 3 phase, 50 Hz supply. All LT motors will be IE2 class, TEFC squirrel cage
induction motor suitable for 415 V, 3 phase, 50 Hz supply. Crane & hoist drive
PROJECT DESCRIPTION

motors will be S4 duty. Motors being fed from VFD will be inverter duty motors.

[Link] Control desk

Control desk with pushbuttons, indication lamps & selector switches is

envisaged. It will be floor mounted, vertically standing type & will match with
control philosophy.

[Link] Local Control Stations

Local Control stations with Emergency stop & start pushbutton & LED
indications have been considered. LCS will be provided with selector switch
matching with operational philosophy.

[Link] UPS

Parallel redundant UPS system of 2X10 KVA will be provided for continuous &
regulated AC power supply to the instrumentation & automation critical loads.

4.4.4 HT, LT and Control Cables

1) HT Power Cable

6.6 kV grade, 3 core, aluminium conductor XLPE insulated, extruded PVC

inner sheath, armoured, FRLS PVC outer sheathed cable is considered.

2) LT Power Cable

1.1kV grade aluminium conductor, XLPE insulated, PVC sheathed,

armoured, FRLS PVC outer sheathed power cables is considered.

RSP 559no. 4.16>

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3) Control Cables

1.1 kV V grade stranded multi-core copper conductor, XLPE insulated, PVC

sheathed, armoured, FRLS PVC outer sheathed control cables have been
envisaged.

4.4.5 Illumination System

Illumination of proposed Pump house, HT substation buildings, like transformer

rooms & control room building etc. are considered. The illumination scheme
includes lighting transformer, lighting board, sub lighting distribution boards,
lighting fixtures, switches, sockets, lighting wires, emergency lighting etc.

MLDB panels will feed LDB panels across the proposed plant area. LED high bay
luminaires will be provided in the shop floor, whereas LED light fittings will be
provided in the proposed plant offices.

PROJECT DESCRIPTION
4.4.6 Earthing & Lightning Protection

Earth strips from the proposed equipment/ items will be connected to the new
earth pits through earth grid. New earth grid will be joined to the existing earth
grid at two points.

Earthing system will be in accordance with the code of practice for earthing in
IS: 3043-1987 and will also comply with the relevant clause of Indian electricity
rules - 1956.

Lightning protection will be provided as per IEC 62305.

4.5 PROCESS CONTROL & AUTOMATION

4.5.1 General

The Process Control and Automation system is envisaged to provide complete

control and monitoring of the proposed hot metal granulation system. The
process will be controlled by the operator from the control room housing HMIs,
automation equipment etc. In order to monitor and control the complete
process of granulation unit in an integrated way all process control equipment
at level-0 and level-1 will be suitably integrated to form a unified control system
transparent to the operator.

4.5.2 Level of Automation

The proposed system will be based on micro-processor based computer

compatible instruments with hierarchical control philosophy consisting of field

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instruments, field sensors, electrics, flow meters, pressure transmitters, pressure

manometers; temperature elements and transmitters, level transmitters, level
switches, load cells, conductivity transmitters, position transmitters etc. at level-
0, PLC based process Control System (PCS) with Supervisory Control and data
acquisition (SCADA) at level-1. The system will be reliable, efficient, and easy to
operate, less maintenance oriented, transparent to operator & with self-
diagnostic features. The envisaged PLC will achieve integrated control of the
complete process including process parameter monitoring & control and
sequential & interlocking functions of the complete system. Common PLC has
been envisaged for both of the instrumentation system and electrical system.
The PLC will have hot stand-by CPU. However, no redundancy has been
envisaged in the I/O system.

One (1) Engineering PC control station and one (1) Operating PC control station,
PROJECT DESCRIPTION

complete with required software, including necessary development and runtime

licenses as well as the hot metal granulation process control application have
been envisaged.

Also, one no. of A4/ A3 laser jet colour printer has been envisaged.

4.5.3 Basic functions of Automation

1) Automation of Level-0
The functions of level-0 automation system will be:

· To send all data coming from the field like pressure, temperature,
flow etc.

· To actuate various drives like compressors, pumps, motors etc.

2) Automation of Level-1

Control & automation system of level-1 will monitor operational

conditions of the granulation unit, analyse the information and control the
concerned technological parameters.

The basic functions of the complete system will be:

· Supervision of process variable: Monitoring and control of process

parameters as per technological requirement.

· Electrical sequential and interlocking functions.

· Graphical display of process information.

RSP 561no. 4.18>

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· Diagnostic and alarm generation.

· Events and report generation for MIS.

4.5.4 Measurement & Control

[Link] Measurements and feedback control loops will be as per the technological
requirements of the entire process.

[Link] PLC control and interlocking has been envisaged for the following equipment:

· Runner car.

· Tundish metal level.

· Tundish car.

· Dewatering screen.

PROJECT DESCRIPTION
· Screw classifier drive.

· Process water flow (CW pumps).

· Process water flow (HW pumps).

· Ejector water & air flow.

· Discharge pump.

· Sump pump.

[Link] PLC initiation has been envisaged for the following processes:

· Start water circulation.

· Prepare granulation.

· Start granulation.

· Stop granulation.

· Finalize granulation.

· Stop water circulation.

· Empty reactor tank.

[Link] The various measurements (Level-0 sensors/ field instruments) envisaged in the
process (at a minimum) have been given below:

1) Level switches for each runner.

2) Position sensors for runner car.

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3) Position sensors for each tundish car.

4) Level switches and weighing system for each tundish.
5) Pressure transmitter, temperature elements and temperature transmitters,
and level switch for hot metal granulation reactor.
6) Flow transmitter and pressure transmitter at hot water inlet of granules
discharger.
7) Flow transmitter at cold water inlet of hot metal granulation reactor.
8) Pressure transmitter, flow element and differential pressure type flow
indicating transmitter, and control valve at compressed air inlet of granules
discharger.
9) Temperature element and temperature transmitter at hot water outlet of
hot metal granulation reactor.
PROJECT DESCRIPTION

10) Temperature element, temperature transmitter, and level switch for each
metal recovery unit.
11) All necessary instrumentation and control items for gas train of each tundish
nozzle preheater.
12) Temperature element and temperature transmitter, level switches, and level
transmitter for hot well.
13) Temperature element, temperature transmitter, and level transmitter for
cold well basin of cooling tower.
14) Pressure gauges and pressure switches at individual discharges of discharge
pumps (metal recovery).
15) Pressure gauges and pressure switches at individual discharges of tank
drainage pumps.
16) Pressure gauges and pressure switches at individual discharges of ejector
water pumps.
17) Pressure gauges and pressure switches at individual discharges of hot well
pumps.
18) Pressure gauges and pressure switches at individual discharges of cold well
pumps.
19) Temperature elements along with temperature transmitters for bag filter
(Fume Extraction System).
20) Temperature elements along with temperature transmitters and level
switches for bag filter hoppers (Fume Extraction System).

RSP 563no. 4.20>

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21) Differential pressure indicating transmitter and differential pressure gauge

across bag filter (Fume Extraction System).
22) Pressure indicating transmitter and pressure gauge at Nitrogen inlet line to
bag filter (Fume Extraction System).
23) Temperature elements and temperature transmitters at inlet and outlet of
bag filter (Fume Extraction System).
24) Level switches for dust silo (Fume Extraction System).
25) Winding and bearing (both at DE and NDE) temperature elements along
with temperature transmitters for ID fan (Fume Extraction System).
26) Vibration measurements (both for X and Y directions at DE as well as NDE
ends) for ID fan (Fume Extraction System).
27) Opacity meter for structural stack (Fume Extraction System).

PROJECT DESCRIPTION
[Link] Data from opacity meter of structural stack will be transmitted wirelessly to both
CPCB (Central Pollution Control Board) and SPCB (State Pollution Control Board)
servers.

[Link] Alarms

Visual alarms have been envisaged to alert the operator in case of abnormal
process conditions. Suitable HMI based annunciation will be considered for the
same. Visual alarms will be provided on the HMI console with simultaneous
printing, by the printer, for critical process parameters.

[Link] Safety Interlocks

Suitable interlocks have been envisaged for the safety of the process and the
equipment.

4.5.5 Fire Detection and Alarm System

Microprocessor based analog addressable type fire detection and alarm system
is being envisaged in the new control room for early warning in case of fire or
smoke so that the same could be extinguished in time.

4.5.6 Telecommunication System

Telecommunication system (telephone handsets – 04 nos.) is being envisaged

for the new control room. Extended plant telephone facilities will be used for
the new hot metal granulation unit.

Necessary telecommunication cables have been envisaged accordingly.

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4.5.7 CCTV System

CCTV system is being envisaged for assisting the operators in full control of the
granulation process from hot metal tapping to screening at the dewatering unit.

The CCTV system will comprise 09 nos. of fixed type IP based HD cameras,
network video recorder (NVR), network switch and 01 no. of CCTV screen.

4.5.8 Power Supply

UPS supply is being envisaged for all microprocessor based instruments, PLC
system, Fire detection and alarm system, CCTV system and telecommunication
system.

4.5.9 Electronic Earthing

New electronic earthing is being envisaged for all microprocessor based

PROJECT DESCRIPTION

instruments, PLC system, fire detection and alarm system, CCTV system and
telecommunication system.

4.6 REFRACTORY

4.6.1 For the installation of proposed hot metal granulation unit under mentioned
table lists the equipment/items are being envisaged under refractory work:

S. Description Quantity Typical dimensions

No. (Nos)

1. Runner (between Torpedo & 03 5.2m x 3.15m x 2.4m

Tundish)
2. Tundish (with Sitting Block, Nozzle, 04 5.5m x 1.1m x 1.8m
Impact Pad & Stopper Rod)
3. Launder (between Tundish & 01 9.5m x 1.2m x 0.35m
Emergency pot)
4. Emergency pot 01 Suitable dimension

5. Refractory spray head - Will be provided by

technology supplier

4.6.2 Refractory Quality and Quantity

All equipment covered under refractory will be suitably lined with latest
refractory materials with optimum thickness to achieve maximum
vessel/equipment life.

RSP 565no. 4.22>

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Typical equipment wise refractory quality & quantity will be as under:

S. Equipment Typical refractory quality & quantity

No.
Working Safety

1. Runner ~ 150 mm thick SiC ~ 150 mm thick 60%

based ultra-low alumina castable
cement castable (~18.5 Tons)
(~21Tons)
2. Tundish ~50 mm thick ~30 mm ceramic
magnesia based board and 150 mm
spray mass thick 70% alumina
low cement castable
+ black refractories

PROJECT DESCRIPTION
(sitting block, impact
pad, stopper &
nozzle)
3. Launder ~ 100 mm thick SiC ~ 100 mm thick 60%
based ultra-low alumina castable
cement castable (~4 (~4Tons)
Tons)
4. Emergency pot SiC based castable 60% alumina
(~3.5 Tons) castable (~3.5 Tons)
5. Refractory spray Under scope of technology provider (500
head nos)

4.6.3 Tundish working lining life will be minimum 8 heats and tundish stopper, sitting
block, tundish nozzle and impact pad life will be minimum 10 heats. Those
materials will be supplied till consumption of 500 heats.

4.6.4 Following has been considered for refractory repair & maintenance:

1) Adequate space and facility for refractory repair/relining of above

equipment/vessel.

2) Provision of tilter for removal of skull.

3) Provision for preheating/drying of relined equipment/vessel.

4.7 STRUCTURAL WORK

4.7.1 The scope of structural steelworks involved is envisaged as below:

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[Link] Supply, fabrication, erection, painting, testing and commissioning of all

structural steel works for the following as per technological requirement:

1) A new structural steel shed for housing hot metal granulation system. The
dimensions of the building will be as per technological requirement.
Compound columns consisting of two legs i.e. crane leg and outer leg will
be provided for the building. Monitor truss will be provided at the roof of
the building. The shed will house an EOT crane of appropriate capacity at a
suitable height along with crane level walkway. A monorail will be provided
at both ends of the building, for electrical hoists of suitable capacity
required for maintenance of EOT crane. Crane maintenance platform of
minimum 2.5m width along with handrails will be provided at one end of
the building. Lighting walkway will also be provided. Roof and sides will
have cladding with CGS sheeting. 18G and 20G CGS sheeting will be
PROJECT DESCRIPTION

provided for roof and wall respectively. Glazing work will be provided on
side walls of the building and at the gable side for sufficient day light
illumination. Access stair, ladder, handrails etc. will be provided as per
requirement. Provision will be kept for future expansion in longitudinal
direction on either side of the building.

2) New working platform within the granulation building around granulation

tank, dewatering unit along with handrails, access staircase/ ladder etc.

3) New Pipe supporting trestles, bridges. Access ladder/ staircase and

platforms at suitable locations.

4) Structural shed of dimensions as per technological requirement near SGP

plant of BF#5 for housing makeup water pumps. The shed will also have
monorail for hoist of appropriate capacity.

5) Cable gallery along with its supporting structures. Cable galley will be
covered with CGS sheeting and translucent sheet will be provided at
regular intervals for natural lighting. Gallery walkway will have gratings
supported on structural steel beams/ frame work, minimum 800 mm width
will be provided all along.

6) Structures for new conveyor gallery along with roof & side sheeting, access
stairs/ ladders, handrails, monorails for handling facilities etc. as per
technological/ technical requirements. Conveyor walkway will have
gratings supported on structural steel beams/ frame work, minimum 800
mm width will be provided all along.

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7) Bag filter supporting structures with working platforms, CGS roof sheeting
work along with access stairs, structures for handling facility & handrail as
per technological/ technical requirement.

8) Duct supporting trestles, bridges, working/ maintenance platform, access

stair, ladder, structure for handling facility, handrail etc. as per
technological/ technical requirement.

9) Self-supported structural steel chimney. Staircase will be provided up to

stack emission monitoring platform with structures for handling facilities as
per technological/ technical requirement.

10) Dust silo supporting structures with platform, access stair, ladder &
handrails etc. as per requirement.

11) Miscellaneous structures like platforms, ladder, stairs, structures for

PROJECT DESCRIPTION
handling facilities, handrails etc. as per requirements.

4.7.2 Design Considerations

[Link] All steel structures will be designed with due consideration to the existing plant
and facilities.

[Link] Apart from technological loads to be supported on steel structures, self-weight

and superimposed loads for the design will be according to IS 875:1987.
Structures will be designed either for wind or seismic forces as applicable.
Structures will be analysed either for wind or seismic as applicable. Wind load
on structures will be considered as per IS: 875(part 3) whereas seismic loads will
be taken as per IS: 1893. Due allowance for impact, vibration & temperature
loads will be kept.

[Link] Design of steel structures will be as per IS 800:2007.

4.7.3 Specifications

[Link] Material for structural steel will be as per IS: 2062-2011, grade as applicable.

[Link] Chequered plates will be as per IS 3502: 2009.

[Link] Design & erection of steel chimney will be as per IS: 6533 -1989 (( part 1 & 2).

[Link] Galvanized corrugated sheets (18 G for roof and 20 G for sides) will be as per IS
277: 2003.

[Link] All steel structures will be of welded construction. The welding procedure will
conform to IS 816: 1969 and IS 9595: 1996. Electrodes will conform to IS 814:

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2004. Fabrication and erection of steel structures will be as per IS 800: 2007.
Tolerances of fabrication will be as per IS 7215: 1974. Tolerances for erection will
be as per IS 12843: 1989.

[Link] Paint specification for new structures

All structures will be given two coats of single pack air drying phenolic modified
alkyd composition with zinc phosphate as a primer (DFT/coat 40 micron);

One intermediate coat of a single pack high built phenolic based paint with
micacious iron oxide (DFT=75 micron) will be applied on outdoor structures.

Two coats of single pack air drying high gloss phenolic alkyd modified synthetic
enamel paint as finishing coat (DFT/ coat=25 micron) will be applied on all
structures.

One coat of primer will be applied before erection and one coat after erection.
PROJECT DESCRIPTION

4.8 CIVIL WORKS

4.8.1 This part deals with the contents of civil works envisaged, design philosophy,
construction materials and other aspects related to civil works for installation of
hot metal granulation unit at RSP.

4.8.2 The major civil engineering works envisaged broadly include the following:

1) Earth work in cutting & filling with final gradation as per technological &
system requirement including disposal of debris within a lead of 10kms
inside plant boundary.

2) Construction of RCC foundations for structural shed including RCC floor

over boulder soling, RCC pit including foundation, pump & equipment
foundations /supports, RCC tank, PCC mass filling, all finishes, inserts,
bolts, grouting etc. as per technological & system requirement.

3) Construction of PLC control room in RCC framed construction inside the

structural shed with brick cladding walls including false ceiling, false floors,
all finishes, doors, windows, etc. as per technological & system
requirement.

4) Construction of RCC cooling tower framed structure with RCC (pre-

cast/cast-in-situ) walls and baffle supporting fills, RCC basin, RCC roof slab
with fan & equipment supporting arrangements, compacted boulder
soling with moorum blinding, RCC staircase, inserts, drilling hole for fixing

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nozzles to pressure grout walls & base of the basin with polymeric
waterproofing grouting compound, etc.

5) Construction of 3 storied building in RCC framed construction with brick

cladding walls for pump & air compressor house and LT substation at
ground floor with cable vault at first floor and switchgear room, battery
room, VFD & UPS room at second floor, RCC floor over boulder soling,
cable trench with chequered plate cover, inserts, rails, pump & equipment
foundations, glazed aluminum partition including doors, windows, doors,
rolling shutters, false ceiling, roof treatment with 4mm thick APP work, all
finishes, etc. as per technological & system requirement.

6) Construction of hydraulic room in RCC framed construction with brick

cladding walls including equipment foundation, floor finish on RCC floor

PROJECT DESCRIPTION
over boulder soling, water proofing by 4mm thick APP membrane on roof,
all finishes, doors, windows, rolling shutters etc. as per technological &
system requirement.

7) Construction of RCC foundations for structural shed near SGP plant of BF-5
including RCC floor over boulder soling, pump & equipment foundation
/supports, all finishes, inserts, bolts, grouting etc. as per technological &
system requirement.

8) Construction of RCC foundations for bag filter supporting structures, ID

fan, structural stack, silo, etc. including RCC columns, inserts, bolts,
grouting etc. as per technological & system requirement.

9) RCC flooring over boulder soling including RCC retaining wall of height 1.5
meter for storage area.

10) Construction of RCC cable trench with inserts, chequered plate covers
inside the building/premises and precast covers outside the building
/premises

11) RCC foundations for 2 & 4 legged structural steel trestles for conveyor
systems, pipe supports & cable gallery along with inserts & bolts, etc.

12) Protections for adjoining railway tracks, facilities, etc on account of deep
excavations have been envisaged by driving H-steel sections, shoring and
strutting.

13) Laying of railway track for movement of torpedo.

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14) Approach road for all facilities for constructional, operational &
maintenance requirement.

15) Peripheral RCC drain & its interconnection with existing plant drain for
building & equipment areas and rerouting of existing storm water drain.

16) Detail sub-surface soil investigation and survey work (over ground as well
as underground) have been envisaged to generate basic design inputs for
detail engineering.

4.8.3 Design Consideration

1) The net allowable bearing capacity is assumed as 20 t/m2 at 2.5 m depth

from existing ground level (EGL) based on available soil report of nearby
areas.

2) All the RCC designs will be done conforming to IS: 456-2000.

PROJECT DESCRIPTION

3) All loads will be considered as per latest relevant IS code, system & safety
requirements and serviceability condition.

4) The movement of men and material for Civil Works will be coordinated to
ensure synergy among other constructional/operational/maintenance
activities in the vicinity of proposed site.

4.8.4 Technical Specification

1) The minimum grade of RCC & reinforcement is envisaged as M25 & Fe500
respectively. The minimum grade of PCC for mudmat is envisaged as M-10
and for mass filling as M-5.

2) The material & workmanship will be based on latest IS codes and

prevailing practices at RSP.

3) Grouting under the structural steel column base plates is envisaged to be

done with M30 with 6mm & down nominal size aggregates and under
equipment base plate with ready mix non-shrink free flow grouting
compound.

4) Major activities relating to civil works are earthwork, PCC, RCC, inserts &
bolts, grouting, dismantling etc.

4.9 MANPOWER REQUIREMENT

A total of 10 manpower including 4 executives & 6 non executives is envisaged
for operation of proposed hot metal granulation unit. Manpower required for

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repair & maintenance work will be sourced from maintenance pool. However,
the required manpower has been considered to be redeployed from existing
resources.

4.10 ENVIRONMENT & POLLUTION CONTROL

Hot metal granulation process is a clean & environment friendly process with
minimal dust & fumes emission. Closed loop cooling water system with usage of
bleed water for existing slag granulation plant will enable zero discharge from
the proposed unit. Equipment will be designed for keeping noise & vibration
under allowable limits

4.11 CORPORATE ENVIRONMENT RESPONSIBILITY & ACCREDITED

CONSULTANT
The guidelines of Ministry of Environment Forest and Climate Change (MoEFCC)

PROJECT DESCRIPTION
for Corporate Environment Responsibility (CER) and engaging NABET accredited
consultant for Environmental Clearance have been considered for this project.
4.12 RISK ASSESSMENT
4.12.1 Risk assessment for the project is attached at Annexure- 4.12.1-1

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE

5.1.1 The project is envisaged to be implemented within a period of 18 months from

the date of Stage-II approval. Pre-ordering activities are envisaged to be
completed within 6 months from the date of Stage-I approval.

5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1 & 5.1.2-2 respectively.

5.2 IMPLEMENTATION STRATEGY

5.2.1 Mode of execution and number of packages:

The project is proposed to be executed through three (3) packages as follows:

1) Soil investigation, survey (Package-IA) – on Non-turnkey basis and through

LTE mode as per empanelment

PROJECT IMPLEMENTATION
2) Underground mapping (Package-IB) – on Non-turnkey basis and through
LTE mode as per empanelment
3) Installation of Hot Metal Granulation Unit (Package-II) – on Turnkey basis

Package-I A & B is to be finalized and ordered in advance. Based on the final

soil investigation, survey & underground mapping report, the tender
specification for Package-II will be finalized.

5.2.2 Pre-requisites/ clearances, special handling eqpt., diversion of any known over
ground or underground facilities that need diversion, etc. for execution of the
project:

a) Required statutory, regulatory, environmental clearances & licenses for

execution & operation of proposed facility.

b) Special handling equipment as per contractor’s requirement.

c) Diversion of any underground facility based on findings of Package-I B.

5.3 DETAILS OF PRE-SHUTDOWN & SHUTDOWN ACTIVITIES WITH DURATION

Proposed hot metal granulation unit will be installed in green field area. Hence,
no pre-shutdown/shutdown activities are envisaged for installation of hot metal
granulation unit.

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6. CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES

6.1.1 The capital cost of the project is estimated as Rs. 63.35 crore net of ITC of Rs.
7.18 crore including IDC of Rs. 3.52 crore. FE component considered in it is
Rs.15.28 crore. The summary capital cost estimate is appended at Annexure -
6.1.1-1.

6.1.2 The Capital Cost is based on budgetary quotation and available in-house
information. Base date for the estimate is 3rd Quarter 2020. FE parity has been
taken as 1 SEK = Rs. 8.85 considering forward premium rate.

6.1.3 Necessary provisions have been made in the estimates as per the details given
below:

1) Taxes and duties

GST@18% has been considered on basic cost of equipment, refractory,

structure, civil works, erection and E&C (Contractor’s) and freight and
insurance. CD @ 7.5% on (CIF), Social Welfare Surcharge @ 10% on CD.

2) Freight & Insurance charges

@2% of basic cost of equipment and @9% of basic cost of refractory and
structure.

CAPITAL COST & FINANCIAL ANALYSIS

Ocean freight & insurance: @7% on FOB cost; Inland freight & Insurance
charges for imported item has been taken @3%.

3) Income Tax @ 11.11% for value of Design & Engineering and foreign
services;

4) Erection & commissioning charges

@12% of basic cost of indigenous equipment & refractory @6% of CIF

cost of imported equipment, @12% on CIF cost of imported refractory &
@ 20% of basic cost of Structure

5) Engineering & Construction

E&C (Contractor) @ 7.5% and E&C (Owner) @ 2.5 % on basic cost of

equipment, refractory, structure, civil works and erection & commissioning
charges have been considered. In addition to above, a suitable provision
for foreign supervision and training has been kept in the estimate.

6) Contingencies: @ 5% on overall basis.

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6.2 Mode of Financing

The total capital requirement of the project is proposed to be provided from

debt equity ratio of 1.0. An interest rate @ 10% per annum is considered for
commercial borrowing.

6.3 Phasing of Capital Expenditure

With the project duration of 18 months from Final /Stage-II approval, the
phasing of capital expenditure is proposed as indicated below:

(Rs. Crore)

Year Plant Cost Equity Loan IDC Total incl.

IDC

1st year 26.81 26.81 1.34 28.15

2nd Year 33.51 33.51 2.18 35.68

(6 months)
6.70 6.70 6.70
Post Comm.

67.01 67.01 3.52 70.53

Capital Cost

Input Tax Credit 7.18

CAPITAL COST & FINANCIAL ANALYSIS

(ITC)
Capital Cost net 63.35
of ITC

6.4 INTEREST DURING CONSTRUCTION (IDC)

Based on the mode of financing and phasing of capital expenditures indicated

above, the total IDC has been worked out to be Rs. 3.52 crore.

6.5 COST-BENEFIT ANALYSIS

6.5.1 The techno-economics has been worked out based on the benefit on account of
converting 0.475Mt of Hot Metal to Granulated Pig Iron (GPI). With the increase
in production from Blast furnaces, additional HM production of 475000 tpa will
be converted to 465500 tpa GPI.

6.5.2 The total operating cost of GPI considering manpower, power, water, refractory,
fuel, oxygen, repair & maintenance and miscellaneous works out to Rs. 255.30/t.

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6.5.3 Based on the above, the Gross Margin has been worked out to be Rs. 14.23
Crore (Considering Avg. NSR of GPI/Gran Shots as 9.1% less than the average
NSR of Pig Iron for last 3 years (2017-20). The details are given at Annexure
6.5.3-1.

6.5.4 For calculation of gross margin, rates of input materials including cost of
production of hot metal have been taken from Standard cost statement of RSP
for 2019-20 and the NSR figures have been furnished by RSP.

6.6 FINANCIAL ANALYSIS

6.6.1 Financial analysis has been carried out on the basis of cash flow during 22 years.
Life of the project is considered 20 years after its commissioning.

6.6.2 Techno-economic indices are presented at Annexure - 6.6.2-1. Some of the

important indices are indicated below:

Indices Value

IRR (Post Tax) 19.87%

NPV (@10%), Rs. Crore 33.77

CAPITAL COST & FINANCIAL ANALYSIS

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7. RECOMMENDATIONS

7.1 The project is technically feasible and techno-economically viable. It is

recommended for implementation.

RECOMMENDATIONS

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 INSTALLATION OF MICRO PELLET PLANT

ROURKELA STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED

CENTRE FOR ENGINEERING & TECHNOLOGY
RANCHI - 834002

OCTOBER 2021 CET/05/RN/4874/FR/IR/01/R=0

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This document has been prepared for Rourkela Steel Plant by:

Centre for Engineering & Technology

Jay Shankar – HOD Lead section

Shyam Ji (Task Force Leader)

Manish Kumar, Iron & Sinter
Suman Saurabh, Electrical
Vikash Kumar, PFC
Kamal Reddy Jambula, Process Control & Automation
Babul Debnath, Rourkela Sub-Centre
Arati Samanta, Rourkela Sub-Centre
A. Rituraj, Mechanical
S. Mukherjee, Structural
Homi Ghildiyal, Utilities & Services
PK Mishra, Cost Techno-Economics & Budget

Document Identification No. CET/05/RN/4874/FR/IR/01/R=0

REVISION HISTORY

Revision No. Brief Description Revision Date

R1

Disclaimer
This document is the property of CET and is exclusively for the use of the intended client. This document has been
prepared based on the inputs provided by the client. No part of this report will be reproduced or transmitted in any form
whatsoever without the written permission from the owner.

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UPSHOT

Integrated Steel Plants recycle some of the generated solid waste fines in the Sinter Plants. However,
higher use of waste fines leads to reductions in the sinter plant productivity. At Rourkela Steel Plant
(RSP), part of generated solid waste fines are recycled in Sinter Plants and sold to outside parties;
however, substantial amount of unused solid waste fines is being dumped. This is an environmental
concern.

The micro-pelletisation process converts solid waste fines to 1-6mm granules which can be used in
the sinter plant.

Accordingly, installation of 0.18 Mt Micro Pellet Plant is being considered near Sinter Plant-3 (SP-
3). The iron bearing waste fines will be converted into micro pellets which will be used in SP-
3 along with base mix fines. RSP is in process of obtaining Environmental Clearance for
installation of 0.18 Mt Micro Pellet Plant.

The project is envisaged to be implemented within a period of 20 months from the date of
Stage-II approval at an estimated cost of at Rs. 79.21 Crore (net of Input Tax Credit of
Rs.10.12 Crore) on base date of 3rd Quarter, 2021, including IDC of Rs.4.46 Crore.

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CONTENTS - CHAPTERS

Chapter no. Description Page no.

1 Summary 1.1-1.2

2 Background 2.1-2.3

3 Selection of Alternatives 3.1

4 Project Description 4.1-4.16

5 Implementation Schedule & Strategy 5.1

6 Capital Cost & Financial Analysis 6.1-6.4

7 Recommendations 7.1

Annexures

Drawings

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ANNEXURES

Annexure No. Description No. of pages

Annexure- 2.10-1 Minutes of meeting held between RSP and CET 3

officials

Annexure-2.11-1 A report on Pot sintering experiments with 5

micro-pellet addition at SP-3/ RSP conditions

Annexure-4.12-1 Risk Assessment Register 1

Annexure-5.1.2-1 Schedule of Pre-Ordering Activities After 1

Stage I Approval

Annexure-5.1.2-2 Schedule of Post-Ordering Activities After 1

Stage II Approval

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DRAWINGS

Sl. No. Drawing No. Description

1 CET/RN/4874/IR/00 001, R=0 Layout- Micro Pellet Plant

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1. SUMMARY

SUMMARY
1.1 In an Integrated Steel Plant, sintering is the accepted and proven route of consuming
iron bearing waste fines. As sludge and ESP dust are of micron size, their addition in
sinter raw mix, adversely increases total micro-fines load in the charge.

1.2 Preparation of micro-pellet using these solid waste materials and consumption
through sintering route is new trend in steel industry.

1.3 Rourkela Steel Plant (RSP) engaged MACO for micro pellet preparation from solid
waste fines. The micro-pellets were tested by RDCIS, Ranchi. As per RDCIS test report,
micro-pellet made with RSP waste material can be used up to 2-3 % of sinter charge
mix through sinter making at Sinter Plant-3 (SP-3).

1.4 RSP has processed for Environmental Clearance (EC) for setting up micro-pellet plant
of 0.18Mtpa capacity. EC is expected by November, 2021

1.5 Micro-pellet plant of 0.18 Mtpa has been considered in this feasibility report. The
plant will be installed near SP-3 in the filled up area of slurry pond-1. Sufficient area is
available.

1.6 During micro-pelletisation, the input waste fines along with suitable binder are mixed
and conditioned correctly before being fed in a controlled manner into the pelletizing
disc. The material is then granulated to a size and shape to meet sinter plant
requirements.

1.7 Indicative recipe of micro-pellets

Solid Waste Indicative Recipe, %

BF Flue Dust 21.78

BF Sludge 14.98
ESP/Bag Filter Dust (Sinter Plant) 13.23
ESP/Bag Filter Dust (SMS-II) 13.23
ESP/Bag Filter Dust (CP-II) 2.20
SMS Sludge 32.08
Binder (bentonite) 2.5

1.8 The micro-pellets will be fed to existing conveyor BC-229, conveying base mix to SP-
3. Micro-pellets will be conveyed to SP-3 bunkers along with base mix in
predetermined proportion. Suitable selection logic will be provided for the same.

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1.9 The project is envisaged to be implemented within a period of 20 months

from the date of Stage-II approval.
SUMMARY

1.10 The project is proposed to be executed through three package(s) as follows:

1) Area Survey and Soil Investigation Work (Through LTE mode as per
empanelment)

2) Underground Mapping Work (Through LTE mode as per empanelment)

3) Installation of Micro Pellet Plant (Package-III) – on Turnkey Basis.

1.11 MANPOWER REQUIREMENT

Total 55 no. manpower, including 10 no. executive, will be required.

After successful installation, the micro-pellet plant will be operated through a

separate O&M contract.

1.12 CAPITAL COST ESTIMATES

Capital cost of the Project is estimated at Rs. 79.21 Crore (net of Input Tax
Credit of Rs.10.12 Crore) on base date of 3rd Quarter, 2021, including IDC of
Rs.4.46 Crore. No FE component has been envisaged.

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2. BACKGROUND

2.1 Integrated Steel Plants generate different types of solid waste in the process of Iron & Steel
Making. In broad sense these wastes can be classified into two categories; as iron bearing

BACKGROUND
and low/non-iron bearing. Major amount of solid wastes generated in the plants fall into
iron bearing category and is in the form of dust, slag, sludge, mill scale etc.

2.2 Over the years, successful efforts have been made to reduce generation and increase
utilization of these wastes. Still, large amount of such iron bearing waste could not be
recycled/ disposed and is posing environmental issues. The solid wastes have many
valuable constituents, which can be recovered economically.

2.3 Solid wastes in an steel plant are generally disposed as follows:

· Granulated BF slag is sold to external Customer

· LD Slag is used as flux for iron & sinter making
· Mill Scale, Lime fines, ESP Dust & BF sludge are recycled through sinter plant
· BOF Sludge, BF Flue dust, Coke dust, Refractory waste etc. are sold to outside
party.

2.4 In an Integrated Steel Plant, sintering is the accepted and proven route of consuming iron
bearing waste fines. As sludge and ESP dust are of micron size, their addition in sinter raw
mix, adversely increases total micro-fines load in the charge. New sinter plants have
facilities for addition of calcined/burnt lime, to mitigate the adverse effects of micro-fines in
sintering.

2.5 Use of micro-fines in sinter bed is very limited because it affects bed permeability and
reduces productivity. Preparation of micro-pellet using these waste materials and
consumption through sintering route is new trend in steel industry. JSW, Torangullu plant is
converting waste fines to mico-pellets for use in sinter plants. RSP is also planning to use
most of its waste material according to prevailing industry trend.

2.6 RSP vide letter No. AMR-M&SC/Consultancy/20/7843 Dtd.09.09.2020 had requested CET
for Agglomeration of BOF sludge and other waste into useful products for charging into
Sinter Plants of RSP. CET requested RSP to get the test done to assess suitability of using
these wastes in sintering, as a prerequisite for report preparation.

2.7 Accordingly RSP engaged MACO for micro pellet preparation. The micro-pellets were tested
by RDCIS to find out effect of using micro pellets made from solid wastes of RSP, on

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sintering parameters, simulating sintering plant condition thorough pot sintering in its lab
at Ranchi. As per RDCIS test report dt. July, 2021, micro-pellet made with RSP waste
material can be used up to 2-3 % of sinter charge mix through sinter making at SP-3, RSP
condition. RSP submitted this report to CET on 10th July’21, considering which this
Feasibility Report has been prepared. The micro-pellets will be used as input raw material in
BACKGROUND

Sinter Plant-3.

2.8 Various types of solid wastes targeted for micro-pellet production at RSP are as follows:

Generation Consumption Available Recipe as Recipe

at 4.65 /Disposal in waste, per suggested
Solid Waste Mtpa HM Sinter Plant Ton/yr available in MACO
Stage, and other waste, % test report,
Ton/yr Units or Sales %
etc., Ton/yr
Calcined Lime 145000 119616 0 0 2.5
fines
Coke Dust 22000 22000 0 0 1.0
BF Flue Dust 77680 28290 49390 21.78 4.5
BF Sludge 33985 0 33985 14.98 2.0
ESP/Bag Filter 30000 0 30000 13.23 7.0
Dust (Sinter
Plant)
ESP/Bag Filter 30000 0 30000 13.23 4.0
Dust (SMS-II)
ESP/Bag Filter 5000 0 5000 2.20 2.5
Dust (CP-II)
SMS Sludge 72750 40645 72750# 32.08 74.0
Total 416415 210551 221125 97.50* 97.5

# Generated SMS sludge will be micro pelletized. Available stock (2 lakh ton
approx.) of will be sold till it lasts.

* Binder will be about 2.5% in the recipe.

Non-disposal of available waste is an environmental concern.

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2.9 As per MACO, above “recipe as per available waste”, at RSP can be converted into micro
pellets with minor variation in process/ binder %.

2.10 RSP has processed for Environmental Clearance (EC) for setting up micro-pellet plant of
0.18Mtpa capacity. RSP informed that the budget requirement for CER – Corporate

BACKGROUND
Environment Responsibility will be known only after Public Hearing and obtaining
Environment Clearance. As informed by RSP, EC is expected by November, 2021.

With process improvements, available waste is expected to decrease over the years. Hence
micro-pellet plant rated capacity may be considered as 0.18 Mtpa in line with EC proposal.

After successful installation, the micro-pellet plant will be operated through a separate
O&M contract. Copy of Minutes of meeting held between RSP and CET officials is attached
as Annexure- 2.10-1

2.11 As per RDCIS report, micro-pellet is made from plant waste material which consists of some
undesirable elements like Na, K, and Zn etc. that may have an ill effect on the operation of
sinter plant and down the line as well for long term sustainability. RDCIS report copy, A report
on Pot sintering experiments with micro-pellet addition at SP-3/ RSP conditions is attached as
Annexure-2.11-1

2.12 Disposal of generated solid waste fines is an environmental issue. By installation of

0.18 Mtpa Micro Pellet Plant, all the above available waste fines can be utilised/ recycled in
SP-3. This will eliminate land fill requirement for these wastes and ensure compliance with
environmental legislation. This will also help in recovery of available Fe, CaO, MgO, C etc in
the wastes.

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3. SELECTION OF ALTERNATIVES

3.1 The main method of solid wastes fines recycling is through sinter plant as raw
material (charge) component for production of the sinter. RSP also is using some of
the wastes fines in sintering. However, addition of such fines in the sintering charge
has a negative impact on sintering process which limits its use in sinter plants.

SELECTION OF ALTERNATIVES
3.2 The other alternative methods of recycling the solid waste fines is their-

3.2.1 Briquetting and subsequent use of briquettes in the BF/ BOF (Alternative-1)

Briquetting is a process used for production of lumps of regular geometric shapes

from iron containing waste fines by applying pressure with or without binders,
followed by drying and firing or curing under natural conditions. The most accepted
type of briquetting technologies are Roller Press Briquetting, Vibro Press
Briquetting, Stiff Extrusion Briquetting.

Briquettes of different shape and size can be produced depending on end use.

High Fe briquettes are normally used in BOF and low Fe one are used in Blast
Furnaces. In India high Fe briquettes are being used in BOFs at JSW, Torangullu and
low Fe briquettes are being used in small BFs of Suraj Products, Rourkela. There is
no reference of briquette use in larger size BFs.

No test/ trials have been conducted by RSP/ SAIL for use of briquettes in BFs/ BOFs.

3.2.2 Micro-pelletisation and subsequent use in sintering (Alternative-2)

In micro-pelletisation, solid waste fines are converted to micro-pellets of size 1-

6mm which are used in sintering process. The micro-pellets were tested by RDCIS to
find out effect of using micro pellets made from solid wastes of RSP, on sintering
parameters, simulating sintering plant condition thorough pot sintering in its lab at
Ranchi. As per RDCIS test report, micro-pellet made with RSP waste material can be
used up to 2-3 % of sinter charge mix through sinter making.

3.3 In view of the above, Alternative-2 has been selected in this report.

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4. PROJECT DESCRIPTION

4.1 Integrated Steel Plants recycle some of their particulate waste to the sinter plants.
However, higher use of waste fines leads to reductions in the sinter plant productivity. The
micro-pelletisation process converts waste fines to 1-6mm granules which can be used in
the sinter plant.

The micro-pellet plant at RSP will be installed near SP-3 in the filled up area of slurry
pond-1, as shown in the attached layout Drawing: CET/RN/4874/IR/00 001, R=0.

During micro-pelletisation, the input waste fines along with suitable binder are mixed and
conditioned correctly before being fed in a controlled manner into the pelletizing disc.
The material is then granulated to a size and shape to meet sinter plant requirements.
Process details have been detailed in following paragraphs.

PROJECT DESCRIPTION
4.2 PROCESS DESCRIPTION

Micro-pelletisation of waste fines will involve different steps, as described below.

4.2.1 Receipt, storage and proportioning

[Link] Sludge and Flue dust will be received by truck and stored at designated place near micro-
pellet plant. Fines received by trucks will be blended together by front end loader bucket
to get a mix as per above mentioned recipe. The mix will be retrieved from the storage
area by use of a front end loader and will be fed to the low level feeder (LLF). The low
level feeder will feed the mix onto a conveyor (BC-1). Conveyor BC-1 will be equipped
with a belt weigher (BW) which will be used to control the mix feed rate. Based upon the
feedback from this belt weigher a VFD on LLF will control the speed of the feeder to
ensure that it delivers at the required TPH. A control loop will be set up such that this
happens automatically. Conveyor BC-1 will feed onto conveyor BC-2. An over belt magnet
(OBM) will be provided on BC-1 to remove trump iron or metallic scrap.

[Link] Dry fines (ESP/Bag filter dust) and binder (bentonite) will be received at micro-pellet plant
by bubble tanker and conveyed pneumatically into designated storage bins Bin-1, BIN-2,
BIN-3 and BIN-4 (for Binder). The feeding airline will also be equipped with pressure
control valve and pressure relief valves to safeguard the tankers and human. Fines will be
fed to bins on getting clearance from control room. Each bin will be equipped with filter,
safety relief valve, vent system etc.

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[Link] The bins will be equipped with load cells to give a continuous read out of the weight
along with a high level indicator which will alarm to prevent overfilling of the bin. The bin
will also be equipped with vibrating bin bottoms. Screw conveyors/loss on weight system
will be located at the BIN outlets and will convey the materials onto conveyor BC-2. All
screw conveyors/Loss-in-weigh feeder will be equipped with a weighing device such that
it can detect material flow. All screw conveyors/Loss-in-weigh feeder will feed on BC-2.

[Link] Conveyor BC-2 will be provided with a belt weigher (BW) to measures the total materials
being fed from bins and low level feeder (LLF). All materials on this conveyor, BC-2, will be
weighed and the feedback will go to VFD such that the TPH can be controlled via a loop
to give the desired thru put. Binder will be added at the rate as needed to achieve proper
quality micro-pellet. A second belt weigher (BW) will be located at the drive end of BC-2
to confirm total TPH and will give feedback to mixer.
PROJECT DESCRIPTION

4.2.2 Mixing and Micro-pelletisation

[Link] Conveyor BC-2 will feed to Pre-Mixer (MX-1). In this unit, the feed will be homogenised.
Homogeneous mix from Pre-Mixer will be discharged into High Intensity Mixer (MX-2) for
secondary & final mixing. Mixed materials from MX-2 will be conveyed by conveyor BC-3
to the Pelletizing disc (PD) where final mix will convert to micro-pellets due to rolling
action. From Water tank, water will be added in controlled volumes into the mixer to
achieve the desired moisture content and water will also be added in controlled volumes
in to pelletizing disc, PD to achieve desired product. Flow meters (FM) will be installed in
the line and be used to control the flow along with a VFD on the pump. A control loop
will be set up such that the pump speed will vary to achieve the desired water TPH.

[Link] The micro-pellets will be discharged from the Disc pelletizer onto a conveyor BC-4 and
then to conveyor BC-5 which will be equipped with a belt weigher (BW) to determine the
amount (tonnage) of product. Then the micro-pellets will be conveyed by BC-6 which will
feed a stockpiling conveyor, Radial Stacker.

4.2.3 Stacking & Curing

The stacking conveyor will stack the micro-pellets in one of four separate areas (one area
for production, two for curing and one for dispatch). The stockpiling areas will be defined
using limit switches such that the stacking conveyor stacks in the correct location. The
stockpile stacking height will be controlled by a sensor on the end of the conveyor. This
will ensure that the conveyor height begins at ground level and then increases in line with
stockpile height such that product drop height is minimized. The aim is to minimize any
product breakage and degradation. The stocking area will be split such that each area will

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be capable of storing about 700 ton micro pellets. Total stock pile area will be under
covered shed.

4.2.4 Dispatch

[Link] After 2-3 days curing, the micro-pellets will be tested to ensure that they comply with the
agreed specifications. Quality micro-pellets will be reclaimed by Pay loader to feed to the
Reclaim Hopper. The micro-pellets from the hopper will be fed by a weigh feeder onto a
belt conveyor PC-1 which will carry it to existing Belt Conveyor BC-229.

Micro-pellets will be fed to existing conveyor BC-229, conveying base mix. Micro-pellets
will not be fed when BC-229 will be carrying other materials (flux, fuel etc.). Suitable
selection logic will be provided for the same.

PROJECT DESCRIPTION
[Link] The plant will operate on continuous basis and will be controlled by PLC. Any fines or
spillages generated by the process will be conveyed back to the front feed end of the
plant and combined within the mix such that they are fully recycled at the facility.

[Link] The micro-pellet produced will be fed to SP-3 proportioning bins; through existing belt
conveyor BC-229 which conveys base mix to SP-3. The micro pellets will be fed into BC-
229 through new conveyor PC-1 at new junction house NJPC-1. The conveyor will have
capacity 100tph, BW 800mm and approx. c/c 100m.

[Link] The junction house NJPC-1 will be erected along with floor of drive pulley. The top
sheeting of conveyor gallery of belt conveyor BC-229 will be dismantled as per
requirement. The skirt board, impact idler and chute to feed belt conveyor BC-229 from
conveyor PC-1 will be installed during normal shutdown.

[Link] The shutdown will be required during interfacing of new conveyor PC-1 with existing
conveyor BC-229. The shutdown will be maximum two days or can be staggered as per
requirement.

[Link] Electric hoist of capacity 3t has been considered for maintenance purpose of head pulley,
gear box, motor of the conveyor PC-1 at new junction house NJPC-1.

4.2.5 Input Raw Material

The micro pellet indicative recipe will be as follows:

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Solid Waste Indicative Recipe, %

BF Flue Dust 21.78

BF Sludge 14.98
ESP/Bag Filter Dust (Sinter Plant) 13.23
ESP/Bag Filter Dust (SMS-II) 13.23
ESP/Bag Filter Dust (CP-II) 2.20
SMS Sludge 32.08
Binder (bentonite) 2.5

4.2.6 For raw material transportation existing facilities, truck tanker etc., will be used.
These facilities will transport the waste fines from generating points to micro-
pellet unit.
PROJECT DESCRIPTION

4.2.7 Raw material stored at Micro-Pellet Plant will be covered with polythene etc.
during rainy season, to ensure dry material availability.

4.2.8 Typical chemical analysis of some of the waste fines is as follows:

Fe2O3 SiO2 Al2O3 CaO MgO Na2O K2O P2O5 SOx ZnO

BF Sludge 41.79 8.9 6.5 2.1 0.8 0.15 0.62 0.21 1.09 0.21

BF-5 Sludge 20.54 18.4 10.5 5.5 1.7 0.92 6.36 0.31 2.20 0.72

SMS-1 Sludge 48.0 2.9 0.6 10.9 2.1 0.07 0.07 0.37 0.47 0.02

SMS-2 Sludge 76.1 1.7 0.1 6.1 1.2 0.05 0.18 0.21 0.61

4.3 MICRO PELLET INDICATIVE PROPERTIES

· Size : <6 mm
· Strength after curing : 12-15 drops
· Fe : < 45% (depending upon input Fe)
· Moisture : <13%

Prior to delivery, the micro pellets will be tested to ensure that they comply with the
agreed specifications. Testing will be carried out once for every 700 tonnes produced to
confirm quality. Micro pellet lots that do not meet the required quality parameters will be

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segregated and reviewed for either use in the sinter plant or recycling again through the
micro pellet facility.

As per RDCIS report, micro-pellet is made from plant waste material which consists
of some undesirable elements like Na, K, and Zn etc. that may have an ill effect on
the operation of sinter plant and down the line as well for long term sustainability.
RSP is requested to evaluate this aspect.

4.4 OPERATING PARAMETERS

Parameter Value
35 tph
Production 700 tpd

PROJECT DESCRIPTION
180000 tpa
Power 14 kwh/t-micro pellet
Water 0.15 m3/t-micro pellet
Bentonite 25 kg/t-micro pellet

Note: There may be handling issues of wet slurry during monsoon period;
accordingly annual production has been kept 180000 tpa.

4.5 LABORATORY EQUIPMENT

analyser –02 No
Hot air oven – 01 No
Muffle furnace -01 No
precision balance –01 No
-01 No
Size measurement set (mm and micron)

4.6 ELECTRICAL SYSTEM

4.6.1 Power Requirement
Estimated electrical power requirement for installation of new micro pellet plant is
as under:

Voltage level Connected Load Maximum Demand

415 V 850 kW 800

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4.6.2 Power Distribution Scheme

6.6 kV HT power will be tapped from 2 nos. available spare feeders of existing
6.6kV switchboard at LBSS-6 substation. Necessary modifications with respect to
protection and metering including CT, etc. have been considered.

These 6.6kV feeders will feed 2 nos. 2MVA power transformers at newly envisaged
LT substation near the micro pellet plant. These transformers will feed new LT
Power Cum Motor Control Centre (PMCC) panel. This LT PMCC will further feed all
Motor loads, Power Distribution Board (PDB), Welding Distribution Board (WDB)
panels etc.

4.6.3 Major electrical facilities envisaged

[Link] LT substation
One LT Substation for installation of new transformers, PMCC, PDB, WDB panels
has been considered. Dry pressurized ventilation system, illumination and
PROJECT DESCRIPTION

appropriate fire extinguishers have been considered.

[Link] 6.6 kV/0.433 kV Dry Type Power Transformer

Two nos. 2 MVA, 6.6kV/0.433 kV indoor cast resin dry type transformer has been
considered at newly envisaged LT substation. These will be fed from above
mentioned 6.6kV feeders of LBSS-6 substation. Secondary of these transformers
will feed proposed LT PMCC panel through aluminium LT bus duct.

6.6kV side of these transformers will be provided with isolator arrangement.

[Link] LT Bus Duct

LT bus ducts with 415V aluminium bus has been considered for the connection
between 6.6/0.433 kV, 2MVA transformers and proposed PMCC. The bus duct
shall be dust and vermin proof.

[Link] Power cum Motor Control Centre (PMCC)

One no. PMCC panel comprising of 3200 ACB incomer feeders, bus coupler and
required numbers of ACB/MCCB outgoing feeders has been considered along with
required control & protection. It will be floor mounted, single front & free
standing and will be suitably located at proposed LT substation.

This LT PMCC will feed all motors, Power Distribution Board (PDB), Welding
Distribution Board (WDB) panels etc.

[Link] Power Distribution Board (PDB)

One no. PDB panel comprising of MCCB incomers, bus coupler and required
number of MCCB outgoing feeders is considered along with required control &

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protection. It will be floor mounted, single front & free standing and will be
suitably located at proposed LT substation.

It will cater to the load requirement of handling hoists, Air-conditioning,

ventilation, illumination and welding loads of the micro pallet plant.

[Link] LT Motors
All LT motors will be of TEFC, minimum IE3 class, energy efficient, IP 55, dust and
vermin proof, squirrel cage induction motor with local control panel near
respective drive as per operational philosophy.

The motors of VFD driven equipment will be suitable for VFD application.

[Link] Local Control Stations

Local Control stations with emergency stop & start pushbutton & LED indications
for ON, OFF & TRIP near the respective drives have been considered as per the

PROJECT DESCRIPTION
operation philosophy.

[Link] Variable Frequency Drives (VFD) with DOL Bypass

VFD Panels with DOL bypass is considered for feeding power to motors requiring
speed control as per operational requirement. The VFD will be IGBT based with
sine coded PWM control.

[Link] Un-interrupted Power Supply (UPS) System

Suitably rated, parallel redundant, industrial UPS system will be provided for
continuous & regulated AC power supply to the proposed instrumentation &
automation loads. UPS system will consist of common SMF battery bank with 30
minutes backup & UPSDB.

[Link] Conveyor Electrics

Conveyor electrics including belt sway switch, zero speed switches, pull chord
switch & chute jamming switch will be provided for all new/modified conveyors.

[Link] Hoist Electrics

One column/floor mounted MCCB panel will be provided for hoist. This panel will
be of IP 54 enclosure protection. Hoist will be provided with pendant push button,
festoon cable arrangement & related electrics.

[Link] Welding distribution board (WDB) and Welding Sockets

One no. WDB panel has been which will feed to adequate nos. of 63 A, 415V, 3-ph,
4-wire welding sockets for repair jobs

[Link] Cables & Cable Laying

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i) HT Power Cables
6.6 kV (UE) grade, 3 core, stranded aluminium conductor, XLPE insulated,
FRLS, armoured cables have been considered.

ii) LT power cable

1.1 kV grade multicores, armoured, heavy duty type cables having aluminium
conductor, PVC insulation and PVC sheathing have been envisaged for LT
power cables.

iii) Control cable

1.1 kV grade, multicore, multi strand, armoured, heavy duty type cables
having copper conductor, PVC insulation and PVC sheathing have been
envisaged for control supply.

iv) 6.6kV cables between LBSS-6 substation and proposed LT substation shall be
PROJECT DESCRIPTION

laid in cable trench.

v) Cables in general are proposed to be laid in ladder type cable tray/ GI pipe/
cable trench. Flexible conduits have also been envisaged near the drives or
specific areas.
[Link] Illumination system
Complete illumination of LT substation, junction house, technological structures,
new conveyors, peripheral area, etc. with LED based luminaries, lighting
distribution board, timer has been envisaged.

[Link] Earthing and Lightning Protection

Complete earthing system for all electrical equipment under proposed system has
been considered as per IS: 3043-1987. New earth pits will be provided and it will
be connected to the existing earthing system.

Lightning protection system will be provided as per IS/IEC 62305-2: 2010.

4.7 PROCESS CONTROL AND AUTOMATION

4.7.1 An Integrated Control System is envisaged for centralized monitoring and control micro
pellet plant. All control functions including start & stop of various electrical drives,
interlock and protection for various drives and gate operation, pneumatic conveying, data
acquisition, alarm annunciation, mimics, report generation etc. will be achieved through
the envisaged system.

4.7.2 The envisaged system will be Programmable Logic Controller (PLC) with processor, power
supply and communication cards. The process and control automation will be complete

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with field instrumentation, cables and cabling accessories. The following levels will form
the hierarchical control system:

· LEVEL-0: Latest field instrumentation system.

· LEVEL-1: PLC based integrated automation system for electrical and
instrumentation.

4.7.3 All Drive data, weighing information and instrumentation signals will be transmitted to
the PLC in control room. Integration with existing sinter plant will be done. For this
hardware and software required for interfacing with the existing PLC and new system is
also envisaged under scope.
4.7.4 All raw materials received will be stored in silos/ hoppers having load cell based level
indicators. These materials will be mixed in desired quantity from each silo through weigh
feeders. Final pallets will be feed to Sinter Plant – 3 (SP-3) through a belt conveyer, BC-
229 having 2 nos. of belt weighing systems (one each before and after the feeding point).

PROJECT DESCRIPTION
Weighing and feeding control will be under micro-pellet plant. However, SP-3 control
room will be provided with display for micro pellet feeding tonnage.
4.7.5 Dedicated electronic earthing system is also envisaged to effectively earth all electronic
equipment like PLC, computer, peripherals etc. Electrical & electronic earthing will be
separate.
4.7.6 Fire Detection & Alarm System

Microprocessor based intelligent addressable type automatic fire detection and alarm
system has been envisaged for timely detection of any fire. Areas to be covered under
such system will be control room, electrical rooms, cable galleries, false floors, false
ceilings, junction houses etc. Fire alarm system will consist of multi criteria detectors, fire
alarm panel, hooters, call points, response indicators, FRLS cables, etc. Micro-processor
based fire detector unit will be provided with audio-visual indication for proper
identification of actual fire / smoke effected location. The hooters will be provided to alert
the operators in case of fire break out. The system will have provision to transmit fire
alarm signal to central fire control station.

4.7.7 Plant telephone system will be extended to all new control room and electrical rooms
including substations. Total Five (05) telephone sets along with requisite cabling (20 pair
PIJFA cable, 2 kms length) from nearest JB is envisaged in this project.

4.7.8 Major control and measurement parameters considered are as per the following:
· Level monitoring in all hoppers
· Feed rate control/ Weighing control
· Water addition control
· Additives control

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4.7.9 Instrumentation Equipment list:

S. No Description Qty.
1 PLC with following: 1 Lot
· Processor, power supply and communication module
· I/O cards with 20 % spare pre-wired I/Os and 1 no.
spare card for each type of I/O cards
· Switch fuse terminals and interfacing relays
· Panel & chassis etc.
· Electronic hooter
· 2 no. of based HMIs with 24” colour monitor,
keyboard and mouse
· 1 no. of based engineering station with 24” color
monitor, keyboard and mouse
PROJECT DESCRIPTION

· 1 no. A3/A4 size multi-function black and white laser

jet printer with 5 spare cartridges
· SCADA software , Programming tool, Application
software & System software along with licences
· 60 days backup for events and alarms
2 Weighing/scales for silos, belt conveyers and weigh feeders 1 Lot
3 Field instruments comprising of: 1 Lot
· Pressure/ temperature/ level gauges
· Pressure/ temperature/ level/ flow switches
· Smart pressure, temperature, level, flow, differential
pressure transmitters
· Solenoid/ pneumatic actuators
· Load cells with weighing electronics including
weighing panels

7 Fire Detection & Alarm System 1 Lot

8 Power and signal cables, OFC cable, cable laying corrosion 1 Lot
proof accessories like cable trays, G.I. protection pipes,
supporting structures, clamps etc.
9 Weather proof transmitter cubicles/canopy, junction boxes 1 Lot
etc.
11 SS impulse pipes, conduits, isolating valves, erection 1 Lot
hardware, etc.
12 Control room furniture including operator’s chair & tables, 1 Lot
PC & peripherals, storage almirah as required.

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4.8 STRUCTURAL WORK

The scope of structural steelworks involved is envisaged as below:

4.8.1 New structures

Supply, fabrication, erection, painting, testing and commissioning of all structural

steel works for the following as per technological requirement:

i) Covered Conveyor galleries for new PC-1 conveyor with supporting trestles
along with CGS sheet for roof and sides, walkway on both sides with pre
cast RCC slab supported on structural floor beams, access stairs, ladders,
supports for handling facilities & handrails etc.
ii) New junction house along with CGS sheet for roof, side & gable end

PROJECT DESCRIPTION
cladding, RCC floors supported on structural floor beams with access
stairs, ladders, platforms, supports for handling facilities & handrails etc.
iii) Supporting structures for handling facilities of 3 ton capacity in new
Junction house.
iv) Part dismantling, modification/ strengthening of existing roof structure of
conveyor gallery BC-229 for receiving material from proposed new PC-1
conveyor.
4.8.2 Design Considerations
i) All steel structures will be designed with due consideration to the existing
plant and facilities.

ii) Apart from technological loads to be supported on steel structures, self-

weight and superimposed loads for the design will be according to IS 875.
Structures will be designed either for wind or seismic forces as applicable.
Due allowance for impact, vibration & temperature loads will be kept.
Seismic load shall be considered as per IS 1893-Part-1-2002 and IS 1893-
Part-4-2005.

iii) Design of steel structures will be as per IS 800:2007.

Conveyor will be designed as per the provisions of IS 11592: 2000.

4.8.3 Specifications
i) Material for structural steel will be as per IS: 2062-2011, grade as
applicable.

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ii) Sheeting material will be as per IS 277: 2018.

iii) Chequered plates will be as per IS 3502: 2009.

iv) All steel structures will be of welded construction. The welding procedure
will conform to IS 816:1969 and IS 9595:1996. Electrodes shall conform to
IS 814: 2004. Fabrication and erection of steel structures will be as per IS
800: 2007. Tolerances of fabrication will be as per IS 7215: 1974. Tolerances
for erection will be as per IS 12843: 1989.

[Link] Paint specification for new structures

i) All structures shall be given two coats of single pack air drying phenolic
modified alkyd composition with zinc phosphate as a primer (DFT/coat 40
micron) and two coats of single pack air drying high gloss phenolic alkyd
modified synthetic enamel paint as finishing coat (DFT/ coat=25 micron). One
PROJECT DESCRIPTION

coat of primer shall be applied before erection and one coat after erection.

ii) For open trestles/other outdoor structures in addition to the above, one
intermediate coat after the primer shall be applied. The paint shall be single
pack high build phenolic based paint with Micaceous Iron Oxide (MIO).The dry
film thickness shall be not less than 75 microns.

4.9 UTILITY AND SERVICES

4.9.1 Makeup water
Required makeup water of 10 m3/h @ 2.5 bar shall be tapped from existing water
header of DN 100 located inside the proposed shop at a distance 200 m from
upcoming Micro Pelletisation unit

4.9.2 Fire Fighting Facilities

The portable fire-fighting as per TAC (Tariff Advisory Committee) norms system
shall be provided for first aid fire-fighting system in Control room with PLC panel
and Electrical room with MCC panel. Passive fire protection shall be provided to
the electrical cables.

Pipeline DN 150 will be laid from nearest fire hydrant to the proposed micro pellet
plant to create fire hydrant facility.

4.9.3 Type of portable fire extinguishers to be provided

Sl. No. Areas to be protected Suitable fire protection system
1. Cable tunnels/ galleries FRC, Compartmentalisation & sealing, fire
basement/ cable vaults doors, FDA & Medium velocity water spray

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(MV\NS),fire extinguishers
2. Electrical panels Sealing, fire trace tube, fire extinguishers
3. PLC Room & control FDA & clean agent system, fire
extinguishers

4.9.4 Suitable Fire extinguishers shall be provided

Sl. No. Type of fire extinguisher Quantity envisaged

1. DCP Type 10 Nos.
2. CO2 Type 10 Nos.
3. ABC Clean Agent Type 5 Nos.

PROJECT DESCRIPTION
4.10 CIVIL WORK
The scope of work for Civil engineering works shall include the following:
4.10.1 Area development Work
· The location for new Micro Pellet Plant has been envisaged at the site of
existing Slurry Pond - 1 area located by the side of Sinter Plant – III. This
pond was constructed for collecting slurry of SMS sludge.
· The earmarked area for proposed Micro-Pellet Plant is presently filled with
plant wastage, dumps over SMS Sludge pond.
· A land area of measuring 200 m (length) x 200 m (Wide) is estimated to be
required for proposed Micro Pellet plant proper.
· Presently the available filled up area in Slurry pond is observed to be
approx. 190 m (Length) x 110 m (Wide) average dimension.
· The top of present filled-up area is not leveled. The top level is varying in
the range of approx. (+) 6 m to (+) 12 m height w.r.t existing road level of
nearby SP-3 area. Top level of adjacent sludge pond is approximately at (+)
4 meter height w.r.t existing road top level of SP-3
· For making the availability of levelled land area of 200m x 200m, area
development work will be carried out by cutting and filling in the area with
existing dumped materials. Additional filling will be required in the adjacent
part of slurry pond area. Retaining wall of Reinforced Cement Construction
(R.C.C) will be provided for retaining of the filling material at the edge of the
developed area.
· After area development work, the area will be levelled at approx. (+) 8 Meter
height w.r.t nearby existing road level of SP-3.

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4.10.2 Sub-Soil Investigation work, Underground Mapping and Area Survey work
· It is required to obtain the data on Soil characteristics, bearing capacity of
soil, soil profile, topography & Contour level of the proposed site,
Underground Mapping, as input data required for carrying out design of
civil engineering work for the proposed Micro-Pellet Plant project.
· Presently the above data is not available with RSP. These data will be
obtained through the following 2 (two) works packages envisaged in this FR:
1) Area Survey and Soil Investigation Work
2) Underground Mapping Work
4.10.3 Civil Works, RCC foundations in Micro-Pellet plant area which will include the
following:
· Chambers / Pits for [Link] Sludge & SMS Sludge
PROJECT DESCRIPTION

· Low-level feeder, conveyor for Mixed Sludge

· Foundation for Silos for storage of ESP dust, Lime Dust, Spillage Material
dusts, Coke Dusts and Binder materials
· Foundation for Screw conveyors, Belt conveyors, Pre-Mixer, Secondary
Mixer, Pelletizing Disc
· Foundation for Stacking conveyor for stock piling
· Civil works for Stock piling beds (beds for fresh pellets, curing & despatch),
Reclaim Hopper
· Civil works for despatch Conveyor of Micro-Pellet, from production area up
to existing base mix conveyor no. BC 229 including Junction Houses.
· Foundation for water storage sump, water tank, pumps
· Roads (R.C.C) and surface area drainage works in Micro-Pellet Plant area
with connection to existing nearby main road in SP-III area.
4.10.4 Civil works for LT Substation building and Control room building
A two-storey building of size 18M (L) x 12 M (W) has been envisaged for housing
LT substation equipment including Transformers, PMCC, PDB, WDP panels, etc. at
ground floor and Main Control room at first floor for housing PLC equipment,
panels, battery rooms etc.

The equipment required for ACVS (Air-conditioning & Ventilation system) of Main
Control room will be housed in the said building.
4.10.5 R.C.C cable trench will be constructed for laying HT Cable from source substation
LBSS-VI in SP-III area up to the proposed LT Substation building. While crossing
roads, the HT cables will be laid through GI pipes underneath the road.

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4.10.6 Following consideration have been taken while estimating the Civil work for
preparation of this Feasibility Report (FR)
1) In absence of data of Soil profile, Soil bearing capacity of the proposed site of
Micro-Pellet Plant, following assumption in regard to type of foundations
have been considered:
· For Heavy foundations, shop building column foundations, equipment
foundations:
Pile foundation with Reinforced cement concrete (RCC) Piles of 550mm
dia, end bearing piles - Length of pile : 15m.
· For lighter foundations, Soil bearing capacity has been considered as 7
ton / SqM at 3 Meter depth.
· Foundations for LT Substation cum Main Control room building

PROJECT DESCRIPTION
Pile foundation with Reinforced cement concrete (RCC) Piles of 450mm
dia, end bearing piles - Length of pile : 15m.
2) In absence of present contour level of the filled up land in Slurry Pond -1
area, envisaged for the proposed Micro-Pellet plant, following assumptions
have been taken:
· The present filled-up area is estimated as approx. 190 m (Length) x 110
m (Wide) average dimension.
· The top of present filled-up area is uneven and is estimated to be
varying in the range of approx. (+) 6 m to (+) 12 m height w.r.t existing
road level of nearby SP-III area. Top level of adjacent sludge pond is
estimated to be approximately at (+) 4 meter height w.r.t existing road
top level
· For preparation of levelled land area of 200m x 200m size, area
development work will be carried out by cutting and filling in the area
with existing dumped materials and additional filling will also be
required in the adjacent slurry pond area.
· After area development work, the area will be levelled at approx. (+) 8
Meter height w.r.t nearby existing road level of SP-III.
4.10.7 The actual data on Soil profile, Soil Characteristics, Contour level, topographical
survey, Underground Mapping data of proposed land location for Micro-Pellet
Plant is envisaged to be obtained after execution of two packages viz. 1) Area
Survey and Soil Investigation Work and 2) Underground Mapping Work.
Based on the actual data obtained after execution of the above two packages, the
estimation of civil works may however vary w.r.t the present assumption
considered in the FR.

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4.11 MANPOWER

Total 55 no. manpower, including 10 no. executive, will be required.

After successful installation, the micro-pellet plant will be operated through a separate
O&M contract.

4.12 RISK ASSESSMENT

Risk assessment for the project is attached at Annexure- 4.12-1

4.13 SAFETY

4.13.1 Safety Factors to be considered during designing

PROJECT DESCRIPTION

Safety aspects as per relevant codes and standards will be ensured during design
of the system. Equipment will be designed following fool proof safety aspects
during engineering.

4.13.2 Safety measures to be considered during implementation of the project

Personal protective equipment (PPE) and safety appliances required to execute the
job will be used during implementation of the project. Safety norms as prevailing
in the Plant and as mentioned in relevant clauses of SBD-2020 will be followed.

4.13.3 Safety aspects as per following codes and standards will be ensured during
execution of the job:

· Safety in Contract Works (as per IPSS: 1-11-011-14)

· Procedure for Working at Height by Contractor‘s (IPSS:1-11- 005-14)

· Guidelines for working in a Confined Space (IPSS: 1-11-006- 14)

4.14 OPERATION & MAINTENANCE SPARES

Two years operation & maintenance spares have been considered for this project.

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5. IMPLEMENTATION SCHEDULE AND STRATEGY

5.1 IMPLEMENTATION SCHEDULE

5.1.1 The project is envisaged to be implemented within a period of 20 months from the
date of Stage-II approval. Pre-ordering activities are envisaged to be completed
within 5 months from the date of Stage-I approval.
5.1.2 Implementation schedules, in the form of bar charts, for pre-ordering and post-
ordering activities are shown at Annexure – 5.1.2-1 & 5.1.2-2 respectively.
5.2 IMPLEMENTATION STRATEGY
5.2.1 Mode of execution and number of packages:
The project is proposed to be executed through three package(s) as follows:

1) Area Survey and Soil Investigation Work (Package-I) - Through LTE mode as per
empanelment

2) Underground Mapping Work (Package-II)- Through LTE mode as per

PROJECT IMPLEMENTATION
empanelment

3) Installation of Micro Pellet Plant (Package-III) – on Turnkey basis. For Package-

III, open indigenous tender with consortium bidding has been envisaged.

5.2.2 Pre-requisites/ clearances, special handling equipment, diversion of any known over
ground or underground facilities that need diversion, etc. for execution of the
project: Not envisaged at this stage
5.3 DETAILS OF PRE-SHUTDOWN ACTIVITIES WITH DURATION
Erection of new junction house NJPC-1

5.4 DETAILS OF SHUTDOWN ACTIVITIES WITH DURATION

a) Water, Power tapping from battery points will be taken during monthly shutdown
of SP-3

b) Interconnection of new conveyor PC-1 with existing conveyor BC-229 will be

done during more than 2 days shutdown of SP-3.

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6 CAPITAL COST & FINANCIAL ANAYLSIS

6.1 CAPITAL COST ESTIMATES:

6.1.1 Capital cost of the Project is estimated at Rs. 79.21 Crore (net of Input Tax Credit
of Rs.10.12 Crore) on base date of 3rd Quarter, 2021, including IDC of Rs.4.46
Crore. No FE component has been envisaged.

The summary of capital cost estimate of the project is as below:

(Rs. in Crore)
Sl. Item Imported Indigenous Total
No. Component Component Amount
1 Plant & equipment including
33.91 33.91
technological structures

2 Spares 1.28 1.28

3 Building Structures 4.67 4.67

4 Refractories

5 Civil Works 16.71 16.71

6 Erection & Commissioning 5.00 5.00

7 Engineering & Construction 6.03 6.03

CAPITAL COST & FINANCIAL ANALYSIS

8 Freight & Insurance 1.12 1.12

9 Taxes & Duties 12.10 12.10

10 Others

11 Contingencies 4.04 4.04

12 Total Plant Cost 84.87 84.87

13 IDC 4.46

14 Capital Cost 89.33

15 Input tax credit (ITC) 10.12

16 Capital Cost net of ITC 79.21

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6.1.2 Capital cost estimate has been prepared based on Bill of Quantity (BOQ) as per
scope of work. The detailed break up is as above. The cost estimate has been
prepared considering available budgetary quotations (BQs), purchase orders (POs)
and engineering estimate (based on updated cost database). However, the major
component of the plant & equipment cost estimate is BQ.

The cost of setting up of Micro Pellet Plant which is major cost element is based
on BQ of MACO of August 2021. The BQ of MACO has been knockdown by 10%.
Civil cost estimate is based on DSR-2021 rates.
Structures cost is estimated based on prevailing market rates.
In total cost estimate of Plant & equipment, 94% is based on BQ/PO and 6% is
based on engineering estimate.
Breakup of basic cost of the project in percentage is depicted in the pie-chart
shown below.
2.26%

Technological Equipment
Mechanical Equipment
29.54% Utility Equipment
Electrical
55.55% PC&A
Structure
8.25%
CIVIL
CAPITAL COST & FINANCIAL ANALYSIS

0.30%
Spares
2.13%
0.24% 1.72%

6.1.3 Estimated block cost of some of the major technological units are as follows:
Sl. Description of units Estimated block Remarks
No. cost (in Rs. Cr.)

1 Setting up of Micro Pelletisation 31.43 The unit wise

facility estimated block cost
is indicative only to
2 New conveyor system BW1000 0.90
give a general idea.

3 6.6kv/0.433kV dry type 0.53

transformer

6.1.4 Necessary additional provisions have been made in the estimates as per the
details given below:
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i. For indigenous items:

GST @18% on basic cost of equipment, structures, civil, erection and E&C
(Contractor’s), freight & insurance.
ii. For imported items: Not Considered
iii. Freight & Insurance charges: @ 2% of basic cost of indigenous equipment
and 9% of basic cost of structures.
iv. Erection & commissioning charges: @ 12% of basic cost of indigenous
equipment, @ 20 % of basic cost of structures.
v. Engineering & construction (E&C): E&C (contractor) @ 7.5% and E&C (owner)
@ 2.5 % on basic cost of equipment, refractory, structures, civil work and
erection & commissioning charges.
vi. Contingencies: @ 5 % on overall basis has been considered.
6.2 MODE OF FINANCING:
6.2.1 The total capital requirement of the project is proposed to be provided from 100%
debt. An interest rate @ 10% per annum is considered for commercial borrowing.
6.3 PHASING OF CAPITAL EXPENDITURE & IDC:
6.3.1 With the project duration of 20 months from the date of stage-II approval,
phasing of capital expenditure and IDC is proposed as indicated below:

Years Internal Loan IDC Total

Resources
1st Year 25.46 1.27 26.73

CAPITAL COST & FINANCIAL ANALYSIS

2nd Year (8 months) 44.56 3.18 47.74

Post Comm. 14.85 14.85

Capital Cost 84.87 4.46 89.33

ITC 10.12

CC net of ITC 79.21

6.3.2 Based on the mode of financing and phasing of capital expenditures indicated
above, the total IDC works out to Rs.4.46 Crore.
6.4 COST-BENEFIT ANALYSIS:
6.4.1 This project is necessary for disposal of waste fines. Techno-economics for this
project has not been worked out as this project is for environmental purpose.

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7 RECOMMENDATIONS

7.1 Steel industry development is focusing on “clean, green & sustainable technology” for its
survival, development and growth. In order to achieve these objectives, the solid waste
management has a vital role without which sustainable development & growth of steel
making will be quite difficult.

7.2 Old ways of waste dump & land fill has its own cost and environmental concerns. Now days,
generated wastes are called co-product and are considered as part of product portfolio, if
recycled/ reused/sold. By installation of 0.18 Mtpa Micro Pellet Plant, available waste fines
can be utilised/ recycled in SP-3. This will eliminate land fill requirement for these wastes
and ensure compliance with environmental legislation. This will also help in recovery of
available Fe, CaO, MgO, C etc in the wastes

7.3 The project is a technical necessity & technically feasible; and recommended for
consideration.

RECOMMENDATIONS

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