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STEEL PLANT
SUBJECT - OPM
TERM – II
JULY 2009
OPM PROJECT
JULY 2009
TABLE OF CONTENTS
3. Location 05
4. Layout Planning 07
5. Capacity Planning 09
7. Quality Requirement 12
1. PRODUCT
Sl.
Production per
No Module
Annum
.
1. 2 x 100 TPD DRI Unit 60000
2. 2 x 8 T SMS Unit 80000
3. 80 MT Rolling Mill Unit 80000
4. Captive Power Plant 5 MW
The Indian steel industry has a history of 125 years and was a regulated
industry till 1991 when it was de-licensed and private players were encouraged
to manufacture steel. The sector received high priority for automatic approval
for foreign direct investment. The demand for steel was expected to race ahead
after liberalization so additional manufacturing capacities were added.
2. PROCESS STEPS
Brief Description
• Steel Melting Shop: Sponge Iron is charged into Steel Melting Shop with
scrap and pig iron to manufacture mild steel. The liquid steel is cast into
semi-finished products such as billets, blooms, slabs etc
3. LOCATION
Chosen location for the Integrated Steel Plant to produce Finished Steel will be
Purulia, West Bengal. Following are the Location Advantages:
Land: Purulia has good road connectivity for the purpose of man and
material movement. As the location has a barren (non agricultural) area
therefore acquisition of land will not pose any kind of difficulty
Civic Amenities: The plant site is situated near Asansol town. All
necessary civil amenities (e.g. educational institution, college, school,
hospital etc) are available.
Water: The requirement of the fresh water to meet process make up and
drinking needs will be made available through pipe lines from nearest
Kasai River.
Power: The total power requirement for the proposed unit can be
sourced from Captive Power Plant. Balance if any can be sourced easily
from nearby power supply station DVC & WBSEDCL.
State Incentive Scheme: Since the location of the plant falls under the
Group C category as categorized under The West Bengal State Support
for Industries Scheme, the unit will enjoy following incentives as
categorized in the West Bengal Incentive scheme 2008 which are
summarized as follows:
4. LAYOUT PLANNING
Medical Room: A Medical room with the entire first aid stuff has to be
considered for the operating and maintenance personnel.
Raw Material Storage Yard: For the Raw Material receipt & storage
would have capacity to store 1 month requirement.
Water Storage Area: To keep fresh water to meet process make up and
drinking needs.
Approach Roads: For the movement of man and material within the plant
area.
Green Belt Area: In the process of steel-making, even with the latest
technologies available, it is not possible to completely eliminate pollution
in any of its diverse forms - air, water, noise or solid waste. Therefore it is
proposed to have a green belt all around the plant site by planting
suitable species of evergreen and broad leaves type. Plantation is also
envisaged on both sides of the plant road.
DRI Unit: For the production of Sponge Iron of the required capacity.
Power Plant Unit: For the Captive production of Power from the Hot
Gases of DRI Unit.
Rolling Mill Unit: For the production of Steel Product/TMT Bars of the
required capacity.
Finished Product Stock Yard: For the final product from Rolling Mill
having capacity to store one month Stock.
Quality Control Check: For the inspection of the final product before
dispatch.
Product Load out Station: The finished product after Quality Control
check can be load into trucks for dispatch to customers.
PLANT LAYOUT
5. CAPACITY PLANNING
Steel Melting
DRI Rolling Mill
Shop
2 Kiln x 2 Furnace x 8
Configuration 80 MT
100 TPD T
Hours per Shift 8 8 8
No. of Shifts in a day 3 3 3
No. of Days in a Year in
300 330 350
Operation
Production per Day in MT 200 242 228
Installed Capacity in
60000 80000 80000
MTPA
Sponge TMT Bars or
Final Product Billets/Ingots
Iron Rolled Products
Maximum Capacity
85% 85% 85%
Utilization
No. of Days required for
65 35 15
Maintenance in a year
one month one month
Inventory one month stock
stock stock
Note:
• For the smooth production line one Kiln of DRI Unit and one furnace of
SMS will always be in the production during any of the maintenance
period which will help to achieve the target or fulfill the customers
demand.
• One month stock will be kept in advance at Raw Material Yard for the
smooth production.
• Finished Products (TMT Bars) can be sold in the open market. In view of
adequate demand in the Eastern Region and does not foresee any
problem in marketing the above products.
Steel Sources of
Rolling
Proportion DRI Melting Raw
Mill
Shop Materials
Will be
sourced
Iron Ore in MTPA 1.6 96000 - -
from mines
of Orissa
Locally
Coal in MTPA 1.4 84000 - -
Available
Locally
Dolomite in MTPA 0.05 3000 - -
Available
Sponge Iron in
Will be
MTPA (Will be
0.75 - 60000 - produced in
transferred from
house
DRI Unit)
Locally
Available
Pig Iron in MTPA 0.25 - 20000 -
from the
market
Locally
Available
Scrap in MTPA 0.10 - 8000 -
from the
market
Billets/Ingots in
MTPA (will be Will be
transferred from 1.00 - - 80000 produced in
Steel Melting house
Shop Unit)
7. QUALITY REQUIREMENT
• Good and uniform response to heat treatment since the components are
always treated in bulk
In order to satisfy these factors, the above tasks must be standardized and
prepared in writing as guidelines or references. Their contents must provide
steps to make it possible to ensure that the results of analysis will be obtained
by taking the provided steps.
A Quality Plan helps to schedule all of the tasks needed to make sure that the
project meets the needs of customer. It comprises two parts; the Quality
Assurance Plan lists the independent reviews needed and the Quality Control
Plan lists the internal reviews needed to meet the quality targets. By using
Quality Assurance and Quality Control techniques, one can create a
comprehensive Quality Management Plan for the project.
Feasibility Study