Annual Business Plan

2014-15
March, 2014
MTI, Ranchi

Highlights: 2013-14
Battery # 5 commissioned in Sept13 after hot
complex repair, 25 days ahead of schedule.
Battery # 4 commissioned on 31st January14
after cold repair.
Common facilities of COB#3&4 were successfully
revamped.
New DE#16 & 17 fabricated in-house, introduced
in COB#5 & 4 respectively.
Modification in hammer crusher to reduce microfines in Coal blend.
Revival of Tar Unloading Facility to reduce
consumption of Furnace oil (4600 Tons unloaded)

Strategy & Key Assumptions : 2014-15

Hot Complex Repair of COB#6 within 6
months.
Composite Contract for Heating Control,
Anchorage regulation, Condition Based
Battery Monitoring system (COMIT) in
COB#1&2
COB#3 under Cold repair Commissioning by
May 2015.
Ceramic welding of Joints after Hot repair of
COB#5
Complete Battery Maintenance & End
vertical repair in COB#8 by M/S Fosbel.

Production Potential : 2014-15

UNIT / ITEM

Best
Achieved
(000 Ts)

Oven Pushing
(Nos.)

531.39

Sinter
Hot Metal
Crude Steel
Mill Wise
Production:

Tot. Saleable
Steel
% Value
Added

2013- 14
ABP
(000
Ts)

383

Likely
(000
Ts)

369

2014-15
Proposed
Plan
(000 Ts)

Growth Planned
over Likely FY 14
(in %)

425

10.9%

Break-up of Production from existing and

new facilities
000 T
ITEM
Oven Pushing/Day
Gross Coke
Sinter
Hot Metal
Pig Iron
Crude Steel
Finished Steel
Product 1
.
Semi Finished
Product 1
.
Total Saleable Steel

EXISTING

NEW
(Cap Utilsn)

TOTAL

425

425

High Impact Initiatives Planned for

2014-15
Particular

Current Status

Planned
Improvement

1.Hot repair of COB#6

Work to start from 1st

week of April.

From 40 unhealthy
ovens we shall gain
60 healthy ovens

Physical contract to be awarded by 15/03/14, Refractory bricks

available, Mechanical spares under procurement.

2.Introduction of new
Door extractor for
COB#6 &
Comprehensive
revamping of all
machines of COB#6

Presently machines of
COB#6 are unhealthy

All machines will be

reliable improving
pushing consistency.

Order for new DE ram for new door extractor (being made in house,)
placed on HEC. Spares & Contract for comprehensive repairs are being
finalised.

Coke oven

Unit : Nos./da
Oven Availability : ABP vs Actual : 2013-14
Apr

Bat
t

1
2
3
4
5
6
7
8

May June July

Aug

Sep

Oct

No
v

De
c

Jan

Feb

Ma
r
69

ABP

69

69

69

69

69

69

69

69

69

69

69

Actua
l

69

69

69

69

69

69

69

69

69

69

69

ABP

69

69

69

69

69

69

69

69

69

69

69

Actua
l

69

69

69

69

69

69

69

69

69

69

69

ABP

37

37

37

69

68

Actua
l
ABP

38
38
38
40
40
0
35.9
27.4 28.5 10.3
35.40 35.39 38.37
36.68 10.40
0
8
7
9
0
0
0
0
0
0
0
0
0

Actua
l

ABP

30

30

Actua
l
ABP
Actua
l
ABP

45
45
60
60
69
67.7
3.43
0
0
0
0.00 44.07
68
68
68
68
4
49
54
54
54
56
56
56
56
56
56
60
39.7
40.7 44.0 44.8 44.8 42.3
47.63 44.16 40.80
38 39.70
7
4
3
1
7
9
0
0
0
0
0
0
0
0
0
0
0

Actua
ll

ABP

54

57

60

60
54.1

64

64

Actua

53.53 55.61 55.37

60.87 62.23

64
64
64
62.9 61.4 62.6

64

64

64

64

69

69
69

60

0
64

Oven Pushing : ABP Vs Actual : 2013-14

Unit : Nos./da
Apr

Bat
t

1
2
3
4
5
6
7
8

ABP
Actu
al
ABP
Actu
al
ABP
Actu
al
ABP

May

June

July

Au
g
89
89
89
90
90
93.2
91.93 92.26 92.97 92.97
9
89
89
89
90
90
91.6
92.57 90.45 91.47 92.03
5
37
37
37
38
38
34.5
34.60 33.94 37.50 34.03
2
0
0
0
0
0

Actu
al

ABP

30

Actu
al
ABP
Actu
al
ABP

De
c
90
90
90
84
93.2 92.4
87.8
92.60
0
8
7
90
90
90
84
92.2 90.1
87.0
91.30
3
4
3
38
40
40
0
26.4
10.3
8.13
26.90
8
9
0
0
0
0
0

Oct

Nov

Jan

Feb

84
90
81.3 84.8
2
6
84
90
80.8 85.3
4
2
0
0

ABP

63

66

69

69

64.37 68.65 69.07 68.42

73
73
73
72.0 74.8 74.1

0
73
71.57

69

70

90

72
79

66

73
73
73
71.1 76.0 74.9
9

Ma
r
90

0.00 0.00

32
48
48
64
64
76
43.8 69.4
74.0 76.1 75.3
3.27
0
0
0
0
72.80
0
8
6
0
2
54
59
59
59
61
61
61
61
61
61
65
42.3 42.6 40.3
44.8 44.2 42.3
53.77 49.00 43.20 45.13
43.70
5
3
2
1
3
6
0
0
0
0
0
0
0
0
0
0
0

Actu
al

Actu

Sep

73

Likely pushing for 2013-14

Unit Nos./Day
Q1

Bat
t A PP
1
2
3
4
5
6
7
8
Tot
al
%

89
89
37
0
0
57
0
66

Q2

A ct

A PP

92
91
35
0
1
49
0
68

90
90
38
0
21
60
0
72

Q3

Q4

A ct A P P

A ct A P P Likely

93
92
25
0
15
43
0
72

91
89
21
0
72
43
0
73

88
88
27
0
53
61
0
73

88
88
0
47
73
64
0
73

338 336 371 340 390 389 433

99.41

91.84

99.76

85
85
0
47
75
44
0
75

412
95.15

2013-14
AP
Likely
P

89 90
89 89
25 21
12 12
37 41
61 45
0
0
71 72
38
3 369
96.45

Battery wise Repair Plan vs. Actual Repair

2013-14
Bat
#

Repair Plan

Actual Repair

None

None

Stopped for Cold repair & Common facilities job on

12/12/13 commissioning by May 2015.

Re-commissioned after Cold Repair on 31st January

2014.

Stopped for a 6 month Hot

repair

None

Under rebuilding, stage 2 obtained in Oct13, contract

finalized in Dec13, Work started on 10/02/2014,
commissioning by 1st June 2016

End vertical repair in 15 HWs

Commissioned 25 days
ahead of schedule.

11 nos completed.
11

Oven Availability vs Pushing Potential : 2014Unit : Nos./da

15
Bat
Ap Ma Jun Jul Au Se Oc No De Jan Fe Ma Avg
t

Availabili
ty

69

69

69

69

69

69

69

69

69

69

69

69

69

Potential

84

84

84

84

84

84

84

84

84

84

84

84

84.0

Availabili
ty

69

69

69

69

69

69

69

69

69

69

69

69

69

Potential

84

84

84

84

84

84

84

84

84

84

84

84

84.0

Availabili
ty

Potential

69
75

69
78

69
82

69
84

69
85

69
85

69
85

69
85

69
85

69
85

69
85

69
85

69.0

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69
74

69.0

Potential

0
0

0
0

0
0

0
0

0
0

0
0

60
60

60
60

60
60

60
60

60
60

60
60

30.0

Availabili
ty

Potential

Availabili
ty

63

62

62

62

62

62

51

51

51

66
12

66

66

60.3

Availabili
ty
Potential

Availabili
ty
Potential

Availabili
ty

83.2
74.0
30.0

Strategy for COB#1&2

Oven
2013- Availability
14
(till
Feb)

ABP

Actual

Oven
Pushing

ABP

Actual

Coefficie
Coking
nt of
Period
Pushing

All 69 ovens are in healthy condition. New Hydraulic

battery machines.
18:23 is consistent.
1 PLC driven
69
69.00
89
90.52Pushing
0.97
To sustain
coefficient
of pushing,
Enablers
18:38 are0.97
2
69
69.00
89
89.55
1.A Composite contract has been started for
Operational Cleaning, Heating, Anchorage regulation
and Condition based monitoring of Battery Health
(COMIT).
2.AMC for Door Maintenance, Compressor
Maintenance.
13

Strategy for COB#3

Oven
Availability

201314

ABP

Actual

Oven
Pushing

Coeffici
Coking
ent of
Period
Pushing
ABP Actual

Battery is under Cold repair (Job started in Feb14)

(till
25:48
Feb)
Commissioning by May 2015.
28
23.51
28 22.41
0.85

14

Strategy for COB#4

Oven
2013- Availability
14
(till
Feb)

ABP

Actual

Oven
Pushing

ABP

Actual

Coefficie
Coking
nt of
Period
Pushing

Battery was commissioned after Cold repair on 31st

23:00
4 January
6 2014, 6as per schedule.
6
6.37
0.95
Oven pushing will increase after due regulation as
indicated in Pushing plan.

15

Strategy for COB#5

Oven
2013- Availability
14
(till
Feb)

ABP

Actual

Oven
Pushing

ABP

Actual

Coefficie
Coking
nt of
Period
Pushing

Battery was commissioned after Hot Complex repair

th
days ahead
22:15 of schedule.
5 on 1034September
35.20 2013,
33 25
37.71
0.90
Oven pushing has been stabilized.
Ceramic welding of joints and Cleaning of
regenerator ports is being done to reduce cross
leakage between Old New brick joints and to
improve the temperature profile of the Battery.

Strategy for COB#6

Oven
Availability

Oven
Pushing

Cokin
Coefficie
g
nt of
Perio
2013- ABP Actual ABP Actual
Pushing
It is a 31 year old battery. Presently d
41 ovens are in
14
operation. Most ovens are damaged and require
(till
constant Ceramic welding / Dry Gunniting for
Feb)
operation.
55
42.45 Hot60complex
44.68 repair
20:44 including
0.85
A 6 month
long
changing Coke side service platform and Gas
collecting mains is planned.
After repair at least 60 healthy ovens will be in
operation.
17

Status for COB#7

Stage 1 approval for rebuilding obtained in
Oct12. Divided into 4 packages
Stage 2 approval obtained in Oct13
Dismantling started on 11.12.12 and
expected to be completed.
LOA issued to Mecon on 05/11/2013.
Final contract signed on 16/12/2013.
Work started 10/02/2014.
Commissioning COB#7 by 01/06/2016.

Strategy for COB#8

Oven
Availability

Oven
Pushing

Cokin
Coeffici
g
ent of
Perio
2013- ABP Actual ABP Actual
Pushing
64 ovens are in operation. Remaining
ovens
d

14
have hole and need to be repaired.
(till
A package of Complete Battery19:50
Feb)
Maintenance
is being62executed
by 71
M/S 71.39
Fosbel, including
All
59.71
0.95
activities except Pushing / Charging.
M/S Fosbel is carrying out End vertical repair
and full wall repair will be carried out in
selected ovens as per plan.
19

REPAIR PLAN: 2014-15

Bat

1
2
3
4
5
6
7
8

Ap
r

Ma
Jun Jul
y

Au
g

Se
p

Oct

No
v

De
c

COLD REPAIR

HOT COMPLEX REPAIR

REBUILDING
END FLUE
REPAIR
20

Jan

Fe
b

Ma
r

Repair/Rebuilding Plans for Next 5

Years
Year
COB
#

1
2
3
4
5
6
7
8
9

2013-14 2014-15

201516

2016-17

201718

Feb14 to May15
Jan12 to
Jan14
Apr13 to Sep13

Apr14 to
Sep14

Jun16 to Mar19

Dec13 to May16
Apr15 to Dec17
Oct14 to Mar18
COLD REPAIR

REBUILDING

HOT COMPLEX REPAIR

NEW CONSTRUCTION

Availability of Indian Prime Coking coal in

2013-14
Blend usage
as per APP: 14%
Sl

Month

1
2
3
4
5
6
7
8
9
10
11

April
May
June
July
August
September
October
November
December
January
February

Allocatio
Receipt
n
20871
35000
17634
27000
22065
31000
25074
31000
15545
31000
19432
27000
15367
24000
14249
22000
15834
15000
17798
23000
17260
28000

% Pro
rata
59.63
65.31
71.18
80.88
50.15
71.97
64.03
64.77
105.53
77.38
61.64

Blend
9.24
10.00
10.00
11.85
8.61
10.33
6.19
6.74
7.16
8.00
7.45

Availability of Indian Medium Coking coal

in 2013-14
Blend usage as per APP: 04%

Sl

Month

1
2
3
4
5

April
May
June
July
August
Septembe
r
October
November
December
January

6
7
8
9
10

Receip
Allocation % Pro rata Blend
t
9468
13135
18268
7029
7029

5000
19000
27000
19000
19000

189.36
69.13
67.66
36.99
36.99

7.43
7.00
7.00
5.21
4.89

12044
16995
8337
10192
7828

30000
17000
15000
15000
12000

40.15
99.97
55.58
67.95
65.23

4.26
6.09
5.53
5.49
5.00