Om Sponge Plant Modification WHRB

Project Report OM SPONGE
Village – Munrethi
Block : Dharsiwa, Distt : Raipur (CG)
PROJECT REPORT
ON
IMPLEMENTATON OF INDUCTION FURANCE, CCM ALONG

WITH HOT CHARGING ROLLING FACILITY WITH REVISED
CAPACITY OF 57600 TPA ,
ALONG WITH WHRB AND BIOMASS BASED POWER

PLANT AND FLY ASH BRICK PLANT ALONG WITH
EXISTING SPONGE IRON KILNS,
:: Project Proponent ::
OM SPONGE
Village- Munrethi, Dharsiwa, Raipur (CGP)
Page No. 0
Project Report for revision of capacity for SMS and Hot charging rolling mill to 57600 TPA and
modernization of DRI kiln from 50 TPD x2 Nos to 100 TPDX1 Nos. While implementation of WHRB,
Biomass based power plant and Fly Ash Brick Plant along with existing Sponge Iron Kilns
1. BRIEF OF PROJECT:
The unit Om sponge has been operating a sponge Iron Plant with 30000 TPA capacity
since the year 2003. The unit has been set up with 50 TPD into 2 No DRI kilns at Kh. No
140/1 (Part), 115/1, 115/2, 136/6, 139/12, Village- Munrethi, Tahsil and District- Raipur
(CG). The unit was set up vide consent No 3433/TS/CECB/2005 Dated 29/07/2005 and
at present operating this facility of two DRI kilns based on CTO No 2626/TS/CEC/2018
dated 26/06/2018. The consent was renewed 1 July 2021 vide letter No 1753/
TS/CECB/2021 till 30 June 2022.
The unit had subsequently decided to set up a 30000 TPA Capacity Hot Billet based
Rerolled steel production through Induction Furnaces and Hot Charging based Rolling
mill; along with 8 MW capacity Bio mass based Power Plant and a 4 MW WHRB based
Power Plant; the unit also sought to set up 30000 Nos per day Capacity Fly ash Bricks
Units for which the unit has obtained the CTE vide letter no 8743/TS/CECB/2022 dated
28/02/2022 as all these facilities proposed were not covered under EIA Notification
2006.
Now the unit wants to revise the Capacity of MS Billets / Hot Rerolled steel production in
the proposed expansion on the unit from 30000 TPA to 57600 TPA capacity hot
charging based Rolling mill with Induction Furnace based on no increase in Pollution
load .
The proposed capacity expansion project will be set up within the existing project area
located at at Kh. No 140/1 (Part), 115/1, 115/2, 136/6, 139/12, Village- M unrethi, Tahsil
and District- Raipur (CG). There is no need to procure additional land. The project falls in
the industrial zone of Siltara being close by to Siltara Industrial Growth Centre. There
are large number of Similar units set up in the area which produce DRI; MS Billets and
Power.
The Proposal is for implementation of revised capacity of Induction Furnaces, CCM, Hot
Charging Rolling Mill, along with already consented capacity of WHRB and Biomass
based power plant, Fly Ash Brick plant along with existing capacity of Sponge Iron to be
produced from one single modern Kiln of 100 TPD in place of presently operated two
numbers of 50 TPD each kilns. The present two numbers of DRI kilns each with 50
TPD are based on quite old technology and are more than 18 years old thus the kilns
require to be replaced to avoid any losses of Iron Ore and Coal also and to improve
better energy efficiency , The 50 TPD kilns are prone to frequent shut downs due to
accretion and consume more Coal and more auxiliary power than 100 TPD kilns. Thus
the management wants to replace these two kilns with one single 100 TPD kiln.
The proposal is based on no increase in Pollution load.
Page No. 1
The details of existing and permitted and proposed capacities are as follows:
Product Capacity
Existing capacity Proposed Final Remarks
capacity in granted in
operation CTE
as per CTO
Sponge Iron 30000 TPA 30000 TPA 30000 30000 No Change in
( with 50 (with 50 TPA TPA Sponge Iron
TPD x 2 No TPD x 2 No (with 100 with 100 production
Kilns) Kilns) TPD x 1 TPD x 1 capacity per
No Kilns) No Kiln) day and per
annum.
MS Nil 30000 TPA 57600 57600 Increase in
Ingot/Billets TPA TPA permitted
and/or (8MT x 3 Capacity of
Rerolled NO IF with Induction
Products CCM and furnaces from
through hot Hot 30000 TPA to
charging Charging 60000 TPA
Rerolling
Mill
WHRB based NIL 4 MW 4 MW 4 MW NO
power CHANGES
THAN
CONSENT
Biomass NIL 8 MW 8 MW 8 MW NO
based Power CHANGES
THAN
CONSENT
Fly Ash bricks NIL 30000 45000 45000 Increase in
plant Nos/Day Nos/Day Nos/Day Capacity of Fly
Ash Bricks unit
Page No. 2
MATERIAL BALANCE
a. SPONGE IRON
Material Balance for Sponge Iron Kilns
(EXISTING) ( 30000 TPA w ith 50 TPD x 2 Nos Kiln)
Input Output
Item Qty Item Qty
Iron Ore 160 Sponge Iron 100
Coal 120 char/dolochar 30
Dolomite 5 Bottom Flue Dust Ash 34
LOI 121
Total:: 285 285
PROPOSED Material Balance for Sponge Iron Kilns ( 30000 TPA

with 100 TPD x 1 Nos Kiln)
Input Output
Item Qty Item Qty
Iron Ore 160 Sponge Iron 100
Coal 120 char/dolochar 30
Dolomite 5 Bottom Flue Dust Ash 34
LOI 121
Total:: 285 285
b. Material Balance for Induction Furnace along w ith Hot Charging Rolling
Mill ( 60000 TPA)
Input Output
Item Qty Item Qty
Sponge Iron 184 Rerolled Products 192
HM Scrap/ Pig
Iron/CI 41 Mill Scale 6
Ferro Alloys 4 Defective Billets/ Miss Roll etc 8
Slag 19
LOI 4
Total:: 229 229
Page No. 3
c. Material Balance for Biomass Based Power Plant
Input Output
Item Qty Item Qty
Paddy Straw, Saw Dust, 181 Ash 33
Firewood, Rice Husk,
Bagasse, Municipal
Waste, Poultry Litter and
other Biomass West
LOI 148
Total:: 181 181
d. Material Balance for Fly Ash Brick Plant (in TPD)

Input Output
Item Qty Item Qty
Fly Ash and other Ash 71 Fly Ash Bricks\ 158
Granulated IF Slag 19
Gypsum & Cement 24
Sand 44
Total:: 158 158
Fuel/ Energy Requirement:

The sponge iron is at present consuming about 120 TPD Coal there will be no change
in this. However there will be possibility of reducing the Coal consumption by installation
of modern style 100 TPD single kiln. This advantage is not being claimed at present but
once the unit is able to get the permission to set up the kiln then this will be attempted to
reduce the Coal consumption as best as possible. It is estimated that by use of High
grade Coal the consumption can be brought down to less than 1.1 Ton Coal per Ton of
DRI. The integration of the 2 nos of 50 TPD kilns to one with 100 TPD will also save
huge amount of power and space also. It will also help in reducing the fugitive dust
emissions also. It is found that at present the 50 TPD kilns flue gas temperature is being
diluted by blowing excess air and cooling through Draft fans air blowing too. By
installation of 100 TPD one kiln it will be better to use the 100% of flue gases to generate
Power so the excessing cooling air blowing requirements will get reduced. It will
substantially save the Power and reduce PM emission.
The process of MS Ingot/Billet through Induction Furnace and Hot charging rolling mill
does not require fuel.
The process is based on electrical energy.
WHRB will generate power through recovery of waste heat from waste flue gases
generated during sponge iron making process.
Page No. 4
In addition power with biomass (paddy straw, rice husk, wood chip etc) as fuel is
proposed.
Total power requirement will be met through captive power however grid connected with
minimum load will be there for safe, smooth and viable operation.
Area Statement:
The unit is located in village M unrethi, Tahsil an district Raipur at Kh. No. 140/1 (Part),
115/1, 115/2, 136/6, 139/12 total land area 5.09 Hectare.
No addition land is being acquired for expansion. The proposed area statement is given
as below:
S. No. Particulars Area (Ha.) Percentage
(%)
1 Built Up area 2.29 45%
2 Paved Area 0.27 5%
3 Green Belt 2.04 40%
4 Open Area 0.49 10%
5.09 1
At present 33% area is covered under Greenbelt with 2500 Trees; it is proposed to
develop 40% area greenbelt.
Water Requirement and Source:

The water is being sourced form CG Ispat Bhumi Limited and for expanded capacity the
water requirement will be met through the same source.
INPUT OUTPUT
Particulars Qty Particulars Qty
(KLD) (KLD)
Make up water for Industrial 310 Evaporation and 310
cooling (Sponge Iron 30 KLD loss to
Induction Furnace 40 KLD atmosphere
Rolling Mill 15 KLD
WHRB CPP 65 KLD
Biomass CPP 150 KLD
Fly Ash Brick 10 KLD)
Domestic 10.00 Domestic waste 8.0
(Domestic make up water) water generation
Evaporation and 2.00

other loss to
atmosphere
Total :: 320 320
Page No. 5
The area is under CRITICAL Zone according to CGWB thus surface water will be used.
Domestic water generated through consumption from workers and other in industrial
premises will be treated through septic tank follows with soak pit, and overflow will be
used in green belt plantation. Zero discharge conditions will be maintained all the time.
Ground Water Recharge:

At present 2 Nos of Rain Water Harvesting Structure is implemented and it is proposed
to implement additional 2 nos. new rain water harvesting structures in plant premises. It
is possible to recharge almost 32000 cum.
Air Pollution Control Devices:

At present Sponge Iron Kiln have been provided with ESP and achieving PM emission
50 mg/Nm3. It will be reduced to 30 mg/NM3 after the single kiln is allowed.
In expansion it is proposed to implement WHRB and also proposed to increase the

efficiency of ESP to maintain PM emission less than 30 mg/Nm3.
Proposed Induction Furnace will be provided with Bag Filter to maintain PM emission
less than 30 mg/Nm3 .
Biomass Power Plant will be provided with ESP to maintain PM emission less than 30
mg/Nm3.
Page No. 6
Other detail
Name of the Unit : OM SPONGE

Regd. Office : Village M unrethi, Munrethi Road, Siltara, Raipur
(Chhattisgarh)
Plant Location : Munrethi Village; Dharsinw a
Contact person : Shri Vikas Kumar Aggarwal
Partners : Vikas Kumar Aggarwal
Aman Bajaj
Amar Nath Agrawal
Tel No. : M. 91099-52015

Mobile No : M. 91099-52015
Land Area : 5.09 Hectare.
Cost of Project : ( in Lakhs Rs)
S. Particulars Project cost Project cost for Fly Ash Total

* No For SID, SMS Biomass Brick Plant Project
and WHRB Power division Cost
T1 Land and Site 10.00
180 30 220.00
h Development
e2 Factory Shed
1260 600
15.00
1875
& Building
3 Plant & 65.00
c 4262 1700 6027
Machinery
o4 Electric 2.00
s 750 300 1052.00
Installation
t5 Misc. Fixed 8.00
220 60 288.00
W Assets
Total :: 6672 2690 100.00 9462.00
Means of Finance :
Means of Finance Total
Equity -Equity & reserve and surplus 3462.00
DEBT - Term Loan from Bank 6000.00
TOTAL :: 9462.00
Page No. 7
Capacity Utilization : @ 60% in I Year
@ 70% in II Year
@ 80% in III Year
No. of Shifts : 3 Shifts
Man Power Utilization :

Existing Proposed Total
Administrative 10 15 25
Production 25 250 275
Total :: 35 265 300
Implementation Period : 18 Months
Pay Back Period of Term Loan : 8 Years
Debt Equity Ratio of Term Loan : 2.33:1
Average Debt Service : 3.47

Coverage Ratio of Term Loan
Break Even Point : 32.10
Internal Rate of Return : 45.12
Page No. 8
2. INTRODUCTION:-
2. 1 Identification of project and project proponent:
The firm “OM SPONGE” is presently managed by three partners namely Mr. Aman
Bajaj, Mr Amar Nath Agrawal and Mr. Vikas Kumar Aggarwal
All the promoters are having long experience in steel manufacturing field. Their
experience in the field is the key of success of the firm .
The Dynamic Synergy available with the promoters is indicated by proposed unit..
Other locational details are as follows:

S. Particulars Details
NO.
1 Villages
Name Distance, Distance
in KM
Munrethi 0.5 SE
Sondra 0.9 SW
Sarora 0.4 SE
Nimora 0.4 Se
Khudmudi 1 NW
Chikhali 2 S
Akoli-2 3.9 SE
Siltara 4 SW
Sankara 4.2 SE
Nimora 4 S
Kanhera 5 S
Kumhi 5 SW
Hardi 4 W
Bhimbhori 5 NW
Charoda 3 E
Mohandi 2.5 NE
Dharsiwa 4.5 NE
Kurra 6 NE
Baratnara 6 NE
Urla 8 SW
Urkura 9
Mandhar 8 SE
2` Nearest District Head Quarter Raipur – 20 KM/S
3 Nearest National Highway NH-30- 3 KM/E
4 Nearest River Kharun River – 1.5 KM/W
5 Nearest Railway Station Raipur – 20 KM/S
Page No. 9
6 Nearest Air Port Swami Vivekanand Airport Mana Raipur – 40
KM/S
7 Nearest Industries 1. Sunil Sponge and Power Ltd.
2. Aarti Sponge Pvt Ltd.
3. Nandan Steel and Power Limited
4. Laxmikripa Steels and Power Pvt Ltd.
5. GR Spogne and Power Limited
6. API Ispat and Power Limited
7. Vaswani Industries Pvt Ltd.
8. Drolia Electrosteels Private Limited
9. Bhagwaroi Power and Steel Pvt Ltd.
10. PD Industries Limites
11. Harekrishna Sponge
12. SK Saroogi
13. Trimurty Rerollers Pvt Ltd.
14. Sarda Energy
15. Jayswal Neco Industries Limited
And other industries in Siltara and Urla Industrial
Area.
8 Seismic Zone Zone-II
Page No. 10
Page No. 11
Figure :1 : District and Tahsil Locat
Figure -2 Google Image of Location
Page No. 12
Figure 3 : Topographic Map
Page No. 13
Figure -4 Proposed Layout
Page No. 14
DETAILS OF MANUFACTURING PROCESS
[A] MANUFACTURING PROCESS OF SPONGE IRON (DRI) (Existing)

In the direct reduction of iron ore, the main furnace used is Rotary kiln. The rotary kiln is
a refractory lined vessel on which several air blowers are mounted. From the blowers, air
pipes go thru the shell and refractory, vertically and axially deliver the required amount of
air, required for the process. The Horizontal rotating kiln has conical out let and inlet
which allows it to holds the material fed in the kiln. Kiln is placed in a slope from feed
end side at a slope of 2.5%.
Iron ore, coal, dolomite/limestone is fed in the weighed quantity in the kiln and the kiln is
rotated at a rotational speed of about 0.5 RPM . A temperature between 10000C to 1050
0
C is maintained in about 70% of the kiln length towards discharge end side; for required
reduction reaction.
After the reduction reaction, the product (reduced iron) is taken into an indirect cooling
drum cooler. The product is cooled to 100 deg. C and taken for product separation. The
product is separated by way of magnetic attraction from the coal ash and coal char and
then taken for final use.
The waste gas from the kiln contain lot of combustibles like coal volatiles, unused CO,
about 10 to 12% carbon particles and lot of other dust. The gas is taken to an after
burner chamber and the Combustibles are burnt and passed to WHRB in which it gets
cooled to about 160 deg. C. The cool flue gas are then taken to ESP for final dust
separation, before going to stack via ID Fans. The construction of kiln and cooler is
made in such a way that no outside air is allowed to go into the system. The outside air if
goes to the kiln, re-oxidizes the product ultimately upsetting the temperature profile. To
avoid this, ID Fan damper is throttled to Maintain +ve pressure in the kiln. The pressure
of about +5mm water column is maintained at kiln firing hood. However, checking the
sponge iron fracture sample checks the setting of pressure parameter. If the sample
shows a re-oxidized periphery the pressure may be increased.
The rotational speed of the kiln is adjustable as per the feed rate and percentage of
metallization. The % of inclination, rotational speed, the length of time the material is
exposed to atmosphere, the kiln temperatures are all to be taken into consideration. So
the kiln has three functions:
A. It is a heat exchanger
Page No. 15
B. It is a vessel for chemical reaction (in which combustion and reduction both takes
simultaneously in different zones)
C. It is a conveyor of solids.
REACTION VESSEL
The kiln is also a reaction vessel. The following reaction takes place inside the kiln:
3 Fe2O3 2 Fe3O4 6 FeO 6 Fe
The degree of reduction in each step is as follows:
3 Fe2O3 11% 2Fe3O4 22% 6 FeO 67% 6Fe
The bye product of the above reaction is CO2. This carbon-dioxide reacts with carbon from coal
to produce Carbon-mono oxide:
CO2 + C = 2 CO
The above reaction is known as Boudouard reaction. So the complete reaction is:
CO2 + C = 2 CO
3Fe2O3 + CO = 2 Fe3O4 + CO2
CO2 + C = 2 CO
Fe3 O4 + CO = 3 FeO + CO
CO2 + C = 2 CO
FeO + C = Fe + CO2
The hydrocarbon of coal breaks down to hydrogen and carbon. Some believe that Hydrogen
also is used in Rotary Kiln as reductant. Since most of the kiln operates at +1000 deg. C the
hydrogen being the lighter gas goes up quickly to the vacant space above the burden and helps
in creating temperature.
The process of rate of reduction to final stage involved three main factors viz :
A. Quantity and quality of reductant
B. Temperature
C. Residence time
A. QUANTITY AND QUALITY OF REDUCTANTS
From the chemical reactions, it is seen that as the percentage of O2 reduces in the ore, the
percentage of carbon requirement increases. If there is a shortfall of carbon, the reaction
proceeds in a reverse way i.e. from reduction to oxidation. The reduction reaction is
Page No. 16
endothermic (absorbs heat) while the oxidation reaction is exothermic. In the absence of
reductant, the temperature goes up for sinter formation, ball formation and accretion starts.
For safe operating of the kiln about 0.45 to 0.50 MT of fixed carbon is required per ton of total
Fe input. Out of this, 0.50 MT, 0.27 to 0.29 MT is given from feed end side and rest is given
from kiln discharge end side. For safe operation and consistent quality, the carbon output per
ton of Fe from kiln discharge is checked hourly and keeping this value at 0.10, final coal
adjustment is done.
B. TEMPERATURE
As the coal is mixed with iron ore, it passes from feed end side and air is blown from the
blowers into the kiln, the liberated CO reacts with oxide material. This reaction lowers the
temperature of the bed due to its endothermic nature. It is necessary to generate sufficient heat
before the bed temperature falls. The gases coming out from the bed are the mixture of
decomposed and partially oxidized fuels. By adding air to these mixtures of gases, combustion
and heat generation takes place and the heat is radiated to the bed, the mechanism of which
has already been discussed. As regards the temperature profile, the first 20 – 25% is preheating
zone where the material is heated up to 8500 C and then to reduction temperature of about
10000C to 10500C. Iron ore once reaches 8500C, the surface gets reduced and generates less
fines. So it is required to heat up the ore to 8500C as quick as possible and 70% of the kiln is
taken to 10000 C to 10500 C for reduction purpose.
C. RESIDENCE TIME
The total residence time of the material in the kiln is a function of the feed rate and kiln rpm with
each increment in feed rate, the kiln rotation is increased to maintain a constant bed loading in
the kiln.
Note: At present WHRB is not provided therefore excess air requirement is higher to maintain
flue gas temperature to suitable level at ESP inlet. Once the WHRB is installed as per
proposal then the excess requirement will be reduced. This will also result in power
requirement reduction for air blowers.
Page No. 17
modernization of DRI kiln from 50 TPD x2 Nos to 100 TPDX1 Nos. While imple mentation of WHRB,
Figure 1:
PROCESS FLOW DIAGRAM SPONGE IRON PLANT
Page No. 18
[B] Manufacturing process of Steel Melting Shop with CCM (Proposed)
The manufacturing process identified for the proposed unit is one which is well established
and proved and presently being followed by majority of similar manufacturing units mostly
in small or medium scale sector.
Sample or Sponge Iron & Pig Iron and mild steel scrap, end cutting from rolling mills or
scrap from user units is taken from raw material storage. This is than tested for its
chemical composition and noted. Before preparation of charge necessary ingredients like
Ferro Manganese, Ferro Silicon etc. are added by weight, Flux is taken up in crucible and
then charge is put into it. Melting of steel along with other alloying element is
accomplished in the crucible of coreless M.F. Induction Furnace. The high A.C. Current is
passed through the copper oil wrapped around the outer periphery of crucible. By
transformer action the A.C. Current induces much higher secondary current at 1000 herts
in charge through the coil. Enormous heat it thus developed by resistance which causes
the melting of charge. As soon as the molten pool is formed very pronounced stirring
action in the molten metal takes place which helps in accelerating the melting. Deoxidising
agents and sometimes specific alloying elements are also added at suitable intervals
during melting. Melting of homogenous mass occurs at 1600 C. If necessary superheating
upto 1650 C is done for specific time.
After completion of melting cycle of an hour and half, the homogeneous mass is poured
hydraulically into the Ladle which transfers the Hot Metal to CCM Tundish which is placed
on above CCM Set. The liquid metal flows through the CCM and forms shape of Billet.
With the help of natural heat transfer the molten metal solidifies in desired shaped. One
On Line shearing Machine cuts the Billets to desired length, The Hot Billets are then
currently being transferred either to cooling Bed, but after proposed expansion these will
be sent to Rolling Mill for Hot Charged Based Rolling into Strips or Structures etc.
The slag generated during the Melting is removed manually through BELCHAS (Steel
Spatulas) Accumulated Slag is used for land fill.
CCM:
The ladle containing liquid steel is placed on the CCM platform and continuous casting
of hot billet is carried out in the same.
Page No. 19
The cooling and casting will be done through a highly automated controlled cooling
software governed mechanism by which the casted billet will be so cooled that the
temperature of billets will not fall below 10500C. The case formation in the CCM mould
starts with drop in surface temperature below 15200C, the liquid metal inside the case
contains enough energy for maintaining the overall temperature of billet for hot online
rolling. In the CCM section hot billet shearing machines will be installed with each
casting strand, so as to facilitate the cutting of billets to proper length for feeding in to the
rolling mill.
Hot Billets are will be directly transferred from CCM to Rerolling Mill / Wire Rod Mill
through conveyor.
The billets in hot form are sized by the Hot Sharing Machine or Gas cutters and then its
directly transferred to wire rod making section without being cooled down and maintain
required temperature for rolling.
The Billets are rolled through the roughing stands and intermediate stands and then
through the finishing stands for cooling. In cased required to be rolled in
strips/TMT/Structures etc.
Page No. 20
Pig Iron, Sponge Iron, Scrap
Flux, Ferro Alloys, De-oxidizers
Induction Furnace
Melting in Crucible
Hot Metal at 1650cC Filling in Ladle
Slag
LRF Removal
Def.
Billets
Casting of Billet in CCM Mill Scale
Hot Billet input in to Rerolling Mill

Miss Roll/
End
cutting
Wire Rods Finished/ TMT/ Structures
Natural Cooling
Finished Material to dispatch

(MS Billets and/or Wire Rod/ TMT/ Structures through Hot Charging)
Page No. 21
MANUFACTURING PROCESS STEEL MELT ING SHOP ALONG WITH HOT CHARGING
ROLLING MILL TO PRODUCE MS STRIPS/ T MT
[C] WHRB POWER GENERATION (Proposed):

The Waste heat Recovery boilers are attached with DRI Kiln. The flue gases released
from DRI Kilns will be passed through Waste Heat Recover Boiler, where waste heat will
be recovered and steam will be generated in required temperature and pressure. The
source of energy is the heat content in waste flue gases released from DRI Kilns.
DRI ABC Waste flue gases WHRB Steam Steam Turbo

Kiln containing heat Boiler Generator
PROCESS FLOW FOR WHRB
[D] BIOMASS BASED POWER GENERAT ION (Proposed for which consent is already granted
by the Board) :
POWER DIVISION:
THE STEAM CYCLE :

It is based on modified Rankin cycle. It is having Five Processes-
1) Collection of Bio Mass, Baling of Paddy Straw; Briquetting and Processing through
Chopping for Fuel feeding.
2) The Bio mass processing will involve chopping of Paddy Straw to feed size and if
required briquetting of it.
3) Heating of feed water.
4) Evaporation of water in boiler.
5) Superheating of steam.
6) Expansion of steam in turbine.
7) Condensation of steam in condenser.
Page No. 22
The temperature entropy (T-S) diagram is probably most use full diagram of all for illustrates
certain fundamental points about steam cycle.
At point the condensate is at boiling temperature corresponding to the back (condenser)

pressure. Heat (sensible) is added to this water to raise its temperature & pressure. At the point
B it reaches its saturation temperature. Eva portion being at point B heat between B & C
addition continuous (latent heat) because no rise in temperature .At point C all the water
evaporates & superheating commences. This is shown by curve CD& of D superheat steam.
Steam then expands is antropically in the turbine & rotates it. As shown by the DEF, at point E
there is no superheat in the steam, so increase the wetness & is passed out of the turbine to the
condenser & condensation of steam take place as represented by the line FA. At point A the
steam has all condensed & condensate is at boiling temperature ready to be gain another cycle.
Thermal efficiency of the cycle is defined as
Thermal efficiency = Useful work
Total heat
Useful heat means that part of total heat, which used in rotating the turbine when the steam
expand adiabatic ally in the turbine represented by DEF. The condensations take place at a
constant temperature until all the latent heat is removed.
Heat removed from steam is shown by the rectangular amount of this rejected can be calculated
as follows.
= Total heat – Rejected heat

Total heat
Page No. 23
Efficiency of the basic Rankin cycle can be increasing by the superheat, reheat the steam, & the
regenerations feed heating.
1) Superheat – this is good, but this scope becomes limited due to limitation of material
which can with stand very high temperature & cost associated with it.
2) Reheating – expanded the steam in the turbine to some suitable intermediate condition
& then pass it back to the boiler to be reheated to the some high temperature. It is
improves efficiency.
3) Regeneration feed heating – If the steam allowed expanding to a certain extent in the
turbine & performs useful work before it is allowed to transfer its remaining heat to the
feed water then the quantity of work is obtained with out any condenser loss & the cycle
efficiency improved.
POWER PLANT DESCRIPTION -

We can mainly divide the Power Plant in Three P arts.
1) Boiler & Aux.
2) Turbine & Aux.
3) Generator & Aux.
Boiler :
It is the equipment where water is boiled & converts in to steam. It is working on
constant pressure & temperature process by the firing we can classify the boiler.
Fluidized bed boiler –
Page No. 24
When air & gas passed through an inert bed of solid particle such as sand supported on
a fine mesh or grid, with the increases in the velocity of air, bed is fluidized & air is
started to bubbling because of bed assumes like fluid & behave like fluid it is called
fluidized bed.
Boiler Description -
1) Drum: - The feed input, separation of steam, boiler water treatment & blow down are all
carried through the drum.
2) Furnace: - it is the primary part of boiler where the chemical energy available in the fuel
is converted to thermal energy by combustion. It is the designed for efficient & complete
combustion
3) Super heater: - These are meant for raising the steam temperature above the saturation
temperature around 550OC (due to the metallurgical problem) the percentage of heat to
super heater is approx 30%.
4) Desuper heater: - To control the super heater temperature & always try to maintain the
steam temperature constant during variation of load, desuper heater is used.
It is working by which feed water are spray the directly in to steam for required cooling.
Amount of feed water to be sprayed is controlled by automatic control system, which is
designed to maintain a set final steam temperature.
5) Draft system: - The combustion process in a furnace can take place only when it
receives a steady flow of air & has the combustion gases continue removed.
System includes air & flue gas flow, generally all modern boiler are fired under
balanced draft condition. Where draft is nearly to negative (-5 mmwc to –10 mmwc).
I.D.Fan creates it.
6) Economiser: - The economizer absorbs heat from the flue gas & adds its mainly as
sensible heat to the feed water by this efficiency of boiler is improved.
7) Water w all/ evaporator: - Where water convert in to steam & latent heat addition is
added is called evaporator, max heat is used or consumed by evaporator.
8) Support: - All modern boilers are top support units. The hanger rods are designed for
the direct tensile stress resulting from the weight of units & the bending tensile stress
from the pressure part expansion.
9) Soot Blow er: - Because of the nature deposit resulting from the combustion of husk &
relatively smaller extent from oil, means have to be provided to prevent an accumulation
of deposit from choking the boiler gas passes & to maintain the boiler heating surface in
a suitably clean condition for effective heat transfer whilst on load. Steam is used as the
soot blower.
10) Air heater: - It is now an essential boiler auxiliary, because hot air is necessary for rapid
& efficient combustion in the furnace & also for drying the husk, & to recover waste heat
from the flue gas to increases boiler efficiency.
Page No. 25
11) Forced draft fan: - To take air from atmosphere at ambient temperature to supply
essentially all the combustion air.
12) Induced draft fan: - To suck the gases out of the furnace & throw them in to stack.
13) Primary air fan: - It is used for drying the Biomass & transportation in to the furnace.
14) Dust/Ash handling plant: - the method used for remove of dust from the gases is two
types mechanical collector & electrostatic precipitator.
In this, consist of two set of electrodes, one in the form of thin wire called discharge or
emitting electrodes & other set called collecting electrodes in the form of plates, they
collect 99% of fly ash.
The emitting electrodes are placed in the center of two plates & are connected usually
to negative polarity of high voltage d.c soures of the order of 25-100KV.
15) Boiler feed pump: - It is multistage pump provided for pumping feed water to
economizer. Generally three pumps each of 50% of total capacity provided. For rated
capacity two pumps will be working parallel & third will be in reverse.
The water with the given operating temperature should flow to the pump under a certain
minimum pressure. The feed water arriving in to the discharge space develops the
necessary operating pressure. 10% of water is taken off from the space behind the last
impeller for the operation of automatic balancing device to balance the hydraulic axial
thrust of the pump rotor.
BOILER PROTECTION: -
All boilers are given some protection to avoid damage to boiler & any auxiliaries.
Tripping
 Drum level low.
 Drum level high.
Page No. 26
 Furnace pressure High.
 Furnace pressure low.
TURBINE & ITS ASSOCIATED SYSTEM: -

Turbine: -
It is a rotating machine, which convert heat energy of steam to mechanical energy.
When steam is allowed to expand through narrow orifice, it assumes that kinetic energy at the
expanse of its enthalpy (heat). This kinetic energy of steam is changed to mechanical
(rotational) energy through the impact (impulse) or reaction of steam against of blades.
Main component & associated system

- Casing Rotor Blades
- Gland sealing system
- condensate system
- Regenerate feed heating
- Turbine at system
- Turbine governing system
Casing: -It is essentially a pressure vessel, which must be capable of withstanding the
maximum working pressure, & temperature that can be produced with in it. The casing is
supported on each end.
Rotor: - It is the part in which moving blade is fitted & its rotary part so need to balance both
(statically & dynamically).
Blades: - These are the most important component of turbine as these are the responsible
for the converting heat energy to mechanical.
 Moving blade
 Fixed blade
Gland sealing system: - Glands are used on turbine to prevent or reduce the leakage of
steam between rotating & stationary component which have a pressure difference across
the, if the cylinder pressure3 is higher then atmospheric pressure then will be a leakage of
steam outwards (HP side), if the cylinder is below atmospheric pressure then will be leakage
of air inwards (LP side), so some part of sealing of sealing system is used to prevent the air
from in the cylinder & condenser.
1) Water seal gland.
2) Labyrinth gland.
CODENSATE SYSTEM:-
 Air Cooled Condenser which minimizes the water requirement by 85%.
 Condensate pump
 Air extraction system
Page No. 27
 Gland cooler & L.P. heater
 Deaerator
Condenser: - It is basically a heat exchanger which provide lowest economic heat rejection
temperature of steam & to convert exhausts steam to water for, make a point for introducing
make up water.
Condensate extraction pump: - Are normally multistage, vertical centrifugal pump,

required to operate or minimum net positive suction head, operate on flow inches of suction
submerge.
Air exhaust system:-Is needed to exhaust air & other non-condensable gases from the
condenser for maintaining vacuum.
L.P. heater: - Is simply a heat exchanger, which is arranged so that water having a
condenser is preheated before it is feed to boiler. The feed heater is supplied by steam,
which has already performed some useful work.
Deaerator: - Feed storage tank

The pressure of certain gases like oxygen, carbon dioxide, & ammonia dissolved in water is
harmful because of their corrosive attack on metal particularly at elevated temperature. To
minimize the internal corrosion, it is achieved by embodying in to the feed system a
deaerator unit apart from this a deaerator also serves following function
 Heating incoming feed water.
 To act as reservoir to sudden or instantaneous demand.
Turbine oil system: - It is provides a supply of oil to the journal bearing to give oil wedges
at the shaft rotor, maintain the temperature of the turbine bearing constant at the required
level. Provides a medium for hydraulic operating the generator gear& controlling the steam
admission valves.
Turbine governing system: - The main purpose of governor is to maintain speed (3000
r.p.m) of turbine during fluctuation of load on the generator by varying steam input to the
turbine.
* To run up of the turbine from rest to the rated speed & synchronizing with the grid.
Meeting the system load variation in a predetermined manner when running in parallel with
other m/c.
Protecting the m/c by reducing the load or shutting off completely in abnormal & emergency
situation.
TURBINE PROTECTION
Hydraulic trip 1) Over speed trip
2) Low vacuum trip
Page No. 28
3) Thrust bearing trip
4) Local manner trip
Electrical trip 1) Manual remote trip

2) Low vacuum trip
3) Low lube, oil trip
Trips due to other causes (generator protection)
The electrical trips act through remote trip solenoids for tripping the set. All then protection
act for closing ESV & control v/v through main trip v/v.
GENERATOR & ITS AUXILARIES

Generator: - It is usually electrical end of turbo generator set. It is cylindrical pole (two pole
for a 50hz supply) synchronies generator known as the pipe of equipment that actually
converts the mechanical energy of turbine into electricity. It is based on the principle of
electromagnetic induction.
Main Component & Associated system
 Stator
 Rotor
 Excitation system
 Cooling system
 Protection
Stator: -
It is the component that the armature corp. & armature winding. Winding for the
stator are made up from copper strips with insulated tape intrigued with varnish &
hot pressed to form a solid insulated bar.
Rotor: -
The generator rotor forms the poles & provides the field. It is the most difficult
part of the generator design. It reverses at a speed of 3000 r.p.m. The rotor
carries the field winding.
Generator bearing: -
These are the pedestal type of spherical sealing to allow self-alignment & are
supported on a separate pedestal on slip ring sided & turbine side.
Generator cooling system: -

The generator loses are dissipated as heat trough stator & rotor bodies. This
heat should be taken off for safe operation of the generator. The primary cooling
Page No. 29
medium is air or hydrogen which is turns is passed trough a water-cooled heat
exchanger.
Generator excitation system: -

Rotor generates magnetic field. To do this a direct current supply is required to
energies the winding on the rotor supply by an exciter, may be coupled to rotor
shaft or drive through a gearbox.
Generator protection: -
Generator has to protected from faults occurring with in generator stator or rotor
& also from external faults /abnormal operating condition in the grid which
effected the generator. Various devise are used to detect, which can give
warning alarm or trip the unit automatically as per fault.
 Stator path fault
 Inter turn fault
 Field failure / loss of excitation.
 Rotor path fault.
 Over voltage
 Under frequency
 External path fault.
 Negative phase sequence current.
 Over voltage/Under frequency in the system.
 Over current in the system
 Reverse power/ Low forward block.
[E] PROCESS AND FLOW DIAGRAM OF BRICK MAKING FROM WASTE (Proposed)
Fly ash, Lime sand (or Grounded Slag) and Gypsum or Cement are manually fed into a
pan mixer, where water is added in the required proportion for intimate mixing. It is
proposed to mix Fly Ash, Grounded Slag from Induction Furnace; Lime; Gypsum and
Cement and if required River Sand in small portion.
After mixing; the Mortar mixture is shifted to hydraulic/ mechanical presses for brick
molding. Then molded bricks are carried on wooded pellets to the open area where they
are dried and cured by autoclave machine. The bricks are tested and sorted before
dispatch.
Page No. 30
PROCESS FLOW DIAGRAM FOR BRICKS MANUFACTURING
POLLUTION CONTROL MEASURES:-

Being an independent DRI with WHRB; Bio Mass Power Plant and CCM based Induction
Furnace with Hot Charging Rolling Mill ; Plant the following equipment will be installed
to ensure effective pollution control :
List of proposed Air Pollution Control Equipment:
S. Name of Type of Equipment Emission controlled

No. Process
1 Sponge Iron Kiln ESP for main source and 4 Particulate matter less
with WHRB No of Bag Filters for fugitive than 30 mg/m3
sources
2 Induction Bag filter with central dust Particulate matter less

Furnace with collection system than 30 mg/m3
CCM and Hot
Charging Based
Rolling Mill
Page No. 31
3 Biomass based ESP for Main Emission and Particulate matter less
Power Plant Bag filter with central dust than 30 mg/m3
collection system for fugitive
dust control
Additional measures will be adopted to reduce/control pollution control:-

 Roads will be frequently sprinkled with water.
 Most of the materials like Sponge Iron, M n ore, Coke will be stored under
covered shed.
 In case of storage of Sponge Iron in open, it will be covered by tarpaulins
to prevent spread of dust from it during transportation.
 Regular maintenance of vehicles and machineries will be carried out in
order to control emissions.
 Green belt development would be taken up all along the haul roads, plant
premises etc.
 Green belt will also be developed on the sides of roads.
 Protective appliances will be provided to all the workers exposed in dusty
atmosphere.
 Avoiding overloading of the trucks.
 Workers will be equipped with all personal protective devices like Gum
Boot; hand gloves; Safety helmet; Safety goggles, earplugs at work place.
 By controlling the speed of the truck.
 Proper gradient of approach roads to reduce cumulative noise.
 Transportation of materials will be limited to day hours only.
 Periodical maintenance of process machinery.
SITE ANALYSIS
Connectivity.
The area is located at Village- M unrethi, Block Dharsiwa, Tahsil and District- Raipur
(CG) which is about about 20 KM in S direction and nearest Air port is Raipur about 40
Km. The project site can be reached from nearest City Raipur through Nartional
highway (NH -30) about 3 KM/ East direction, through connecting road
The nearest railways station is Raipur located in main Howrah Mumbai rail track at
about 20 KM distance.
Land Form, Land use and Land ow nership.

The proposed project is proposed in existing premises on the existing land
(5.09 Hectare) in already owned by company. No additional land is requirement to be
acquired.
The 33% of area is developed as Greenbelt and it is proposed to increase this up to 40%
( 2.04 Ha.) area.
Page No. 32
COST OF PROJECT AND MEANS OF FINANCE
The total cost of project has been estimated as follows:
Cost of Project :
S. Particulars Project cost Project cost for Fly Ash Total

* No For SID, SMS Biomass Brick Plant Project
and WHRB Power division Cost
T1 Land and Site
180 30
10.00
220.00
h Development
e2 Factory Shed
1260 600
15.00
1875
& Building
3 Plant & 65.00
c 4262 1700 6027
Machinery
o4 Electric 2.00
s 750 300 1052.00
Installation
t5 Misc. Fixed 8.00
220 60 288.00
W Assets
Total :: 6672 2690 100.00 9462.00
Means of Finance : (In Rs. Lakhs)
Means of Finance Total

Equity -Equity & reserve and surplus 3462.00
DEBT - Term Loan from Bank 6000.00
TOTAL :: 9462.00
The above finance mix is based on the following assumptions:

1. The promoters shall contribute about atleast 30% of the total cost of project, the
promoters will contributing around Rs.3462.00 lakhs as Share Capital.
2. It is estimated that a sum of Rs.6000.00 Lakhs will be source as Term Loan from Bank
or Financial Institution.
Page No. 33
OTHER FINANCIAL INDICATORS:
Debt Equity Raito : Including the Equity being brought in by the promoters the DER is 2.33:1.
Promoters Contribution : Considering the Equity of the Promoters Contribution is about 30%
of the Project Cost.
DSCR: Average Debt Service Coverage Ration for Term Loan is estimated to 2.87.
Break Even Point: Break Even Point is estimate to 37.%.
IRR: Internal rate of return is estimated to over 15 years time. 32.%
Page No. 34
CONCLUSION AND RECOMMENDATION
The proposed integration of two number of 50 TPD DRI kilns into 100 TPD kiln will help to
reduce substantial power consumption required in material handling and in Kiln operations.
This modernization and expansion will lead to better energy efficiency and reduced pollution.
WHRB will help to reduce air pollution and also reduce the GHG emission as well as reduce
water consumption also.
There will be no additional Coal consumption in the DRI Kiln or in the Plant than permitted in the
past.
Induction Furnace and Hot Charging Rolling Mill and Biomass based power generation is a
Green and Clean process . It will also reduce the GHG emission.
The proposed change in configuration and expansion will not lead to any additional Pollution
load. There will be no increase in Pollution load.
Zero Discharge will be maintained.
Hence the company is confident to get required environment clearance and sanction from the
concerned authorities of State level Authority and committee set up by MOEFCC; Centre
Government dealing in Environmental Laws.
This will give an extra advantage to the company.
Looking in to the Technological and Financial Strength of the Promoters, Financial viability of
the Project.
We find the project worthy for promotion and implementation.
In view of these facts the Project is recommended from all angles. All concerned are requested
to extend their whole hearted support to the company.
***
Page No. 35

Om Sponge Plant Modification WHRB

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Project Report OM SPONGE

IMPLEMENTATON OF INDUCTION FURANCE, CCM ALONG

ALONG WITH WHRB AND BIOMASS BASED POWER

The proposal is based on no increase in Pollution load.

PROPOSED Material Balance for Sponge Iron Kilns ( 30000 TPA

d. Material Balance for Fly Ash Brick Plant (in TPD)

Fuel/ Energy Requirement:

The process is based on electrical energy.

Water Requirement and Source:

Evaporation and 2.00

Ground Water Recharge:

Air Pollution Control Devices:

In expansion it is proposed to implement WHRB and also proposed to increase the

Name of the Unit : OM SPONGE

Tel No. : M. 91099-52015

Cost of Project : ( in Lakhs Rs)

S. Particulars Project cost Project cost for Fly Ash Total

No. of Shifts : 3 Shifts

Man Power Utilization :

Implementation Period : 18 Months

Pay Back Period of Term Loan : 8 Years

Debt Equity Ratio of Term Loan : 2.33:1

Average Debt Service : 3.47

Break Even Point : 32.10

Internal Rate of Return : 45.12

Other locational details are as follows:

Figure :1 : District and Tahsil Locat

Figure -2 Google Image of Location

Figure 3 : Topographic Map

Figure -4 Proposed Layout

DETAILS OF MANUFACTURING PROCESS

[A] MANUFACTURING PROCESS OF SPONGE IRON (DRI) (Existing)

PROCESS FLOW DIAGRAM SPONGE IRON PLANT

[B] Manufacturing process of Steel Melting Shop with CCM (Proposed)

Pig Iron, Sponge Iron, Scrap

Flux, Ferro Alloys, De-oxidizers

Hot Metal at 1650cC Filling in Ladle

Hot Billet input in to Rerolling Mill

Finished Material to dispatch

[C] WHRB POWER GENERATION (Proposed):

DRI ABC Waste flue gases WHRB Steam Steam Turbo

PROCESS FLOW FOR WHRB

THE STEAM CYCLE :

At point the condensate is at boiling temperature corresponding to the back (condenser)

= Total heat – Rejected heat

POWER PLANT DESCRIPTION -

Fluidized bed boiler –

TURBINE & ITS ASSOCIATED SYSTEM: -

Main component & associated system

Condensate extraction pump: - Are normally multistage, vertical centrifugal pump,

Deaerator: - Feed storage tank

Electrical trip 1) Manual remote trip

GENERATOR & ITS AUXILARIES

Main Component & Associated system

Generator cooling system: -

Generator excitation system: -

PROCESS FLOW DIAGRAM FOR BRICKS MANUFACTURING

POLLUTION CONTROL MEASURES:-

List of proposed Air Pollution Control Equipment: