Technology By product recovery type /

Non recovery/ heat recovery

type

Capacity MPTA 0.85

No. of battery Nos. 2
No. of Oven in each battery Nos.
Oven length mm 13500
Oven Width mm 490 / 510
Oven height mm 4300
0
Oven temperature C 1250 1300
Type of coal charging Stamp charging/ top charging

Qty. of coal charged per oven MT 23

32
Useful volume M3 26.68 41.6
Oven availability per year Day
Cycle time Hrs. 18 22.5
Coke cooling Wet (water) / Dry (Inert n2
gas)
Combustion technology Underjet firing system
Oven pressure
Coal consumption (Net on dry MT 1.4
basis)per ton of Coke
Stamp charging 2
Pusher car Nos. 2
Guide car Nos. 2
Quenching car Nos. 2
Quenching time Sec 90
Coke cutter MT/hr 280 300
Coal silo Nos. 16 x 500
Coal bunker Nos. 4 x 400
Coal tower MT 2754
Coke conveyor MT / hr 250 300
Coke oven gas / MT of coke NM3 480
Input energy reconciliation 68% as coke, 12% coke oven
(Coal) gas, 8% oil, 4% chemical, 8%
waste heat

Energy consumption per ton of 3.2 mBtu/3.36 GJ

Coke

By-products like benzene, toluene, xylene, napthalene, coal tar, creosote oil, pitch, ammonium sulphate and benzol products are also r

By product
Light oil(Benzene, 12500 gallon/day
toluene,Xylene)
Heavy oil (Napthalene)
Coal tar 29000 gallon /day
Pitch
Amonium sulphate 12 t/day
Benzol

Coke specification
Physical: (measured at the Mean Min Max
blast furnace)
Average Coke Size (mm) mm 52 25 60
Plus 4" (% by weight) % 1 4
Minus 1"(% by weight) % 8 11
Stability Minute 60 58
Coke strength after reaction Minute 65 61 68
with CO2 (CSR)
CRI 22 27
M 10 7 10
M 40 75 80
Physical: (% by weight)
Ash % 8 12
Moisture % 2.5 7
Fixed carbon % 86
Sulfur % 0.65 0.82
Volatile Matter % 0.5 1.5
Alkali (K2O+Na2O) % 0.25 0.4
Phosphorus % 0.02 0.33

Raw material specification (Coking coal) Coking coal Bituminus

Ash % 9.7
Volatile Matter % 18 38
Total moisture % 10
Moisture (IM) % 1
Phosphorus % 0.04
Sulfur % 0.58
MMR % 1.15 1.3
Fluidity ddpm 400 1600
Fixed carbon

LAMC Low ash metallurgical coke

Coke Size
Foundry coke mm >75
BF grade coke mm 25-75
Nut coke mm 15-25
Pearl coke mm Jun-15
Coke breeze mm 0-6

Input
Coal

Output
Coke
CO gas
Light oil(Benzene,
toluene,Xylene)
Heavy oil (Napthalene)
Coal tar
Pitch
Amonium sulphate
Benzol
nd benzol products are also recovered from the coke ovens gas.
Bituminus Lignite

25 4
25 51

10 17

0.6 0.3

50 45
Technology Grate Kiln technology
Capacity
Grate area Sqm 768
Thermal energy /ton GJ 0.627 0.9614
Electrical energy / ton KWh 78 84

Input
Iron ore less than 325 mesh (45 micron)
Limestone,dolomite
Bentonite
Output
Iron ore pellet

Iron ore pellet specification

Particular Chemical (ON DRY

BASIS) Grade % Tolerance
Fe 65 Minimum
FeO 0.3 Maximum
SiO2 + Al2O3 5 Maximum
CaO 0.03 ± 0.01
MgO 0.06 ± 0.01
Basicity 65 Maximum
Phosphorus 0.05 Maximum
Physical Properties Value Tolerance
Bulk Density 2.2 T/m3 ± 0.2
Tumbler Index 93% Minimum
Abrasion Index 3% Min ± 0.5 %
Cold Crushing Strength (Avg) 250 Kg/P Minimum
Size Analysis
8 - 16 mm 94% Minimum
-5 mm 2% Maximum
+16 mm 4% Maximum
Metallurgical Properties
Porosity 18% Minimum
Reducibility 62% Minimum
Capacity MTPA 0.15 6.5
Travelling Grate area Sqm 36 600
Machine width Mtr 2 5
Availability Day/year 330 345
Specific production rate MT/m2/24 hrs 45
Solid and gaseous fuel per MJ 1250 1400
ton of sinter
Electrical energy / ton KWh 28 32
Thermal energy /tpn GJ 0.056
Process water per ton of M3 0.03 0.05
sinter
Manpower ( 4 shift basis) Nos. 16 20
pera day
CO2 generation /ton Kg 5

Bed height mm 500 730

Suction m bar 130 190
Return fine rate % 18 25

ISO strength (+6.3 mm) % 75 80

RDI (-3 mm) max % 28 32
FeO (max) % 5 8
Basicity CaO/SiO2 1.2 2.9

Input
Iron ore fine kg 850 100 mesh-10mm
Coke breeze kg 70 0~6mm
Limestone kg 120 0~3 mm
Dunite / pyroxenite (magneskg 40
Lime fine kg 30
Solid waste kg 80

Sinter
0.15 mm <10%
+10 mm 70%
- 5 mm 6%
Fe
CaO
MgO

Advantage of Sinter
Technology
Capacity TPD
Loading / charging system

Combustion system
Fuel consumption
Thermal energy /ton GJ 3.47
Electrical energy / ton KWh 30 40

Input

Output
Technology Cryogenic /Non cryogenic
Capacity TPD
Purity of oxygen
Product Nitrogen, oxygen, argon
Start up time Hr 72 96

Air filter
Multi stage cenrifugal air compressor
Chilling and air washing unit
Air purifier
Cold box
Air expansion unit
Liquid oxygen extraction syatem
Liquid oxygen storage tank
Gas oxygen compressor
Gas oxygen storage tank
Cooling tower
Circulating water pump house
Technology Gas based (Midrex , HYL) ; Coal base (SL/RN, ACCAR)
Capacity TPD
Kiln size
Operating temp (reduction
zone)
0C 900 1100
Operating temp (pre heating
zone)
0C
Waste heat recovary
Energy consumption
(Thermal) / Ton of sponge of
GJ 20 27 2.6Gcal/mt
Energy consumption
(electrical) / Ton of sponge
of
KWh 60 70
Metalization % 92
Feed Iron ore lump (60%), pellet

Properties of sponge iron

Size mm 5 20
Fe metallic % 82 84
Fe total % 91 92
Metalization % 89 93

Density gm/cc
Crushing strength
Weather resistance
Carbon content % 0.06 0.2
Sulphur % 0.02 0.04
Phosphorus % 0.05 0.08
Non metallic % 1 2

Input requirement
Pellet / lump Mt 1.43 1.45
Coal (Fixed carbon) Kg 380 400
Electricity KWh 80 100
Water m3 2.5 3.5
Manpower Man-Hr 0.35 0.6
Plant availability % 90 92

Iron ore spec for DRI

Fe total % 67.4
Sio2 % 1.5
Al203 % 1
CaO % 0.05
Mgo % 0.05
Tio2 % 0.009
P % 0.03
Size mm 5-15
Useful volume m3 35 5775
Capacity MTPA 0.075 4
Productivity MT/m3/day 1.7 2.54
Coke rate Kg/ THM 500 756
Charge
Blast temperature 0C
Top pressure Kgf/cm2 2.5
Tap hole Nos.
Hearth dia mtr 13.8
Slag granulation
Top gas pr. recovery tubine
Top feeding arrangement
Coal injection rate Kg/ THM 160 200
Energy consumption
(electrical)
KWh 106 214
Energy consumption
(thermal)/TCS
GJ 33
BF gas / ton of hot metal MT / m3 2.5 3.5

Specific energy consumption in europe 17.1 GJ/Ton of crude steel

Energy consumption / ton of DRI 10.8 GJ

Input
Iron ore lump (Iron bearing material)
Sinter
Iron ore pellet
Coke (Fuel & reductant)
Lime stone (Flux) mm 25-60

Output
Hot metal
Slag basicity 0.9~1.0 with MgO content 8~11%
BF gas
Technology
Capacity
Technology
Heat size MT 340
No. of heat per day
Energy consumption (Electrical)
/ TCS
Energy consumption
(Thermal) / TCS
LD gas /TCS Nm3 100

Input
Technology
Capacity
Heat size MT 180
No. of heat /day Nos. 16
Tap to tap time Min
OX consumption / heat (100%hot Nm3
metal)
Carbon injection
Door lance
EBT lance
Continuous DRI charging
Electrode consumption / ton
Cooling water / ton
Energy consumption (Electrical) / KWh 650 800
Ton of steel

Input
Hot metal
Scrap
DRI

Lime
Dolomite
Coal
Pulvarized coal
Oxygen
Nitrogen/argon

Out put
Crude steel

Rmoval of
Phosporus
Sulphur
silicon
Manganese
Aluminium
Carbon
Nitrogen
Hydrogen
Energy consumption KWh 550 800
(Electrical) / Ton of steel

Energy consumption GJ 2
(Thermal) / Ton of steel
Theoritical Energy KWh 300
consumption (Electrical) /
Ton of scrap
Electrical energy / Ton of
ferroalloy
KWh 3000 4000
Thermal energy / Ton of steel
GJ 16
Capacity MPTA 1.2
No. of strand Nos. 1 2
Thickness mm 230 350
Width mm 800 2600
Length Mtr
ladle size MT 60 300
Machine length Mtr 19
Machine radius Mtr 8
No. of segment 10 19

Mould oscillator
Tundish capacity
Capacity MPTA 2 5
Width mm 1850
Thickness 1.2 25
Descaling
Rougher Nos
Finishing stand
Coil box
Laminar cooling
Down coiler Nos

Thermal energy /ton GJ 1.3

Electrical energy / ton KWh
Capacity
Thickness
Width mm 1500 4900
Energy consumption (Electrical) /
Ton of steel
KWh 260
Energy consumption (Thermal) /
Ton of steel
GJ 3
Reheating furnace
roughing stand
Intermediate stand
finishing stand
Hot shear
Progressive cooling
Finishing and packaging
McNally Bharat Engineering company Limited
Unit Technology partner Country
Sinter plant Tyazhpromexport (TPE) Russia
Sinter plant China Metallurgical Group Corporation (MCChina
Coke oven by product DMT Germany
Continuous caster Simens VAI Germany
EAF steel making cost -2010
Item
$/unit Factor Unit Unit cost Fixed Variable Total
Steel
scrap 1.132 t 315 356.58 356.58 74.35
Scrap
delivery 1.132 t 5 5.66 5.66 1.18
Pig iron /
DRI 0t 395 0 0 0.00
Pig iron /
DRI
delivery 0t 40 0 0 0.00
Oxygen 14 m 3 0.08 1.12 1.12 0.23
Ferroallo
ys 0.014 t 1400 19.6 19.6 4.09
Fluxes 0.043 t 30 1.29 1.29 0.27
Electrode
s 0.002 t 8900 13.35 13.35 2.78
Refractori
es 0.005 t 600 3 3 0.63
Thermal
energy 1.33 GJ 12.5 16.63 16.63 3.47

Electricity 0.34 MWhr 90 4.59 26.01 30.6 6.38

Labour 0.351 Man hr 35 3.07 9.21 12.29 2.56
Depreciat
ion 1 8 8 1.67
Interest 1 11.5 11.5 2.40
Total 27.16 452.45 479.61 100.00

Blast furnace route steel making cost

Item $/unit Factor Unit Unit cost Fixed Variable Total

Iron ore 1.435 t 62 88.97 88.97

Iron ore
transport 1.435 t 20 28.7 28.7
Coking
coal 0.519 t 128.5 66.69 66.69

Coking
coal
transport 0.519 t 19.5 10.12 10.12
Steel
scrap 0.162 t 325 52.65 52.65
Scrap
delivery 0.162 t 5 0.81 0.81
Oxygen 80 m 3 0.08 6.4 6.4
Ferroallo
ys 0.014 t 1400 19.6 19.6
Fluxes 0.521 t 30 15.63 15.63
Refractori
es 0.011 t 600 6.6 6.6
Other
costs 1 13 3.25 9.75 13
By-
product
credits -20 -20
Thermal
energy,
net -2.68 GJ 12.5 -33.5 -33.5

Electricity 0.122 MWh 150 2.75 15.56 18.3

Labour 0.64 Man hr 35 5.6 16.8 22.4
Deprecia
tion 40 40
Interest 44 44
Total 95.6 284.78 380.37

Therm Coal Coking Coal Iron Ore Natural Gas Electric

Steel Scrap
Year/ Month $/tonne $/ton C/dmtu $/000m3 $/tonne C/KwH
2008 M1 98.3 140.6 369.7 385-400 6.39
2008 M2 141.4 140.6 369.7 390-405 6.38
2008 M3 126.7 106.1 140.6 369.7 490-510 6.54
2008 M4 131.8 140.6 428.4 510-530 6.64
2008 M5 142.7 140.6 428.4 570-580 6.8
2008 M6 171.2 113.9 140.6 428.4 635-660 7.4
2008 M7 192.9 140.6 517 630-640 7.78
2008 M8 169.7 140.6 517 385-390 7.63
2008 M9 160.7 122 140.6 517 240-245 7.35
2008 M10 115.7 140.6 576.7 220-225 7.23
2008 M11 98.8 140.6 576.7 205-210 7.04
2008 M12 84.3 129.1 140.6 576.7 230-235 6.88
2009 M1 85.7 101 576.7 270-275 6.9
2009 M2 80.8 101 520.9 200-205 6.98
2009 M3 65.4 137.1 101 412.9 195-200 6.84
2009 M4 68.1 101 309.6 220-230 6.78
2009 M5 69.1 101 309.6 220-225 6.89
2009 M6 76.5 143.4 101 309.6 230-235 7.18
2009 M7 79.1 101 244.4 245-250 7.11
2009 M8 77.7 101 222.5 320-325 7.17
2009 M9 72.5 151 101 222.5 285-290 6.99
2009 M10 76.1 101 232.2 260-265 6.67
2009 M11 84.4 101 232.2 290-300 6.44
2009 M12 89 142.2 101 232.2 340-350 6.52
2010 M1 103.9 101 273.2 335-345 6.54
2010 M2 100.9 101 273.2 325-335 6.55
2010 M3 101.1 n/a 101 273.2 435-440 6.5
2010 M4 107.3 n/a 167 300.6 415-420 n/a
2010 M5 107.3 n/a 167 283.3 n/a n/a

Hot metal cost

Raw material 86%

Saleble steel
raw material cost 57.70%
Iron ore lump
Iron ore fines
Iron ore concentrate
Non coking coal
Coking coal
Natural gas
LPG
LDO
HFO
Lime
Capacity MTPA 0.012 0.36
Capacity MPTA
Coil width mm
Coil ID mm
Coil wt MT
Line speed mpm
Thickness mm

Coil car
Decoiler
Entry support device
Width adjustor device
Straightening machine
Gauge table
Shearing machine
Run off table
Pneumatic discharge and stacker device
Unloading table
Pueumatic system
Electrical system with computer PLC program control
Hydraulic system
Uncoiler
Double cut shear
Bridle roll
Side trimmer
Fine masher
Entry loop tower
Deflector roll
Vulcan annealing furnace
Water cooling
Galvanizing equipment
Steering
X ray thickness measuring
Skin pass mill
Tension leveller
Chromate tank
Dryer
Marking machine
Exit loop tower
Flaw detector
Exit shear
EPC unit
Recoiler
Uncoiler
Press joining machine
Entry loop tower
Degreasing unit
Scotch bite unit
Grain refining unit
Drier
Back coater 1&2
Oven1
Prime coater 1&2
Oven2
Drier 3
Top coater 1&2
Printer 172
Oven3
Drier4
Exit loop tower
Tension roll
Guard film laminator
Shear
Pay off real
Scale breaking
Entry shear
Welder
Bridle roller
Entry looper car
Hot water dip tank
Acid pickling
Cascade rinse
Drier
Exit looper
Side trimmer
Bridle roll
Drier
Exit shear
Mill housing
Coiler
Welder
Hot alkali dip cleaning
Electrolytic cleaning
Hot water tank drier
Bridle roll
Shear
Skin pass mill
Pinch roll
Flattner
Shear
Slitter
Looping device
Batch annealing furnace
Rewind
 India World
Per capita consumption of steel in (2009) kg 47 190
Steel industry (directly and indirectly) CO2 emission worldiwde 6%

India's Tata Steel made a successful $11.3 billion

Jan-07
offer to buy European steel maker Corus Group PLC.

Bulk production of steel began after development of

Bessemer converter by Henry Bessemer's in 1857.
1857
Steel industry was delicensed in 1991 1991
Steel industry was decontrolled in 1992 1992
1. Next to Aluminum, Iron is the most widely distributed and abundant metal, consisting about 4.6% of the Earth’s
2. The essential iron minerals which are commercially exploited are MAGNETITE (Fe3O4) containing 72.4% Fe,
3. In addition certain important iron ores are composed to some extent of Hydrous iron silicates, such as Chamos
4. Even though the iron content (Fe) of the mineral is a important factor, an equally important issue is type and pr
5. Specific energy consumption/ TCS -6.5Gcal

The aver
Among the elements composing the crust of the earth, iron (Fe) exists in the largest quantity next to
 During mining of iron ores run of mine (ROM) is crushed and screened for sizing, producing both iron
Continuous casting accounts for 95% of steel production in the world
Continuous casting technology started in late 1950s
ting about 4.6% of the Earth’s crust.
e3O4) containing 72.4% Fe, HAEMATITE (Fe2O3) containing 70% Fe, Goethite [FeO(OH)] containing 68.5% Fe, LIMONITE and the carbonates name
on silicates, such as Chamosite, Thuringite, Greenalite and Glauconite.
mportant issue is type and proportion of gangue material present in the said mineral which may influence the metallurgical operations because of proc

he largest quantity next to oxygen (O), silicon (Si), and aluminium (Al).
sizing, producing both iron ore fines (IOF, size minus 10 mm) as well as calibrated lump ore (CLO, size 10-30 mm).
ITE and the carbonates namely SIDERITE, CHALYBITE or SPATHIC IRON ORE, containing 48.3% Fe. Less important ores are the Sulphides, Pyrite,

al operations because of process of fluxing involved in separation of Iron metal from the gangue in the furnaces.
res are the Sulphides, Pyrite, (FeS2), Pyrrhotite (Fe1-nS) and the complex oxide like Franklinite (FeZnMn) (FeMn)2O4.
Sl. Process unit Function
No.

Pickling line To remove the oxides and mill scale from strip
surface to enable further reduction of thickness
to desired level in cold rolling mill.

Cold Rolling Mill To reduce the thickness of the pickled hot rolled
coil to desired level.
Electrolytic To remove the oil from the surface of the cold
Cleaning line rolled coil to produce bright and corrossion free
steel

Batch Annealing To obtain desired properties in the finished cold

Furnace rolled coil.

Continuous To obtain desired properties in the finished cold

annealing Line rolled coil.

Skin Pass Mill To obtain desired surface finish and improve

flatness and suppresses the yield point
elongation

Temper Mill To enhance the physical properties through cold

forming of the steel product in the bite of the
work roll

CR Slitter To cut the CR coil length wise and to remove side

trims to obtain uniform width throughout the
coil as per requirement.

Cut To Length To cut the slitted coil to desired length as per

requirement
Coil Inspection To inspect the coil aginst any defect.
Line

Hot Dip To provide protective zinc coating to the cold

Galvanizing Line rolled coil.

Galvalume To provide protective zinc and aluminium coating

to the cold rolled coil.
Colour Coating To provide protective colour coating to the cold
Line rolled coil.
Electrolytic tin & To provide protective tin or chromium coating to
Chromium the cold rolled coil.
plating Line

Plate Mill To produce plate of varying thickness by hot

rolling of slab.
Hot Strip Mill To produce strip of varying thickness in the form
of coil by hot rolling of slab.
Skelp Mill To produce strip of varying thickness and narrow
width in the form of coil by hot rolling of billet.

Merchant mill To produce plain or TMT rebar for billet by hot

rolling
Section mill To produce joist,channel,angle from bloom by
hot rolling
SMS-II 2 mt
SMS-III 4 mt