JSW STEEL LIMITED

DOLVI, MAHARASHTRA

BASIS OF DESIGN FOR

PELLET PLANT #2 & SINTER PLANT -3
PELLET PLANT -2
 CONTENT

CHAPTER
DESCRIPTION Page
NO.
1
1. INTRODUCTION

OPERATING REGIME :
2. 2-5
 QUALITY OF RAW MATERIALS
 MATERIAL BALANCE
 QUALITY OF PRODUCT PELLETS
 SPECIFIC CONSUMPTION OF RAW MATERIALS,
UTILITY & POWER
3. RAW MATERIAL LINKAGES 6

4. SITE AND INFRASTRUCTURE FACILITIES 7-9

5. MAIN PLANT FACILITIES 10-17

6 WATER FACILITY 18-19

6.1 FUEL GAS FACILITY 20-21

6.2 COMPRESSED AIR FACILITY 21-23

AIR CONDITIONING AND VENTILATION 23-24

6.3
SYSTEM
6.4 PROCESS AND PLANT DEDUSTING 24-28

6.5 CIVIL WORKS 28-29

6.6 BUILDING STRUCTURES 30-32

6.7 ELECTRICAL FACILITY 33-38

6.8 FIRE FIGHTING FACILITY 38-39

CHAPTER PAGES
DESCRIPTION
NO.

6.9 DG STATION 39

MANPOWER AND ORGANISATION

7. STRUCTURE 40-41

8. PROJECT IMPLEMENTATION 42-43

LIST OF DRAWINGS

SL.
DRAWING NO. DESCRIPTION
NO.
1 MEC/11/02/Q7GK/FR/PP/01 LAYOUT OF PELLET PLANT

2 MEC/11/02/ Q7GK/FR/PP/02 PROCESS FLOW SHEET

3 MEC/11/E1/ Q7GK/FR/PP/03 ELECTRICAL SINGLE LINE DIAGRAM

4 MEC/11/PY/Q7GK/FR/PP/04 PROJECT IMPLEMENTATION

SCHEDULE
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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

1. INTRODUCTION

1.1 Background

JSW Steel Limited (JSW), Dolvi Works intends to install one 816 m2 Pellet Plant #2 at
Dolvi, Raigad, Maharashtra near its existing Pellet Plant #1.

1.2 Scope of this Report

The broad scope of this report is to familiarize the suppliers with the existing conditions
at JSWSL, Dolvi so that their offer is in line with the expectation of JSWSL from them.
The scope includes all facilities from ore receipt to pellet discharge to the Blast furnaces
and specifically,

• From receipt of iron ore fines (pellet grade) on one reversible conveyor at top
of Day bins for wet grinding unit; limestone, dolomite, coke & bentonite by
truck at coarse additive ground storage unit of proposed pellet plant,
• Upto discharge of finished pellets from pellet storage bins onto two numbers
Client’s conveyors coming out from the pellet storage unit,
• Technological Layout,
• Process flow sheet,
• Raw material linkages,
• Raw material requirement,
• Requirement of auxiliary & services facilities like power, water, fuel gas,
compressed air etc.,
• Manpower estimate,
• Implementation schedule.

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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

2. OPERATING REGIME
The proposed pellet plant will be operating on the basis of three shifts a day and 350 days
in a year after taking into consideration the shutdowns required for the planned
maintenance and unscheduled breakdowns.
The break-up of the planned maintenance and unscheduled stoppage & shut down of the
plant are as indicated below.
Sl.
Item Duration in Days /
No. Year
1. Capital repairs (once in a year) 6
2. Scheduled repairs (once in a month)
6
(12 hours / month)
3. Unscheduled stoppage and shut 3
downs
Total 15

2.1 Quality of Raw materials

The quality of input raw materials (as provided by Client) used for pellet production is
furnished below in Table -2.1.
Table –2.1 Chemical analysis of raw materials
Quality (%)
Raw mat.
Fe(t) SiO2 Al2O3 CaO MgO LOI
IOF 66.9 2.75 0.5 0.15 0.13 0.57
Limestone 0.5 1.5 0.3 53.5 2.5 40
Dolomite 0.2 0.4 0 32.5 17.5 40
Bentonite 8 52.5 16 1.5 1.5 15.5

The Proximate analysis of Coke (as provided by Client) is as furnished below:

Fixed carbon (total) 82 to 88 %

LHV 7200 kcal/ kg
Moisture Max. 15 %
Ash Max. 18 %
Volatile matter 3.5 %

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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

2.2 Material balance

The indicative material balance for production of 9.0 MTPA high basicity pellets
has been placed at Table - 2.2.

Table - 2.2 Material Balance for production of pellets, (net and dry)

2.3 Quality of product pellets

Based on the raw material analyses as per Table -2.1, the expected chemical composition
of pellets is furnished below in Table -2.3.

Table - 2.3 Quality of pellets

Constituents Value
Fe(t) 63.48
SiO2 3.07
Al2O3 0.62
CaO 4.13
MgO 0.8
Basicity (CaO/SiO2) 1.3

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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Table -2.4 Expected Mechanical and metallurgical properties of indurated pellets

Sl. Item Value

No.
i) Size 9 to 16 mm + 16 mm 92 %
5 % max.
ii) Porosity 25 % min.
iii) Cold crushing strength >= 250 kg/ pellet
iv) Tumble index (+6.3 mm) 92 % min.
v) Abrasion Index (-1 mm) 5 % max.
vi) JIS swelling Index 20 % max.
vii) JIS reducibility 65 % min.
viii) Compression strength after reduction 30 kg/ pellet

However, the same shall be firmed up upon pot grate test.

2.4 Specific & Total consumption of raw materials & services
The indicative specific consumption of raw materials, fuel gas (mixed gas or Coke Oven
gas), power and water for the proposed pellet plant is furnished in Table –2.5.
Table –2.5 Raw Material (Dry & Net), kg/ tonne of pellets
i. Iron ore concentrate 950
ii. Bentonite 5
iii. Coke 11
iv. Limestone 56.5
v. Dolomite 30

2.5 Services (per tonne of pellets)

i. Fuel gas Mixed gas (BF + CO), CV : 1860 kcal/ 166300 kcal
Nm3 or Coke oven gas, CV : 4000 kcal/ Nm3
ii. Make up water 0.2 m3
iii. Electric power ~ 47.2 kWh
iv. Compressed air 32 Nm3

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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

The Specific consumption of raw materials, fuel & power shall be firmed up through
pelletizing test work. The indicative total consumption of raw materials, fuel gas (mixed
gas or Coke Oven gas), power and water for the proposed pellet plant is furnished in
Table –2.6.
Table –2.6 Raw Material (Dry & Net) (t/year)

i. Iron ore concentrate 8550000

ii. Bentonite 45000
iii. Coke 99000
iv. Limestone 508500
v. Dolomite 270000

Services (per year)

i. Fuel gas Mixed gas (BF + CO), CV : 1860

kcal/ Nm3 or Coke oven gas, CV : 4000 kcal/ 804.7 x 106 Nm3
Nm3 374.2 x 106 Nm3
ii. Make up water 1.8 x 106 m3
iii. Electric power ~ 425 x 106 kWh
iv. Compressed air 288 x 106 Nm3

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JSW STEEL LIMITED, DOLVI WORKS

FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

3. RAW MATERIAL LINKAGES

The raw material required for the proposed pellet plant #2 are iron ore fines, limestone,
dolomite, coke and bentonite. Sources of various raw materials are furnished below:

- Iron ore fines

Superior quality iron ore fines (pellet feed) shall be received by conveyor from
RMHS yard to day bins near wet grinding unit. Iron ore fines shall be sourced from
Anglo American Mines at Brazil.

- Limestone and dolomite

Limestone and dolomite will be sourced from Dubai for the proposed pellet plant.

- Coke
Coke shall be imported from China for use in pellet plant.
The following quality of coke (dry basis) is being considered for use in Pellet plant:

Ash - max. 18
% Volatile matter - 3.5 %
(total) Fixed carbon - 82 – 88
%(total)

- Bentonite
The Bentonite requirement of the proposed pellet plant will be met through
purchase from mines in Gujarat. The bentonite deposits in Gujarat are sodium-
based bentonite.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

4. SITE & INFRASTRUCTURE FACILITY

4.1 Site and infrastructure

Location of Site
The proposed site for the pellet plant is situated at Dolvi, Raigad district of Maharashtra.
The plant site is located at approximately 18°41'15.54" Latitude, 73° 1'47.46" Longitude.
The Location map of the site is shown in the location map & regional plan drawing no.
MEC/11/14/Q7GK/001, R0.

Land and terrain

The land for proposed plant is already within the boundary wall of M/s JSW and total
area available for the plant is approximately 33 acres. Land is almost flat having average
altitude +3.5 m above MSL.

Road linkage
National Highway NH66 connecting Mumbai to Goa and state highway SH88
connecting Pen to Alibag are passing along the plant site on its east and north
respectively. The plant site is connected to NH66 through Goa gate on the east and to
SH88 at the North-west corner through Alibag gate.

Railway linkage
The nearest railway station to plant site is Pen under the Panvel-Roha section of Central
railway. At present site is connected to Pen through single line connection.
Port
A captive riverine port-Dharamtar port located on the right bank of Amba River about
16 km from its mouth and operated by JSW infrastructure. The port is located North-
West of the plant and at a distance of about 1 km from the Alibag gate.
Power
The source of power for proposed pellet plant is from MSEB grid only and will be
received from MSEB substation, Nagothane to GIS inside Dolvi plant.

Water
Water will be made available by JSW near boundary of proposed pellet plant from their
existing water source of Dolvi works. The existing water source is Nagothane River.
Meteorological Data

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Wind
Predominant wind direction is Southwest to northeast.

Ambient Temperature
Highest Temperature: 42°C
Lowest Temperature: 9.4°C
Relative Humidity
During summer: 77 % avg.
During monsoon: 89%
Rainfall
Annual Rainfall: 2124.9 mm/yr. avg.
Annual Wind Speed: 3.7 m/s
Seismic Zone: SZIV
4.2 General Layout & Transportation

Rationale for Layout

The layout of the proposed pellet plant has been developed keeping in view the following
factors:
• Smooth and uninterrupted flow of materials in accordance with the
technological requirement,
• Optimum lead for transport of material and for services lines,
• Logistic approach in location of technological units as well as services
facilities.

Locations of Various Units

The relative location of various units has been shown in the layout drawing no.
MEC/11/02/Q7GK/FR/PP/01.
It has been proposed to receive iron ore fines by belt conveyor and additives by road to
the pellet plant. The location of raw material storage and handling facilities has been
planned in west side to existing pellet plant to have smooth unloading and optimum
conveyor length from storage yards to the day-bin building.
The location of pellet plant has been suitably planned in accordance with the
technological requirements as well as dispatch of pellet product.
The location of services units and auxiliary facilities viz electrical substations, water
supply facilities, compressed air facility etc. have been suitably finalised to meet the
technological requirements.
A well-planned road network has been planned to cater to the needs of various plant units
and auxiliary services.
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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Salient Features of the Layout

The actual area identified for the proposed plant is 33 acres. The salient features of the
layout have been indicated in Table 4.1.

Table – 4.1 Salient Features of Plant Layout

Sl. No. Items / Facilities Values
1. Area within plant boundary 33 acres
2. Length of road
a. 7.0 m wide 1.2 km
b. 4.0 m wide 7.7 km

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

5. MAIN PLANT FACILITIES

The proposed pellet plant #2 shall comprise the following major technological units. The
facilities described below shall be able to produce iron ore pellets upto 9.0 MTPA.
• Day bin
• Wet grinding of iron ore fines
• Thickener & slurry tanks
• Filtration
• Coarse additives (limestone, dolomite, coke, bentonite) ground storage
• Coarse additives storage bins & grinding
• Storage cum mixing
• Balling
• Induration
• Pellet screening
• Product pellet storage bins
• Process gas de-dusting system
• Emergency filter cake stock pile
• Belt conveyors, junction houses & inter-connecting galleries

Apart from the above major units which are elaborated in details below, other auxiliary
facilities like material handling, water supply system, compressed air system, fuel gas
distribution, air-conditioning & ventilation system, plant de-dusting system, electrics,
instrumentation & automation facilities etc. have also been envisaged. Adequate hoisting
& handling facilities have been provided in all the units for ease of maintenance and
operation.
5.1 Day bin unit
The iron ore fines shall be received on one reversible conveyor at top of day bins in this
unit. This reversible conveyor will feed to two parallel reversible cum shuttle conveyors
envisaged over two bays of day bins. Eight numbers of bins with effective volume 500
m3 shall be envisaged for storage of iron ore fines.
The proportioned quantity of iron ore fines will be extracted from these bins through weigh
feeders onto conveyors for further transportation to wet grinding unit. The flexibility of
feeding any ball mills out of three from any iron ore fines bins shall also be envisaged in
this unit. GCP dust shall also be received by dust tanker and pneumatically conveyed to
dust bins. Total three numbers of GCP dust bins shall be envisaged in three junction
houses before wet grinding unit. The required quantity of GCP dust shall be extracted
through rotary airlock valve and fed to conveyors leading to wet grinding unit.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

5.2 Wet grinding unit

The receiving conveyor from the day bin building shall feed the raw material to the
screens provided before ball mills in wet grinding unit. The screen overflow shall be fed
to three numbers ball mills and underflow shall be collected in a slurry tank. The slurry
from slurry tank shall be pumped to classifying cyclones having #325 cut point. The
overflow from classifying hydro-cyclones shall be collected in thickeners and the
underflow shall be fed to the ball mills. Product from ball mills shall be collected into
sump from where the slurry is pumped to hydro-cyclones.
Ball mills shall have hydro-cyclones in closed circuit for grinding raw material to 45
micron. The overflow of the hydro-cyclones shall be collected into thickener having
approx. 80%, (-) 45 micron size passing. The underflow of the hydro-cyclones shall be
reground in the ball mills.
5.3 Thickener & Slurry tanks
One number concentrate thickener of 55 m diameter shall be envisaged for thickening of
Iron ore concentrate slurry received from hydro-cyclones overflow from wet grinding
unit. The thickened slurry shall be pumped to slurry storage agitator tanks which shall be
pumped to the Filtration unit for getting filter cake for further transportation to mixing
unit. The thickener overflow shall be fed to Pump house. This thickener is provided with
flocculent system.
5.4 Filtration
The slurry from the slurry agitator tanks (2 nos.) shall be pumped to the filters for
filtration and the filter cake shall be discharged to the cake conveyors. The filter cake
from the cake conveyors below each filter shall be collected on a common reversible
conveyor which shall either convey the material to the mixing unit or to emergency
storage area. The water required for cloth wash and manifold flush water shall be pumped
from pump house. The filtrate water shall be collected in filtrate tanks and shall be
pumped to thickener to reduce the mineral content in the filtrate water.
Each filter will be equipped with cloth shaking and cloth flushing system for improved cake
discharge and reliability. Cloth flushing will be applied after each cycle when the plate
pack is open and cake discharge is complete. Flushing water will be collected with swivel
plates underneath the plate pack.
5.5 Coarse additive ground storage unit
Coarse additives like limestone, dolomite, coke & bentonite shall be received at one
common ground storage unit inside pellet plant #2 by truck. The individual raw additive
shall be fed by pay loaders onto one outgoing conveyor through over-ground hoppers &
vibro-feeders as per requirement and transported to respective bins in coarse additive
storage bins unit.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

5.6 Coarse additives storage bins & grinding

Coarse additives shall be stored in separate bins, two numbers each for limestone,
dolomite, coke & bentonite. The effective volume of each bin shall be approx. 200 m3.
Limestone & coke and dolomite & coke shall be fed from the storage bins, to two ball
mills on time sharing basis and bentonite to one vertical roller mill for grinding, by means
of belt weigh feeder & feed hopper. Ball mills shall be complete with mill feed hopper, air
slide, damper, cyclone, bag filter, hot gas generator, circulation fan, surge hopper and
transport vessel. Roller mill shall be complete with rotary airlock valve, classifier, bag
filter, hot gas generator, circulation fan, surge hopper and transport vessel. Ground
additives from this unit shall be carried to respective ground material storage bins in
storage cum mixing unit by pneumatic conveying.
5.7 Storage cum mixing unit
Ground ore concentrate (filter cake) shall be received from filtration unit by belt conveyor
and fed to four numbers of bins, two of effective volume 780 m3 and other two of 730 m3
through one reversible and slewable belt conveyor on top of the bins. Ground bentonite
and mix (flux-tone & coke) from additive grinding unit shall be fed pneumatically to
respective bins in this unit. Four number of bins, each of effective volume 400 m3 for mix,
two numbers each of effective volume 450 m3 for bentonite and one bin of effective
volume 200 m3 for ESP dust shall be envisaged. ESP dust shall be pneumatically
transported to ESP dust bin from process & plant dedusting ESPs. ESP dust bin shall
have twin outlet with rotary weigh feeders.
Belt weigh feeders shall be mounted at outlet of filter cake bins and rotary weigh feeders
at outlet of ground additive & ESP dust bins. All additive bins are equipped with bag filters
for cleaning the transport air. Materials discharged from these bins shall be transported
to two (02) High intensity mixers by belt conveyors for thorough mixing. Belt weigh
scale shall be installed on conveyors before the mixer to control the feed rate of raw mix
to the mixer.
The HI mixer shall be provided for thorough mixing of raw materials with controlled
addition of process water to form green pellets with sufficient mechanical strength to
withstand the subsequent transportation, screening and heat treatment process, and to
adjust the chemistry of the pellets to favour the production of mechanically resistant
product pellets with a high compression strength and low abrasion indices, and to adjust the
chemistry of the product pellets. The moisture content of the raw mix is raised to
approximately 9.5%. The mixed material from the mixer shall be transported by series
of belt conveyors to balling unit.
5.8 Balling unit
The production of green pellets is performed in thirteen (twelve operating and one stand-
by) closed pelletizing discs circuits. The mixed material received from storage cum
mixing unit shall be distributed to mixed material bins, each with storage capacity of 40

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

m3, installed directly above each balling disc. All the bins shall be load cell mounted. A
horizontal conveyor equipped with pneumatically operated ploughs will distribute the
mixed materials into the mixed material bins. Any spillage passing under these ploughs
will be discharged at the head end of the conveyor and re- circulated through mixed
material route or stored in emergency stockpile.
The material discharge from each mixed material bin will be controlled by dosing belt
weigher equipped with variable speed drive, thus feeding the required amount of mixed
material onto the corresponding pelletizing disc. The dosing belt weigher will discharge
mixed material into the disc feeding chute, which are equipped with fluffing device for
disintegration of any compacted material as well as for a distribution of the mixed
material on the pelletizing disc. The green pellets will be formed in the discs with a
diameter of 7.5 m each, with simultaneous and variable addition of water. The inclination
of each disc will be variable and optimum setting (approx. 44 to 53 deg.) is to be
determined during start-up, according to mixed material properties, desired green pellet
diameter and feed-rate. The rotary speed of the disc can also be varied during operation
by means of frequency-controlled motor, depending on the pelletizing characteristic of
the concentrate mixture. It can be possible to regulate the disc rpm from 5 to 7.5 during
operation. The green pellets from the pelletizing discs will be conveyed to a single deck
roller screens where undersize (<9 mm) and oversize (>18 mm) green pellets will be
crushed in disintegrators installed on belt conveyors for reject pellets. In case of
emergency and during start- up of a disc, when the green pellets will not have the required
properties, the disc discharge can thus be recycled or discharged to an emergency
stockpile by conveyors. The green pellet of (9-18) mm from the single deck roller screens
will be finally discharged to the green pellet collecting belt conveyor, which is equipped
with a reciprocating head.
A belt weigher will be installed at the collecting belt conveyor for weighing the total
amount of green pellets discharged from the pelletizing discs. This belt weigher is used for
mass balancing and serves as a standby signal for the speed control of the induration
machine. The head pulley of this conveyor is supported in a reciprocating carriage, which
moves the head pulley over the width of the downstream perpendicularly arranged wide
belt conveyor. The forward velocity of the carriage with the head pulley is identical to
the belt speed and during the backward stroke the green pellets are discharged onto the
wide belt conveyor. The wide belt conveyor will discharge the green pellets onto the
double deck roller screen. The bi-layer double deck roller screen will split the green
pellets into two layers on the indurating machine. The screen sorts pellets with smaller
diameter at the bottom of the bed and the larger pellets at the top. Undersize & oversize
green pellets from the bi-layer double deck roller screen will be recycled by belt
conveyors back to the green pelletizing area after crushing in disintegrator. The rollers on
screen deck shall be chain driven by variable speed drive/ individually driven rollers. A
belt weigher will measure the amount of undersize & oversize green pellets.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

5.9 Induration
The traveling grate machine on which the green pellets will be heat treated, indurated and
cooled will have a minimum reaction area of 816 m² (4 m wide and 365 m long). This
travelling grate will consist of an endless chain of pallets, which continuously revolve. One
of the process pre-requisites for obtaining a uniform product quality is a uniform bed
height. This will be ensured by automatic control of the traveling grate speed as a function
of the ultrasonic level measuring devices installed after green pellets are charged to
travelling grate. Grate speed control by ultrasonic has significantly reduced the response
times and thus improved pellet bed leveling on the indurating machine. Thermal attack
on the pallets and grate bars, which would lead to excessive wear, will be avoided by
using a hearth and side layer of indurated pellets. Side layer is used for protecting the
sidewalls of the pallets. A storage bin for hearth and side layer will be arranged at the
feed-end of the travelling grate. A motor-driven discharge gate can adjust the height of the
hearth layer on the pallets. The standard height for this application is approx. 80 mm. The
three components are fed onto the pallets in the following order:
• Hearth layer
• Side layer
• Green pellets
The hearth and side layer bin is equipped with an emergency chute which permits
additional filling of the pallets with hearth layer in case of failure in the green pellet
feeding system and thus protecting the pallets and grate bars from over-heating. The
required green balls, in the size range of 9 to 16 mm shall be fed to the indurating machine
for heat hardening.
Green pellets are then subjected to the following different thermal zones during the
process of induration on travelling grate machine:
Thermal Zones Process Gas Temperature
(deg.C)
Up-draught drying Zone (UDDZ) 330
Down-draught drying Zone (DDDZ) 380
Preheating Zone 400 - 1270
Firing (Induration) & After firing Zone 1270 - 1190
First cooling zone 30
Second cooling zone 30

After drying of green pellets in the up-draught and down-draught drying zones, the dried
pellets will be preheated to a progressively higher temperature to initiate oxidation and
sulphur burning with fuel (coke) present in the green pellets.
The dried pellets will then be fired at approx. 1300 C to provide the re- crystallization

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

and slag bonding which will impart adequate strength to the pellets. An unfired short
section designated as ‘after firing’ allows the heat front to completely penetrate into the
bottom of the bed thereby eliminating sudden quenching of pellets and consequent
deterioration of pellet properties.
Cooling of indurated pellets shall be accomplished by up-draughting ambient air,
supplied by cooling air fans, through the pellet bed. The cooled pellets will leave the
indurating machine at 100 C or less.
Process gas flow
The induration process is characterized by maximum recovery of heat from the cooling
zones as well as firing zone of the travelling grate machine. This calls for recirculation
of hot gases through ducts to different process zones using five fans.
A total of five process fans have been envisaged and are as follows:
• Cooling air fans
• Up-draught drying fan
• Wind box recuperation fan
• Hood exhaust fan
• Wind box exhaust fans
For the purpose of recovery of heat, the travelling grate will be provided with a
refractory-lined hood above the machine all along the length. Seal boxes are used in
different zones to seal this indurating hood against the moving pallets to avert heat loss.
The hood will be provided with water- cooled side and transverse lintels.
The following is a brief description of the process gas flow:
Hot combustion gases from the cooling zone 1 will enter the firing zone by the direct
recuperation principle. Burners will be arranged opposite to each other on the longitudinal
sides of the preheating and firing zone. The arrangement and sizing of the burners will
ensure a uniform hot gas temperature over the width of the pellet bed. Since the burners
are divided in several control zones, an optimum temperature profile can be adjusted thus
permitting an optimum heat treatment of the green pellets. The burners will operate with
mixed gas (blast furnace gas & coke oven gas) or coke oven gas. The temperatures in the
individual control zones of the preheating and firing zone are measured with
thermocouples and indicated by the central control system. They will serve as control
variables for the automatic supply of fuel to the burners. Intake and circulation of the air
& gas required for the process will be ensured by the application of process fans.
The induration process is characterized by the recovery of maximum heat from cooling of
the hot pellets meaning transportation of recovered hot air from the first cooling zone to
the preheating and firing zone without a fan. The cooling air fans will suck in ambient
air through a silencer and force this air through an air duct into the wind-boxes of cooling
zone no. 1 and no. 2. The cooling air which becomes heated after passing through the hot
pellet bed is collected in the first and second cooling hood. These hoods are installed
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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

directly above and sealed against the travelling grate. Hot air collected in the second
cooling hood will be extracted by the up-draught drying fan and forced through duct into
the wind-boxes of the up-draught drying zone. Wind-box pressure in the up-draught
drying zone is automatically controlled by a damper which leads excessive air to the hood
exhaust gas system. Hot process gas from the wind-box recuperation system (supplied
via a bypass) will be extracted and forced through a duct & a damper into the hood above
the preheating zone. The hot gases of the downdraft drying, preheating and firing zone are
sucked in "downdraft" through the pellet charge by fans. The wind-boxes of the downdraft
drying zone, the preheating zone and a part of firing zone are connected to the wind-box
exhaust fans. Before being exhausted, the process gases are cleaned by electrostatic
precipitators. The wind-box exhaust fans discharge the waste gases to atmosphere through
waste gas stack. Recovered dust discharged from the ESPs will be transported to the dust
collecting bin (ESP dust bin in mixing unit) through pneumatic conveying system. The
collected dust is added in a controlled way to the process. All clean gases from the process
ESPs system will be released via one common stack to the atmosphere. The hot
combustion gases from the last section of the firing and the after-firing zone will serve
as drying gases in the downdraft drying zone. They will be sucked through the pellet bed
by the wind-box recuperation fan and then forced via gas ducts into the hood above the
downdraft drying zone. An appropriate temperature profile in the preheating zone is
essential for the production of high quality oxide pellets. This temperature profile can be
adjusted easily by mixing controlled quantities of second cooling air / wind-box
recuperation air, supplied by a fan. In order to maintain a constant and optimum
temperature of the drying gases and to protect the wind-box recuperation fan from
overheating, a bleed-in for ambient air, equipped with control dampers, is provided at the
suction side of the wind-box recuperation fan. One by-pass between the wind-box
recuperation and the updraft drying system will allow the passing of heat from the one to
the other system. The humid exhaust air from the up-draught drying hood is sucked off
by the hood exhaust fan. Hot excess gas from the recuperation fan is added in order to raise
the temperature of this air and to control the pressure in the downdraft hood. The exhaust
gas will be cleaned in an electrostatic precipitator and directed to atmosphere together
with the waste gases via the common waste gas stack. A grate bar cleaning device will
be located near the lowering station on the return track of the travelling grate.
The cooling zone of the indurating machine is designed to cool down fired pellets in
normal operation to temperature of approx. 100 °C or below. The product belt conveyors
will be equipped with emergency water spray systems, which help to protect the belt
conveyors in case hot pellets are discharged from the indurating machine. The cooled
pellets will be discharged from the indurating machine into the discharge bin, mounted on
load cells and then transported to pellet screening unit.
5.10 Pellet screening
In this unit, vibrating screen is installed to separate out certain quantity of fired pellets

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from the product pellets, which will be recycled as hearth layer to the indurating machine.
The product screen will mainly consist of vibrating screen decks to segregate the
following size fractions of fired pellets:
• hearth layer pellets : 12.5 – 16 mm
• product pellets : balance 12.5 -16 mm, <12.5 mm and >16 mm
Sized pellets are used as hearth layer to avoid clogging of side layer chutes and improve
the permeability of the hearth layer and thus reduce pressure drop and energy
consumption of the system. Screened hearth and side layer will be transported by belt
conveyors to the hearth layer bin at the feed end of the indurating machine. Vibrating
feeders determine the portion of on-spec product pellets to be used as hearth layer and is
controlled by the level of the hearth and side layer bin. A belt weigher will register the
production rate of the pellet plant. A sampler shall be installed in the discharge chute of
product conveyor, which will take samples for pellet quality control.
Suitable arrangement shall be made in pellet screening unit to by-pass the screen, if
required.
5.11 Pellet storage bins
Product pellet from pellet screening unit shall be transported to pellet storage bins by belt
conveyor. The storage capacity of the unit shall be approx. 11 hours of finished pellet
production.
However, one emergency finished pellet ground stock pile near pellet screening unit shall
also be envisaged.
5.12 Emergency filter cake stock pile
One covered shed for emergency filter cake storage shall be provided near filtration area.
The filter cake shall be discharged to the stock pile by tripper conveyor. The provision for
reclamation of the filter cake from stock pile and feeding to the conveyor leading to
storage cum mixing unit shall also be provided.
5.13 Belt conveyors, junction houses & inter-connecting galleries
Various belt conveyors, interconnecting structural galleries and junction houses shall be
envisaged as per the technological layout of pellet plant. The typical layout and process
flow sheet of the proposed pellet plant are shown in drawing nos.
MEC/11/02/Q7GK/FR/PP/01 and MEC/11/02/Q7GK/FR/PP/02.

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6. Water Facility
01 General

Water for the proposed wet grinding & filtration units and pellet plant proper will
mostly be required for direct and indirect cooling of plants/ machines/ equipment
with a minor part to be consumed for drinking & sanitation purpose and other
direct process & general purpose needs. Individual recirculation system has been
envisaged for water system of various plant units to effect extensive recycling
and reuse of return water from plant processes after necessary treatment and
conditioning.
02 Requirement of Water

The total make-up water requirement for the proposed pellet plant is estimated as
205 m3/h (approx).
03 Make up water requirement

The estimated maximum make-up water requirement for the proposed plant
facilities is indicated below:
Sl. Make up water
Description
No. Requirement, m3/h
1. Grinding & Filtration Unit 125
2. Pellet plant 25
3. Compressed air station 25
4. Service water 15
5. ACVS 10
6. Drinking water (pellet plant complex) 2
7. Fire water 1
8. Misc. Consumers 2
Total 205

04 Water System Facilities

To cater to the water requirement of the proposed plant, the following water
system facilities have been envisaged:
a) Process cooling water system
b) Make-up water system
c) Drinking water system
d) Water based fire-fighting system
e) Emergency water system including overhead tank
f) Interplant pipelines
g) Water pollution control & conservation.
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Process cooling water system

A. For open direct cooling water cycle
B. For open industrial water cycle
The above water recirculation systems will mainly comprise the following main units:

For open direct cooling water cycle

 Pumping system
 Thickeners & Filter Press
 Make-up Water supply
 Interconnecting piping
 Chemical dosing system
 Electrics, instrumentation & control system
For open industrial water cycle
 Cooling Tower
 Pumping system
 Partial stream filters
 Interconnecting piping
 Chemical dosing system
 Electrics, instrumentation & control system
Make-up water system
Industrial quality make-up water shall be tapped from TOP with an isolation valve. It
shall be used as make-up to industrial re-circulating water circuit for grinding & filtration
unit, pellet plant, compressor cooling, make-up to fire water reservoir, service water
needs etc. Make up water will be distributed to various consumers through a makeup
water network.
Drinking Water System
For meeting the drinking water needs of the plant, drinking water shall be tapped from
TOP with an isolation valve. Drinking water will be distributed to various consumers
through a drinking water network.
Fire Fighting water system
A firefighting water hydrant network shall be provided for the proposed plant
encompassing the various fire hazards units/ areas of the entire plant territory. The water
hydrant network shall comprise adequate number of indoor and outdoor hydrant along-
with hoses and nozzles. A tapping from industrial water network shall be connected to
respective storage tank of firefighting pump house for initial filling & top-up.
Emergency Water Overhead tanks
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Emergency overhead tanks will be provided at a staging height of 40-50 m for 30 minutes
supply of emergency water to critical consumers of pellet plant units for a short duration
in the event of interruption in normal cooling water supply. The overhead tanks will be
multi-compartment type, compartment serving emergency water, service water
requirements of individual consumers. The filling of emergency water tanks for loss of
water under normal operation and supply of cooling water from the tanks under
emergency conditions will be under automatic control.
Overhead tanks will be provided with overflow, drain and air vent connections. Overflow
from various tanks will be collected for reuse in the plant water system.
Interplant pipelines
Industrial water for make-up water supply and general plant usage will be met through
the proposed make up water pipeline to be laid from the make-up water pump house.
Firefighting water networks have been envisaged with adequate number of yard hydrants
as well as indoor hydrants covering the entire plant area.
Drinking water will be met through proposed drinking water pipe networks. Service
water, fire-water and drinking water pipelines will generally be laid buried underground.
Process cooling water supply and return lines will generally be laid overhead on steel
structural trestles & bridges and in underground tunnels.
Water pollution and conservation
Extensive recycling has been adopted in the design of plant water system. Quality of
circulating water will be maintained through dosing of conditioning chemicals for
controlling corrosion, scale deposit and microbial growth. Waste water from makeup
water treatment plant will be neutralized before discharge from the plant. The sludge
arising out of different circuits will be disposed of at suitable location
6.1 FUEL GAS FACILITY
Mixed gas (BF+CO) or coke oven gas shall be used as fuel for the proposed Pellet Plant.
The calorific value (CV) of mixed gas (BF+CO) and coke oven gas shall be
approximately 1860 kcal/Nm3 and 4000 kcal/Nm3 respectively.
It is proposed that separate pipe lines from take over point (TOP) near pellet screening
unit of proposed pellet plant shall be laid along with supporting structures for supply of
mixed gas and coke oven gas to new pellet plant. Further, steam and nitrogen pipe lines
shall also be laid along with mixed gas & coke oven gas lines for purging application of
the fuel gas lines, as and when required. Fuel gas pipe lines shall be laid in slope. Hence,
necessary vents, purge connection and condensate seal pots shall be provided in the
mixed gas line and coke oven gas line for which required hoses, piping, valves & fittings
are to be provided for the completeness of the piping system.

In addition to above, compressed air / instrument air pipe lines shall also be laid upto
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consuming points from compressed air stations.

The interplant piping network shall consist of a common trestle/ stocked/ bridge carrying
above mentioned fluid pipes up to consumers points. However, in-shop piping network
shall consist of pipes carrying above fluids supported with building columns/ structures.
Approach ladders, hand railings etc. shall be provided for valve operation on overhead
interplant & in-shop piping network.
Bigger fuel gas pipelines shall be fabricated from carbon steel plates. However, small
diameter fuel gas pipes shall be of IS:1239 ERW.
For steam services, all pipes, valves & fittings (i.e. bend, TEE, reducers etc.) shall be of
IBR quality. Mineral wool and aluminum cladding shall be used for insulation of the
steam line. Steam traps shall be used for removal of condensate from steam line. For
steam services, all pipes shall be of ASTM A106 Gr. B and valves (gate or globe valve)
shall be of “forged steel”.
For nitrogen service, ASTM A106 Gr. B pipes shall be installed with forged steel Class-
800 for DN50 & below gate valves and for above DN50, class 150 cast steel gate valve
shall be used for isolation.
For compressed air/ instrument air, pipes shall be ERW and CI lubricated taper plug
valves, CI ball valves along with moisture traps and Y-strainers shall be used. For
instrument air, pipes shall be galvanized.
6.2 COMPRESSED AIR FACILITY
For Filter Press
Air compressors
Oil lubricated, screw type air compressors complete with all accessories and mountings
along with all necessary electrics & control and instrumentation are envisaged to cater
the need of compressed air for different units/ sub-units of filter press. Compressors will
have matching accessories/ facilities etc. as required.
No. of Compressors 6 nos.
Air volume flow (each compressor) 64 m3/min FAD
Discharge Pressure at outlet flange of 12.5 kgf/cm2g
after cooler and moisture separator
Service duty Continuous
Installation Indoor
Environment Dusty

Each compressor shall be designed to meet the flow parameter as mentioned above at the
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rated discharge pressure. These compressors shall be located on ground beneath filter
cake conveyors platform in filtration unit.
Air Receivers
There will be three (3) nos. of air receivers of 150 m3 capacity and working pressure of
12.5 kgf/cm2g. Air receivers shall be of carbon steel material (SA516, Gr70) and welded
construction complete with all accessories.
For Pellet Plant proper
Air compressors
Integrally geared centrifugal air compressors complete with all accessories and
mountings along with all necessary electrics & control and instrumentation are envisaged
to cater the need of compressed air for different units/ sub-units of filter press.
Compressors will have matching accessories/ facilities etc. as required.
No. of Compressors 4 Nos.
Air volume flow (each compressor) 115 Nm3/min
Discharge Pressure at outlet flange of after 8 kgf/cm2g
cooler and moisture separator
Service duty Continuous
Installation Indoor
Environment Dusty

Each compressor shall be designed to meet the flow parameter as mentioned above at the
rated discharge pressure. One compressed air station shall be envisaged to cater the
requirement of pellet plant proper and instrument air.
For Instrument air
Air compressors
Oil lubricated, screw type air compressors complete with all accessories and mountings
along with all necessary electrics & control and instrumentation are envisaged to cater
the need of compressed air for different units/ sub-units of filter press. Compressors will
have matching accessories/ facilities etc. as required.
No. of Compressors 2 Nos.
Air volume flow (each compressor) 25 Nm3/min
Discharge Pressure at outlet flange of after 8 kgf/cm2g
cooler and moisture separator
Service duty Continuous
Installation Indoor
Environment Dusty

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Each compressor shall be designed to meet the flow parameter as mentioned above at the
rated discharge pressure.
Air drying plant
The air drying plants are envisaged to install adjacent to the compressors in the
compressed air station building to meet the requirement of instrument air. The dryer shall
be completed with all accessories and mountings.
The dryer shall be supplied along with all necessary auxiliaries. Design considerations
of the drying units are indicated below:
No. of Air Dryer Unit 2 Nos. (2W)
Air volume flow (each) 25 Nm3/min
Inlet air pressure 8.0 kgf/cm2 (g)
Service duty Continuous
Inlet air temperature Same as compressor outlet

6.3 AIR CONDITIONING AND VENTILATION SYSTEM

Air conditioning & ventilation systems shall be provided for proper working conditions
necessary for maintaining environment compatible with human hygienic requirement
and to maintain conditions necessary for proper storage of materials and working of plant
& equipment. The air conditioning & ventilation systems shall generally include
equipment and accessories such as fan, air washer unit, air filter, air conditioning unit,
duct work, pump set, cooling tower, air supply grills, dampers, insulation, electrics,
instrumentation and controls etc.
Air conditioning & ventilation systems shall be designed considering the climatic
conditions prevailing in the region and the system shall generally be installed in separate
plant room independent of the served premises. The plant room shall be provided integral
with or adjacent to the served premises at proper locations on considerations of
convenience of routing of ducts/ pipes, availability of fresh uncontaminated air and
creating least disturbance to the adjacent premises in terms of vibration and noise.
Air conditioning & ventilation systems shall be provided with adequate measures for
safety and fire fighting for fire hazardous areas and shall be of flame proof / explosion
proof construction.
6.3.1 Ventilation facilities
Buildings and shops shall generally be provided with natural ventilation. Mechanical
ventilation shall be provided for premises where adequate ventilation cannot be provided
by natural means alone.
Depending upon the specific requirement, the shops / buildings shall be provided with
either exhaust ventilation or plenum ventilation. The system design shall take into
account the requirement of air changes as well as excess heat removal. Filters shall be

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provided with plenum system. By plenum ventilation, the served premises shall be
pressurized to 2-3 mmWC to avoid ingress of dusty air. Hot work areas shall be provided
with portable man-coolers for spot cooling. Man-coolers shall also be provided in a few
other areas where the premises are manned and have high heat radiation. The details and
types of systems proposed are indicated in the table given below:

Location/ Shop Facilities

Electrical premises, Switch gear room, Cable Plenum ventilation with
basements of Electrical sub-stations washed air.
Battery room, pump house, compressor room, Exhaust ventilation
toilets, stores etc.
MCC room of compressed air station Plenum ventilation with fan
and filter

6.3.2 Air conditioning facilities

Premises requiring stringent environmental conditions of temperature and humidity shall
be air-conditioned. Room air conditioners, package air conditioners shall be provided for
air conditioning of these premises; the selection depends on the specific requirement of
the application in terms of cooling capacity, temperature, humidity and freedom from
dust. The instrument control rooms shall be generally maintained at a temperature of
23+20C and relative humidity 55+5%. Dust concentration shall not exceed 0.1 mg/m3.
Office rooms/ In-charge's rooms shall be provided with room air conditioners for
personal comfort.
The types of air conditioning system proposed are as indicated below:
Location/ Shop Facilities
Main Control room Centralized/Package type air conditioning system with
standby
provision as per cooling load calculation
Office rooms/ In-charge Split type room air conditioners
rooms

6.4 PROCESS AND PLANT DEDUSTING

6.4.1 General
The pollutants in the form of solids, liquids and gases are generated from the various
technological units, and if let out as such, will have hazardous effect on the environment.
Pollution of the environment not only adversely affects the flora and fauna but also
shortens the life of plant and equipment. This vital aspect, therefore, has been taken into
account while planning the plant and equipment and adequate measures have been
proposed to limit the emission of pollutants within the stipulations of statutory norms.

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Air Pollution
Air, in and over the plant area and beyond its boundaries, gets polluted with gases, fumes
and dust particles emanating from the processes, chimneys, transfer points of conveying
and handling equipment. The air pollutants in Pellet plant are mainly dust and gases like
sulphur dioxide, carbon monoxide, nitrogen oxides etc.

Water Pollution
Water pollution mainly comprises inorganic solids, oil, grease etc. in suspension,
solution and emulsion.
Noise Pollution
Many operations in the Pellet plant will produce objectionable level of noise, which may
not be eliminated entirely, but in most areas it can be brought down to acceptable level.
The major noise generating equipment are process fans, compressors, ball mills etc.
6.4.2 Pollution Control Measures
Air pollution control
The measures to control the air pollution will ensure that the emissions conform to the
norms stipulated by the State Pollution Control Board and the Central Pollution Control
Board. Moreover, it will be ensured that the ambient air quality in nearby areas conform
to the National Ambient Air Quality Standards stipulated by the Central Pollution
Control Board. The work zone air quality will conform to the norms stipulated by the
Factory Act.
The system proposed for air pollution will provide acceptable environment conditions in
the working areas and abate air pollution in the surrounding areas of the pellet plant
complex. The technological equipment and processes have been selected with the above
objective. The efficiency of ESPs/ bag filters shall be such that the emission of dust from
stack will not be not more than 10 mg/Nm3. Depending upon the quality of emissions
from different sources, suitable air pollution control systems will be provided. The
chimney heights will be as per CPCB norms to ensure Ground Level Concentration
(GLC) of different pollutants within permissible limits.

Sl. Location / Shop Air Pollution control facilities

No.
1 Indurating machine charging & Fume extraction system comprising ESP,
discharging areas, HL bin centrifugal fan and motor, ductwork including
discharge, screening etc. suction hoods, duct supports, stack etc.

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Sl. Location / Shop Air Pollution control facilities

No.
2 Limestone, dolomite, coke and Dust extraction system comprising pulse jet type
Bentonite storage bins in additive bag filter, centrifugal fan and motor, duct work
storage and grinding unit including suction hoods, duct supports, stack etc.
3 Ground mix Dust extraction system comprising pulse jet type
(limestone + coke, dolomite + bag filter, centrifugal fan and motor, duct work
coke) and bentonite bins including suction hood, duct supports, stack etc.
4 Hood Exhaust and Wind box Fume extraction system comprising ESP,
exhaust gases centrifugal fan and motor, ductwork including
suction hoods, duct supports, stack etc.
5 Junction houses Dust extraction system comprising pulse jet bag
filter, centrifugal fan and motor, duct work
including suction hood, duct supports, stack etc.

Details of stacks envisaged for different pollution control systems are indicated in below
table:
Sl. Description Parameters Remarks
No.
1. Common Stack height = approx. 80 m
Stack for Flue gas velocity = As per IS 6533 part-1 (normally
hood exhaust in range 15 -18 m/s)
and wind box Flue gas flow (approx.) = 2147520 m3/hr, rated
exhaust ESPs and 2506140 Nm3/hr, design
Top diameter = approx. 9.7 m
Exit temperature = 140 - 165 deg.C
2. Stack for Stack height = approx. 50 m
Plant de- Flue gas velocity = As per IS 6533 part-1 (normally
dusting in range 15-18 m/s)
system Flue gas flow (approx.) = 198000 Nm3/hr, rated
and 210000 Nm3/hr, design
Top diameter = approx. 2.6 m
Exit temperature = 50 - 95 deg C
3. Stack for bag Stack height = approx. 45 m
filter of Pellet Flue gas velocity = As per IS 6533 part-1 (normally
bins storage unit in range 15 - 18 m/s)
Flue gas flow (approx.) = 170000 Nm3/hr
Top diameter = approx. 2.2 m
Exit temperature = 60 deg C

However, in order to meet the statutory ground level concentration limits for SO 2, NOx
and other gaseous pollutants, suitable stacks height will be provided for proper
dispersion as per CPCB norms. Stacks will be provided with porthole and working
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platform so that stack monitoring can be done as per norms of statutory authority.
Water Pollution Control
All effort will be made to ensure minimum discharge of polluted water. Whatever water
is discharged, it shall conform to the norms specified in schedule-V of Environmental
Protection Act, 1986.
The pollutants present in waste water will be reduced to acceptable levels by adoption of
the following schemes:
• Re-circulating water in the process whereby discharged volume is minimum.
• Clarifier and sludge pond for removal of suspended solids.
• Neutralisation of acidic water by lime.
• Removal of oil and grease from contaminated water by means of oil traps,
skimming devices etc.
Noise Pollution Control
Various measures proposed to reduce noise pollution will include reduction of noise at
source, provision of acoustic lagging for the equipment & suction side silencers,
vibration isolators, selection of low noise equipment and isolation of noisy equipment
from working personnel. In some areas where it is not feasible to bring down the noise
level within acceptable limits due to technological process, personnel working in these
areas will be provided with noise reduction aid such as ear muffs/ ear plugs and also the
duration of exposure of the personnel will be limited as per the norms.
Waste material management
The various waste materials arising out of the technological processes will be re-utilised
to the extent possible.
Green Belt
Adequate green belt will be provided inside and all around the plant premises. Green belt
will be developed along the roads and around various shops & offices.
6.5 CIVIL WORKS
6.5.1 General
Civil work comprises all plant units, its auxiliaries, roads, drainage, sewerage and all
other infrastructure within the plant boundary. In general, specification/ details in respect
of type of structures, grade of concrete, materials etc. for all major units have been
assumed to be similar to standard practice of civil works.

6.5.2 Geo-technical data

As the soil in the proposed plant is having very low bearing capacity, the entire plant has
been considered to be supported on Pile foundations. The exact load bearing capacity of
Piles shall be as per geo-technical data.
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6.5.3 Type of Civil Work

• Underground transfer point/ junction houses shall consist of RCC basement
structure supported on Piles.
• Pile foundations for steel structure trestles carrying over ground conveyor
galleries shall be provided.
• Pile foundations shall be provided for all Super Structure units with Structural
Steel, along with RCC floor slabs/ steel chequered plate floors supported on
Structural Steel Beams. The ground floor/ grade floors shall be provided as
RCC base slab on PCC sub-base over boulder/ stone soling.
• RCC framed structures shall have Pile foundations, RCC column, beams, floor
slab and roof slab. Floors with suitable floor finish and roof with suitable water
proofing treatment shall be provided.
• The surface drainage system of the plant has been considered to have open
drains of RCC construction. RCC culverts/ pipe culverts shall be provided at
road crossings for drains.
• All underground RCC basement structures (base raft, walls etc.) shall be
designed as cracked section. However, water retaining structure like
underground/ partly underground/ on ground water reservoirs/ sumps etc. shall
be designed as per latest IS: 3370.
6.5.4 Concrete Grade
Design Mix Concrete of minimum following grades shall be used:
For RCC works:
M-30 Water/ Liquid Retaining RCC Structures
RCC works for all foundations/substructures, superstructure elements
M-25 of all buildings, equipment foundations etc
M-20 For drains, minor structure like pits etc.

For PCC works:

M-7.5 Lean concrete below foundations, etc.
M-10 For PCC works
M-15 Screed concrete, grade floor, apron & pavement

6.5.5 Building Material

Cement
In general, 53 grade Sulphate resisting Portland Cement confirming to IS: 12330 shall be

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used.
Reinforcement Steel for RCC
For all RCC work, Fe-500 Grade TMT Bars (reinforcement) conforming to IS: 1786 shall
be used.
6.5.6 Standards & Codes of Practice
In general, following latest IS codes shall have to be referred:
IS : 456-2000 Code of practice for plain and reinforced cement concrete.
IS : 875-1987 Code of practice for design loads for buildings and structures.
IS : 2974 Code of practice for design and construction of
machine foundations.
IS : 3370 Code of practice for concrete structures for the
storage of liquid.
IS: 1893-2002 Criteria for earthquake resistant design of
structures.

General provisions and buildings.

Apart from the above, wherever necessary, other relevant Indian Standard Code of
practices/ IRC standards shall be considered as per BIS.

6.6 BUILDING STRUCTURES

6.6.1 Steel structural work shall cover all building structures viz. columns, beams,
storage bins, roof structures, wall structures, platforms, crane girders,
monorails, bracings, ladders, staircases, handrails etc. The work shall also
include sheeting work for roofing and side cladding in various junction houses,
buildings and conveyor galleries. Total structural work shall be complete in all
respect for proper functioning of all plant and equipment.
Units / buildings
• Covered ground storage unit for coarse additives (limestone, dolomite, coke &
bentonite)
• Coarse additive storage bins & grinding
• Day Bin
• Wet grinding
• Slurry storage tanks
• Filtration
• Emergency filter cake storage shed
• Storage cum mixing
• Balling
• Induration
• Pellet screening

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• Pellet bin storage

• Electrical sub-stations
• Pump house
• Compressed air station
• Chiller plant
• Process Gas Stack
• Plant de-dusting stack
• Junction Houses
• Conveyor Galleries
• Pipe supporting structures
• Cable Galleries
Steel Structures
• Columns (rolled section or built-up), Column bracings.
• Stairs, ladders and crossovers with safety hoops.
• Handrails, Roof Handrails.
• Walkways with chequered plate / gratings / pre-cast slabs.
• Working platforms, maintenance platforms, Gable Platforms.
• Silos/ Hoppers, Roof Trusses, Roof Girder.
• Crane Girders, Monorail Beams & Supports.
• Purlins, Floor Beams, Sheeting Posts, Side runners, Louvers, Bracings, Sag
angles, Sag rods, wind-ties on roof.
• Expansion provision.
• Steel gates, doors, shutters, metallic partitions.
• Wind girders, Gutters and Down-comers.
• Gallery truss, Gallery Trestles, Bracings, Rafter & rafter bracings for gallery
truss, End portal, Top & Bottom chord Bracings for Gallery Trusses, Roof &
side cladding with Colour coated metallic and Translucent sheeting etc.
• Rail & Rail Fixtures.
• Cable Bridges & Pipe Racks.

6.6.2 Design Considerations

Design of steel structures shall be done in accordance with IS: 800 - 2007 or any
equivalent international code of practice. The following loads shall be considered while
designing the structures:
• All live loads shall be in accordance with IS: 875 in addition to the
technological loads indicated by the equipment manufacturer/ supplier
• Wind loads shall be in accordance with IS: 875 (Part-3)-2015
• Seismic loads shall be in accordance with IS: 1893-2015 part IV
• For design of bins and loading hopper, IS: 9178 (Part I to III)-1979 shall be
followed
• Temperature load
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• Dynamic load factor due to impact from vibratory / reciprocating machinery,

motor etc.
Resonance in Structures
Structures supporting vibratory/ reciprocating equipment shall be designed so as to
obviate occurrence of resonance. The ratio of applied frequency to natural frequency
shall not lie within the range of 0.7 to 1.4.
6.6.3 Material of Construction
The material for the structures to be designed shall be as follows:
• All rolled sections and plates up to 20 mm thick shall conform to Grade- E250
& quality A of IS:2062-2011 and shall generally be of tested quality ( semi-
killed ).
• Plates beyond 20 mm thick and up to 40 mm thick subjected to dynamic
loading shall conform to Grade- E 250 & quality BR as per IS:2062-2011 (
rolled in killed condition ).
• Plates beyond 40mm shall conform to Grade- E 250 & quality BR as per IS:
2062-2011 in normalized and ultrasonically tested quality.
• High strength micro-alloyed steel shall conform to SAILMA 350 HYA/ HYB
(SAIL product).

Steel sheets shall conform to IS: 1079-2009. Chequered plates shall conform to IS: 3502-
2009.
All gratings shall be of MS pressure locked electro-forged.
The electro-forged gratings shall be of approved brand and of approved manufacturer
unless otherwise agreed by purchaser. The type of grating selected shall be based on the
loading, for the area in which the grating is provided and shall be subject to approval of
purchaser.
Steel tubes for structural purposes shall conform to IS: 1161-2014 Grade Y St-240).
Crane rails shall conform to IS: 3443-1980.
Collectors and down-comers shall be ERW410 pipes conforming to IS:3589-2001.
Roof and side sheeting shall be with 0.5mm BMT permanent colour coated metal sheets
as per IS: 15965-2012.
6.6.4 Method of Construction
Steel structures to be fabricated shall generally be of welded construction. Covered
electrodes will conform to IS: 814–1991. Elements will be fabricated in largest possible
dimensions optimal with the transport requirement so as to minimise site work. Site
connection will be by permanent bolts.
6.6.5 Fabrication

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AT DOLVI, MAHARASHTRA

Fabrication of all structural steel works shall be in accordance with IS: 800. Fabricated
structures shall conform to tolerance as specified in IS: 7215–1974.
6.6.6 Inspection
All structures will be offered for inspection by the Contractor. Material certificate for the
fabricated structures will also be provided.
6.6.7 Erection of Steel Structures
Erection of structures, alignment of all structures, tolerances for erection of steel
structures shall be as per IS:12843–1989. Erection shall be carried out in accordance
with IS:800.
6.6.8 Painting
Painting system to adopt shall be as follows:
Surface preparation: - Blast cleaning shall be done by shot blasting as per Grade SA-2.5
according to Swedish Standard SIS055900.
Primer paint: Two coats of zinc phosphate in phenolic alkyd medium (DFT = 35
microns/coat).
Intermediate Paint: One coat of epoxy based MIO micaceous iron oxide (DFT =80
microns).
Finishing paint: Two coats of Polyurethane (DFT=50 microns/coat) after intermediate
coat of paint.
Total DFT of paint after finishing shall be 250 microns.
6.7 ELECTRICAL FACILITY
6.7.1 Power requirement
The estimated power requirement of the proposed 9.0 MT Pellet Plant #2 is as follows:
Maximum Demand (MVA) 80
Annual energy consumption (106 kWH) 425

6.7.2 Source of Power Supply

Power requirement for the proposed Pellet Plant shall be made available from MSEB 220
kV Nagothane Grid Substation located approximately 30 km (by aerial route) from the
proposed plant site.
Presently, Power from MSEB 220 kV Nagothane Grid Substation is being received at
220kV level at existing 220/33 kV GIS MRS sub- station of JSW through one 220 kV
double circuit transmission line. Power at MRS is stepped down to 33 kV level by
180/210 MVA, 220/33/33 kV power transformers. Secondary & tertiary of 180/210
MVA, 220/33/33 kV power transformer is connected to 33 kV switchboard at MRS.

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AT DOLVI, MAHARASHTRA

Power for the proposed Pellet Plant #2 shall be tapped from JSW’s existing 33 kV
switchboard located at 220/33 kV MRS sub-station to 33 kV switchboard located at new
33/6.6 kV Main sub-station (ESS-1) for Pellet Plant #2, which will be located
approximately 3.0 km apart from the MRS.
6.7.3 Power Distribution Scheme
Power requirement for the proposed Pellet Plant#2 shall be met from import from the
MSEB 220 kV Nagothane Grid Substation.
Presently, Power from MSEB 220 kV Nagothane Grid Substation is received at 220kV
level at existing 220/33 kV GIS MRS sub-station of JSW through One 220 kV D/C
transmission line. Power at MRS is stepped down to 33 kV level by 180/210 MVA,
220/33/33 kV power transformer. Secondary & tertiary of 180/210 MVA, 220/33/33 kV
power transformer is connected to 33 kV switchboard at MRS.
As described earlier, power for the proposed Pellet plant shall be tapped from existing
33 kV switchboard located at 220/33 kV MRS GIS sub- station to the new 33 kV
switchboard located at proposed 33/6.6 kV Sub-station (ESS-1) near induration building
of Pellet plant #2 area, located approximately 3.0 km apart from the MRS.
The 33/6.6 kV Main sub-station (ESS-1) near induration building is the main feeding
sub-station for the entire Pellet Plant #2 complex. The power received at 33 kV shall be
stepped down to 6.6 kV level by two nos. of 25/31.5MVA, 33/6.6kV power transformers
at ESS-1 and two nos. of 25/31.5MVA, 33/6.6kV power transformers at ESS-3.
To cater the load of Pellet plant #2 area, following 4 nos. of HT cum LT sub-stations has
been envisaged:
Sl. Sub-station Qty. Major Tr. Capacity Area covered
no.
1 ESS-1 2 25/31.5 MVA, 33/6.6 Fan, ESP,
6 kV Screening
2 MVA, 6.6/0.433 kV
2 ESS-2 6 2 MVA, 6.6/0.433 kV Day bin building &
Wet grinding
3 ESS-3 2 25/31.5 MVA, 33/6.6 Filtration, coarse additive
12 kV storage yard, pump house,
2 MVA, 6.6/0.433 kV chiller
plant, additive grinding ball
mills
4 ESS-4 10 2 MVA, 6.6/0.433 kV Additive grinding area, storage
cum mixing, induration &
balling.

The power distribution network shall comprises of 33/6.6 kV substations at ESS-1 &
ESS-3 and 6.6 kV sub-station at ESS-4. For feeding the power supply to various 33 kV
& 6.6 kV loads shops/ units, above mentioned 33/6.6 kV sub-stations have been

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

envisaged, which shall be fed from 33 kV switchboard at MRS. From the 6.6 kV
switchboard at ESS-1, ESS-3 & ESS-4, various HT & LT loads are fed by stepping down
the voltage to LT level through 6.6/0.433 kV distribution substations.
Power factor compensation has been foreseen to achieve overall power factor in the
region of 0.96 or better.
One 2000 KVA, 415 V DG set shall also be envisaged for feeding the emergency loads
which shall be connected to emergency LT switchboard. Various emergency loads shall
be fed from this emergency board.
The power distribution scheme envisaged for the proposed pellet plant is shown in the
Single Line Diagram No. MEC/11/E1/Q7GK/FR/PP/03 (1 sheet).
6.7.4 Design Considerations
The power distribution network shall be designed as a radial system, with two alternative
supply feeders to each load centre.
The design of power distribution system and selection of equipment shall be done based
on the considerations of safety, reliability, ease of operation & maintenance as well as
convenience of future expansion.
The equipment shall 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.

Basic design parameters

Incoming Power supply : 220 kV, 3 Ph, 50 Hz.

Distribution & Utilisation : 33 kV & 6.6 kV, 3 Ph, 50 Hz
Motor rated above 250 kW : 6.6 kV, 3Ph, 50Hz
Motors rated 250 kW & below and
Other consumers : 415 V, 3 Ph, 50 Hz
Illumination and small power : 240 V, 1 Ph. 50 Hz
Control power supply AC : 240 V, 1 Ph, 50 Hz
(+10% and -15%)
DC : 110 V (from battery), ± 10%
Voltage variations :
220 kV : ± 10%
33 kV : ± 10%
6.6 kV : ± 10%
415 V : + 10%, -15%

Frequency variations : ± 5%

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

System earthing
- 220 kV : Effectively Earthed

- 33 kV : Resistance Earthed
- 6.6 kV : Resistance Earthed
- 415 V : Solidly earthed

Symmetrical short circuit rating for equipment design:

- 220 kV bus : 40 KA for 3 seconds
- 33 kV bus : 31.5 KA for 3 seconds
- 6.6 kV bus : 40 KA for 3 seconds
- 415 V bus : 50 KA for 1 second

6.7.5 Major Facilities

HT Switchgear
The 33 kV & 6.6 kV switchgear shall be indoor type sheet metal clad, draw out type
comprising of VCB circuit breakers and provided with necessary protection, control
gear, metering and audio-visual alarm annunciation system. The circuit breaker
mechanism shall be mechanically and electrically trip free. The circuit breakers shall be
electrically operated, stored energy type suitable for operation on 110 V DC control
power supply.
6.7.6 415 V Switchgear
The 415 V switchboards shall comprise of air circuit breakers, in draw out design and
multitier formation. The switchboard shall 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 shall 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 centers (MCCs), large drives (above 75 kW) and power distribution
boards (PDBs) shall be supplied power from the 415V switchboard. The 415 V
switchgear shall confirm to relevant IS/IEC specifications.
6.7.7 Transformers
The transformers shall be copper wound, oil immersed, three phase and ONAN design.
The maximum temperature at the rated output and at principal tap shall be 85°C for top
oil by thermometer method and 95°C for winding by resistance method. Core shall be
made of low loss CRGO silicon sheet. Transformer shall be capable of withstanding 40%
over fluxing corresponding to rated voltage.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

The winding shall be made of electrolytic grade copper and shall be vacuum dried. Inter
turn and inter coil insulation shall 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 shall be designed to
withstand short circuit on the secondary side for a duration of 5 seconds without any
damage.
The 33/6.6 kV power transformers shall be provided with OLTC and local & remote
control cubicles. Off circuit tap-changers shall be provided for 6.6/0.433 kV distribution
transformers.
All the standard accessories such as conservator, breather, Buchholz relay, OTI, WTI, oil
level gauge, valves, explosion vent etc. shall be provided for all the transformers.
The transformers shall conform to relevant IS/IEC specifications.
Cables
Power inside the plant shall be distributed through cables to various premises. Wherever
necessary and where the cables are in small number, these will be directly buried
underground. Wherever cables are in large number, concrete channels shall be used. GI
pipes/ pipe blocks shall be used at road crossings and paved area.
Inside the substations and covered premises, the cables shall be laid in basement or in
concrete channels (over cable supporting structures) or on columns and other available
structures. Power cables shall be laid 1on ladder type GI cable trays, whereas control
cable shall be laid on perforated cable trays.
All 11 kV cables shall be heavy duty, XLPE insulated, PVC sheathed multi core,
aluminum conductor steel wire armoured and shall be suitable for unearthed system. All
cables shall be FRLS type.
Cables for 415 V systems shall be heavy duty, 1.1 kV grade, PVC insulated PVC
sheathed aluminum conductor, armoured / unarmoured as required.
The control cables shall be multi strand copper conductor, PVC insulated and PVC
sheathed with minimum cross section of 2.5 sq.mm for voltage circuit and 4.0 sq. mm
for current circuits.
The HT cables, LT power and control cable shall confirm to relevant IS/IEC
specifications.
6.7.8 Shop Electrics
Power supply to all drives up to 75 kW and other loads operating at 415V, 3 phase, 50
Hz system is envisaged through motor control centers (MCCs). Drives beyond 75 kW
shall be supplied power from 415 V switchboards comprising of air circuit breakers
(ACBs).
The MCCs / PDBs shall be sheet steel enclosed and of modular, multi tier design. MCCs
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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

shall be in draw out execution whereas PDBs shall be in non-draw out execution. The
enclosure class shall be IP-4X for switchboards installed inside switchgear room and IP-
55 for boards installed at shop floors. The use of MCCBs / MCBs in general has been
foreseen for power supply to small loads.
All motors shall have TEFC construction and provided with class F insulation with
temperature rise limited to that permissible for class B insulation with enclosure class
IP54/ IP55 as required. The motors generally shall be squirrel cage type suitable for
direct on line starting.
Slip ring induction motors shall be considered for intermittent duty drives requiring
frequent switching operations and for heavy duty applications requiring speed control
DC motors will be used for drives requiring frequent reversals, high starting torque wide
range of speed and precise speed control.
Use of energy efficient drive motors shall be preferred in general.
6.7.9 Automation
The automation of operations shall be achieved through HMI system using
Programmable Logic Controllers (PLCs) from the central control room of each unit. It
shall be possible to operate any motor in Remote mode from the control room. To
monitor the status of various drive motors, VDUs shall be provided in the control room.
The technological drives shall be grouped in logical control blocks, for the purpose of
sequence of operations, monitoring and fault annunciation. Mimic display of the status
of various drives is also foreseen.
6.7.10 Illumination
For supply of various illumination loads in the plant, provision of lighting distribution
boards (LDBs) has been considered. These LDBs shall be installed in LT substation and
shall be fed from the 415 V switchboards. LDBs shall supply power to the various sub-
lighting distribution boards (SLDBs) installed in various buildings.

The internal illumination of low roof buildings shall be with fluorescent tube light fittings
whereas shops as well as high roof building shall be illuminated with HPSV lamp
fittings. Wherever high color rendering is required (low colour distortion), metal halide
lamp fittings shall be used.
Average illumination level inside the shop building shall be 100-150 lux. However, the
illumination level in control rooms shall be 300 lux.
Illumination in open yard and area illumination shall be provided with HPSV flood light
fittings. The average illumination level shall be 15 to 30 lux for outdoor illumination.
The use of energy saving, high power factor lamp fittings shall be preferred.
6.8 FIRE FIGHTING FACILITY
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FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

6.8.1 General
Many working premises in a pellet plant have hazardous and fire prone environment. To
protect the working personnel, equipment and machineries, adequate safety and
firefighting measures have been planned for the proposed pellet plant.
6.8.2 Fire Protection Facilities
In order to combat any occurrence of fire in plant premises, the following fire protection
facilities have been envisaged for the various units of the plant:
Portable fire extinguishers
All plant units, office buildings, stores etc. will be provided with adequate number of
portable fire extinguishers to be used as first aid fire appliances. The distribution and
selection of extinguishers will be done in accordance with the requirement of IS-
15683:2006 & IS-2190:2010.
Hydrant System
A fire hydrant network system has been envisaged for the proposed plant. Internal
hydrants will be provided at suitable locations and at different levels inside the major
plant units. Yard hydrants will be provided normally along the road and in the close
vicinity of the units to meet the additional requirement of water for extinguishing fire.
Clean Agent based Fire Extinguishing System
Clean Agent based firefighting system is a very effective measure to control Electrical
Fires. It shall be provided in control rooms, substations, various other units. It shall be
provided in all premises having sophisticated and expensive equipment. Clean agent is
a gas mixture consisting of Inert gases. Clean agent based firefighting system shall be
provided in areas including above false ceiling and below false floors of control room.
Nitrogen Purging System
Nitrogen purging system shall be provided for transformer having more than 10 MVA
capacity or more than 2000 lt. oil capacity for protection against fire. Nitrogen purging
system shall be of standard make like CTR/ SERGI system.
Automatic fire detection & alarm system
Unattended and vulnerable electrical premises like electrical control rooms, MCC,
transformer rooms, switch gear rooms, oil cellars etc. will be provided with automatic
fire detection and alarm system.

6.9 DG STATION
To meet the emergency power requirement for the proposed pellet plant & equipment,
one (1) number DG station of 2000 kVA has been envisaged. The fuel for DG set will
be HSD.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

DG set shall be of four stroke, radiator cooled, turbo charged diesel engine capable of
driving synchronous generator to give rated output of 2000 kVA, at 0.8 lag pf at
generator terminals with speed regulation +/- 1 % or less. The DG set shall be suitable
for outdoor installation having automatic / manual start facility.
The diesel engine shall be multi-cylinder, radiator cooled, turbo charged, single acting,
in line combustion with direct mechanical fuel injection. The DG set shall be capable to
withstand 10 % overload for 1 hour, for a period of 12 hours operation. The engine shall
be designed to burn HSD fuel having specific gravity 0.85 & conforming to IS: 1460-
1995 / equivalent.
The DG set shall be complete with control/ metering/ protection chargers and all
accessories & auxiliaries like governor, flywheel with turning gear arrangement for hand
cranking facility. The DG set shall be complete with suction filter cum silencer, inter-
cooler, vibration damper, forced feed lubrication system with piston cooling, lube oil
multistage filter, day storage fuel oil tank (990 litres), batteries with battery charger, all
necessary instruments, controls and safety system. The DG station shall be provided with
auto main failure (AMF) panel to start the DG set automatically. DG set shall be housed
within an acoustic enclosure. DG set shall be equipped with exhaust gas pipe with
silencer including exhaust hood & weather cowl, expansion joints, supporting structures,
insulation, encasing pipes etc. DG set shall be installed over anti- vibration mounting
pads to ensure isolation of vibration of rotating assemblies, enabling the set to be placed
even on an uneven surface without any detrimental effects.
7. MANPOWER AND ORGANISATION STRUCTURE

7.1 Organisational structure

The proposed organisational structure takes into account the organisational practices
prevailing in similar plants.
The plant will be headed by Vice president. General Manager (GM - Operation,
Maintenance, Electrical), Dy. General Manager (DGM - Quality, Personal, Accounts,
Logistics, Purchase, Commercial, Stores) will directly report to him. DGM will be
assisted by Sr. Managers, Managers, Dy. Managers.
7.2 Manpower
The requirement of manpower for the operation and maintenance of the proposed pellet
plant with associated facilities has been estimated taking into consideration the
following:
• Capacity of the pellet plant complex
• Types of equipment to be installed
• Degree of automation envisaged
• Number of operating shifts to achieve the rated capacity
• Requirement of personnel as off and leave reserve etc.
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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

The overall manpower requirement for the pellet plant including the general administration
personnel has been estimated at 409.
Apart from operational and maintenance (mechanical and electrical), the proposed
manpower also includes preventive maintenance and shut down requirements.
A summary of category-wise manpower requirements for the pellet plant is indicated
below:
Category-wise

Executives including managerial staff - 84

Supervisors / technicians - 212
Labour / House-keeping - 113
Total 409

7.3 Recruitment
Top executives like GM, DGMs and a few key personnel of other categories shall have
to be recruited to take necessary advance actions for project construction.
Some of the construction personnel can progressively be absorbed with the tapering of
the construction work, particularly in the maintenance and services areas of the plant. A
certain portion of junior executives and supervisory staff have to be recruited / placed
during the construction stage itself as acquaintance with equipment erection will be very
much beneficial for them in running the plant units later on.

7.4 Training
The executives of various categories are to be trained mostly in the operation and
maintenance of the pellet plant of similar type and capacity. They, in turn, would share
the technical knowledge attained during the training with their colleagues and sub-
ordinates. At least 3-4 months before the commissioning of the project, these employees
ought to complete their training and be associated with the commissioning activities of
the plant.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

8. PROJECT IMPLEMENTATION
8.1 General
The project envisages installation of new pellet plant #2 near their existing pellet plant
#1 to produce BF grade pellets at Dolvi.
The project has been planned to be completed in 22 month from “Zero date” which is
reckoned as “Placement of order on Technological Supplier’’.
However, the execution of the proposed project would call for meticulous planning,
monitoring and control during engineering, procurement and construction stage. Salient
aspects relating to project implementation strategy are covered in this chapter.
8.2 Implementation Schedule
The overall implementation schedule for the project, taking into account the facilities
proposed, is given in drawing no. MEC/11/PY/Q7GK/FR/PP/04 (R-0). According to the
schedule, the overall project will be commissioned in 22 months from zero-date.
8.3 Implementation Plan
With the “zero-date”, it is planned to complete basic engineering within 9 months.
Technical specification for long delivery items has been planned to issue within 8 th
month and other items within 12 months. Vender drawing approval for long delivery and
major items has been planned to be completed within 12 th month and other items within
15th month. The civil engineering has been planned to start from 4 th month onwards so
that sufficient drawings can be made available before start of the civil work. The civil
work for plant construction has been planned to start from 5 th month onwards.
The structural engineering has been planned to start from 3rd month and completed within
14th month. The structural supply is planned to start from 7th month and completed within
18th month, so that the structural erection can be started from 8th month onward and shall
be completed by 19th month.
It is envisaged that the supply of plant and equipment at site shall start from 10th month
and shall be completed by 19th month. Accordingly, the equipment erection shall
commence from 11th month and is expected to be finished by 20 th month.
The testing, trial run and commissioning of proposed pellet plant has been planned to be
taken up progressively from 19th month to 22nd month as shown in the schedule.
8.4 Advance Actions
In addition to the above, it will be imperative to complete many of the activities prior to
zero-date of the project. These shall include the following:
• Preparation & issue of tender document for main technological unit,
• Action for placement of order for main technological unit,
• Financial tie-ups, if any,
• Finalization of terms with overseas agencies, if any,
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AT DOLVI, MAHARASHTRA

• Statuary Clearance,
• Soil investigation,
• Actions for enabling works like construction of water line, power line,
sewerage, etc.,
• Site leveling,
• Advance action to be taken to ensure availability of construction material and
construction manpower.

In order to adhere to this schedule for timely completion of the project, following points
shall have to be taken care of:

• Simultaneous working in many fronts,

• Selection of capable and reputed construction and erection agencies,
• Mobilization of requisite resources of men, materials and construction
machinery,
• High levels of mechanization for construction and erection work,
• Proper planning for movement of construction equipment and material,
• Timely availability of site infrastructure in terms of water, electric power etc.,
• Adoption of advanced methods of construction and erection.

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SYMBOL LEGEND
 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

CONTENTS

CHAPTER TITLE PAGE

NO.
1. INTRODUCTION 2
2. SITE LOCATION & METEREOLOGICAL 3
DATA
3. GENERAL LAYOUT AND TRANSPORT 4-5
FACILITIES
4. RECEIPT, STORAGE AND HANDLING OF 5-7
RAW MATERIAL
5. SINTER PLANT AND AUXILIARIES 7-11
6. SINTER PLANT PROPER: 12-21
7. SERVICE FACILITIES 21-26
8. CIVIL WORKS 26
9. STRUCTURAL WORK 26-28
10. VENTILATION, AIR CONDITIONING & 28-32
POLLUTION CONTROL
11. POLLUTION CONTROL 32-35
12. ELECTRICAL FACILITIES 35-38
13. CONSTRUCTION PLANNING 38-41
14. PRODUCTION COST 41-48

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

1. INTRODUCTION
1.1 Preamble
JSWSL have decided to install a Sinter Plant complex of 4.0 MTPA capacity in the
existing Integrated Steel Plant at Dolvi, District Raigad, Maharashtra to supply sinter as
burden material for their two Blast Furnaces for hot metal production.
1.2 Assignment
In line with the above background, M/S JSWSL have commissioned MECON to prepare
a techno-economic feasibility report for the installation of the Sinter Plant Complex of
4.0MTPA capacity.
1.3 Approach
M/s JSWSL are putting up a blast furnace with 1250 m3 useful volume. They also
propose to install a second blast furnace with 1670 m3 useful volume, under 4 Mt
expansion. Both these Blast Furnaces shall be operated with BF burden consisting of
Sinter, Iron Ore Lump and Iron Ore Pellets in the ratio of 70:20:10. Sinter required will
be produced in the proposed Sintering Plant Complex. The requirement of burden sinter
has been estimated to be 2.07 Mt/yr. To meet this requirement, it is planned to produce
4.0 Mt/yr of BF sinter considering the fines generated in transporting sinter from the
sinter plant to the blast furnace plant (estimated as 10% of sinter production, i.e 0.23
MTPA). This production will be achieved on a sintering machine of 365 m2 area with a
productivity of 1.424 t/h.m2.
After reviewing the feasibility of utilizing the vacant space at 3 places in the plant, It is
proposed install the new Sinter Plant having sintering machine of 365m2 sintering area
along with related services and auxiliary facilities, in the area adjacent the existing Pellet
Plant.
This report highlights various aspects of Sinter Plant Complex envisaged.
1.4 Contents of the reports
This report covers details of the general layout, raw materials, main production unit,
various services & auxiliary facilities, construction schedule, capital cost and the
financial appraisal of the complex.

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

2. SITE LOCATION AND METEROROLOGICAL DATA

2.1 Site Location
The proposed site of Sinter Plant Complex is located adjacent the existing Pellet Plant
Complex which becomes close to the Blast Furnaces being constructed and also the Raw
Material Handling system/yard of M/s Jindal Vijaynagar Steel Ltd. The area earmarked
for sinter plant complex is located on the Northern side of the exiting Pellet Plant. The
Plant of M/s Jindal Vijayanagar Steel Limited is located at village Dolvi, Raigad District
in Maharashtra around 340 km from the capital city of Bangalore. Dolvi station is located
on the Raigad – Hospet railway line as well as about 35 km from each of the cIties by
road. The eastern port of Chennai is 460 km and western port of Goa is 430 km. Mumbai
is about 740 km on the north west.

2.2 Meteorological Data

Temperature : 44 °C (max.)/11 °C (min.)
Relative Humidity
Summer : 21 %
Monsoon : 87 %
Rainfall
Annual avg. (June to September) : 519 mm
Maximum intensity of rain in single day : 162.3 mm
Seismicity
Earthquake Zone –II (As per IS code – 1893: 2002 (Part –I)
Predominantly northwest to South-East
Basic wind speed 33 m/s (119km/h) as per IS: code – 875: 1987
Altitude
Height from mean sea level
Ground level : 483 m
Finish floor level : 483.6 m corresponds to 0.00 level
Land Terrain : Plain site slopes down from South to
North
Global Position : Latitude 15 degree North and longitude
76 degree East.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

3. GENERAL LAYOUT AND TRANSPORT FACILITIES

3.1.1 Rational for layout
The general layout of the proposed Sinter Plant Complex has been developed keeping in
view the following factors:
Existing units/ facilities of M/S JSWSL (RMHS, Blast Furnaces, Captive Power plant & other
facilities)
• Smooth and uninterrupted flow of materials in accordance with the
technological requirements.
• Maximum utilization of area and optimum material transportation distances/
conveyors
• Logistic approach to location of technological units as well as services
facilities.

3.1.2 Location of various units

The major technological & services units envisaged for the plant are as follows:
• Raw materials storage yard and transportation of raw materials
• Base Blending yard & associated facilities viz. Proportioning building / bins,
twin boom travelling stacker, barrel type blender reclaimer, stock piles, etc.
• Fuel & Flux Crushing unit
• Sinter Plant Proper
- Storage and proportioning building
- Mixing and balling building
- Sintering building
- Sinter cooler
- Sinter screening building
- Waste gas dedusting unit
- Exhauster fan building
- Waste heat recovery unit
- Plant dedusting unit
- Automation & Control System
• Pump houses & cooling tower
• Electric sub-station
• Compressor station

The relative location of all units have been shown in the general layout drg. No.
MEC/01/02/U999/JVSP-FR//001. Base blending facility and Fuel & flux crushing
building have been planned in between RMHS and Sinter Plant proper.
Sinter plant proper is planned in a compact way to fit the units in the space available
without disturbing the existing railway track and roads.
The Electrical sub-station is planned in between Sinter Plant and Captive power plant.

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AT DOLVI, MAHARASHTRA

Other services units like water supply facilities, Compressed air station have been
suitably located.
A well neat road has been envisaged to provide access to all the plant units
3.1.3 Salient features of the layout
The salient features of the layout are as follows:
Sl. No. Unit Area

1. Base blending & FFCS 300mX200m

2. Sinter Plant Proper 260mX80m
3. Services units
3.2 Transportation
3.2.1 Iron Ore fines will be received by railway wagons through existing facilities i.e. wagon
tipplers / track hopper and stored in the existing ore handling plant or the new raw
material storage yard being planned to cater to the proposed new Sinter Plant. Two new
piles will be created with a new stacker-cum-reclaimer for handling, storage and
reclamation of iron ore fines. Other raw materials like Limestone, Dolomite, Coke breeze,
Sinter fines, BF/BOF sludge (dry), Mill scale, Flue dust etc. will be received at the new
raw material handling yard by means of trucks/ dumpers from existing stockpiles and /
or Plant arising.
3.2.2 Transportation of materials from the Raw Material Handling/ storage yard to various units
of sinter plant complex shall be by a set of conveyors.
3.2.3 Calcined lime shall be transported to proportioning bins in Sinter plant by pneumatic
tankers.
3.2.4 The internal transportation of semifinished products between various sub-units / systems
shall be by conveyors.
3.2.5 Transportation of finished sinter from Sinter Plant to Blast Furnace stock house and return
fines from BF stock house, back to sinter plant shall be by set of conveyors.
3.2.6 The transportation of spares, refractories, stores material etc. from various shops are
proposed to be carried out by road vehicles through the contractor’s vehicle/ road
transport equipment of the plant.

4. RECEIPT, STORAGE AND HANDLING OF RAW MATERIAL

The system envisages supply of the following raw materials to the Base Blending Yard/
Fuel & Flux crushing system / Sinter Plant proper:
1. Iron Ore fines
2. Coke breeze
3. Limestone
4. Dolomite
5. Mill scale
6. Flue dust
7. BF / BOF sludge
8. LD slag
9. Calcined lime

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 JSW STEEL LIMITED, DOLVI WORKS
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The raw materials unloaded at the existing tipplers / track hoppers will be conveyed by
conveyor system having capacity of 1000 tph to the stacking conveyor gallery. The
storage yard will be provided with a new slewing / swiveling boom type stacker having
capacity of 1100tph for stacking and piling of raw materials in the two numbers of beds.
Two new piles will be created with a new stacker-cum-reclaimer for handling, storage
and reclamation of iron ore fines. Other raw materials like Limestone, Dolomite, Coke
breeze, Sinter fines, BF/BOF sludge (dry), Mill scale, Flue dust etc. will be received at
the new raw material handling yard by means of trucks/ dumpers from existing stockpiles
and / or Plant arising.
The storage capacity of various raw materials for Sinter Plant at the new raw material
storage yard is given below:
The raw materials from the yard will be reclaimed by the stacker cum reclaimer having
a reclaiming capacity of 800tph and / or by front-end loaders and conveyed by a system
of conveyors to the proportioning bins or primary crushing house near the base blending
yard. The iron ore fines, prior to being fed to the proportioning bins, will be screened to
eliminate the oversized particles, which will be conveyed to the existing iron ore
stockpiles.

Calcined lime is transported by pneumatic tankers and stored in the proportioning bins
of proportioning building in Sinter Plant proper.
It is proposed to keep seven (7) days' requirement of the raw materials in the new raw
material storage yard.
Coke breeze, Fluxes (Limestone and Dolomite) and balance feed materials will be
reclaimed from the new raw material storage yard by front end loaders or the new
stacker-cum-reclaimer. Coke breeze (fuel) and Lime stone / dolomite (flux) shall be
conveyed to primary crushing and screening house crushing & screening.
The source of major raw materials for the sinter will be as given below.

Size, mm
Raw material Source
Iron ore fines -10 Bellary Hospet area
Coke breeze -30 Internal
Limestone -20 Bagalkot/ Dronachalam
region
Dolomite -20 Bagalkot/ Dronachalam
region
Dunite -20 Salem
Other - Internal generation
materials

The Principal scheme for raw materials supply to Sinter Plant is shown in general layout

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Drg. No. MEC/01/12/U999/JVSP-FR/001 (Rev. 0). Under the proposed scheme, the raw
materials preparation, sinter mix preparation and base-blending facilities will be
provided to supply the base mix to the Sinter Plant.
The storage capacity of various major raw materials for Sinter Plant at the new raw
material storage yard is given below:

Sl.N No. of Total storage Consumption No. of

Materials
o beds Capacity ( t) per day (t) Days
1 Iron Ore fines 2 70,000 9,850 7
2 Lime stone 2-Parts 11,000 1,500 7
3 Dolomite 2-Parts 11,000 1,500 7
4 Coke Breeze 1 4200 600 7

5. SINTER PLANT AND AUXILIARIES

5.1 General
The sinter plant complex shall consist of following units:
1. Base blending facility
2. Fuel & Flux crushing system
3. Sinter plant
Location of the above units is indicated in the general layout drawing no.
MEC/01/02/U999/JVSP-FR/002.
Following raw materials and plant waste shall be used for making Sinter:
Raw Materials:
Iron ore fines
Lime stone (crushed)
Dolomite (crushed)
Dunite (crushed – as replacement of dolomite)
Coke breeze
Calcined lime
Plant Rejects:
Mill Scale
Flue dust
BF & BOF sludge
LD slag
Sinter fines (in plant & BF returns)

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AT DOLVI, MAHARASHTRA

5.2 Production program

Plant Capacity and Operating conditions
Plant Capacity
Production of finished SP sinter : 2,300,000 t/year

Operating conditions
Normal calendar time : 8,760 h/year
Maintenance (10 times/year for 36 hrs : 360 h/year
Annual shut down for major repair : 120 h/year
Unscheduled shut down : 360 h/year
Operating time (actual) : 7,920 h/year (330 days/yr)
Sintering rate of sinter plant : 291 t/h
Specific productivity : 1.424 t/h.m2

5.3 Material Balance (estimated) - t/h

Material balance of sinter plant proper is indicated in drg no.
MEC/A3/01/02/U999/JVSP-FR/001)
IN
Base mix : 329
Limestone (wet) : 10
Solid fuel (wet) : 4
Calcined lime : 3.5
Return fines (dry) : 58
ESP dust pellets (wet) : 3
Water : 9.5
Total sinter mix (wet) : 417
Hearth layer (dry) : 25

Total 442

OUT
Sinter : 291
Waste gas (balance) : 65.5
ESP dust (dry) : 2.5
Return fines : 58
Hearth layer : 25

Total 442.0

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

5.4 Chemical analysis of main raw materials

Iron ore
Characteristics Limestone Dolomite Coke breeze
fines

Fe 64.07 5.40 3.20 3-5

SiO2 2.32 6.00 7.60 52-58

Al2O3 1.86 1.40 - 26-32

CaO 0.07 40.80 27.30 1.5-3.5

MgO 0.01 5.55 17.60 0.7-1.2

P 0.04 - - -

S 0.00 - - 0.8

Moisture % 6.20 1.20 1.20 10

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5.5 Chemical analysis of other feed materials

Characte Flue LD Mill LD Corex Calcined BF

Dunite
ristics Dust Sludge Scale Slag Sludge lime Sludge
Fetot 28-32 50-58 70-74 16-22 3.1-3.8 38-42 0.1-0.3 30-36
SiO2 8-12 2-3 0.6-1 8-12 34-38 7-10 1-3 3-5
Al2O3 4-7 2-3 <1 2-3 1-2 3-6 0.5-1.5 2-4
CaO 5-8 5-7 <1 40-44 1-2 4-6 80-85 8-11
MgO 3-5 1-2 <0.5 4-6 35-42 2-4 2-4 0.5-1.5
Na2O+
1.5-1.8 <0.1 <0.4 <0.18 <0.5 <0.5 - 1.2-11.6
K2O
S - - - <0.4 - 28-34 - -
LOI 20-25 - - - 5-8 - 5-8 -

5.6 Requirement of raw materials (on wet basis, t)

Sl.No. Material Annual Daily Hourly

1. Base Blended mix 2605680 7896 329

2. Flux
(Limestone/Dolomite) 79200 240 10

3. Coke breeze 38016 115.2 4.8

4 Calcined lime 27720 84 3.5 (dry)

5 Sinter Return fines 459360 1392 58(dry)

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5.7 Sinter Quality

Based on the quality of feed materials furnished above, the expected quality of
sinter is projected below:

Expected chemical analysis of finished sinter

Constituent Percentage

Total iron : 55-56 %

FeO : 7-9 %
SiO2 : 5.0 %
Al2O3 : 2.5 %
CaO : 8.7 %
MgO : 2.5 %
Basicity (CaO/ SiO2) : 1.74
Size (mm) : >40 5%
10-40 50%
5-10 40%
<5 5%
Physical Properties:
Tumbler strength : >6.3mm >72%
RDI : -3.15m <25%

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

5.8 Basic Plant Data

Sinter machine sintering area : 365 m²

Sinter machine pallet width : 3m

Sinter machine length (C.L TO C.L) : 77 m

Side wall height of pallets : 700 mm

Suction below grate : 160 mbar

Process gas volume (STP) : 1.2 x 106 m³/h

Energy for ignition hood : Corex gas recycled hot

combustion air from sinter cooler

Energy consumption for ignition : 15,000 kcal/t of gross

sinter (Corex gas)

Sinter cooler type : Annular circular pressure

cooler

Effective cooling area : 202 m²; diameter: 22.5 m,

width-3.5m, bed height-1.5m

Sinter Crushing and Screening : 1 cascade chute

1 double roll crusher
1 combined coarse / hearth layer
sinter screen
1 return fines screen

Waste gas cleaning system :Electrostatic precipitators

1 double unit for process
gas De-dusting
1 unit for plant De-dusting

Raw material storage bins : 4 bins for blended mix

1 spare bin
2 bins for flux
2 bins for coke
2 bin for return fines
2 bins for calcined lime

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 JSW STEEL LIMITED, DOLVI WORKS
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5.9 Technological features and operating parameters

5.9.1 Fuel and flux preparation unit
Coke breeze will be used as solid fuel in the sintering plant. Limestone and
dolomite will be used as flux. Feed size of Lime stone / dolomite is –20mm.
Feed size of coke breeze is –30mm. These materials will be crushed to below
3 mm size in FFCS building.
Fluxes (Limestone and Dolomite) will be reclaimed from the new raw material
storage yard by front end loaders or the new stacker-cum-reclaimer and
conveyed to primary crushing and screening house where the fluxes will be
crushed in hammer mills (2 nos. x 100tph) and screened. The oversized particles
will then be conveyed to the secondary crushing and screening house where
they will be fed to secondary crushers (2 nos. x 50tph). The fluxes will then be
screened and oversized particles removed to a temporary ground pile. (-) 3 mm
size product obtained in secondary crushers will then be conveyed to the
proportioning bins located near the base-blending yard.
Coke breeze from the new raw material storage yard will be reclaimed by front
end loaders and conveyed to primary and secondary crushing units having
primary and secondary crushers (1 no. X 12 tph each). Primary crushers will
crush the coke breeze from 25 mm size to below 10 mm size for further
reduction to (–) 3 mm size in the secondary crushers. The crushed fuel will then
be conveyed to the proportioning bins located near the base-blending yard.
About 80% of required qty of both flux & fuel shall be used in the base mix.
Balance 20% qty shall be transported to the proportioning bins in Sinter plant
area.
Provision to replace dolomite with Dunite shall be kept in the system design
and accordingly the crushing system selected shall be suitable for crushing
Dunite also.

5.9.2 Base Blending unit

Unique feature of the system is preparation of base mix materials by

proportionate mixing of iron ore fines, ground flux/fuel, mill scales, flue dust,
LD slag, BF/BOF sludge, BF return fines followed by layer by layer stacking
of the same in the storage yard by “chevron” method of stock piling with the
help of twin boom travelling stacker and subsequent reclaiming by a barrel type
blender reclaimer working across the full width of the stock pile face and then
desptach the blended materials so reclaimed to the proportioning building of
sinter plant through belt conveyor system.
2nos stock piles shall be made (1 for stacking and 1 for mixing & reclaiming)
of 50000t capacity each for the base mix materials.

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

Specific consumption of base blend per ton of sinter is given below:

Iron ore fines : 850~900 Kg
Lime stone +Dolomite : 300 Kg (ratio- 1: 1)
Coke breeze : 65 Kg
Mill scale : 20~25 Kg
Flue dust : 20~25 Kg
BF/BOF sludge : 20~25 Kg
LD slag : 10~15 Kg
BF return fines : 10% of finished sinter

All the raw materials except fuel & flux shall be transported from raw material
storage yard to the proportioning bin building of base blending unit. Fuel & flux
is transported from FFCS building.
Iron Ore fines, waste materials like BF/BOF sludge, mill scale, crushed fuel &
flux and BF sinter fines will be conveyed to the proportioning bins. Two series
of overhead blending bins will be provided for 12 hours storage. From these
blending bins, materials will be extracted in pre-set quantities and fed to
common belt conveyors leading to base blending yard. There will be a bypass
route provided for taking a portion of fuel and fluxes directly to the
proportioning bins located in the Sinter Plant for final blend correction.
For one sintering machine complex, two number of base mix piles with a twin
boom stacker and barrel type blender reclaimer have been envisaged, of which
one pile will be under formation and the other under reclamation. The reclaimed
blended mix will be conveyed to the storage and proportioning unit of Sinter
Plant proper.

6.0 SINTER PLANT PROPER:

General Facility Description

Raw materials for sinter making are received at Proportioning building of

sinter plant proper as given below:

Base mix : from Base blending unit

Fuel & Flux : from FFCS building / through proportioning bins of
base blending yard (only correction qty of about 20%)
Calcined lime : from lime plant

Sintering of iron ore fines will be effected after mixing the base mix and in
plant sinter return fines with correction quantities of limestone / dolomite and

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

coke breeze. Lime stone/ dolomite acts as flux and coke breeze acts as solid
fuel in sintering.

A preset quantity of these materials will be withdrawn from storage bunkers and
thoroughly mixed in a mixing and nodulising drum. This will also allow
formation of micro pellets to some extent. The mix will then be laid out on a
grate machine over 10 to 50 mm thick hearth layer with the help of a roll feeder.
As the sinter-mix passes through the furnace, the top layer will be ignited with
the help of COREX gas. The combustion zone will gradually descend across the
bed due to under grate suction as the machine travels towards the discharge end.
The sinter cake thus formed will be crushed in a hot sinter breaker to –200 mm
size. It will then be cooled on a circular annular dip rail type cooler to below
100 deg C. The cooled sinter will be screened into three fractions, -6 mm fines,
6–40 mm final product and 10 to –20 mm sized hearth layer
6.1 Sinter plant proper

The sinter plant proper will consist of the plant and equipment for storage and
proportioning of raw materials received from base blending yard, mixing and
balling, sintering and cooling, cold sinter screening, exhauster building,
emergency sinter storage, plant de-dusting, waste heat recovery system etc.

The major technological units in sinter plant proper are as follows:

 Storage and proportioning building

 Combined Mixing and balling building
 Sintering building
 Sinter cooler
 Sinter screening building
 Exhauster fan building
 Waste gas de-dusting unit
 Waste heat recovery unit
 Plant de-dusting unit
 Emergency sinter storage

6.2 Storage and proportioning building

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

Blended mix, crushed limestone and crushed coke breeze from base blending
yard will be received by means of conveyor and fed in the storage and
proportioning bins by two shuttle reversible conveyors. In plant sinter return
fines will be received from the cold sinter screening building by means of a
system of conveyor. The dust collected at various points of sintering unit
through plant de-dusting and process gas cleaning system shall returned to the
sinter return fines bunker through conveyors for recycling in the process.
Blended mix, crushed limestone & coke breeze, in plant sinter fines, calcined
lime will be stored in 12 overhead cylindrical steel bins of different volumetric
capacity. The materials will be extracted from the bins by load cell mounted
electronic belt weigh feeders with supervisory weighing controller for accurate
proportioning of sinter mix constituents.

The bottom of all the bins except for return fines bins shall be provided with
vibro hoppers for smooth flow of materials. The return fines bins shall be
mounted on load cells and shall be provided with stationary hoppers.

Limestone and coke breeze bins shall be provided with twin outlet while all the
other bins shall have single outlet. Each of the bin outlet shall be provided with
load cell mounted electronic belt weigh feeder. For accurate proportioning of
blended mix and additives in a preset ratio, supervisory weighing controller
shall be provided.
Calcined lime bins are provided near the combined mixing & balling building.

6.3 Distribution of storage and proportioning bins:

Storage
Sl.N Volume Weight in
Materials No. of bins capacity
o (total m3) tonnes
in hours

1 Blended mix 4+1 2000 3600 8.5

2 Limestone 2 300 480 40

3 Coke breeze 2 300 210 36

4 Sinter returns 1 200 320 5

5 Calcined lime 2 100 100 16

6.4 Combined mixing and Balling unit & Sinter Mix transportation

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

A combined mixing and nodulising drum of 4 m uniform dia and 18 m length

will be located at the ground floor of the building. Bulk of water shall be added
to the mixing section while controlled quantity of water in the form of fine
sprays will be provided in balling section for micro pellet formation. The total
retention time of the mix in the drum shall be five minutes to ensure thorough
mixing and balling. Capacity of mixing drum shall be 424 tph rated and 560tph
designed.
In the mixing drum the material mix shall be homogenized and granulated. In
order to finally adjust the required moisture content of sinter raw mix, water
shall be added in both sections (mixing section and rerolling section). After
rolling the sinter raw mix shall be transported via a belt conveyor system to the
top of mixed material bin of sinter machine charging station. For equal and
proper charging of the said bin, a shuttle conveyor is foreseen.

6.5 Sinter Building

6.5.1 Sinter Machine Charging

The sinter machine charging consists of hearth layer and mixed material
charging system. Hearth layer thickness on the sintering strand and sinter raw
mix layer thickness on the drum feeder can be adjusted according to the
requirements.
The speed of the drum feeder is controlled by the volumetric conveying capacity
of the sintering machine as well as by sensing probes.
To ensure that even with small flow fluctuations the sinter mix is fed to the
sinter strand loosely and evenly distributed, probes monitor the material slope
ahead of the mixed material charging chute on the sinter strand and control the
drum feeder speed. The position of the mixed material main gate (equipped with
individually adjustable segmental gates, to ensure even distribution along the
width of the grate) can be adjusted accordingly. Hearth layer bin and mixed
material bin are supported on load cells.
Technical parameters of the sinter machine envisaged are:

Sintering Area 365 m2

Length: 77m (C.L to C.L)
Pallet width : 3m
Side wall height: 700mm (max bed height – 650mm)
Speed of machine: 1.0 to 4.0 m/min
No. of pallets : 164
Ignition furnace: 4m long
Burners: 2 rows of roof mounted burners
Fuel: Corex gas
Main exhauster fan: 20000 Nm3/min @ 160°C

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

Under grate suction: 1600mmWC pressure

Special feature: Closed sinter machine, enabling recirculation of waste
gas

6.5.2 Ignition Furnace and Radiation Hood

The heat required for the ignition is supplied by 2 rows of roof mounted burners.
A fuel gas with a heating value of minimum 1800 kcal/Nm³ shall be used. The
whole ignition furnace chamber is lined with refractory material. Refractory
lined slide gates at the inlet and outlet walls can be adjusted to match to the
material layer thickness on the traveling grate. For combustion ambient air is
used. Provision is envisaged to recirculate hot dust free air from sinter cooler to
substitute combustion air. Fuel gas and air are continuously controlled by means
of butterfly valves and/or regulating dampers. Ignition of the roof burners is
done by means of ignition burners. Gas and air quantities are measured by
orifice gauges and regulated by control devices. Purging of the gas mains before
gasifying and after degasifying is performed by using Nitrogen. A quick-acting
safety valve shuts-off the gas supply, when required. The Radiation Hood
consists of 3 units and is located adjacent to the ignition furnace outlet and is
preventing the freshly ignited sinter surface against cold ambient.

Hearth Layer Transportation

The hearth layer, that is the 10 - 20 mm grain size fraction from the primary
sinter screen/hearth layer screen, is transported to the distributor chute by a belt
conveyor. It is collected from the overflow type distributor chute by a speed
controlled discharge vibrating feeder and transported via a steep inclined belt
conveyor into the hearth layer bin. The vibrating feeder will be controlled
automatically by the preselected filling level in the hearth layer bin. The
remaining amount of the 10 - 20 mm fraction, which is not needed as hearth
layer, is diverted to the sinter product conveyor line.

Driving Station & Lowering Station of Sinter Machine

The driving station of the sinter machine is equipped with a planetary type gear
box adequate to the heavy duty requirements. The position of the loose bearing
of the driving shaft may be adjusted by means of a slip-on-gear box and
adjusting device, so that the straight run of the sinter machine can be ensured.
As an overload protection of the drive a safety coupling is installed which cuts
off the machine in case of mechanical disturbances. Moreover the safety
coupling of the drive is monitored by a differential speed control. The lowering
station of the machine is moveable so as to be able to absorb the normal thermal
expansion. When the expansion is too large, alarm or shut down, respectively,
is effected by limit switches (2 limit switches on each side of the lowering
station). Due to a special design of the guideway of the pallets during discharge,
the pallets will at first be horizontally separated from each other and then the

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AT DOLVI, MAHARASHTRA

pallet to be emptied will be lowered. Thus, the wear between the contact
surfaces of the pallets will be minimised. In addition easy exchangeable wear
plates are bolted to the contact surfaces of the pallets. The material dropping
between the pallets will be collected in a chute and laterally discharged from the
machine. The sinter cake dropping from the pallets is falling in a material box
and then slides into the star crusher. To protect the adjacencies against dust, the
entire discharging station is covered and connected to the plant dust collecting
system.

Grizzly and Primary Crusher

At the discharge point of the sinter machine, the sinter is directly fed by the
material box to the primary crusher. The star crusher forces the sinter cake
through the grizzly bars arranged there and crushes it to grain sizes of less than
approx. 200 mm. For maintenance purposes, the star crusher can be moved
upwards by means of the bay crane. After primary crushing the hot sinter is
directly charged onto the sinter cooler by use of special designed chute in order
to reach a certain grain size distribution on the sinter cooler.

Connecting Lines / Downcomers

The connecting lines / downcomers between the wind boxes of the sliding track
and the waste gas main duct are equipped with expansion joints to absorb the
heat expansion. In the connecting lines / downcomers under the ignition hood
orifices are installed.

Chutes
Various chutes at the drive and lowering station are used for collecting and
discharging of the spilled grain accumulating in the area of the sinter machine.

Sinter Discharge and Spiked Roll Crusher

A hot sinter crusher is installed at the discharge end of the sinter machine; it
breaks the sinter cake to a size of about < 200 mm.
Sinter Cooler

For cooling the sinter a circular trough - updraught pressure type - dip rail cooler
(22.5m dia X 3.5 m wide X 1.5m bed height) is provided. The moving troughs
with louver-type bottom plates form a ring. The cooling area shall be approx.
202 m². The cooling air is pressed through the louver-type bottom of the moving
troughs.
The cooled sinter is discharged by lowering the louver-type bottom at the
trailing end, so that the sinter falls down into a discharging bin, which is
supported on load cells for level monitoring.
The cooler is driven by 2 driving stations via friction drive and variable speed
motors. The traveling speed of the cooler is variable between 0.5 - 2 revolutions

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 JSW STEEL LIMITED, DOLVI WORKS
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AT DOLVI, MAHARASHTRA

per hour.
The optimum filling of the circular dip rail cooler is controlled by level sensors
at the feeding chute.

For sinter cooling two blowers with a total delivery quantity of approx. 1800
Nm³ cooling air per ton of material fed onto the cooler are provided. The
capacity of the cooling blowers can be adjusted to the required temperature of
the cooled sinter in order to optimize electric power consumption. Inlet silencers
are provided for noise level reduction.

Cold Sinter Screening and Hearth Layer System

From the cooler discharge bin the cooled sinter is withdrawn by a speed
controlled vibrating feeder, which feeds the material onto a belt conveyor,
conveying the –40mm material via a chute to the primary sinter screen/hearth
layer screen. +40mm material is fed to a sinter crusher which is fed back after
crushing to –40mm size, on to the hearth layer screen.
The total amount of material is charged onto the primary sinter screen/hearth
layer screen, where the grain size fraction 0 – 10 and 10 - 20 mm are screened
out.
The grain size 0 - 10 mm is fed to the secondary sinter screen / return fines
screen.
The grain size of 10 - 20mm is partly used as hearth layer and transported to the
hearth layer bin as already described. The grain size of > 20 mm is fed to the
finished sinter product belt conveyor. On the secondary sinter screen, the grain
size 0 - 6mm (in-plant return fines) is screened out of the 0 - 10 mm fraction
and transported into the sinter return fines bin by belt conveyors. The overflow
of the secondary sinter screen (grain size 6 - 10mm) is fed to the finished sinter
product belt conveyor.
Exhauster Fan Building
The air quantity required for sintering is sucked trough the sinter mix by one
sinter main blower. The main blower is designed for about 2250 Nm³ waste gas
per ton of sinter product with a total suction pressure of 160 mbar and an average
waste gas temperature of 160 °C. The one-stage double-sucking radial blower
is equipped with forced-oil lubricated bearings. The bearing temperatures are
monitored by remote contact thermometers. The bearing vibrations are
measured and recorded in the control room. The blower is equipped with a brake
which may be actuated at a speed below 50 rpm while the blower slows down.
The brake serves mainly to hold the impeller in position in case of maintenance
work. The adoption of the volumetric flow to the varying operation conditions
is obtained by an adjustable louver-type damper. The damper is actuated by an
electric positioner. During automatic operation, control is effected depending
on the power input of the blower drive motor which is kept constant and on the

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suction upstream of the electrostatic precipitator.

Waste Gas De-dusting System

For de-dusting of the sinter waste gases electrostatic precipitator is envisaged.
The electrostatic precipitator is energized by high negative voltage applied to
the discharge electrodes, which creates a high electrical field between the
discharge electrodes and the grounded collecting plates. Because of the
geometry of the electrode system the highest electrical field strength will occur
near the surface of the discharge electrodes. With high negative voltage applied
to the discharge electrodes, the electrical breakdown strength of the gas is
exceeded and local breakdowns of the gas close to the electrode surface will
take place. This breakdown or corona produces a large number of gas ions, and
they drift towards the collecting plate forming an ionic space charge.
In this flow of negative ions between discharge electrode and collecting plate
the suspended dust particles will acquire an electric charge. Under the influence
of the electrical field, the negatively charged particles migrate towards the
grounded collecting plate. When the charged dust particles reach the collecting
plate they adhere to it while giving off their charge, forming a dust layer. The
deposited dust is periodically dislodged by rapping and falls by gravity towards
the precipitator bottom hopper, from where it is removed by suitable extraction
equipment.

Plant De-dusting Unit

All transfer stations generating dust are covered with exhaust hoods. These
hoods are connected to the plant de-dusting ESP by a duct system. The dust-
loaded air is cleaned in the ESP, the cleaned air is discharged into the open
atmosphere through a stack. The dust separated by the ESP is withdrawn by
chain conveyors and finally recycled to the sinter process. The suction, required
for the proper function of the dust collecting system, is created by the plant de-
dusting fan. One silencer is provided for noise level reduction.
A common Steel stack of 100m height is envisaged common for both waste gas
system and plant dedusting.
Emergency sinter storage
Provision has been kept for emergency storage of finished sinter in six
overhead bins each of 500 m3 effective volume with total holding capacity of
about 12 hours sinter production.

Hoisting and handling facilities

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Adequate hoisting and handling facilities have been envisaged in each of the
units for ease of maintenance and repairs. EOT cranes of adequate capacity have
been envisaged in the main plant units. Besides above, electric hoists will be
provided in main plant units, junction houses and auxiliary units.

7.0 SERVICES FACILITIES

7.01 WATER SUPPLY FACILITIES

Source of water

The source of water for the steel plant is from Rayabasavanna Canal of
Tungabadra dam, flowing at a distance of about 40 km from JSWSL plant. An
intake structure adjacent to Rayabasavanna canal with 5 nos. vertical turbine
pumps are already installed for pumping raw water to steel plant. Raw water
pond of capacity 5.5 x 106 m3 takes care of the complete water requirement of
the steel plant including the requirement of water during summer months. Raw
water treatment plant already constructed at JSWSL plant site will meet the
present and future requirement of makeup water.

Requirement of water
Water- requirement for- the proposed sinter plant complex will be mainly Fin
the Mixing & Balling drum, cooling of equipment, dust suppression, floor
washing etc., besides firefighting and drinking purposes. In order to
economise on the requirement of fresh water from source and for pollution
control, closed system of water supply has been envisaged.
The water requirement of the plant for the proposed sinter plant complex is
given below:
Process water (make-up water) : max. 25
Cooling water/soft water : 201
Industrial water (clarified water) : max. 15
Fire- fighting water : 200 (design)
Proposed facilities
To cater to the water requirement of sinter plant complex, the following
facilities are envisaged.
Clean water
The clean water- shall be supplied for cooling of various equipment. Hot
uncontaminated water, wherever possible, shall be recovered and cooled in
cooling tower before mixing with fresh cold make—up water- and pumped
back to the consumers in the system. A pump house and cooling tower- is

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envisaged for this purpose.

Slurry Disposal
Slurry from hydro washing of various buildings shall be collected and pumped
to the central contaminated water sump located in the pump house, from
where it will be pumped to the Ash Pond for recovery of clean water.
Fire- fighting Water- Supply
To cater to the water based fire- fighting system needs, a wet riser ring main
exist which covers the sinter plant complex. Main fire- fighting pumps,
jockey pumps and diesel engine driven pumps shall be provided for the fire-
fighting network
Sewerage
Storm water sewerage
The surface drainage shall be collected in the drainage channels covered with
removable precast chequered slabs. These channels shall be connected to rain
water sewer-age network of the JSWSL Plant after removing coarse particles
in settling pits provided at suitable locations. Storm water sewerage of the
plant is envisaged to take care of the peak precipitation.
Faecal Sewerage
Faecal sewerage will be collected from different service units like toilet
blocks, office buildings etc., and conveyed to the Faecal Sewer-age Network
of the Steel Plant through underground faecal sewer-age piping network and
suitable lifting pump installation proposed for this purpose. The effluent from
the gas seal pots on the gas lines bearing phenols shall also be connected to
this network.
Drinking water facilities

At present the raw water after necessary treatment and chlorination is supplied
to various consumers of the steel plant through a dedicated network.
The network will be extended to cover the drinking water needs of the units
planned in Sinter Plant complex.

7.2 COMPRESSED AIR FACILITIES

To meet the compressed air requirement of the sinter plant complex, one central
compressed air station is proposed.
Compressed air station will be installed with oil free, water cooled, two stage,
electric motor driven screw type air compressors complete with water cooled
inter coolers, after coolers, moisture traps, air receivers, interconnecting air and
water piping, pipe fittings, cooling towers etc. Desiccant, automatic blower

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reactivation type air dryers will also be installed one per working air compressor
with interconnecting piping, for removing moisture from air.

The compressors will be located inside an RCC building along with air dryers,
auxiliary equipment and electric’s. Cooling towers will be located outdoor.
The compressed air requirement of the plant for the proposed sinter plant
complex is given below:
Compressed air- plant grade : 35 m3/hr @ 6-7bar
Compressed air, instrument air : 171 m3/hr @6-7 bar

7.3 FUEL GAS FACILITIES

The main by product fuel gases of the plant will be Corex, BF and BOF gases
produced in the respective units. The fuel gas generating units are two units of
Corex C-2000, one blast furnace of 1250 m3 capacity, one blast furnace of 1670
m3 capacity and BOF units. After meeting the requirements of the various
consumers of fuel gas, surplus gas will be consumed in power plant of JTPCL (a
sister organisation of JSWSL) and proposed 2 x 100 MW power plant of JPPL (a
sister organisation of JSWSL). However, Corex gas shall be used as fuel gas in
Sinter Plant complex.
Inter plant gas pipelines
Inter plant gas pipeline network will be provided to supply Corex gas to the
sinter plant complex. Requirement of Corex gas (approx. Calorific Value – 1900
Kcal/Nm3) for the Sinter Plant Complex is: 2300 Nm3/hr with a specific
consumption of 15000Kcal/t of finished sinter produced.
The diameters of the pipelines will be so selected as to ensure minimum pressure
loss while transporting the gas.
The pipelines will be supported on structural columns at a convenient height so
that necessary clearance from ground level is maintained to allow free access for
all movements.
The pipelines will be provided with all necessary shut off devices, expansion
bellows, condensate removal devices, venting and purging points, measurement
and control instruments etc.

7.4 AUXILIARY FACILITIES

7.4.1 General
Similar to the services facilities all auxiliary facilities have been planned in an

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integrated manner to cater the needs of Sinter Plant Complex

7.4.2 Quality control
It has been envisaged to carryout analysis of various raw materials such as iron
ore, coke, lime stone, dolomite etc. as well as analysis of base mix, finished
sinter, waste gas in a laboratory provided for the proposed Sinter Plant complex.
The samples will be collected manually from various sampling points round the
clock and will be brought to the laboratory, prepared for chemical analysis and
physical testing. The analysis will be carried out in all three shifts.
7.4.3 General plant storage
It has been envisaged to provide a stores for storing various spare items.
7.4.4 Telecommunication
Telecommunication system will be provided in all the Sinter plant units to have
intercommunication among the operation/maintenance personnel, to have
communication with the outside subscribers.

7.4.5 Design Features

The Electronic Private Automatic Exchange (EPABX) can be initially equipped
for 72 extensions with 16 trunk lines and expandable to 112 extensions with 32
trunk lines is envisaged complete with control cards, extension cards, tie – line
cards, power supply equipment with rectifier charger, back – up battery and all
interconnecting cables and wires. This exchange along with power supply
equipment and power supply backup for 4 hours operational will be provided.

Spare lines of existing EPABX will be used wherever expansion is carried out
in existing area. New exchange will be provided for new areas like RMHS etc.
Direct link between this exchange and the existing exchange will also be
possible.
The exchange will be designed and built to offer utmost reliability and
efficiency in operation, ensuring instant communication and will employ TDM
– PCM switching technique.
The exchange will be modular in construction, thus enabling system up
gradation to meet further requirements and also to easily located and rectify
faults.
The exchange will be suitable for both electronic push buttons telephone (DP/
DTMF) and the conventional rotary dial type telephones.
The exchange will have all familiar distinct tones like dial tone, busy tone, ring
back tone etc. complete details of the frequency and duration of different types
of tones depends on the make and model no. of the exchange.
Adequate protection of exchange will be provided against electrical short
circuits and heavy currents as result of induced or conducted lighting or power

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system fault etc., provision will be kept for all routine test measurements and
checks of exchange equipment and subscriber lines.
The telephone exchange system will broadly comprise of

 Telephone exchange equipment and peripherals.

 Main distribution frame.

 Power supply equipment.

 Telephone instruments.

 Inter connection cables and wires.

 Telephone cable network comprising cables, wires, distribution and

termination devices and accessories etc., required from exchange
equipment up to the instrument.
In case of power supply failure, 4 hours battery backup will be provided
through SMF batteries and battery charger.

7.4.6 Fire protection facilities

In order to combat any occurrence of fire in Sinter Plant complex, the
following fire protection facilities have been envisaged.
7.4.7 Portable fire extinguisher
All Sinter Plant complex units will be provided with adequate number of
portable extinguishers to be used as first aid fire-fighting appliances. The
distribution and selection of extinguisher will be done in accordance with
requirement of IS: 2190.

7.4.8 Fire hydrant system

The entire plant area is provided with underground fire water pipe network in
the form of a ring main withstand post type ingle outlet type yard hydrants as
per BIS: 908. Yard hydrants are proposed to be located along the plant roads.

8. CIVIL WORK
8.1 General
Civil work comprises of all main plant buildings and equipment foundations,
such as, Sintering building, Proportioning building, mixing & nodulising
building, sinter screening building, etc. and its auxiliaries, and non-plant

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buildings such as electrical premises, Compressed air station , ESP’s, Material

handling, water supply facilities, storage yard, roads, drains, etc. within the plant
boundary for various units of the proposed plant.
8.2 Topographical features at site
The proposed plant is located near the existing Pellet plant of M/S JSWSL,
Vijaynagar, Maharashtra. The plant site is generally flat and does not require
any site clearance and site leveling.
8.3 Sub-Soil Condition
The detailed soil investigation of the existing Vijaynagar Steel Plant adjoining
the present site is available. The report shows black silting clay in top 1 to 3 m
depth. Below that highly weathered granite rock is present upto a depth of
approx. 5 m to 7 m. It is proposed to use open foundation with founding level
varying from – 3.0 m to –5.0 m. The Bearing capacity at founding level has
been assumed to be 40 t/m2.

8.4 Design Features

All civil engineering design will be based on the norms laid down in the relevant
specification of Indian Standard. Where such norms are not available, the
relevant international standard will be adopted. All buildings, except steel
structural buildings, shall be of RCC framed with filler brick wall cladding. All
RCC work will be generally of M-20/M-25 grade of concrete and the
reinforcement will be of high yield strength deformed bars.

8.5 Constructional Features

Concreting
All concrete work will be generally cast-in-situ. Ordinary portland cement
shall generally be used. Suitable methods will be adopted to make all
basement and underground premises water tight. All constructional work will
conform to prevailing standards and practice for quality and safety. In areas of
high temperature, suitable protection shall be provided to the concrete by
using heat resisting concrete depending on temperature.

Flooring
Flooring will be provided to suit the functional requirements of the buildings.
The ground floor of various plant buildings will be of concrete with nominal
reinforcement if required laid over soling course. The ground floors of other
non plant buildings will also be suitably designed.
Doors and windows
Mild steel (MS) rolling shutters and MS doors will be provided in plant
buildings as per requirement. Wooden flush doors will be provided in non-plant
building. Windows with MS frame with glass panes will be provided as per the
requirement. The doors will be made air tight, wherever required.

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Finishing
Granolithic floor finish will be provided in the buildings in general. The control
room, laboratory buildings, etc. can be provided with or terrazzo floor finish.
For heavy duty floor, ironite topping will be provided.

The brick/block masonry wall and concrete surfaces of the building will be
plastered with cement mortar. The external surface of all the buildings will be
painted with two coats of cement based paint over a coat of primer and the
internal surface will be given three coats of white wash. Superior finishing will
be given to the inside walls of laboratory, control rooms, etc. as per the
requirement. All the rolling shutters, MS doors, wooden doors and exposed
faces of MS inserts will be given two coats of synthetic enamel paint over as
coat of primer. False ceiling for control room shall be provided. Apron of
P.C.C. (M-10) will be provided all round the buildings.
Road and Drains

Road will be of 7 m and 4 m width. It will have wearing course of bituminous

carpet over water bound macadam laid compacted sand murrum mixture over
well compacted subgrade. The storm water drains will be provided by the side
of the roads and around the building.

Construction Materials:
Construction materials like sand, aggregates, reinforcement bricks etc. will be
of approved quality confirming to the specification of relevant Indian
Standards.
Approximate volume of work in Sinter Plant Proper:

Excavation 150,000 m³
Backfill 68,000 m³
Blinding concrete 2,000 m³
Concrete foundations and structures 15,000 m³
Reinforcement steel 3,300 tons
Masonry 3,000 m²

9 STRUCTURAL WORK
9.1 Description of work

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Steel structures shall be provided in the following units as broadly described

against them.
- Base blending facility
- Fuel & Flux crushing system
- Sinter plant
- Storage and proportioning building
- Mixing and balling building
- Sintering building
- Sinter cooler
- Sinter screening building
- Waste gas de-dusting unit
- Exhauster fan building
- Waste heat recovery unit
- Plant de-dusting unit
- Emergency sinter storage
Roof and side sheeting of the building will be of color coated sheets of industrial
profile. Plant buildings will be provided with monitors at roof and louvers on side
walls for effective natural ventilation. Glazing having a depth of about 1000 mm
to 1500 mm will be provided alongside walls and at gable ends as horizontal band
all along the building at more than one location to provide natural lighting inside
the shop which will be in addition to translucent roof sheeting in specific areas.
This will also enhance the architectural appearance of the building. Due
importance will be given in the matter of selection of roof slopes, design of gutters
and down comers for effective drainage of rain water from roof. While the
requirements will be met in the building design/detailing in respect of
construction, operation and maintenance, architectural appearance will be given
due importance.
9.2 Design parameters
Steel structures will be designed to meet the technological requirements and
general conditions of the project.
Design of steel structures will be carried out as per IS:800-1984 and
super-imposed loads for design shall be according to IS:875-1992 and
technological loads.

9.3 Material for construction

All steel will conform to IS: 8500-1991, IS: 2062-1992 and IS: 2002 Gr-II-1992
Roof and side walls will be of GCS sheets conforming to IS: 277 - 1992

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9.4 Method of construction

Steel structures will generally be of welded construction at shop. Site

connections and splice joints will be by bolting followed by site welding.

9.5 Painting
Generally steel structures will receive one coat of epoxy zinc rich primer over
the blast cleaned surface conforming to Swedish standard Sa 2 ½ to be followed
by one coat of high build micaceous iron oxide and two coats of high build
enamel or polyester paint as finishing paint. However, where painting system
has been mentioned specifically by the process know how supplier in their
specification / drawings the same will be followed.

9.6 Approximate Volume of work in Sinter Plant Proper

Buildings (including bins) 5,000 tons

Conveyor galleries and junction towers 1000 tons
Miscellaneous 500 tons
Roofing and siding 34,000 m²

10 VENTILATION, AIR CONDITIONING & POLLUTION CONTROL

10.1 General
Ventilation and air-conditioning systems are proposed to provide proper working
conditions necessary for maintaining environment compatible with human hygenic
requirements and to maintain conditions necessary for proper storage of materials
and working of plant and equipment. The ventilation and air-conditioning systems
generally include one or more items of equipment and accessories such as fans, air
filters, air-conditioning units, duct work, pumps, cooling tower, air supply grills,
dampers, insulation, instrumentation and controls, electrics, etc.
Ventilation and air-conditioning system will be designed considering the climatic
conditions prevailing in the region and the plants will generally be installed in
separate plant rooms independent of the served premises. The plant rooms will be
provided integral with and adjacent to the served premises at proper locations on
considerations of convenience of routing of ducts/pipes, availability of fresh
uncontaminated air and creating least disturbance to the adjacent premises in terms
of vibration and noise.
Ventilation and air-conditioning systems will be provided with adequate measures
for safety and fire fighting for fire hazardous areas and shall be of flame
proof/explosion proof construction.

10.2 Ventilation facilities

Buildings and shops will generally be provided natural ventilation. Mechanical

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ventilation will be provided for premises where adequate ventilation cannot be

provided by natural means alone.

Depending upon the specific requirement, the shops/buildings will be provided

with either exhaust ventilation or plenum ventilation. The system design will take
into account the requirements of air change as well as excess heat removal. Filters
will be provided with plenum systems. By plenum ventilation, the served premises
will be pressurised to 2-3 mm WC to avoid ingress of dusty air. Hot work areas
will be provided with portable man-coolers for spot cooling. Man-coolers will be
provided also in a few other areas where the premises are manned and have high
heat radiation. The details and types of system proposed shall be as shown in the
following Table.
10.3 Air conditioning facilities

Sl. No. Location / Shop Facilities

i. Electrical premises, Switch gear room, Pressurised
Cable basements of Electrical sub-stations Ventilation
ii. Battery rooms Exhaust
ventilation
Premises requiring stringent environmental conditions of temperature and
humidity will be air conditioned. Room air conditioners, package air conditioners
will be provided for air conditioning of these premises; the selection depends on
the specific requirement of the application in terms of cooling capacity,
temperature, humidity and freedom from dust. The instrument control rooms will
be generally maintained at a temperature of 23 + 2 0 C and relative humidity 55 +
10%. Dust concentration will not exceed 0.1 mg/m3. Office rooms/In-charge's
rooms will be provided with room air conditioners for personal comfort. The types
of air conditioning system proposed are as indicated below:

Air conditioning facilities

Sl. No. Location/Shop Facilities

i. Control rooms of all units Water cooled Package type air

conditioning system

11 POLLUTION CONTROL

11.1 General
The pollutants in the form of solids, liquids and gases are generated from various
technological units of iron making plant and if let out as such, will have hazardous
effects on the environment. Pollution of the environment not only adversely affects
the human beings, flora and fauna but also shortens the life of plant and equipment.

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This vital aspect, therefore, has been taken into account while planning the plant
and equipment and adequate measures have been proposed to limit the emission of
pollutants within the stipulations of statutory norms.

11.2 Air pollution

Air in and over the plant area and beyond its boundaries gets polluted with gases,
fumes and dust particles emanating from the processes, chimneys, transfer points
of conveying and handling equipment. The air pollutants in an iron making plant
are mainly dust and gases like sulphur dioxide, carbon monoxide, nitrogen oxides
etc.
11.3 Water pollution
Water pollution mainly comprises of inorganic solids, oil, grease etc. in
suspension, solution and emulsion.

11.4 Noise pollution

Many operations in the sinter plant complex will produce objectionable level of
noise which may not be practicable to eliminate entirely, but in most areas it can
be brought down to the acceptable levels. The major noise generating areas are
main exhauster blower station, compressed air station, etc. where necessary
measures are taken care.

11.5 Pollution control measures

11.5.1 Air pollution

The measures to control the air pollution will ensure the ambient air quality
standards as laid down by Central Pollution Control Board for industrial and
mixed use areas. In addition, the emission from the chimneys will be kept below
the permissible limits of statutory norms for dust. Gaseous emissions will be
released through stacks of required height so as not to exceed ambient air quality
norms due to the entire plant.

Ambient air quality standards

Sl. No. Pollutant Concentration, µg /m 3 *

8 hours 24 hours

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i. Suspended particulate matters - 500

ii. Sulphur dioxide - 120

iii. Nitrogen oxides - 120

iv. Carbon monoxide 5,000 -

* 95 percentile value
The system proposed for air pollution control will provide acceptable
environment conditions in the working areas and abate air pollution in the
surrounding areas of the hot metal complex. The technological equipment and
processes have been selected with the above objective. Depending upon the
quality of emissions from different sources, suitable air pollution control systems
will be provided. The chimney heights will be as per requirement to ensure
Ground Level Concentration (GLC) of different pollutants within permissible
limits after considering the background GLC.

However, in order to meet the statutory ground level concentration limits for SO 2,
NOx and other gaseous pollutants, suitable stack heights will be provided for
proper dispersion. All stacks will be provided with port hole and working
platform so that stack monitoring can be done as per norms of statutory authority.

The collected dust from ESP’s shall be transported and utilised back in the sinter
making, thus reducing the dust pollution.

11.5.2 Water pollution control

The pollutants present in the waste water will be reduced to acceptable levels by
adoption of the following schemes.

* Recirculating water in the process whereby discharged volume is

minimum.
* Clarifier and sludge pond for removal of suspended solids
* Neutralisation of acidic water by lime
* Removal of oil and grease from the contaminated water by means of oil
traps and skimming devices

11.5.3 Noise pollution control

Various measures proposed to reduce noise pollution include reduction of noise
at source, provision of acoustic lagging for the equipment and suction side
silencers, selection of low noise equipment, isolation of noisy equipment from

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working personnel. In some areas where due to technological process, it is not

feasible to bring down the noise level within acceptable limits, personnel
working in these areas will be provided with noise reduction aid such as ear
muffler and also the duration of exposure of the personnel will be limited as per
the norms.

11.5.4 Pollution monitoring

The pollution monitoring laboratory facility shall be utilized to monitor the
level of various pollutants in the plant namely air, water and noise.

11.5.5 Waste material management

The various waste materials arising out of the technological processes would be
re-utilised to the extent possible. Other waste materials which cannot be reused
are planned to be dumped in an environmental friendly manner in a separate area.

11.5.6 Green belt

Adequate green belt will be provided all around the plant and inside the plant
premises. Locally available types of trees which are resistant to pollutants will
be planted.

12 ELECTRICAL FACILITIES

12.1 Power Distribution Arrangement

The estimated maximum demand figures for the Sinter Plant complex is 18
MVA.
It is assumed that power shall be made available at 33 kV at the terminals of the
incomer circuit breakers, being proposed to be installed in the Sinter Plant
substation.
At the 33/6.6 kV substation, the power shall be stepped down to 6.6 kV through
2 nos. 33/6.6 kV, 12.5 MVA ONAN transformers for further distribution to the
6.6 kV drives and 6.6 kV distribution. The secondary winding of these 12.5
MVA transformers shall be connected to the 6.6 kV switchboard through 6.6
kV, 1250 A segregated phase busduct. The 6.6 kV switchboard shall supply
power to various HT drive motors and the LT distribution transformers.
The estimated connected load, 30 minutes maximum demand and annual
energy consumption for Sinter Plant complex with base blending facilities
work out to 18 MW, 15.5 MW, 13 MW respectively.
The annual energy requirement has been calculated on the basis of specific
energy consumption per tonne of sinter produced, as obtained from similar type
of units operating in other steel plants. The maximum demand figures are
calculated on the basis of estimated connected load and demand factor for

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similar units working in other steel plants.

12.2 Design considerations

The power distribution network has been considered as a radial system, with
two alternative supply feeders to each load centre.
The equipment shall conform to relevant IEC/IS/IPSS specifications and code
of practice to meet the operational requirements and to ensure reliable and
trouble free service in the plant.

Basic Design Parameters

All the electrical equipment will be designed to suit the following site
condition.
Site Conditions
Ambient for equipment located near sinter machine : 55 °C
Ambient for equipment located in outside area : 50 °C
Ambient for equipment located in other area : 45 °C
Relative humidity : 84 %
Voltage Levels
High-voltage: 33 KV + 10 % - 15 %, 3-phase

Medium high-voltage: 6.6 KV + 10 % - 15 %, 3-phase

Low voltage: 415 V + 10 % - 15 %, 3-phase, 3 wire
Frequency: 50 Hz + 6 %
Combination of voltage & frequency variation:± 10 %
Plant lighting voltage: 415 / 230 V, 1-phase

Solenoid valves: 24 V DC

Motor control circuits: 110 V AC, 1-phase

Control voltages for
Medium high-voltage switchgear: 110 V DC
Sequence control and field supply: 24 V DC
For motors less than 180 KW: 415 V
For motors from 180 KW up to 3,000 KW 6.6 KV
For motors above 3,000 KW 11 KV
Illumination and small power 240 V, 1 ph. 50 Hz

System Earthing

- 6.6 kV : Resistance earthed

- 415 V : Solidly earthed

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12.3 Major Facilities

HT Switchgear
The 33 kV and 6.6 kV switchgear envisaged shall be indoor type and shall
comprise SF6/VCB circuit breakers, with necessary protection and control gear
and audio-visual alarm annunciation system.

415 V Switchgear
The 415 V switchboard shall comprise of air circuit breakers, in draw out design
and multitier formation. The switchboard shall have two bus sections with a bus
coupler breaker, with provision for auto changeover in the event of loss of power
on one bus section.
The circuit breakers shall be equipped with static type direct acting releases for
over load and short circuit protections, as well as earth fault protection.
Cables
Power inside the plant shall be distributed through cables.
Inside the substations and covered premises, the cables shall be laid in
basement or in concrete channels (over cable supporting structures) or on
columns and other available structures. In the open areas generally the
cables shall be laid in concrete encased GI pipe block or directly buried in
ground in cable trenches, as applicable.
All 6.6 kV cables shall be XLPE insulated, multi core, aluminum conductor
armoured and suitable for use on unearthed system
Cables for 415 V system shall be 1.1 kV grade, PVC sheathed, PVC
insulated aluminum conductor, armoured / unarmoured as required.
The control cables shall be multi strand copper conductor, PVC insulated
and PVC sheathed with minimum cross section 2.5 sq.mm.

12.4 Shop Electrics

Power supply to all drives below 200 kW and other loads operating at 415 V, 3
phase, 50 Hz system is envisaged through motor control centers (MCCs).

The MCC shall be sheet steel enclosed, modular, multitier design in draw out
execution. The enclosure class shall be IP-4X. The use of MCCB/MCB in
general has been foreseen for power supply to small loads.

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AT DOLVI, MAHARASHTRA

All motors shall have class F insulation with temperature rise limited to that
permissible for class B insulation with enclosure class IP54/IP55 as required.
The motors generally shall be squirrel cage type suitable for direct on line
starting.

12.5 Automation & Control System:

 The control system shall be a PLC based system and shall fulfill all
functions that are necessary for the automatic operation of the plant as
given below:.
 Automatic sequencing of individual drives, e.g. feed back after start,
time monitoring of valves, alarming on upset conditions
 Automatic group sequencing of drives, e.g. start-up warning, starting
up and shut down in according the material flow and idling time for
emptying a group
 Safety inter lockings
 Prohibiting of starting of devices if the necessary conditions are not set
 Shut down of equipment in case of abnormal process conditions
 Closed loop control with combinations of function blocks
 Handling of analog input/outputs
 Temperature and pressure correction for flow measurements
 Temperature and pressure correction for square root extraction
 PID and advanced control modes
 Limitation of output changes by ramps
 Ratio control
 Calculation for external set-point control
 Function blocks like: divide, multiply, add, subtract
 Bump-less change over from manual to automatic control, bump-less
change from internal to external set-points
 Bus communication to other systems
 Bus communication to field devices

Each control station will be equipped with following hardware:

 CPU
 Memory modules
 Power supply
 I/O cards
 Communication module
 Mounting rack
 Assembly cabinet including marshalling terminals with fly wiring
 Interface card for serial links

The PLC shall be programmable through high level software using windows

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

resort.
All digital output cards are galvanically isolated by either optical couplers or
relays. The status of each digital input and output is indicated by a LED. All
input/output cards will be of plug-in type firmly held by screws into the rack.
All signals from and to the field will be routed via marshalling racks and not
connected directly to the input/output cards.
All input signals are 4-20 mA, mV or Pt 100 with maximum 500 Ohm load on
the transmitter. Input signals are filtered against spikes. The resolution of input
signals is 10 bits. In case of open loop an alarm signal is generated. Output
signals are 4-20 mA with protection against short circuit and overload.

The main Control loops are given below:

 Burn Through Point control (BTP control)
 Drum feeder control
 Surge hopper level control
 Raw mix feed control
 Raw mix ratio control
 Moisture control
 Waste gas blower control
 Cooler control
 Ignition hood control

12.6 Instrumentation
Adequate measurement and control facilities have been envisaged for all the shops
/ units of the plant with a view to achieve safe, reliable and efficient operation of
the plant, optimum utilisation of raw materials and fuels, safety of plant machinery
and operating personnel. For this purpose, state – of – the – art instrumentation
equipment have been envisaged for all the shops / units of the plant.
The instrumentation system will be generally based on 4-20 mA unifield current
signal system. Control room instrumentation equipment of all the main plant units
/ shop will be installed in air conditioned control room. Final control elements will
be pneumatically/ electrically / Hydraulically actuated types depending on specific
application.
12.7 Illumination
For supply of various illumination loads in the plant, provision of lighting
distribution boards (LDBs) has been considered. These LDBs shall be installed in
LT substation and shall be fed from the 415 V switchboard. LDBs shall supply
power to the various sub-lighting Distribution Boards (SLDBs) installed in
various buildings.
13. CONSTRUCTION PLANNING

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

13.1 General

The project envisages setting up of a 4.0 MTPA sinter plant complex at Dolvi in
Maharashtra including RMHS, Base blending yard and Fuel/Flux crushing unit. In
addition to the above, required services facilities have also been envisaged like
compressed air facility, water circulation system, air conditioning and ventilation,
power distribution and electric system etc.

The time schedule for implementation of the project is proposed to be 18 months

from the zero-date which is reckoned as “Go-ahead” for the project. However, this
would call for meticulous planning and monitoring timely decision making both at
site and corporate level, and effective coordination and supervision of the project.

The salient features of the implementation schedule are highlighted in the following
sub-chapters.

Volume of work

A preliminary estimate of the volume of work for major plant units and auxiliaries
is furnished below. It is understood that all the units of the plant will be new.

Sl. Item Unit Estimated volume

No.
1 Concreting Cum 25000
2 Structural erection Tonnes 10500
3 Equipment erection Tonnes 9000

The above estimates, however, are tentative at this stage and are furnished to
facilitate advance planning purpose only. These will be updated progressively
during the detailed engineering and work execution stages of the project.

Implementation Schedule
The proposed implementation schedule in the form of a bar chart for the Sinter
Plant complex and its auxiliaries envisaged is given elsewhere in this chapter. The
project is planned to be implemented in 18 months from the zero-date, which has
been reckoned as the date of go-ahead for the project for implementation.

Project Implementation
It is understood that Basic engineering of the 365m2 sinter plant will be readily
available with various process know how suppliers as 365m2 area sinter machine is

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AT DOLVI, MAHARASHTRA

mostly a standard size /module being followed by many International process know
how suppliers. In line with this a period of 2 months is considered for basic engineering
from know how supplier.
Detailed engineering would start immediately on 1st lot receipt of basic engineering
right from 2nd month onwards concentrating on order placement of long lead items and
civil/structural works.
A non-turnkey approach has been assumed for the implementation of the project.
Accordingly, all equipment will be procured through identifiable and workable
packages and based on feedback data, civil, structural work will be carried-out through
separate packages. The erection of equipment will be through separate contract under
the supervision of respective equipment suppliers. It has been planned that the detailed
engineering work will start immediately within one month from the go-ahead for the
project and is expected to be completed by 10th month. This will enable to start civil
work from the 2nd month onward as shown in the schedule.

It is also assumed that the site preparation work will be completed quite early to
facilitate the opening of a number of frontages for civil work. The structural
fabrication & supply is planned to commence from 4th month so that the structural
erection can be started from mid of the 4th month onwards.

It is expected that the orders for the major critical equipment like sinter machine
proper, mixing drum, Sinter cooler, Hot sinter breaker, Blowers, Screens, Fuel/Flux
crushers, Raw Material Handling System etc will be finalised within 3 months from
zero-date. The orders for other technological units and auxiliaries may be taken up
progressively to meet the proposed schedule.

It is planned that the supply of plant and equipment is needed to be commenced from
7th month onwards to suit the equipment erection work from 8th month onwards and
it is likely to be completed by the 13th month from the zero-date It is to be noted that
the structural fabrication & erection are to be completed 2 months prior to taking up
of mechanical equipment erection in respective areas. Accordingly, these activities
have to be planned at micro level during project execution. The proposed schedule
necessitate simultaneous work on many fronts and these are likely to become more
critical in case of delayed receipt and non-sequential supply of critical sinter plant
equipment and this is to be guarded against.

As per the proposed schedule the integrated commissioning of all-technological units

and auxiliaries will be completed by 18th month as shown in the schedule.

The timely completion of the project also depends on the association of proven
construction agencies in the similar field, who can mobilise requisite resources of
men, materials and construction machinery as well as construction and erection
expertise to execute the above project.

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FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

13.2 CAPITAL COST

13.2.1 General
The proposed sintering plant complex envisages production of 2,300,000 t/yr of
sinter.

13.2.2 Estimated capital cost

The investment required for the proposed sintering plant has been estimated at
Rs 306 Crores. The summary details of the cost under various items of
expenditure are given in table 14.01.

The cost towards major facilities include the raw material handling facilities,
base blending station, fuel and flux crushing system and the sinter plant along
with related services like power distribution and lighting equipment, material
handling equipment, ventilation system etc

The sintering plant complex is proposed to be located within the premises of the
existing steel plant of JSWSL and as such no extra requirement of land is
considered. It is considered that properly leveled land shall be available for
setting up the project.

The detailed breakup of the total capital cost is furnished in Annexure 14.01.
The various items of expenditure are briefly discussed below.

13.2.3 Buildings
The estimated cost of buildings has been worked out on the basis of preliminary
layout and design of facilities detailed in the previous chapters and the derived
rates for civil work applicable in the region. The facilities included in the
estimates are factory buildings including main plant and auxiliary units.
Provision has also been made in the estimate for equipment foundations.

13.2.4 Plant and machinery

The major facilities under plant and machinery include material handling
facilities, base blending station, fuel and flux crushing system and sinter plant
along with related services like power distribution and lighting equipment,
material handling equipment, ventilation system etc. The estimates are
generally based on budgetary quotations. Wherever budgetary quotations are
not available, costs have been estimated based on prices of similar equipment
installed in other projects. The estimates also include expenses towards ocean
freight, customs duty, port handling etc for imported equipment as well as sales
tax and inland freight for indigenous equipment.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Provision has also been made in the estimate for installation charges for plant
and machinery.

13.2.5 Engineering and project management

The cost under this head includes engineering and consultancy charges which
mainly comprise preparation of project reports and technical specifications,
detailed engineering and project management during implementation stage
comprising procurement of materials and equipment, co-ordination between
construction site, engineering agency, equipment suppliers and contractors and
monitoring their progress of work etc.

13.2.6 Preliminary expenses

Cost estimate under this head includes legal expenses, upfront fee for loan etc.

13.2.7 Pre-operative expenses

This includes establishment expenses, travelling expenses, insurance during
construction including erection insurance, start-up expenses etc.

13.2.8 Contingencies

Contingencies at the rate of 5% of the total capital cost have been provided to
cover unforeseen aspects of the estimate.

13.2.9 Interest during construction

This includes interest charges to the tune of Rs18.5 Crores accruing on long
term borrowings during the construction period.

13.3 Margin money for working capital

Details of requirement of working capital and margin money are given in

annexure 14.02. It has been considered that margin money will be financed in
the debt: equity ratio of 2:1. The balance portion of the working capital
requirement shall be met from bank borrowings bearing an interest rate of 12.5%
per annum.

13.3.1 Assumptions

The assumptions made in working out the capital cost estimates are enumerated
below:

- Cost estimates are based on prices prevailing during the first quarter of
2004 and no provision has been made for future escalation in costs.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

- Cost data for major plant and equipment are based on budgetary
quotations. Wherever quotations are not available, costs are based on
broad estimates.

- A provision of 5% of equipment cost is made in the estimate towards

spares to be procured initially along with the equipment for normal
operation of the plant for two years.

- The cost of civil engineering work is based on indications received from

the area regarding local labour rates and prices of construction materials.

- It is assumed that the project will be commissioned in 18 months from

the zero date.

- The project is proposed to be financed in the debt equity ratio of 2:1.

- Long term loans bearing an interest rate of 12.5% per annum is proposed
to be repaid in 16 equal consecutive semi-annual installments, the first
installment falling due six months after commissioning of the project.

- Interest during construction is worked out based on the above

construction schedule and mode of financing.

14 PRODUCTION COST

14.1 General

The annual production capacity envisaged for the proposed sintering plant is 4.0
million tons.

It is assumed that the plant would operate at a capacity utilisation of 90% in 1st
year and 100% thereafter.

14.2 Annual production cost

Taking into account the above factors, production costs for the plant have been
estimated on an annual basis at 100% capacity utilisation based on various

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FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

technological parameters and specific consumption of raw materials and various

services dealt within the technological chapters and are given in table-15.01.
Year wise production cost is shown in Annexure-15.01.

The estimated costs are based on the cost of materials, labour and supervision,
consumables, power, fuel and other services costs as prevailing in the first
quarter of 2004. No provision has been made in the estimate towards future
escalation in costs. The various assumptions made in working out production
cost are given in the following paragraphs.

14.3 Materials
The raw materials required for production of sinter are iron ore fines, lime stone,
dolomite, coke breeze, mill scale, flue dust, calcined lime, blast furnace return
dust etc.

14.4 Utilities

The unit rates for various utilities adopted for calculation of production cost are
indicated in table-15.02.

Sl. No. Item Unit Rate

1 Power Kwh 2.65
2 Corex Gas Nm3 1.48
3 Water cum 5.5

Table 15.02

14.5 Stores & spares, over heads and salaries

Stores & spares cover cost towards repair and maintenance of plant, machinery
and buildings. Overheads include provision for rent, rates and taxes, insurance
and miscellaneous expenses. Expenses towards salaries & wages are also
considered in the estimate.

14.6 Interest
Following interest rates have been considered for various types of financing
arrangements.

- Long term loan : 12.5 % p.a

- Working capital loan : 12.5 % p.a
14.7 Depreciation
Depreciation has been considered on straight line basis.

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

15. FINANCIAL ANALYSIS

15.1 General
The financial analysis for the proposed sintering plant complex has been carried
out on the basis of capital and production costs as enumerated in the previous
chapters and considering the benefits arising out of using sinter in the blast
furnace burden. The salient financial indices are given in table-16.01.

SALIENT FINANCIAL INDICES

Sl.
Index Unit Value
No.
1. Cumulative profit over 10 years of
Rs. Lakhs 58128
operation
2. Average profit per year over 10
Rs. Lakhs 5813
years of operation
3. Cumulative cash surplus over 10
Rs. Lakhs 52705
years of operation
4. Break even capacity
i) 1st year of stabilised operation
 Conventional % 38.2
 Cash % 27.5
ii) 3rd year of stabilised production
 Conventional % 33.0
 Cash % 22.3
5. Internal rate of return % 29.7
6. Debt service coverage ratio 2.2
7. Payback period Years 3.9

Table 16.1
Note: Debt service coverage ratio of 2.2 is the average of the initial 8 years of
operation.

15.2 Estimates of working results and cash flow statements

Estimates of working results and cash flow statements for the proposed sinter
plant complex have been worked out for 10 years of operation. Details are given
in Annexures 16.01and 16.02 respectively.

15.3 Break even capacity

The break even capacity for the proposed sintering plant complex in the first

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 JSW STEEL LIMITED, DOLVI WORKS
FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

year of stabilised operation works out to 38.2% of the rated capacity of the plant
on conventional basis and 27.5% on cash basis. Details of the working for 1st
and 3rd years of stabilised operation are given in Annexure 16.03.

15.4 Internal rate of return

Based on the cash flow statements for 10 years of operation, the internal rate of
return (IRR) has been calculated employing the discounted cash flow method.
The IRR after tax works out to 29.7% and IRR on pretax basis works out to
37.1%. Details of the workings are given in Annexure 16.04.

15.5 Debt service coverage ratio

Debt service coverage ratio (DSCR) defines the project's ability to meet its
commitment with respect to repayment of loans and payment of interest charges.
The average DSCR for the project over the repayment period of term loans i.e.
the initial 8 years of operation works out to 2.2. Details of the workings are
given in Annexure 16.05.

15.6 Payback period

The payback period of a project is defined as the period required to recuperate

the original investment outlay through cash accruals. The payback period for
the sintering plant complex works out to 3.9 years from the begining of
operation. Details of workings are given in Annexure 16.06.

15.7 Assumptions

The following assumptions have been made while carrying out the financial
analysis.

- The benefits accruing by the use of sinter in the blast furnace burden has
been considered as the returns for the project. The benefits are reduction
in the works cost of hot metal as well as the increase in productivity of
the blast furnace. Notional net sales realisation for sinter has been arrived
at by adding the above benefits to the works cost of sinter. The notional
net sales realisation works out to Rs 2336 /t

- Interest rates on loans have been taken as follows:

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FR FOR PELLET PLANT #2
AT DOLVI, MAHARASHTRA

Long term loan : 12.5 % p.a

Working capital loan : 12.5 % p.a

It is proposed to repay the long term loan in 16 equal consecutive

semiannual installments, the first installment falling due 6 months after
commissioning of the project.

- Depreciation has been considered as follows :

For tax For profit & loss

WDV account st. line
Buildings 10% 3.34%
Plant and machinery 25% 5.28%

- Investment towards preliminary expenses including its contingencies

has been written-off over a period of 10 years.

- It has been assumed that the plant would be able to achieve production
capacities of 90% and 100% in first year and second year onwards
respectively after commissioning of the plant.

- Corporate tax has been considered at the rate of 35% of the taxable profit
and a surcharge of 2.5% thereon.

15.8 Conclusion

It is seen from the financial analysis that the setting up of the sintering plant
yields attractive returns. In addition, it also helps in productive utililsation of
various fines generated in the plant during various production processes. In view
of the above, it is recommended to implement the project.

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