Professional Documents
Culture Documents
For
(February 2015)
:: Prepared by ::
Indus Technical and Financial Consultants Ltd.
205, Main Road, Samta Colony Lalit Kumar Singhania
Raipur (CG) 492001 Chief Consultant
Tel: 0771 4266037, 3267187 Email: lalit1954@gmail.com
Fax: 0771 2254188
Website: www.itfcl.com
Email: indusryp@gmail.com
INDEX
S . No. Heading Page No.
1 Executive Summary 1
2 Introduction of project/ Background information 7
2.1 Identification of project and proponent. 7
2.2 Brief description of the nature of the project 9
2.3 Need for the project and its importance to 9
the country and region.
2.4 Demand –Supply Gap 13
2.5 Imports Vs. Indigenous production 16
2.6 Export possibility 16
2.7 Domestic/ Export market 17
2.8 Employment Generation (Direct and 17
Indirect) due to the project
3 Project Description 20
3.1 Type of project including interlinked and 20
interdependent project, if any.
3.2 Location (map showing general location, 22
specific location, and project boundary and
project site layout) with coordinates
3.3 Details of alternate sites considered and the 27
basis of selecting the proposed site,
particularly the environmental
considerations.
3.4 Size and magnitude of the operation 27
3.5 Project description with process details (a 31
schematic diagram/ flow chart showing the
project layout, components of the project
etc.)
3.5.1 Manufacturing Process of Sponge Iron 31
(DRI)
3.5.2 Manufacturing process of Pig Iron through 37
Mini Blast Furnace
3.5.3 Process and Process Flow diagram of Iron 42
Ore and other Mineral Ore Beneficaiton
Plant
3.5.4 Process and Process Flow diagram of Coal 49
Washery
3.5.5 Manufacturing process of reducing metallic 59
mineral ore to metal power such as Iron
Powder through Tunnel Kiln
3.5.6 Process and Process Flow diagram of 66
Mineral Briquetting Plant
3.5.7 Manufacturing process of Ferro Alloys 67
Plant
3.5.8 Manufacturing process of Semi finished i.e. 69
Billet through Induction furnace based
Steel Melting Shop with CCM
3.5.9 Manufacturing process of Rerolled steel 72
through Rolling Mill
3.5.10 Process and Process flow diagram of Power 74
generation through CFBC based Power
Plant
3.5.11 Process and Process flow diagram of Brick 77
making from waste
Figures
Figure Heading Page No.
No.
1. District and Tahsil Location 23
2 Location Map of proposed site 24
3 Location and Layout of the Proposed Project 25
4 Road Network for Raw Material and Finished good 26
transportation
Appendix
Appendix Heading Page No.
No.
1 List of Sponge Iron Plants in Odisha 142
2 List of Sponge Iron Plants in Raigarh 147
(Chhattisgarh)
3 Mahanadi Coal field Limited’s Coal field in 148
Orissa
4 List of Iron Ore Mines in Odisha 151
5 Estimation of Profit and Loss Account 155
6 Margin Money and Working Capital Calculation 156
7 Cash Flow Statement 157
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
1. EXECUTIVE SUMMARY:
Page |1
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
gasification capacity or
3500 Nm3/hr i.e. 21
Million m3 per year
producer gas.
Page |3
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
(Rs.in Lakhs)
Cost of Project Existing Proposed Total Amount
(In Rs. Lakhs)
Phase-I Phase-II ( Tunnel
(Modernizati Kiln, Ore
on of Blast Beneficiation, Coal
Furnace, Washery, Power
SMS, Rolling Plant, Submerged
Mill and Arc Furnace ( Ferro
expansion of Alloys Plant), Brick
Cold making )
Briquetting
Plant)
Land & Site 580.00 100.00 680.00
Develop.
Building & Civil 746.00 849.00 1833.00 3428.00
Work
Plant & 1249.00 3296.00 7642.00 12187.00
Machinery &
Other equipments
Misc. Fixed 1079.00 180.00 145.00 1404.00
Assets auxiliary
Electrical 508.00 625.00 175.00 1308.00
Installations
Pollution Control 678.00 500.00 222.00 1400.00
Equipment
Pre. And 421.00 269.00 690.00
Preoperative Exp.
Contingency 478.00 504.00 982.00
TOTAL :: 4840.00 6349.00 10890.00 22079.00
DEBT 15500.00
Term Loan from Bank
TOTAL :: 22079.00
Page |4
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Page |5
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Page |6
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
2. INTRODUCTION:-
Page |7
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Page |8
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
2.3 Need for the project and its importance to the country and/or
region.
Steel is one of the most important products of the modern world and is
of strategic importance for any industrial nation. Historically, all
nations during their industrialization phase have been supported by a
strong steel industry of their own. From construction, industrial
machinery to consumer products, steel finds a wide variety of
applications. It is also an industry with diverse technologies based on
the nature and extent of use of raw materials.
India is the 4th largest producer of steel in the world accounting for
production of 81.54 million tons of crude steel in 2013-14. It also holds
the third position in consumption of steel. Thus there is great potential
in steel industry in India.
Honorable Prime Minister Shri Narendra Modi has envisage the growth
of steel sector to attain a production capacity of 300 Million Tonnes by
Page |9
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
In addition to these the proposed coal washery is also going to add for
promotion of cleaner technology in which a lower grade coal would be
beneficiated to higher grade coal as result of which better energy
efficiency will be achieved in the existing sponge iron kilns who would
be utilizing high grade beneficiated coal and similarly better energy
efficiency will be achieved in the thermal power plants which would be
utilizing high energy content beneficiated coal. It is reported under a
study that the beneficiated high calorie coal can bring down the GHG
emission by more than 11%; by improving the energy efficiency. This
also results in lower capital cost for handling and transport of fuel and
ash at the non pit head power plants located beyond 1000kms distance.
P a g e | 10
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
It also reduces the cost of fuel transport and reduces the burden of
transport on Railway infrastructure too.
Several advantage to the nation with respect to the sponge iron plant
and power plants sector by setting up Coal washery are presented
herewith:
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 12
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
GLOBAL SCENARIO
• In 2013 the world crude steel production reached 1606 million
tonnes (mt) and showed a growth of 3% over 2012. (Source:
World Steel Association or WSA)
P a g e | 13
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
DOMESTIC SCENARIO
• The Indian steel industry has entered into a new development
stage from 2007-08, riding high on the resurgent economy and
rising demand for steel.
• Rapid rise in production has resulted in India becoming the 4 the
largest producer of crude steel and the largest producer of
sponge iron or DRI in the world.
• As per the report of the Working Group on Steel for the 12 th
Plan, there exist many factors which carry the potential of
raising the per capita steel consumption in the country, currently
at 59.2 kg. These include among others, an estimated
infrastructure investment of nearly a trillion dollars, a projected
growth of manufacturing from current 8% to 11-12%, increase in
urban population to 600 million by 2030 from the current level of
400 million, emergence of the rural market for steel currently
consuming around 10 kg per annum buoyed by projects like
Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv
Gandhi Awaas Yojana among others.
P a g e | 14
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
• At the time of its release, the National Steel Policy 2005 had
envisaged steel production to reach 110 million tonnes by 2019-
20. However, based on the assessment of the current ongoing
projects, both in greenfield and brownfield, the Working Group
on Steel for the 12th Plan has projected that the crude steel steel
capacity in the county is likely to be 140 mt by 2016-17 and has
the potential to reach 149 mt if all requirements are adequately
met.
• The National Steel Policy 2005 is currently being reviewed
keeping in mind the rapid developments in the domestic steel
industry (both on the supply and demand sides) as well as the
stable growth of the Indian economy since the release of the
Policy in 2005.
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
50% of the Coal produced is used only after washing. Thus there
is a great need to create facility for washing of Coal around the
Coal mines.
In view of this also the importance for a good quality washery becomes
most essential. The Indian infrastructure sector is likely see a massive
growth due to increasing economic status thus in order to keep the
supply ready to match the demand of construction steel the additional
capacity of TMT steel Bars is most immediate requirement of time.
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 18
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
575.00 1203.00
Add : Benefits 30.00% 360.90
Sub Total :: 1563.90
P a g e | 19
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
3. PROJECT DESCRIPTION
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
capacity. The Tunnel kilns will require the producer gas for the thermal
energy so the Coal producer gas plants are proposed. Two producer gas
plants for these two tunnel kilns will be built. These tunnel kilns are
also being setup with a semi commercial intention to carryout
technology development program also. In which reduction of various
metallic mineral through direct reduction process is proposed to be
attempted, as well as trial for producing pellets of iron ore or other
mineral by way of indirect heat transfer through saggers are exposing to
direct flame heat through the carrier trolleys is also proposed. For the
sake of considering the viability the proposed capacity of tunnel kilns in
form of Iron Powder is assessed as 60000 TPA for both the kilns in
total, whereas, the capacity in terms of other mineral reduction may
vary but not likely to beyond 60000 TPA. The fundamental technology
proposed in the tunnel kiln is use of saggers in which reductent and
mineral metal are filled in and pushed in to the staged trolleys in the
tunnel kiln in which around 12000C temperature is maintained for
reduction energy required. The thermal energy in the tunnel kiln is
produced through the producer gas plants proposed in the project.
P a g e | 21
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 23
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 24
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 25
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 26
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
3.3 Details of alternate sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone
into should be highlighted.
- Not required.
P a g e | 27
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
m3
Total 200 TPD 60000.00 TPD
Capacity
of Blast
Furnace
after
expansion
c) Iron
Powder Tunnel Kilsn Iron Powder 60000.00 TPA
and other based Iron
direct Power making
reduced about 100 TPD
metal from x 2 Nos,= 200
ore; Like TPD
Manganes
e; Chrome;
Nickel
d) Induction 12 MT X 3 Mild Steel 110000.00 TPA
Melting Nos.Induction Billets
Furnaces Furnace and 1
and LRF No. 25 MT
LRF with
three strand 4
meter X 8
meter
Continues
Casting
Machine
(CCM)
e) Re-rolling Direct hot Re Rolled Steel 100000.00 TPA
mills charging Products like;
facility with TMT; Wire Rod
steel rerolling
mill having
about 300 TPD
f) Power Circulating Electrical 8.00 MW
Plant Fluidized Bed Energy in terms
boiler with 8 of generation
MW STG capacity
based on installed
washery reject
P a g e | 28
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
producing Pig
Iron
l) Brick Fly Ash and Brick/Blocks 66000.00 TPA
making other waste
from waste material based
Brick making
unit of 200
TPD
P a g e | 30
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The other important property of iron ore for making sponge iron
is its deductibility. Since the process of sponge iron manufacture
is solid and gas reaction, the gas should penetrate the ore to take
oxygen from ore. If the deductibility characteristics of iron ore
are good, processing can be done at even a lower temperature and
thus the problems of accretion can be avoided. Due to low
temperature processing, consumption of coal per ton of sponge
iron is also reduced and as a whole the campaign life becomes
higher.
P a g e | 31
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
FeT 65 to 67%.
SiO2 0.7 TO 1.0%.
P 0.05% max.
S 0.01% max.
AL2O 3 0.5 to 1.7%.
MgO 0.02 to 0.03%.
CaO 0.10%.
Physical Property
Tumbling Index More than 88%.
Abrasion Index Less than 2%.
Reductibility 7.00 to 10 hFE minimum.
Size 5mm to 20mm.
The proposed sponge iron plant can also utilize the Iron ore
Pellets, which are now being manufactured by a large number of
iron ore beneficiation cum pelletization plants. A number of
units have already commence production in Odisha and West
Bengal form whom substantial quantity of iron ore pellets is also
available.
2. COAL :
Coal is a combustible solid fuel formed by the burial of partially
decomposed vegetation in past geological ages. The coal used for
sponge iron manufacture should be of the following property :
Volatiles 28 – 32%
Ash 25 – 30%
F.C. 40 – 42%
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Size of the coal also plays an important role. The size of the coal
to be fed from the feed and side should be of 5-20mm size. 10%
of 20-25mm size can also be tolerable. Bigger size coal
segregates and floats on the bed and gets burnt without going into
the bed.
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The waste gas from the kiln contain lot of combustibles like coal
volatiles, unused CO, about 10 to 12% carbon particles and lot of
other dust. The gas is taken to an after burner chamber and the
combustibles are burnt is cooled to about 160 deg. C and taken to
ESP for final dust separation, before going to stack via ID Fans.
The rotational speed of the kiln is adjustable as per the feed rate
and percentage of metallization. The % of inclination, rotational
speed, the length of time the material is exposed to atmosphere,
the kiln temperatures are all to be taken into consideration. So the
kiln has three functions :
A. It is a heat exchange.
B. It is a vessel for chemical reaction.
C. It is a conveyor of solids.
P a g e | 34
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
REACTION VESSEL
The kiln is also a reaction vessel. The following reaction takes
place inside the kiln :
3 Fe2O3 2 Fe3O4 6 FeO 6 Fe
CO2 + C = 2 CO
Fe3O4 + CO = 3 FeO + CO
CO2 + C = 2 CO
FeO + C = Fe + CO2
A . Quantity of reductant
B . Temperature
C . Residence time
P a g e | 35
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
A . QUANTITY OF REDUCTANTS :
From the chemical reactions it is seen that as the % of O2 reduces
in the ore, the % of carbon requirement increases. If there is a
shortfall of carbon the reaction proceeds in a reverse way i.e.
From reduction to oxidation. The reduction reaction is
endothermic (absorbs heat) while the oxidation reaction is
exothermic. In the absence of reductant the temperature goes up
and sinter formation, ball formation and accretion starts.
B. TEMPERATURE
As the coal is mixed with iron ore, it passes from feed end side
and air is blown from the blowers into the kiln, the liberated CO
reacts with oxide material. This reaction lowers the temperature
of the bed due to its endothermic nature. It is necessary to
generate sufficient heat before the bed temperature falls. The
gases coming out from the bed are the mixture of decomposed
and partially oxidized fuels. By adding air to these mixtures of
gases, combustion and heat generation takes place and the heat is
radiated to the bed, the mechanism of which has already been
discussed earlier. As regards the temperature profile, the first 20
– 25% is preheat zone where the material is heated up to 850 deg.
C and then to reduction temperature of about 1000 deg. C to 1050
deg. C. Iron ore once reaches 850 deg. C, the surface gets
reduced and generates less fines. So it is required to heat up the
ore to 850 deg. C as quick as possible and 70% of the kiln is
taken to 1000 to 1050 deg. C for reduction purpose.
P a g e | 36
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
C. RESIDENCE TIME
The total residence time of the material in the kiln is a function of
the feed rate and kiln rpm. With each increment in feed rate, the
kiln seed is increased to maintain a constant bed loading in the
kiln.
P a g e | 37
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
or
FeO + C = CO + Fe
At the same time the iron oxides are going through these
purifying reactions, they are also beginning to soften then melt
and finally trickle as liquid iron through the coke to the bottom of
the furnace.
The coke descends to the bottom of the furnace to the level where
the preheated air or hot blast enters the blast furnace. The coke is
ignited by this hot blast and immediately reacts to generate heat
as follows:
C + O2 = CO2 + Heat
Since the reaction takes place in the presence of excess carbon at
a high temperature the carbon dioxide is reduced to carbon
monoxide as follows:
CO2+ C = 2CO
The product of this reaction, carbon monoxide, is necessary to
reduce the iron ore as seen in the previous iron oxide reactions.
The limestone descends in the blast furnace and remains a solid
while going through its first reaction as follows:
CaCO3 = CaO + CO2
This reaction requires energy and starts at about 1600°F. The
CaO formed from this reaction is used to remove sulfur from the
iron which is necessary before the hot metal becomes steel. This
sulfur removing reaction is:
FeS + CaO + C = CaS + FeO + CO
The CaS becomes part of the slag. The slag is also formed from
any remaining Silica (SiO 2), Alumina (Al 2O3), Magnesia (MgO)
or Calcia (CaO) that entered with the iron ore, pellets, sinter or
coke. The liquid slag then trickles through the coke bed to the
P a g e | 39
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 40
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
At present the liquid pig iron is being casted in Pigs and sold in
market. In future after the Steel melting facilities are created then
the Liquid Iron will be transferred to SMS area for the production
of liquid steel. For this the cast house will be bye passed and the
Laddles will be used for transfer of liquid iron.
P a g e | 41
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
3.5.3 Process and Process Flow diagram of Iron Ore and other
Mineral Ore Beneficiation Plant
Magnetic Separator
Cyclone (separates
Rinser Mixer(wash
Dewatering Screen
& Final Product
Hopper Screen
(Concentrate)
with water)
Material)
Hopper & Screener
Vibrating screens are used to separate bulk materials in a mixture of
different sized particles. For example sand, gravel, river rock and
crushed rock, and other aggregates are often separated by size using
vibrating screens. Screener one of the unique product or equipment
manufactured and is used for separating the stuff. Screener is compiled
of mainframe, eccentric bock, and screen web, rub spring, electric
motor, coupler and some more.
-
P a g e | 42
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ball Mill
- A Ball Mill a type of grinder is a cylindrical device used in grinding
(or mixing) materials like ores, chemicals, ceramic raw materials
and paints.
Ball Mills rotate around a horizontal axis, partially filled with the
material to be ground plus the grinding medium. Different materials
are used as media, including ceramic balls, flint pebbles and
stainless steel balls. An internal cascading effect reduces the
material to a fine powder.
Industrial ball mills can operate continuously fed at one end and
discharged at the other end. Large to medium-sized ball mills are
mechanically rotated on their axis but small ones normally consist of
a cylindrical capped container that sits on two drive shafts (pulleys
and belts are used to transmit rotary motion.
P a g e | 43
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Magnetic Separator:
Hi Gauss magnetic separator will be used for separation of Iron
bearing oxides from the grounded ore. This magnetic separator will
also be useful in beneficiating other metal ores also in which Iron
bearing oxides form an essential impurity which requires to be
removed. The magnetic separation step will be deployed as per the
quality of the mineral being processed. The magnetic separation also
will be done on the wet slurry stage. The outflow of Magnetically
selected sludge will then be passed thru the Rinser to remove the
dissolved clay with the Ores.
P a g e | 44
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
-
P a g e | 45
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Cyclone Machine
- In closed circuit grinding system, it features high classification
efficiency and fine over fall fineness under high mine concentration.
(Hydrocyclone)Classification efficiency is higher for 5-10% than
common screw grader. It benefits for enhancing grader
utilizing. Fine materials, in gangue cannot be used as dam materials
during selecting mine. After the classification by cyclone, coarse
granule left in the bottom of dam, fine granule move to the tail of
gangue. (Hydrocyclone) Fine granule graded naturally during the
movement. There is section full of clean water, which can be used
for calling back of water. In the process of filling tail, we utilize
hydro cyclone for grading and concentrating to separate coarse
granule so that to reduce load of filtering machine and to reach at the
best effect. (Hydrocyclone) Use cyclone to finish dam and filling
work so that to solve problems such as leaking mine, sink and over
proof water discharged. So it can receive obvious economic and
social benefit.
P a g e | 46
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
De-Watering Screen
Dewatering is an important process in mineral beneficiation
processing. The purpose of dewatering is to remove water absorbed
by the particles which increases the pulp density. This is done for a
number of reasons, specifically, to enable ore handling and
concentrates to be transported easily, allow further processing to
occur and to dispose of the gangue. The water extracted from the ore
by dewatering is re-circulated for plant operations after being sent to
a water treatment plant. These processes increase in difficulty and
cost as the particle size decreases.
P a g e | 47
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Water + Ore
Hopper
Ball Mill
More than 1
Magnetic
Separator
Wet Screen
Less than 1 mm
Washed Material
Concentrate Ore with Water/Clay + moisture
De-watering Screen
P a g e | 48
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The selection of Wet Coal washing process depends mainly upon the
following criterion.
From the above table is clear that HY Bath process is the suitable
process for treating high NGM Indian Coal. Moreover from the
efficiency point also the HM Bath process is most suitable process
which gives lowest EQ (Escort probable –means Error probable)
Lowest misplacement .A comparison of EP achievable in various
processes are given below.
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Process
It is proposed to procure install and commission a 1.85 LTPY (35 TPH)
coal processing unit for SPL. The 35 tph plant is likely to run in two
shifts for 330 days to cater to the need of the internal requirements of
washed Coal.
The proposed washery shall incorporate the latest designs and the latest
equipments and shall be a heavy media cyclone/bath based coal
beneficiation processing unit.
ROM shall be delivered to the truck dump station via tippers and the
capacity of the truck dump hopper shall be 25tons and above. The truck
P a g e | 50
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
dump shall be an elevated bunker with access for trucks to unload the
ROM into the hopper.
Rotary Breaker:
It is also proposed to set up a Rotary breaker by which it will be
possible to remove the shell and stone to a great extent and the semi
beneficiated coal will be further washed for the improvement of quality.
P a g e | 51
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 52
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
A separate pan section under later part of each drain and rinse screen
shall collect the heavy medium which has been rinsed and diluted with
screen spray water. This dilute medium shall be collected in the dilute
medium sump and pumped to one magnetic separator for recovery of
the magnetite. Recovered magnetite from the separators and the fresh
dry magnetite from the raw magnetite storage bin shall be directed to
the heavy Medium cyclone feed sump The tailings from the magnetic
separator shall be piped to raw coal desliming screen for use as sluice
push water.
The reject coal from the reject D&R screen is discharged over the
reject coal belt conveyor for suitable stockpiling. The clean coal is
discharged over the clean coal belt con veyor where the clean coal
P a g e | 53
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
may be blended with the raw bypass coal if required in the ratio to
give final ash content as required by the end user. The product on
conveyor is carried to a clean coal load out bin which has Clamshell
gate at the discharge for loading coal onto trucks.
The effluent treatment plant consists of one Hi-rate thickener and its
associated flocculent dosing system, underflow sludge carrying pump
and a multi roll belt press.
The effluent from the plant, which reports (Flows) to the hi-rate
thickener is collected in the thickener tank. This tank is dosed with
suitable amounts of flocculent which aids settlement of suspended
solids and helps to give a clearer overflow.
The settled solids are collected at the bottom cone of the thickener tank
by rotating rake arms the height of which can be adjusted if the amount
of solids in the effluents increases.
The solids which are collected in the bottom of the thickener is pumped
using a special centrifugal pump to the multi roll belt press for
reclamation of water. The dried cakes are blended with the rejects.
The proposed plant is a zero effluent plant and the process selected
ensures minimum generation of dust.
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 55
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
• Area in and around the coal washery shall be pucca either asphalted
or concreted.
• Green belt must be developed along the road side, coal handling
plants, residential complexes, office building and all around the
boundary line of the coal washery.
P a g e | 56
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 57
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 58
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 59
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 60
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The cars are then pushed through the tunnel kilns. Figure 4 shows
the photograph of car pushing system. The time between two cars
entering the kiln is called the "pushing time". The tunnel kiln
consists of three zones; the preheating zone, the reduction zone,
and the cooling zone. Schematic of the tunnel kiln is depicted in
Figure 5. The kiln cars first travel through the preheating zone,
then through the reduction zone, where the ore is reduced into
iron at a constant high temperature of 1100-1200°C. The kiln
cars are then cooled in the cooling zone of the kiln. It takes
approximately 28-36 hours for a kiln car to travel through a kiln.
The time of travel may vary from plant to plant. The combustion
air flows in the opposite direction of the kiln cars. Cold fresh air
first cools the hot cars and after passing through the reduction
zone, hot exhaust gases preheat the incoming cars before the
gases exit the kilns. Because of concentric feeding of raw
material inside the sagger, the coal ash and sponge iron, a
product, remain separate inside the sagger. The product, thus
formed, can be separated easily. Figure 6 shows the iron powder
in the form of a cylinder.
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The consumption norms will vary as per the quality of input raw
materials. Instead of coke if coal is used then the quantity will
further increase. With Chinese/anthracite coal the consumption is
about 0.9 to 1.1 tonnes per tonne of iron powder. With Indian
coal, the consumption is expected to be more. However the use of
Washed Coal will ensure that the total consumption of Coal does
not exceed 0.9 tonnes per tonne of Iron powder produced. Out of
P a g e | 62
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
the total coal, 75% will be utilized for iron ore reduction and the
remaining 25% will be used to produce coal gas.
P a g e | 63
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The next generation gasification system are equipped with LTC shaft
and 100% top off take of producer gas conversion system. In which
Low Temperature Carbonization (LTC) is the term for the conversion
of organic substance of volatile matter into carbon and light carbon-
containing compound through low temperature destructive distillation
of feed coal. As about 90% heavy organic compound (sticky tar) of the
total volatile matters of Coal convert in to free hydrogen, carbon and
lighter hydrocarbon (Free Flow Tar) which makes gas free from heavy
hydrocarbon vapor (Sticky TAR).
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
coal– bed has been introduced above the insignificant product gas space
and minimal distillation zone of the single stage gas-producer the
product gas has been diverted fully through this extended coal bed to
come out from the top of the extended shaft at a temperature much
below the cracking temperature of sticky TAR.
P a g e | 65
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 66
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The alloy cake from C.I. pan is removed and broken manually
with hammer to required lump size.
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 68
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
(iii) CCM:
The ladle containing liquid steel will be placed on the CCM
platform and continuous casting of hot billet will be carried out in
the same for which one 3 strand CCM with 4 mtr x 8 mtr radius
will be setup, the casting will be done through a highly
automated controlled cooling software governed mechanism by
which the casted billet will be so cooled that the temperature of
billets do not fall below 1050 0C. The case formation in the CCM
mould starts with drop in surface temperature below 15200C, the
liquid metal inside the case contains enough energy for
maintaining the overall temperature of billet for hot online
rolling. In the CCM section hot billet shearing machines will be
installed with each casting strand, so as to facilitate the cutting of
billets to proper length for feeding in to the rolling mill.
P a g e | 70
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 71
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
1. Raw Material i.e. Billet coming from CCM in red hot condition
is cut either by Gas Cutting or automatic hot billet Shearing
Machine. In the proposed plant automatic hot billet shear
machines are going to be installed with each strand. The gas
cutting facility will be maintained as a backup to the hot billet
shearing machine,
2. After the Billet is cut into required length, then pushed out to
rolling stands for re-rolling. Steel Pieces are rolled through all
stands in order to get required shape of finished goods i.e.
TMT/Wire rod/ Bars. It is proposed to produce TMT bars at
present; however in future the Mills may be used to produce Wire
Rod or Structure also.
P a g e | 72
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 73
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The condensed water (condensate) is then fed back to the boiler by the
PUMP (P), and the cycle goes on repeating itself. The working
substance water, thus follows along B-T-C-P path of the cycle
interacting externally. Since the fluid is undergoing a cycle process,
there will be no net change in its internal energy over the cycle and
consequently, the net energy transferred to the unit mass of fluid as heat
during the cycle must equal the net energy transfer as work from the
fluid.
P a g e | 74
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 75
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Deoxidation:
Steam from the turbine is fed from the bottom. By contact, the
steam condenses and the feed water is heated to the saturation
temperature. Dissolved oxygen and carbon di-oxide gases gets
released from the water and leave along with some vapour, which
is condensed back in the vent condenser, and the gases are vented
out. To neutralize the effect of residual dissolved oxygen and
carbon-di-oxide gases in water, sodium sulphite (Na2SO3) is
injected in suitable calculated doses into the feed water at the
suction of the boiler feed pump (BFP)
Generator:
The mechanical shaft power generated in steam turbine is
converted by the generator in to electricity which is generated at
11 KV. The generated power is then boosted to 33 KV for
internal consumption as well as grid synchronization. The
generated power being mainly for captive use thus the
synchronization at 33 kV is sufficient. However if for any reason
the plant is not able to consume the power then the surplus power
will be exported to the grid at 33 kV itself. The grid connectivity
at 33 kV will be obtained from nearest substation at Rajgangpur.
P a g e | 76
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 77
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 78
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 79
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 80
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 81
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 82
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
transported
through
covered trucks.
Un Washed Coal 177834.86 From market. By rail/road
(ROM) through
covered truck
For internal use
transported
through
covered trucks.
Heavy Media 370.00 From market. By road
(Magnetite) through
covered truck
For internal use
transported
through
covered trucks.
Low grade Iron 264000.00 From outside iron By rail/road
Ore ore mines. through
(list of iron ore covered truck
mines in Odisha is For internal use
provided in transported
Appendix 4) through
covered trucks.
Mn Ore 46700.00 From market. By road
through
covered truck
For internal use
transported
through
covered trucks.
Manganese Slag 4670.00 From market. By road
through
covered truck
For internal use
transported
through
covered trucks.
Paste 583.75 From market. By road
through
covered truck
P a g e | 84
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 85
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 86
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Coal Washery:-
Raw Material Total Internally Net to be
quantity transferred purchased from
required outside
ROM Coal 177834.86 177834.86
required 0.00
ROM coal 7165.14
required from job 7165.14 (to be provided
provided 0 by Job provider)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
calculation)
(Other mineral
may be like
Manganese Ore;
Nickel Ore;
Chrome Ore etc)
P a g e | 89
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 90
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 91
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
- The fly ash generated shall be given free to cement industry and
remaining ash if any will be given to bricks making units.
- The Ferro Alloy slag will be used for road making, as the slag has
good mechanical strength for road making.
- Char- dolochar from sponge iron plant will be used for power
generation in own power plant.
P a g e | 92
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
- The waste water generated from reverse osmosis system will be used
in coal washery.
- Mill scale generated in the rolling mill will 100% be used in ferro
alloys plant.
P a g e | 93
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Prodn
/Annum Water Required Total Water
(MT/ MW) KL/Ton required
a) Sponge Iron
Plant 45000.00 MT 0.10 KL/MT 4500.00 KL
b) Iron Powder 60000.00 0.10 KL/MT 6000.00 KL
b) Blast Furnace 60000.00 MT 0.10 KL/MT 6000.00 KL
c) Steel
Production 110000.00 MT 0.10 KL/MT 11000.00 KL
d) Power
Production 46334.05 MWH 2.00 KL/MWH 92668.09 KL
e) Ferro Alloys 25000.00 MT 0.15 KL/MT 3750.00 KL
f) Coal washery 185000.00 MT 0.20 KL/MT 37000.00 KL
g) Ore Beneficiation 264000.00 MT 0.20 KL/MT 52800.00 KL
h) Cold
Briquetting Plant 200000.00 MT 0.05 KL/MT 10000.00 KL
i) for Re-rolling Mill complex 100000.00 MT 0.10 KL/MT 10000.00 KL
j) Fly Ash brick Making 5500.00 MT 0.10 KL/MT 550.00 KL
g) Human Consumption considering
persons
641 @ 25 Ltr/day for 330 days 5288.25 KL
P a g e | 94
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Power Requirement
Power requirement will be around 32.73 MW and out of which
Captive Power Plant of 8 MW will be built within the project
balance power will be drawn from electricity board (WESCO).
P a g e | 96
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 97
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
- The waste water generated from reverse osmosis system will be used
in coal washery.
- Mill scale generated in the rolling mill will 100% be used in ferro
alloys plant.
Waste for disposal sent Qty. Utilization /disposal
outside: MT/Year method
CFBC bottom Ash 38.42 Given to cement plant for
iron oxide supplementation
Shale & Sand Stone 5550.00 Either returned to job
provider or will be disposed
for road making or land fill
Broken Saggers 600.00 Sold in market
Low Grade Ore 66000.00 To be given to cement
plants like OCL
Fly Ash Bricks 66000.00 Used by metal recovery
plants and land filling
Granulated Blast Furnace 12000.00 To be given to cement plant
Slag or brick plants
Slag Generated due to 20000.00 Used by metal recovery
Ferro Alloys plants and land filling
Non Granulated Induction 2115.00 Used by metal recovery
Furnace Slag plants and land filling
Misc Dust like ESP 600.00 To be given to cement plant
or brick plants
Defective billets, miss-rolls 4683.67 Used by metal recovery
generated plants
P a g e | 98
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 99
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 102
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
4. SITE ANALYSIS
4.1 Connectivity.
The area is located at Village Barpali (Laing), Tehsil-Rajgangpur,
District- Sundergrh, Nearest Railway station Rajgngpur about 10 KM in
W direction and nearest Air port is Ranchi about 180 Km.
P a g e | 103
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Area in
Land Use Statement Sq.meter
Green Belt 60400
Road 5400
storage area 9100
open area 9100
Factory Shed 82300
residential 0
Parking 3600
Water Storage 10000
Admin building and Laboratory,
Workshop etc 3200
Total Area 183100
P a g e | 104
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
(1) TOPOGRAPHY :-
1 Topographic Location Latitude - 21º36’ N to 22º32’ N
Longitude- 83º32’E to 85º22’E
(Toposheet No. : 72 B/11 and 72 B/12)
2 Geographical Area 9712 SqKms
(Second largest district in the State
accounting for 6.23% of the total area)
3 Normal Rainfall 1657.1 mm
4 Forest Cover 4232.57 SqKms
(Second largest in the State accounting for
8.53% of the State total )
5 Major River Brahmani
Sankh & Koel – Tributary of Brahmani
IB- Tributary of Mahanadi
6 Major Soil Type Alluvial and Lateritic
(2) DEMOGRAPHY (As per 2011 Census)
1 Population 2,080,664
2 Males 1,055,723
3 Females 1,024,941
4 Density 214 (2011)
5 Sex Ratio (No. of Females per 1000 971
Males)
3. SOCIO-ECONOMIC FEATURES :-
1 Cultivated Land 3,36,000 Hects
High 1,86,000 Hects
Medium 95,000 Hects
Low 55,000 Hects
2 No. of cultivators 1,97,019
3 No. of Agricultural labourers 91,068
4 Average size of operational holdings 1.73 Hects
5 Class-wise number of operational
P a g e | 105
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
holdings
Class Number
Marginal 65,281
Small 51,767
Semi-medium 35,696
Medium 12,279
Large 984
TOTAL 1,66,007
6 Per capita availability of food grains Qtls.1.55
4. HEALTH UNITS :-
P a g e | 106
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Project Site
Project Site
P a g e | 107
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The Barhajore River flows from South to North at distance of about 1.5
KM from the project site, and joins the Shankh river after travelling
around 3.5 KM towards East site. The Shankh river flow from West to
East.
The project site is located about 207 meter above MSL whereas the
Shankh river flows around 190 meter above MSL.
The area is plain with moderate slope and having forest cover in small
patches.
P a g e | 108
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Permanent Land
Misc.Tree pastures & put to Barren & Net
Sl. Cultivable Current Other Forest
Block Geo.area crops & other non cultivable area
No waste fallow fallow area
grooves grazing agril. land sown
area uses
1 Hemgir 93238 250 3050 1122 2568 2709 8166 1925 21833 19324
2 Lephripara 64022 733 2024 1639 2092 638 4259 2391 12331 16174
3 Tangarpali 24966 693 1878 919 2786 445 3105 2987 2143 17251
4 Sundargarh 35988 315 1566 900 2869 1076 4697 3256 10128 19176
5 Subdegga 32428 642 1128 3889 3009 4466 1356 1763 6641 16607
6 Balisankara 108476 71 2030 6725 2602 893 1342 4063 10922 18418
7 Bargaon 35661 256 2445 959 2295 692 4380 2291 5883 16314
8 Kutra 31885 141 1090 1947 2859 305 3905 1167 3476 19433
9 Rajgangpur 34897 167 3360 2071 4656 2647 2774 2911 5251 18865
10 Lathikata 74904 22 1550 956 3610 1471 3679 1939 6832 24695
11 Kuarmunda 57672 79 1925 3955 5366 1934 2019 1697 12517 22519
12 Nuagaon 38888 70 1228 1816 2707 2407 4651 2582 2360 27480
P a g e | 109
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
13 Bisra 22560 12 874 508 1405 115 944 2509 1625 9364
14 Lahunipara 77768 46 1435 3135 2733 3160 4068 2708 8080 19244
15 Bonai 27077 314 985 1756 1939 535 1801 1103 9883 17088
16 Gurundia 125874 86 2144 2783 3146 6741 3862 2875 22394 16779
17 Koida 84940 - 1637 4865 2607 11428 6100 3158 18284 14269
Total 971244 3897 30349 39945 49249 41662 61108 41325 160583 313000
P a g e | 110
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
% of % of
Area(in Name of the % of the
Agroclimatic Geo.area Name of the Area (in Geo.area Area (in
'000 Blocks AES
zone of the AES '000 ha) of the ha.)
ha) covered zone
dist. dist.
AES-V
Lathikata 74904 32.63
High Rainfall
229552 17.06 Gurundia 125874 54.83
Black & Brown
Lahunipara 28774 12.54
forest Soil
Special group of
AES-III & V
High Rainfall
Lahunipara
Lateritic, Blacvk
& Brown forest
Soil
P a g e | 111
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 113
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
5 Planning Brief
Project concept:
The project is conceptualized in accordance to the present challenge of
minimizing Green House Gas (GHG) emissions from core sector of
industries like steel, power, mining etc.
The simplest solution for this is to utilization only high grade coal,
which is obtained from beneficiation of poor grade raw coal available
from Indian mines.
The second problem faced by the sponge iron industry was non-
availability of good quality iron ore at consistent prices. This
bottleneck has been now overcome by inception of a large number of
iron ore beneficiation cum pelletizatioin plant. This has made ample
P a g e | 114
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 115
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
In view of these facts and as per globally accepted mandate; that proper
( better) quality of fuel will result in to better energy efficiency in terms
of power generation as well as any process efficiency also. Even
Government of India imposed restriction on the quality of coal to be
used in power plants beyond a certain limit of ash percentage; located
beyond 1000 KM of coal mines.
P a g e | 116
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 117
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 118
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
The area has adequate facilities to transport the small and large quantity
of raw material as well as processed finished products as well as some
solid waste generated in the industry. The Rail net work as well as Road
net work is adequate. The Power transmission lines are also close bye.
However, due to increase economic growth the local youth will get
employed. And additional population influx of around 1000 people in
the 10 KM radius of plant can at best be estimated, which includes the
addition of persons dependent on the job seeking persons.
P a g e | 119
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
5.3 Land use planning (breakup along with green belt etc).
- Around 33 % (i.e. 6.04 Hect) of industrial land will be used for
green belt development. The details of land use planning is as
below:
Area in
Land Use Statement Sq.meter
Green Belt 60400
Road 5400
storage area 9100
open area 9100
Factroy Shed 82300
residential 0
Parking 3600
Water Storage 10000
Admin building and Laboratory,
Workshop etc 3200
Total Area 183100
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
- The DG set with about 1820 kVA (500 KVA X3 Nos and 320 KVA
X1 No) capacity is already installed for emergency backup supply to
meet the contingencies of power cut and power failure. Thus no
additional emergency arrangement is required.
- There is no other major infrastructural requirement for the project.
5.5 Amenities/Facilities:
- The project does not require additional large amenities or facilities.
As it already has necessary arrangement for proposed expansion for
meeting water supply for drinking purposes, toilet facilities for
workers as well as inward/outward transport operators, parking
facilities, as well as small canteen for workers and guests. The
septic tank has been built for disposal of domestic effluent
generated. A canteen with rest room is also available for the supply
of tea; snacks; food to the workers and drivers, visitors etc.
Sufficient parking space is already created for the parking of Trucks;
cars etc.
P a g e | 121
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
6. Proposed Infrastructure
6.1 Industrial Area (Processing Area)
Out of the total 183100 Sq.meter area, about 82300 Sq.meter land will
be used for constructing total shed including the existing sheds
remaining area will be for open space as well as road development,
water storage and green belt development etc as given in land use
statement.
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 123
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 124
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 125
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 126
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 127
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
In the second phase Tunnel Kiln ( Iron Powder) ; Coal beneficiation Plant;
Ore Beneficiation Plant, Power Plant and Ferro Alloys plants will be setup.
But in this phase the production of Iron Powder and Beneficiated Iron Ore
will require further 20 months to complete as per given schedule
P a g e | 128
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 129
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
DEBT 15500.00
Term Loan from Bank
P a g e | 130
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
TOTAL :: 22079.00
P a g e | 131
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 132
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 133
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 134
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 135
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
a) Profit & Loss A/c. 1204.50 2447.38 4818.74 5231.50 5004.61 4834.22 4748.51 4767.52
Term Loan 15500.00 13285.72 11071.44 8857.16 6642.88 4428.60 2214.32 0.00
Working Capital Loan 10762.43 12356.30 14095.30 14096.30 14096.30 14096.30 14097.30 14097.30
Fixed Assets.(Net) 19507.11 17434.22 15361.33 13288.44 11215.55 9142.66 7069.77 4996.88
Current Assets 14349.90 16698.30 19048.30 19049.30 19049.30 19049.30 19050.30 19050.30
Cash & Bank Balance 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06 1286.64
P a g e | 136
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
D.S.C.R. has been calculated for first 8 years because, the repayment of
term loan gets completed within 7 years in 12 half yearly installments,
after giving 1 years moratorium. The average DSCR has come to 1.63
which shows the sound and surplus position of reparability of term loan
and its interest.
(Rs.in lacks)
SERVICES
a) Net Profit After
Tax 1204.50 1268.24 2419.76 1763.83 1782.46 1840.11 1926.52 2033.38
b) Interest On Term
Loan 1937.50 1799.11 1522.32 1245.54 968.75 691.97 415.18 138.40
b) Installment of
T.L. 0.00 2214.28 2214.28 2214.28 2214.28 2214.28 2214.28 2214.32
P a g e | 137
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 138
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
YEARS GROSS INVENT- TOTAL OPERATING INTER- DEPREC- GROSS NET DISCOUNTED
FIXED -ORIES INVEST- PROFIT -EST -IATION CASH CASH VALUE AT
ASSETS -MENT INFLOW FLOW 25% 30%
-
0 22079.00 22079.00 22079.00 -22079.00 -22079.00
1 14349.90 14349.90 1273.50 3282.80 2072.89 6629.19 -7720.71 -6176.565 -5939.005
2 2348.40 2348.40 1337.24 3343.65 2072.89 6753.78 4405.38 2819.445 2606.735
3 2350.00 2350.00 2673.01 3284.23 2072.89 8030.13 5680.13 2908.227 2585.403
4 1.00 1.00 2731.66 3007.58 2072.89 7812.13 7811.13 3199.439 2734.894
5 0.00 0.00 2995.45 2730.79 2072.89 7799.13 7799.13 2555.619 2100.533
6 0.00 0.00 3260.23 2454.01 2072.89 7787.13 7787.13 2041.350 1613.308
7 3260.23 2454.01 2072.89 7787.13 7787.13 1633.080 1241.006
8 3260.23 2454.01 2072.89 7787.13 7787.13 1306.464 954.620
9 3260.23 2454.01 2072.89 7787.13 7787.13 1045.171 734.323
10 3260.23 2454.01 2072.89 7787.13 7787.13 836.137 564.864
11 3260.23 2454.01 2072.89 7787.13 7787.13 668.909 434.511
12 3260.23 2454.01 2072.89 7787.13 7787.13 535.128 334.239
13 3260.23 2454.01 2072.89 7787.13 7787.13 428.102 257.107
14 3260.23 2454.01 2072.89 7787.13 7787.13 342.482 197.775
15 3260.23 2454.01 2072.89 34231.99 34231.99 1204.431 668.778
-6731.58 -10989.91
= 4258.33
I.R.R. = 19.73%
P a g e | 139
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
9.1 Financial and social benefits with special emphasis on the benefit to
the local people including tribal population in the area.
The strength of the project lies on the use of washed coal in DRI
making, and use of thermal energy in liquid steel to maintain re-
rollable temperature in rolling of steel along with Captive Power
Generation technology based on the Waste Coal and Char Dolochar and
the technical strength of the promoters.
P a g e | 140
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
A sincere approach adopted for the Air Pollution Control and Resource
conservation by recycling the 100% waste water also gives the
additional advantage to the company. Power generation from Waste
Coal will give financial strength to the Company and Protect
Environment.
XXX
P a g e | 141
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 146
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 147
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
and lb River coalfield by V.Ball in 1871 yet the real impetus for
resource assesment by systematic exploration efforts was
accorded only in the post nationalisation era of the coal industry
since 1973, the importance of Orissa coalfields further enhanced
due to their vicinity to east coast.
P a g e | 149
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
IB Valley Coalfield
(Geological Reserve 24.198 BT As on 01.04.2014)
P a g e | 150
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 151
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 152
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 154
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
P a g e | 155
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
PARTICULARS Period 1st 2nd 3rd 4th 5th 6th 7th 8th
(days) Year Year Year Year Year Year Year Year
Raw Material 30 3242.10 3782.00 4323.00 4323.00 4323.00 4323.00 4323.00 4323.00
Consumables 30 77.30 77.30 77.30 77.30 77.30 77.30 77.30 77.30
Goods-in-process 10 1418.50 1647.00 1876.00 1876.00 1876.00 1876.00 1876.00 1876.00
Finished Goods 10 1383.00 1592.00 1800.00 1801.00 1801.00 1801.00 1802.00 1802.00
Receivables 45 8229.00 9600.00 10972.00 10972.00 10972.00 10972.00 10972.00 10972.00
TOTAL CURRENT ASSETS 14349.90 16698.30 19048.30 19049.30 19049.30 19049.30 19050.30 19050.30
LESS : BANK
FINANCE 75.00% 10762.43 12356.30 14095.30 14096.30 14096.30 14096.30 14097.30 14097.30
MARGIN 26.00 3726.00 4342.00 4953.00 4953.00 4953.00 4953.00 4953.00 4953.00
P a g e | 156
Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant
Detailed Project Report Suraj Products Limited
Village- Barpali, PO: Kesramal; Rajgangpur
District- Sundergarh (Odisha)
SOURCES OF
FUND CONST. 1st 2nd 3rd 4th 5th 6th 7th 8th
Year Year Year Year Year Year Year Year
Net Profit before 4487.30 4611.89 5888.24 5670.24 5657.24 5645.24 5633.24 5619.24
taxes with intt.
added back but
after depreciation
Increase in Share
capital 6579.00
Depreciation 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89
TOTAL : 22079.00 17322.62 8278.66 9700.13 7744.13 7730.13 7718.13 7707.13 7692.13
DEPOSITION OF
FUND CONST. 1st 2nd 3rd 4th 5th 6th 7th 8th
Year Year Year Year Year Year Year Year
Increase in Capital
expenditure 21580.00
Deposits/Investments 110.00
Decrease in Term
Loan 0.00 2214.28 2214.28 2214.28 2214.28 2214.28 2214.28 2214.32
TOTAL 21690.00 17632.70 7931.69 8081.16 7472.76 8098.41 8029.91 7934.23 7814.55
Opening Balance 389.00 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06
Net Surplus (A-B) 389.00 -310.08 346.96 1618.97 271.37 -368.28 -311.78 -227.10 -122.42
Closing Balance 389.00 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06 1286.64
* * * * *
P a g e | 157
Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant