Material Balance & Process

Flow Sheet of Plant

Material Flow

Input raw materials

Generation (Production)

Product (main) // By Product

Saleable // Waste (not consumed by process)

Intermediate Product Final Product

Saleable (finished) product

 PFD FOR PFR 8MT - TSK
Material Flow Sheet represents all the sub processes of the plant and related material in
puts , out puts & wastes.
Coking 2*88 SC(5m) Sinter Pellet Purchase
+3*62（6.25m) 1×496m
2
1×744m
2
Pellet
with provision for
4th battery 6.27 (Gross) 6.34 (Gross) 1.53
3.56 (3.75 Gross)

BF
1×4330m +1×5870m3
3

7.74

Steelmaking
DRI 0.887 3×310t
7.97, say 8

Caster 2150mm
3 x 2 strand
7.8

HOT STRIP MILL

2050MM (8Mt Capacity)
7.64
2.45 ~ 2.55
CRM
1870mm

2.4 ~ 2.5 5.09 ~ 5.19

Hot Metal: 7.74 Liquid Steel: 8.00 HR Products: 7 ~ 8 CR Product: 2.4 ~ 2.5
1 Ton of ? Requires – How much of ?
Unit (Ton) Item
1HOT ROLLED COIL REQUIRES 1.0183299 CAST SLAB
1CAST SLAB REQUIRES 1.0254307 LIQUID STEEL
HM TO
1LIQUID STEEL REQUIRES 1.112 CONVERTER+PIG+SCRAP
1HM TO CONVERTER REQUIRES 1.0394278 HM PRODUCED

1HM PRODUCED REQUIRES 0.41000 CHARGE COKE

1HM PRODUCED REQUIRES 0.6981915 CHARGE SINTER
1HM PRODUCED REQUIRES 0.84 CHARGE PELLET
1HM PRODUCED REQUIRES 0.0817681 CHARGE IRON ORE

1CHARGE COKE REQUIRES 1.1111111 GROSS COKE

1CHARGE SINTER REQUIRES 1.25 GROSS SINTER
1CHARGE PELLET REQUIRES 1.0208333 GROSS PELLET
 Material Balance KPO - MATERIAL FLOW SHEET
CAPACITY 6,343,000 TONS PER YEAR HRC
IOF req'd 3,674,008 943,800 LSF+Dolomite req'd

Iron Ore fines (Purchased) Limestone fines (Plant Return)

3,591,807 221,991 COAL BLEND FOR COKE OVENS
Pellet Fines Prime Coking Coal : Semi-Soft Coking Coal
252,551 Iron Ore fines (Plant Return) Limestone + Dolomite 20% 80%
82,200 721,809
Lime Fines req'd
Limestone Fines Flue Dust Lime fines (Plant Return) 113,256 Imported 90% 10% Local Prime
Iron Ore fines 104,145 37,752 133,811 Prime Coking Coal Coking Coal
5,363,455 710,526 78,947
Bentonite Mill Scale Lime fines (Purchased)
Pyroxinite 52,072 61,347 -20,555 Imported 50% 50% Local Semi-Soft
0 WRP Semi-Soft Coking Coal Coking Coal
Dolomite LD Slag Anthracite Coal 87,500 1,578,947 1,578,947
Anthracite 52,072 37,752 70,785
104,145 Pyroxinite LD Sludge
169,884 37,752
COKE OVENS
PELLET PLANT SINTER PLANT 386,958 By -product recovery type
5,207,238 1 x 496 sqm Coke Breeze 4x88 Ovens

22%
Gross Pellet Return Sinter Gross Sinter Coal Tar
Pellet Fines 5,051,020 1,331,000 6,050,000 98,684 Gross Coke
151,531 3,000,000
Sulphur to sale
Gross Pellet to BF Stock House Coal Tar to Pellet Plant Coal Tar to sale 5,526
5,051,020 BF Stock House 0 98,684
Purchased Coke
Coke Breeze 90,692
Screen House
BF Stock House 322,482 As per DCO
Charge Sinter 123,000 CDQ Dust
4,719,000 15,000
BF and Nut Coke to BF Stock House
2,753,210
Pellet Fines
101,020 Excess Pellet
0 Coke Breeze 2
BF Stock House
Iron Ore Lump Charge Pellet 47,210
922,992 4,950,000 2,706,000
Coke Breeze for sale Limestone
pyrox + quartz (9,784) 99,000
99,000 @kg/thm 7,482
Pyroxinite 160
BF Stock House Quartzite 0 Coal for PCI Charge Coke @kg/thm
99,000 1,056,000 2,706,000 410

Sized Iron Ore

Iron Ore fines to 840,791 carbon rate @kg/thm
Sinter Plant 467
82,200 BLAST FURNACE
2x4330 Cu.M

BURDEN IN BLAST FURNACE 1,191

sinter pellet ore Lime (if PCM
44.9% 47.1% 8.0% Flue Dust used)
715 750 127 Hot Metal 132,000
@kg/thm @kg/thm @kg/thm iron Scrap Slag 6,600,000 3.80%
0 2,039,400 250,800

Limestone Hot Metal to HMDP

1,476,986 Granulated Slag 6,349,200
1,937,430
CAD MAG PCM /
SCREENING GRANULATED HM
16,698 2,349

15%
Limestone fines Iron Scrap Pig iron
HOT METAL DESULPHURISING PLANT
221,548 Sized Limestone 12,540 238,260
1,255,438
90%
Recovered fines Lump iron ore Hot Metal to Converter @ kg/tcs
to Sinter Plant LIME CALCINING PLANT 290,672 6,317,454 @ kg/tcs 30.34
199,393 3x600 +1x600TPD 978 Pig iron to converter Pig iron for Sale
1,217,775 Pet Coke 196,000 42,260
1,453 LD CONVETER
3% 41% 3 x 310 Ton Converter
Kiln Dust Gross Lime Loss on Ignition Aluminum
37,663 718,487 499,288 14,146

60% @ kg/tcs Scrap Scrap Slag

Recovered fines 100.22 647,336 Liquid Steel to Secondary refining 42,631 993,750
to Sinter Plant Gross Lime net of RPD Fines 2% 6,625,000
22,598 696,933 RPD Fines HC Ferro-Manganese SCRAP + PIG IN CONVERTER
14,370 17,821 Scrap+Pig req'd in SMS 843,336
@ kg/tcs 131
HC Ferro-Silicon CAS-OB/RH/LF
SCREENING 1,988

Purchased Lime Liquid Steel

0 6,625,000
Lime fines
24% 167,264
(24% in Jsr) Net Lime SLAB CASTER
529,669 2 x 2 strand Slab Caster
80% 529,669
Recovered fines lime from LCP to SMS
to Sinter Plant
133,811 Lime for PCM
0 Scrap Scale
102,025 Cast Slab 12,588
LIME KILNS FOR SMS 6,459,375
Total lime required in Converter 529,669
@ kg/tcs 82
KILNS TPD 600 600 600 377
to Stock Slab to Mill to Sale
0 6,459,375 0

HOT STRIP MILL

Scrap Scale
74,300 42,000
Hot Rolled Coil
6,343,000

to Stock HRC to PLTCM to Sale

339,916 2,263,747 3,739,075
Fuel, Gcal
Fe balance – Hot metal
% of FE
burden PER TON CHARGE CONTENT TOTAL FE
0.43SINTER 0.698 0.520 0.363
0.52PELLET 0.840 0.630 0.529
0.050ORE 0.082 0.645 0.053
0.000DRI 0.000 0.840 0.000
1.000Burden 1.620 0.945

REQUIRED FE 945
 SINTER PLANT PELLET PLANT 5,207,238

BASIS GROSS SINTER 6,050,000 BASIS GROSS PELLET 5,051,020

CHARGE SINTER 4,719,000 sp. Cons sp. Cons

sp. Cons IOF 1030 1.03 5,202,551
IOF-PURCHASED 810 0.81 3,822,390 PYROXINITE 15 0.015 75,765
IOF-PLANT
RETURN 0 0 ANTHRACITE 0 0 0
FLUE DUST 8 0.008 37,752 COKE BREEZE 25 0.025 126,276
LIMESTONE
MILL SCALE 13 0.013 61,347 FINES 25 0.025 126,276
BENTONIT
LD SLAG 8 0.008 37,752 E 10 0.01 50,510
PYROXINITE 36 0.036 169,884 COAL TAR 0 0 0
LIMESTONE FINE-
PURCHASE 200 0.2 943,800
LIMESTONE FINE-RETURN 0 0 CHARGE PELLET 4,950,000
LIME FINES-
RETURN 24 0.024 113,256 GROSS PELLET TO BF SH 5,051,020
LIME FINES-PURCHASE 0 0 EXCESS PELLET 0
ANTHRACITE 15 0.015 70,785 PELLET FINES 1 % 0.03 156,217

COKE BREEZE 82 0.082 386,958 PELLET FINES 2 % 0.02101,020

LD SLUDGE 8 0.008 37752

RETURN SINTER 0.22 1,331,000

CHARGE SINTER 4,719,000 0.72 0.75

 COKE OVENS
BASIS GROSS COKE PH 1+ PH 2 3,000,000 BASIS BLAST FURNACE - HOT METAL PRODUCED 6,600,000
GROSS COKE PH 1 1,500,000 sp.
DRY COAL 1,973,684 Cons/GEN
PRIME C.COAL 394,737 sp. Cons ERATION
SEMI-SOFT C.COAL 1,578,947 Fe66 CHARGE PELLET 0.75 4,950,000
Fe64.5 CHARGE IRON ORE 0.1273926 840,791
ANTHRACITE 0
Fe56 CHARGE SINTER 0.715 4,719,000
PYROXINITE+QUARTZ 10 0.01 66,000
COAL TAR 0.025 98,684
LIMESTONE 5 0.005 33,000
SULFUR 0.14 0.0014 5,526 COAL - PCI 160.00 0.16 1,056,000
CDQ DUST 0.5 0.005 15,000 CHARGE COKE 410.00 0.41 2,706,000
COAL TARTOPELLET PLANT 0 0 0 0
COAL TAR TO SALE 0 98,684 IRON SCRAP 0 0
BF+NUT COKE REQUIRED 0.978 2,766,871 SLAG 270 0.27 1,782,000
CHARGE COKE 2,706,000 GRANULATED SLAG 0.95 1,692,900
COKE BREEZE 1 0.1 300,000 FLUE DUST 0.025 165,000
COKE BREEZE 2 0.022 59,400
BF+NUT COKE PRODUCED 0.9 2,700,000 HOT METAL TO
PCM 0.0312205,920

HOT METAL TO HMDP 6,394,080

HOT METAL TO
CONVERTER 0.9956,362,110

IRON SCRAP FROM PCM 0.0510,296

PIG IRON FROM PCM 0.95195,624

PIG IRON TO SALE -

PIG IRON TO CONVERTER 195,624

 Fe Balance – Steel Making
Charge Mix Options %Fe HOT METAL + DRI, Kg/tcs Equivalent Fe in Hot
Metal & DRI, Kg/tcs

Hot Metal 94.56

985.64 932.0
Granshot / pooled iron 94.5

Re-melting Scrap 98.8 51.28 50.7

I/ore 64 0
DRI 88 113.85 100.2
Total Fe input 1150.77 1082.9
Avg Fe in Steel, Kg/tcs 99.806% in liq. Steel 1023.651 1023.651

Slag in Process End 108.718 182.564

Fe of FeO and Fe2O3 in slag of Process End 19.487 32.821

Fe of steel in slag 14.359 20.513

Fe in Converter Fume 8.205 8.205
Total Fe output 1065.703 1085.190
Heat Available in BOF charge - KWH/T -52.91 -36.43

Heat Requirement, KWH/t – Hot Metal = -120, Pig Iron = 250, Scrap = 375, I/ore= 1000, DRI=550

Note: In case of hot metal and iron ore in the charge mix, more heat availability is required to be
maintained as the lime requirement is more. Si in hot metal considered as 0.8%.
 Consumption Grain Bulk
Designation of Raw Transport
No. Capacity (wet, Size Density Moisture Remarks
Material & Fuel Way
103t) (mm) (t/m3)
Iron ore fines for
1 6,817.8 0~10 2.1 8~10% railway
Pellet
2 Bentonite 49.61 0~40 1.0 10.5% railway
3 Olivine 422.44 0~8 1.5 10% Rail/road
4 Anthracite 166.3 0~34 0.8~0.9 9~10% Rail/road
Iron ore fines for
5 4,197.80 0~10 2.1 8~10% railway
Sinter
6 Pyroxenite 189.38 10~50 1.5 4~5% Rail/road
7 Coking Coal 5,240.88 0~25 0.8~0.9 9~10% railway
8 PCI Coal 1,367.96 0~10 0.8~0.9 9~10% railway
9 Purchased Pellet 1,611.58 6~18 2.1 5% railway
Limestone+Quartzite
10 122.21 10~50 1.5 4~5% Rail/road
for BF
Limestone +
11 958 0~25 1.5 4~5% Rail/road
Dolomite fines
12 Quick Lime fines 7.65 0~10 1.5 2% tanker
13 Limestone LCP 1652.63 0~80 1.5 4~5% railway
14 Lump Ore-SMS 428.57 10~40 2.2 8~10% Rail/road
Total 23233
Raw Material Requirement & Finished Product – 8Mt & 16 Mt
Gross Qty Sources
Commodity Source
8 Mtpa 16 Mtpa (8 Mtpa) (16 Mtpa)
Indonesia, USA &
Coal 7 14 Imported Australia
Canada
Captive+
Iron Bearing OMQ, NMDC, South Africa, Brazil,
13 28 Domestic +
Material Barbil, Rungta Australia
Imported
Lime Stone SMS
2 4 Imported Dubai/ Oman Dubai/ Oman
grade.
Domestic + MP, Gujarat, MP, Gujarat,
All Fluxes 2 3
Imported Norway Norway
Internal
BF Slag + LD Slag 5 8 In Plant -
Generated
All Finished Internal
8 16 In Plant -
Products Generated
TOTAL 37 73
Key Points :-
 @16 Mtpa, 20 Mtpa of RM will be imported (incl. iron bearing material)
 Existing ports & rail connectivity saturated. To be augmented existing on PPP model and DFC to be
developed.
 Feasibility of different modes of logistics (Rail + Road + Conveyor) is under study
 TSK FUEL
TSK FUEL balance - 8 Mt(BALANCE
With 3.75 Mt@ 8 production
Coke MPTA: 3.75 Mt coke
& 7 Kg/Ton plant
of Coal – 1/2 in PP)
Tar Consumption
Coal Tar Gen Coal tar Cons.
Gas Generation(Nm3/hr) Gas Consumption(Nm3/hr)
( Kg/hr) ( Kg/hr)
Area COG BF Gas LD Gas Coal Tar COG BF Gas LD Gas Coal Tar
Coke Ovens 180,237 14,081 22,121 357,505
SP 2,516 3,600
PP 13,676 56,459 5,600

BFs 1,455,857 26,299 412,295

LCP &SMS 73,796 23,833 20,921
HSM & CRM 64,101 69,404
Losses 2,213 22,427 738

Total 180,237 1,455,857 73,796 14,081 154,759 942,610 738 5,600

Gas & Coal Tar available for power generation 25,479 513,247 73,058 8,481
TOTAL ENERGY GENERATED 18,615,724 Gcal/yr Steam generation TPH 989
TOTAL ENERGY CONSUMED 12,307,857 Gcal/yr Process steam requirement TPH 384
TOTAL ENERGY balance for power 6,307,867 Gcal/yr Steam Availability from CDQ TPH 250
Available Energy (Including Tar) 719 Gcal/hr Process steam requirement from CPP-1 TPH 134
Gas & Coal Tar available for
251 MW Balance steam TPH for power 855
equivalent power