Document No.

:
Adhunik Metaliks Ltd BUSINESS PROCESS AML/BP/DRI/001
(A member of
Liberty Steel Group) PRODUCTION OF DRI
Department : DRI PLANT Process : DRI Production

Purpose:- To ensure effective operation of DRI plant with high efficiency

Scope: This covers the operational requirement of DRI Production
Source of input Responsibility / Receivers of output
(Predecessor processes at Input Process / Activity Control doc./ checkpoint Output
providers) Interaction (Subsequent processes)

Annual Production Targets Preparation of Annual Production, Maintenance

Strategic / Long Term Annual Business plan by mid of March for the
from the strategic business Business Plan DRI Head Annual Business Plan of DRI and Production Planning
Business Plan next financial year
plan Control

Annual Business Plan of Monthly Production Targets Procurement of Raw

DRI from the annual business plan Preparation of Monthly / daily plan by 4th week Material
Preparation of Monthly/ DRI Head of every month for the next month Monthly / Daily Business Plan
Procurement of Spares &
Annual Maintenance Data from annual Maintenance Daily Business plan AML/F/DRI/05; Consumables
Plan of DRI plan Specification of raw material as per Annexure
Marketing Data from Marketing 01, AML/QA/CHEM/WI/63
Top Management Data from top management
Iron ore / Pellet
Raw material Coal WI for inspection of testing of incoming raw material
Procurement from Dolomite Receiving of Raw Material Stores AML/QA/CHEM/WI/23, WI for inspection for screen
approved Suppliers analysis and preparation of sample for chemical analysis
AML/QA/CHEM/WI/24, WI for moisture determination for
- IRON ORE / PELLET DRI Raw material storage
moisture analysis AML/QA/CHEM/WI/25, WI for analysis OK Material
- COAL of Iron ore and dolomite AML/QC/CHEM/WI55, WI for yard
- DOLOMITE analysis of Coal AML/QA/CHEM/WI/54, Incoming
(As per approved inspection report, No. F/QC/ICI/01 (Coal), FQC/ICI/02
supplier list) (Iron / pellet / dolomite)
Accepted
No under No Inspection & QA team
testing of Raw
deviation Material
(AUD)? as per Process/WI for AUD ________ & Accepted under Information to Supplier
Manpower process ___ Deviation Report ZQA32, through Raw Material
Reject the material DRI team
Manpower as per skilled matrix Accepted under deviation
and identification procurement department
of the same & Rejection Report ZQA32 for CAPA
Shifted to
OK Raw Material
designated place Yes
List of Equipment's Appropriate Equipment's Procurement SWP for preservation of raw material ________ Return to Supplier through
Reject Material Raw Material procurement
List of Chemical Appropriate Chemicals SWP for identification of raw material_________ department for CAPA
Identification of Stacking of raw material at raw
Control of material AUD,
nonconforming material yard, preservation and
Appropriate SOPs / SWPs for shifted to the
List of SOPs / SWPs of product and CAPA designated place
identification of the same Process of supplier management for control of
inspection and testing for Iron/ by Supplier nonconforming product and CAPA, Doc.
QA & QC, No.________________
Pellet, Coal & Dolomite,
Quality Plan,
Raw material specification and
Raw Material
Quality Plan of Iron/ pellet, Coal
Specification
& Dolomite,
Iron Ore
Ground hopper, Vibro feeder, (Oversize) Crushing & Screening(off
conveyor, Numeric System, Crusher, Sized Iron Ore/ Pellet, Coal, Dolomite line)
Screen, Feed Pipe, Lobe Type of
-5mm Iron ore Sinter plant
compressor, Stock house, DSC, Raw Change Management process for change in 4M
Machines : List of A Material
Weight Scraper, Weigh feeder, Kiln, Shift in charge condition__________
Machines / equipment's Fans, Motor, Gear box, Support >18mm Iron ore MBF
Size? DRI
for DRI Operation Roller, RALF Injector, Collar, I-bin,
PH Screen, Magnetic Separator, +5mm to +5mm to 18mm Iron ore RM Charging
R.M.Charging from Ground hopper as per 18mm -5mm
Hydro Thrust, Transfer Chute,
plan
Cooling Tower >18mm
Dispatch to
Sinter Plant
Material: Raw material Inspected and approved Change Management process for change in 4M
Shift in charge
yard of Iron / Pellet, Coal identified Raw material i.e. condition__________ Size coal as per plan
Iron/ Pellet RMHS Crusher & Screen
& dolomite Iron / Pellet, Coal & dolomite Coal ,
Dolomite Internal Recrushing
Dolomite dispatch /
Coal Change Management process for change in 4M
Recrushing Crushed and screened Iron Ore
Method: List of SOPs / Appropriate SOPs / SWPs for condition__________
SWPs for Production Production (Size of as per plan)
Shift in charge
Iron, Pellet F/DRI/CC/RHMS/1 Crushed and screened Coal RM Charging
Internal RMHS
dispatch
(Size of as per plan)
Man: Manpower Skilled manpower as per skilled Crushing Change Management process for change in 4M Size of Dolomite as per plan
matrix Dispatch to MBF
condition__________
Power: WASCO, MRSS,
Electricity Aspect/Impact analysis
CPP B Screening
Transport: Logistics Vehicle

Page 1 of 5
 Source of input Responsibility / Receivers of output
(Predecessor processes at Input Process / Activity Control doc./ checkpoint Output
providers) Interaction (Subsequent processes)

WI for inspection for in process inspection of raw material

& DRI AML/QA/CHEM/WI/17, WI for inspection for
Not OK screen analysis and preparation of sample for chemical
Crushed and screened raw Stock House In process analysis AML/QA/CHEM/WI/24, WI for moisture
inspection
Crusher and screening Shit in charge DRI determination for moisture analysis Storage of Raw Material (Iron /
material (Iron / Pellet, Coal) & RM Charging to Kiln
output / QC AML/QA/CHEM/WI/25, WI for analysis of Iron ore and Pellet, Coal & dolomite)
Dolomite Process
dolomite AML/QC/CHEM/WI55, WI for analysis of Coal
correction
OK AML/QA/CHEM/WI/54
In process inspection F/DRI/QA/IPI/01,
SWP Process Correction document _____

Log sheet, AML/F/DRI/01, Daily Feed Loss Report

AML/F/DRI/03, Raw Material consumption & production
Shit in charge AML/F/DRI/02, AML/F/DRI/06
Charged Material Kiln Process
Hazard identification and risk assessment
After Burning Chamber
Charging to Kiln (ABC) & DSC (Dust WI for quality plan for raw material (for Kiln feed &
Settling Chamber incoming stage) AML/DRI/OPN/WI/03, WI for
heating cycle AML/DRI/OPN/WI/01,
WI for Process control of DRI AML/DRI/OPN/WI/02,
Stocked house Material (Iron / WI to maintain Fe-Metallic AML/DRI/OPN/WI/04, WI
Stock house Dust collection at Wet
Pellet, Coal & dolomite) Processing of Raw material in Kiln for Corrective action against nonmagnetic Cooler for hot metal
Scrapper Reduced Material
C Shit in charge DRI AML/DRI/OPN/WI/05, WI for Corrective action - Cooling
/ QC Fuse Material AML/DRI/OPN/WI/06, WI for
Dust
Specification of Sponge Iron AM:/DRI/OPN/WI/07 Sinter Plant
Dispatch to Sinter plant Log book_____
WI for Transfer Chute Opening
'Aspect/Impact analysis

Kiln Solid hot metal from Kiln WI for Use of produced less then 50% metallic Product - DRI
Cooling Through cooler Shit in charge Testing of DRI & Char
B Iron, AML/DRI/OPN/WI/15 By Product - Char
Plant Water Reservoir, Water for cooling activity Aspect/Impact analysis
Utility department
Sample collection Cooling discharge point
Shift in charge QC Inspection as per Annexure 01, AML/QA/CHEM/WI/63
- OK Material for I-bin /
- OK Material
Product House for
Product - DRI &
Cooler A In process inspection F/DRI/QA/IPI/01 screening and separation
By Product - Char Inprocess - Reject Material
inspection and - Reject Material to RM
testing
Reject Work instruction for handling of non-conforming product, Charging for reprocessing
AML/QA/CHEM/WI/20, Revisiting of FMEA, Doc. No.
AML/DRI/FMEA/01
OK Corrective and preventive action AML/F/DRI/07

D Product / by product storage in I -bin B

WI for Product Hopper Operation
Shift in charge AML/DRI/OPN/WI/10
Oversize Contaminated Material SRP for processing
Oversize & DRI / QC
OK Material Contaminated Aspect/Impact analysis
QC Inspection Product - DRI & Screening Dispatch to SRP
By Product - Char at PH
Undersize
Shift in charge
Aspect/Impact analysis
Separation of magnetic / non magnetic DRI
B Classified Material :
material in Product House Non magnetic (Char / Dolo
Char) QC
Magnetic (Lumps / Fines)
Char /
Magnetic (Lumps
Classification Criteria Dolo Char Classification of Shift in charge QC
Dolo material
Non Magnetic
Char
Magnetic (Fines)
Verified & identified material :
CHP
Inspection as per Annexure 01, AML/QA/CHEM/WI/63
Non magnetic (Char / Dolo
Not Ok
Product House Classified Material :
Identification & Not Ok
Quality 'Work instruction for handling of non-conforming product, Char)
Quality shifting to
Non magnetic (Char / Dolo Verification Verification Shit in charge DRI AML/QA/CHEM/WI/20,
Storage Shed Revisiting of FMEA, Doc. No. AML/DRI/FMEA/01 Verified material & identified :
Customer Specification Char) / QC WI for testing, handling, storage, packaging and PPC
(Internal / External) Magnetic (Lumps / Fines) Ok preservation of finished product AML/QA/CHEM/WI/18, Magnetic (Lumps / Fines)
D identification of material as per customer Product house report
Dispatch to CHP requirement (internal / external) Product Storage yard
Mix up material
Material inspection Verified material & identified :
report Daily MIS / DRI/ QA team /
Stock Preparation Weekly MIS / Daily Production Report, Monthly DRI Report Stocked material PPC
Marketing Plan Magnetic (Lumps / Fines) as Data Analysis PPC
PPC Plant per customer requirement Monthly MIS

Page 2 of 5
 Source of input Responsibility / Receivers of output
(Predecessor processes at Input Process / Activity Control doc./ checkpoint Output
providers) Interaction (Subsequent processes)

Yes
Data analysis as per the documented
Sustenance plan process __________
Dispatch as per plan to Target
Dispatch to internal / external Internal / External
Dispatch Plan SMS / External customer Achieved? DRI Head / PPC Daily Analysis report, Monthly Analysis Report Dispatched Product
customer Customer
Daily Dispatch report, Monthly Dispatch Report
CAPA No Action Plan Report

PM Schedule F/DRI/MECH/05, F/DRI/E&I/02

Silo Bag filter SMP for maintenance / replacement of Bag Filter
Waste dust control waste Dust Dispatch to CHP B Maintenance Waste dust collection and
SMP/13, CHP
system operator storage
Inspection Check sheet for bag house (weekly)
Aspect/Impact analysis

WHRB Operation C

Aspect/Impact analysis
-After Burning Chamber(ABC)
Clean gas At chimney WI for ESP operation AML/DRI/OPN/WI/10, WI
Temperature Variation .
ESP operation for ESP Shut down AML/DRI/OPN/WI/11, WI for STEAM to CPP
- WHRB temp variation. Steam
WHRB & Waste gas ESP Operation (in case of Power Failure) 12 Clean Gas to air
Plant operator Clean Gas
Pollution system
-Improper Cleaning & Cooling Waste Dust
PM Schedule F/DRI/MECH/05, F/DRI/E&I/02 Waste Dust - Sinter plant
of Silo
Waste Gas.
SMP for SILO & ESP SMP/13

Dispatch to Sinter Plant

Efficiency / Effectiveness Measures

Efficiency:- 1) Conversion cost (Rs/MT), 2) Reduction in specific energy consumption, 3) Reduction in specific consumptions of consumables, 4) Reduction in specific consumptions of raw material
Effectiveness:- 1) Compliance to DRI Plan, 2) Overall Equipment Effectiveness
Note: Targets as per Role and Objective document

Risk / Opportunity

Risk / Opportunity Description Existing Control Probability Severity Risk Score Action Plan KAM / Target date

Defining and Maintaining the

Procurement planning
Minimum / Maximum Stock of
of raw material, Raw Material department,
Risk Production plan interruption due to non availability of Raw Material, Consumables & Critical spares 3 3 12 Raw material - consideration for
consumables and Purchase, DRI / YTD
three procurement cycle after
spares
start of the production

Annual Inspection &

Maintenance WHRB, MOU will be introduced and
Risk Failure / Leakage of WHRB unit at CPP shall lead to major breakdown of DRI plant SOP of maintaining the 3 3 9 agreed for the uninterrupted CPP / DRI / MR June'21
WHRB in place functioning of WHRB
CPP/WHRB/01

Preventive maintenance Predictive maintenance (CBM &

Risk Major Breakdown of Critical Equipments 3 3 9 Maintenance head
plan TBM) to be introduced

Currently dispatch to Project has been taken for the

Opportunity Dedusting of bag filter dust in ABC to enhance steam generation 2 2 4 DRI / June'21
CHP/Sinter same

Proposal prepared for Capex

project and submitted for
Opportunity Mechanism to be introduced to reduce moisture of coal by Installation of coal dryer Atmosphere drying 2 2 4 DRI / TBD
approval. After approval will be
implemented
Proposal prepared for Capex
project and submitted for
Opportunity Procurement of Broke Machine for accreation cutting Manual cutting 3 3 9 DRI / TBD
approval. After approval will be
implemented

Project taken for the same.

Opportunity Separation of -2mm DRI fine for briquette making Dispatch as it is 3 3 9 DRI / 20-Apr-21
Project plan under progress

Revision History
1 14-Apr-21 Reviewed and revised to make it more elaborated A.K MALLIK K.K PRADHAN K.K PRADHAN Ratan Jhankar Ray

0 1-Mar-21 Initial Preparation A.K MALLIK K.K PRADHAN K.K PRADHAN Ratan Jhankar Ray

Revision no. Revision no. / Date Description (Reason for Change) Prepared by Reviewed by Approved By (HOD) Issued by (MR)

Page 3 of 5
 Risk Assessment Criteria Matrix for AML
Conseq

Insignificant Minor
1. Operational Efficiency
1. Confined Impacts impacted but not pervasive

Probablity Measures 2. Low Financial Loss or 2.Business Plan Objectives

Probability Score ( Probablity of Oppurtunity not threatened
Occurrence)

Measure 1 2
Will be almost a routine feature
Almost every month/ quarter within the 5 > 90% 5 10
Certain
immediate next month

Likely May arise several times within the 4 67 - 89% 4 8

next 12 months.
May arise once or twice within the
Possible 3 34-66% 3 6
next 12 months
May occur once or twice between 2-
Unlikely 2 10-33% 2 4
3 years
Almost impossible to occure
Rare 1 < 10% 1 2
between 2-3 years
Consequ
Insignificant Minor
Probability Measures
Probability Score ( Probability of < 1% of Revenue 3 to 5 % of Revenue
Occurrence)
< 1% of Cost 3 to 5 % of Cost
< 1% of PAT 3 to 5% of PAT
Measure < 1% of Total Assets 3 to 5% of Total Assets
Very high, will be almost a routine
Almost feature every month/ quarter within 5 > 90% 5 10
Certain
the immediate next month

Likely May arise several times within the 4 67 - 89% 4 8

next 12 months.

Possible May arise once or twice within the 3 34-66% 3 6

next 12 months
May occur once or twice between 2-
Unlikely 3 years 2 10-33% 2 4

Rare Almost impossible to occure 1 < 10% 1 2

between 2-3 years
nt Criteria Matrix for AML
Consequence ( Qualitative)

Moderate High Extreme

1. Serious breaches of legal and regulatory
1. Occurrence of personal injury 1. Major loss of operational Capability compliance

2.Customer Dissatisfaction 2.Extensive Adverse Media Exposure 2. Customer Market disintegration

3.Adverse Publicity 3.Significant CEO involvement (or relevant 3. Significant impact on Shareholders
entity management group)
4.Impacts on Operational Capabilities 4. Serious reputation implication 4.Fundamental demise of key personnel
5.Requires intervention by relevant entity 5.Catastrophic business continuity
Management Group exposure
3 4 5

15 20 25

12 16 20

9 12 15

6 8 10

3 4 5

Consequence ( Quantitative)
Minor Moderate High Extreme
3 to 5 % of Revenue > 10% of Revenue
3 to 5 % of Cost > 10% of Cost
3 to 5% of PAT > 10% of PAT
3 to 5% of Total Assets > 10% of Total Assets

10 15 20 25

8 12 16 20

6 9 12 15

4 6 8 10

2 3 4 5