RKL 1

ROURKELA STEEL PLANT
Installation of new Coke Oven Battery (COB#7) within the

existing Steel Plant at Rourkela
Pre-Feasibility Report
1 - EXECUTIVE SUMMARY
1.1 IDENTIFICATION OF THE PROJECT AND PROJECT

PROPONENT
Steel Authority of India Limited (SAIL) is the largest steel-
making company in India and one of the eight Maharatnas of the
country’s Central Public Sector Enterprises. Rourkela Steel Plant (RSP) is
among one of the five integrated iron and steel plants of SAIL
Presently, RSP has six top charged Coke Oven batteries

which serve the coke requirement of the steel plant. RSP has planned for
cold repair of their Batteriers in sequence starting with Battery No - 5
and then Battery Nos. 1, 4 and 6. Therefore, the requirement of coke
would not be possible to be met from the remaining existing batteries.
Hence RSP is planning for construction of a new 0.77 MTPA

stamp charge coke oven battery (COB#7) (1.02 MTPA coal throughput)
with by product recovery plant to meet the coke requirement during cold
repair of Batteries. However, there will not be any increase in overall
plant production capacity w.r.t hot metal, crude steel and saleable steel.
1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project would fall under Category ‘A’ of item
4(b) “Coke oven Plants” but it will be installed within the complex of
existing Steel plant hence, it fall under Category ‘A’ of item 3(a)
“Metallurgical Industries (ferrous & non-ferrous)” of the Schedule to the
EIA Notification 2006 and amendments thereof.
1-1
1 - Executive Summary (cont’d)
1.3 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

DUE TO THE PROJECT
It is anticipated that 500 to 600 casual/contractor workers
will be required during construction phase. Subsequently in the
operation phase, approximately 529 personnel would be directly
employed (51 executives and 478 non executives) and 200 personnel
would be indirectly employed.
1.4 LOCATION WITH CO-ORDINATES

The proposed Coke Oven plant would be installed in the
existing Steel plant of RSP at Sundargarh District of Odisha state. No
additional land is required for the present project. The project site is
located within 22 o 12’ 30.5” to 22 o 12’ 20.7” North latitude and
84 o 51’ 51.7” to 84 o 52’ 31.83” East longitude.
1.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

The proposed battery will have a coal throughput of approx.
1.02 MTPA. It will be a stamp charge battery with coke dry cooling
facility. Required blended coal will be received from the existing coal
handling network for Battery#6 after its suitable modification/extension.
Produced coke from the new Coke Dry Cooling Plant (CDCP) will be
discharged in to the existing belts (2 belts of 200 tons/hr each)
underneath the existing CDCP chambers for Battery#6. Blast Furnace
(BF) grade coke, nut coke and breeze coke will be dispatched to the Blast
furnace No. 5 by the existing BF coke conveyors. Existing gas network
will be used for drawing gas for initial heating and later on for exporting
produced clean gas. New By product facilities will be provided for
handling the entire gas from the Battery#7. Existing plant infrastructure
will be used for other facilities.
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The battery will operate for 24 hours a day, 365 days a year.
Coal consumption and coke production and coke quality for proposed
battery are as given in Table 1-1.
TABLE 1-1 - MAJOR PLANT UNITS AND FACILITES
Sl. No. Parameter Envisaged/year

1 Dry coal charge 1.02 MT (min)
2 Run-off oven coke (dry) 76% 0.77 MT
34 to 80 mm BF coke (dry)67 % 0.68 MT
(-) 34 mm Breeze coke (dry) 0.09 MT
The expected yields and other parameters of various

products will be as mentioned in Table 1-2.
TABLE 1-2 - YIELDS AND OTHER PARAMETERS OF PRODUCTS
Parameter Envisaged/year
Oven pushing/day 90 (max))
Dry Bulk density of coal blend 1 T/m 3 (min)
Cake volume 31.5 m 3
Yield of run-off oven coke from dry coal charge 76 %
Yield of 34 to 80 mm BF grade coke from run-off
88.1 %
oven coke
Yield of 34 to 80 mm BF grade coke from gross dry
67 %
coal charge
Yield of (-) 34 mm coke from run-off oven coke (dry) 11.9 %
Yield of coke oven gas per ton of dry coal blend 320 Nm 3
Yield of Tar per ton of dry coal blend 32 kg
Yield of elemental Sulphur per ton of dry coal 1.05 kg
Gas 45000 Nm 3 /hr (max)
Tar 37000 TPA (max)
Sulphur 1220 TPA (max)
Tail Gas 5000 Nm 3 /hr
CDCP unit will produce about 52 ton/hr of steam at about

500 o C and 66 atm pressure which will be fed to a Back Pressure turbine
to produce about minimum 5.0 MW of power and also tail steam of same
quantity at about 300 o C and 18 - 19 kg/cm 2 pressure which will be fed
to the steam grid.
1-3
1.5.1 Battery Proper

It will be a stamp charge, twin flue, under jet, compound and
regenerative heating type with partial recirculation of waste gases
heating system. Specific heat consumption per kg of coal blend with
10% moisture content is expected to be around with 600 kcal with CO
gas and 650 kcal with mixed gas. The battery will have fuel main on both
sides of the Battery and will be capable of heating both with CO gas and
BF gas/mixed gas. The indicative salient features of the battery are given
in Table 1-3.
TABLE 1-3 - SALIENT FEATURES OF BATTERY
No. of ovens/battery 46 + 46
Height of ovens, mm 5000 (min) 5500(max)
Length of ovens, mm 14000 (max)
Avg. width of ovens, mm 500 min to 550(max)
Oven taper, mm 20 min
Coal cake weight (Dry), t 31.5( BD=1.0)
Coking period, hrs 25 max
No of pushing per day 90 max
Heating system Twin flue, under-jet, compound, regenerative
type with re-circulation of waste gases
1.5.2 Mode of Coke Oven Battery Operation

After the SCP machine bunker has been filled with blend
from the coal tower, SCP machine moves up to the oven to be pushed.
Simultaneously coal cake is getting formed by means of stamping bars in
the SCP (stamping time taken would vary between 7 – 8 minutes).
1.5.3 Coke Processing

The coke output from new CDCP will be fed to the existing
conveyors BC-401 and BC-402 which was extended during installation of
COB#7 for future CDCP chamber and having the in-built capacity of
200 tph. Thereafter coke handling will follow the same route of existing
coke handling and sorting plant provided with Battery#6. The inbuilt
capacity of existing coke handling and sorting plant is sufficient to
handle the coke from two batteries in operation.
1-4
1.5.4 Coke Cooling

Coke pushed from the oven will be at around 1050 oC
temperature. The hot coke would be cooled by three chamber 50 tph coke
dry cooling plant. The entire system will be suitable for achieving an
average cycle time of maximum 8 minutes from bucket lifting to bucket
lowering. Additional three spare buckets will be provided for
maintenance purpose.
1.5.5 By-Product Plant

The existing by-product of Battery#6 is having a capacity of
50,000 Nm 3 /h with a standby capacity of 50,000 Nm 3 /h. This by product
plant will be suitably augmented so that the gas handling capacity of the
BPP after augmentation will be 1,00,000 m 3 /hr. This augmented BPP
will handle gases from Batteries#6 & 7.
1.6 RAW MATERIAL

Around 1.02 MTPA coking coal would be required for the
proposed project. The coking coal would be purchased from indigenous
source. It would be received by rail from existing Bondamunda Exchange
Yard. The existing railway sidings at Dumetra would have sufficient
capacity to handle this additional load.
1.7 AVAILABILITY OF WATER AND POWER

1.7.1 Water
The estimated raw water requirement for the proposed
project is around 560 m 3 /hr. This requirement will be met by i) existing
lagoon water (435 m 3 /hr) after treatment and ii) recycling effluent
(125 m 3 /hr) of the proposed project. No additional make up water would
be required from the existing source.
1-5
1.7.2 Power
The estimated total average load of power requirement of the
proposed project is envisaged as 12 MW approximately.
1.8 WASTE GENERATION AND MANAGEMENT

1.8.1 Waste Water Management
A new Phenolic Effluent Treatment Plant [PETP), generally
called BOD plant would be constructed to treat contaminated waste
waters arising out of excess flushing liquor, coke oven gas
condensates, process vessel drains, contaminated overflows and
washings. Capacity of the new BOD plant will be 60 m3 /hr. Treated
effluent from BOD plant would further treated by Moving Bed Biofilm
Reactor (MBBR) / Membrane Bio Reactor (MBR) technology. The cooling
tower blow down and effluent from MBBR/MBR would be further treated
in RO plant. Filter water would be recycled to the plant make up water
system and reject will be sent to Coke Quenching.
1.8.2 Solid Waste Management

Major solid wastes produced in the proposed project would
be namely coal tar sludge and BOD sludge.f 4R principle - Reduce,
Reuse, Recover and Recycle principle would be adopted to maximize
utilization of solid wastes. The coal/coke fines collected through dust
extraction systems will be recycled back to Ore Bedding & Blending Plant
for making Base mix which is a raw material for making sinter.
1.8.3 Air Pollution

Various mitigation measures adopted in the proposed project
is mentioned below:
For PLD (Percent Leaking Door)

 Air cooled spring loaded diaphragm type doors
with self-sealing arrangement.
1-6
 Machine mounted door cleaner for doors and doorframe.

 Hydro jet door cleaner of 600 bar pressure.
 Mechanised frame cleaner.
 Hydraulic governors to control fluctuation of

collecting main pressure within + 1 mm WC.
For PLO (Percent Leaking Off-Take)

 Ceramic rope sealing at base socket of AP.
 Water sealed ascension pipe (AP) caps.
 Proper sealing arrangement between IV and goose neck.
 Arrangement for easy cleaning of gooseneck.
For PLL (Percent Leaking Lids)

 Water seal in the U-tube connecting mechanism in the
oven top.
For Charging Emissions
 High pressure ammonia liquor aspiration (HPLA)
system for on main charging.
 Gas collecting main along with U tube facility in CGT
car for transferring the gas in adjacent ovens for easy
evacuation of gas during on-main charging.
 Speedy cake charging along with hood for extracting
gases.
 Charging frame in the SCP car.
Pushing Emissions
 Land based pushing emission control system to control
emissions during oven pushing.
 Computerised Heating Control system.
Stack Emissions
 Use of low sulphur content coal
 Sulphur removal from by product gases is envisaged in
the by-product plant by Claus process
 Provision for re-circulation of waste gas in flues to
control NOx
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 Load transfer from buckstay to heating wall through

liner bricks and not through central axis of heating
wall to reduce dust generation.
 Proper combustion by control of air gas mixture to

reduce CO emission.
1.9 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project will be installed within the complex of
existing Steel plant, hence the entire land belongs to RSP and the
present status of the land is industrial land. The proposed site primarily
consists of barren land.
1.10 EXISTING LAND USE OF PROJECT SITE

Approx 19.1 Ha of land would be required for the proposed
project. The proposed site primarily consists of barren land. The
proposed plant is located in the notified area as per Odisha Gazette
Notification no. 1189 dated 23/08/1978 (Please refer Appendix 4-1).
Following facilities have also been considered in the proposed project
 A new By product plant of 50,000 Nm 3 /hr gas handling

capacity
 Augmentation of existing coal handling and coke sorting

facilities of Battery No. 6 to meet the requirement
 Installation of 50 ton capacity (each) three chamber

CDCP with BPTG to facilitate recovery of sensible
heat of hot coke
 Oven machines include two SCP machines, two Gas

transfer cars, two coke transfer cars, two coke bucket
wagon and four electric loco (two for new bucket wagon
and two for existing coke bucket car). Land based
Pushing Emission Control system has also been
envisaged.
 Installation of a new DM plant and augmentation of

intake well for water.
1-8
1.11 DRINKING WATER MANAGEMENT

The total water requirement for drinking & sanitation would
be 30 KLD which is proposed to be drawn from the plant water system.
1.12 R&R
The proposed project does not require additional land and
would be housed within the available plant boundary. Hence, there
would not be displacement of any human settlement. Hence there are no
issues relating to ‘Rehabilitation and Resettlement’.
1.13 SCHEDULE
The project is envisaged to be implemented within a period of
forty two (42) months from Stage-2 approval and receipt of EC. Pre-
ordering activities are envisaged to be completed within 6 months from
the date of Stage-1 approval.
1.14 CAPITAL COST ESTIMATE

The capital cost of the project is estimated at
Rs. 2,317.64 cr. including IDC of Rs. 304.74 cr with net of input tax
credit (ITC) of Rs. 287.05 cr. The FE component considered in the project
cost is Rs. 604.16 cr.
1.15 FINANCIAL AND SOCIAL BENEFITS OF THE PROJECT

The proposed project of installation of new Coke Oven
Battery (COB#7) would
i) generate local direct & indirect employment

opportunities and improve local income
ii) augment the development of ancillary small-medium

scale industries, trade & commercial establishments
and local entrepreneurship
iii) promote diversification in skill set amongst young

adults
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iv) contribute to the district and state revenue through

road tax, income by registration of trucks & trailers,
income tax, corporate tax etc
The peripheral development activities that would be

undertaken by the proposed project under Corporate Environment
Responsibility (CER) will focus on marginal communities and attempt to
bring forward an overall social development with emphasis in the areas
of education, training, health and social & physical infrastructure.
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RKL 1

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ROURKELA STEEL PLANT

Installation of new Coke Oven Battery (COB#7) within the

1.1 IDENTIFICATION OF THE PROJECT AND PROJECT

Presently, RSP has six top charged Coke Oven batteries

Hence RSP is planning for construction of a new 0.77 MTPA

1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

1 - Executive Summary (cont’d)

1.3 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

1.4 LOCATION WITH CO-ORDINATES

1.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

1 - Executive Summary (cont’d)

TABLE 1-1 - MAJOR PLANT UNITS AND FACILITES

Sl. No. Parameter Envisaged/year

The expected yields and other parameters of various

TABLE 1-2 - YIELDS AND OTHER PARAMETERS OF PRODUCTS

CDCP unit will produce about 52 ton/hr of steam at about

1 - Executive Summary (cont’d)

1.5.1 Battery Proper

TABLE 1-3 - SALIENT FEATURES OF BATTERY

1.5.2 Mode of Coke Oven Battery Operation

1.5.3 Coke Processing

1 - Executive Summary (cont’d)

1.5.4 Coke Cooling

1.5.5 By-Product Plant

1.6 RAW MATERIAL

1.7 AVAILABILITY OF WATER AND POWER

1 - Executive Summary (cont’d)

1.8 WASTE GENERATION AND MANAGEMENT

1.8.2 Solid Waste Management

1.8.3 Air Pollution

For PLD (Percent Leaking Door)

1 - Executive Summary (cont’d)

 Machine mounted door cleaner for doors and doorframe.

 Mechanised frame cleaner.

 Hydraulic governors to control fluctuation of

For PLO (Percent Leaking Off-Take)

 Water sealed ascension pipe (AP) caps.

 Proper sealing arrangement between IV and goose neck.

 Arrangement for easy cleaning of gooseneck.

For PLL (Percent Leaking Lids)

1 - Executive Summary (cont’d)

 Load transfer from buckstay to heating wall through

 Proper combustion by control of air gas mixture to

1.9 LAND FORM, LAND USE AND LAND OWNERSHIP

1.10 EXISTING LAND USE OF PROJECT SITE

 A new By product plant of 50,000 Nm 3 /hr gas handling

 Augmentation of existing coal handling and coke sorting

 Installation of 50 ton capacity (each) three chamber

 Oven machines include two SCP machines, two Gas

 Installation of a new DM plant and augmentation of

1 - Executive Summary (cont’d)

1.11 DRINKING WATER MANAGEMENT

1.14 CAPITAL COST ESTIMATE

1.15 FINANCIAL AND SOCIAL BENEFITS OF THE PROJECT

i) generate local direct & indirect employment

ii) augment the development of ancillary small-medium

iii) promote diversification in skill set amongst young

1 - Executive Summary (cont’d)

iv) contribute to the district and state revenue through

The peripheral development activities that would be

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