Jindal Stainless Limited

EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF

STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Technological parameters
Parameter Quantity
3
Useful volume, m 1600
Productivity, t/d/m3 2.23

Production, t/d (max) 3571

Coke rate, kg/thm: (dry) 380
Slag rate, kg/thm 220
Slag basicity (CaO/SiO2 ) 0.95
Top gas pressure (max), atg , kg/cm2 2.5-3.0
Hot blast temperature (design), deg. C 1,200
Oxygen enrichment 4%
Blast volumes, Nm3/thm 959
Humidity of blast, g/Nm3 60
Gas volume (dry), Nm3/thm 1560
CV of top gas, kcal/Nm3 750-780
Coal dust injection 140-160 kg/thm

Description of plant and equipment

Blast furnace will be provided with twin cast houses, stock house, conveyor
charging system, bell less top charging system, three numbers of cowper
stoves, cast house slag granulation unit, slag pit, dust catcher and venturi type
gas cleaning system. Necessary pig casting and storage facilities, ladle repair
facilities and other miscellaneous facilities required for the plant has also been
envisaged.

The hot blast to BF will be supplied through 20 numbers of tuyeres in the blast
furnace. The solid burden charged from the top will be smelted on its way down
and liquid slag and hot metal will be collected in the hearth. The same will be
tapped through the two holes. The hot metal and slag from the tap hole will flow
through the trough/runner systems. Hot metal will be tapped into open top
laddles. The slag will flow into the cast house slag granulation system. The
outgoing gases will be led through four off takes, two uptakes and one down
comer to the dust catcher for primary dust seperation.

The BF is being provided with state of art closed circuit plate cooling system in
conjunction with under hearth water-cooling. The cooling system is a soft water
cooling system.

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Cast House: the cast house design is based upon the latest technology of cast
housees implementing the essential features such as long campaign trough and
runner design, non draining trough and cast house fume extraction system.

Hot Blast System: the hot blast stove design is based upon high temperature
internal combustion chamber stove technology. The cold blast from blowers will
be heated in 3 regenerative type internal combustion chamber hot blast stoves
provided with ceramic burner. The stove system will consist of flue gas and
combustion air facilities, flue gas exhaust, flue chimney, cold blast, hot blast
system and preheating system along with valves and controls. The fuel gas
used in the hot blast stoves is BF gas without any enrichment. The CV of BF gas
alone is sufficient to achieve a hot blast temperature of 1250 C. in order to
achieve the required hot blast temperature, it has been envisaged to install a
preheated system for BF gas and combustion air. The temperature of BF gas
and combustion air is thus increased to 280 C at the stove inlet.

Gas Cleaning System: the BF produces raw gas as a by-product of the iron
making process. The raw gas has a calorific value, which allows it to be used as
fuel. However BFG must be suitably cleaned prior to further use. The gas
cleaning plant consists of two-stage scrubber and a demister. The resulting
slurry is discharged into a clarifier. The clean gas is supplied to various users.
The clarified water requirement for GCP will be approximately 700 m3/h at 8
kg/cm2 at ground level. The normal gas composition % by volume as follows:

Sl. No. description % by Volume

1. Carbon di oxide, CO2(dry) 20.9%
2. Carbon monoxide, CO 26.0%
3. Oxygen, O2(dry) 0%
4. Hydrogen, H2(dry) 4.6%
5. Nitrogen, N2(dry) 48.5%
6. Moisture, H2O(max) 5%

Pulverised Coal Injection System: the system will comprise of coal storage, raw
coal handling, drying unit and pulverizer, conveying facility, coal dust collection
unit, storage bunker and pulverised coal injection system.

Pig casting machine

For casting the hot metal into cold pigs two numbers of pig casting machines
(PCM) of capacity 1,800 t/d each has been envisaged for the BFs. The PCM will
be equipped with lime milk spray system, water spray for pigs cooling, etc. The
pigs will be discharged into the pig storage yard and thereafter handled by a

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

magnet gantry crane. Each PCM will be provided with hoists at the discharge
end and lime milk preparation building. An underslung crane has been
envisaged in the pouring end for maintenance and shot disposal.

Ferro- alloy plant

Ferro-chrome: The proposed capacity of the plant will be 150,000t/yr in Phase-I

and 450,000 t/yr high carbon liquid ferro-chrome (HCFeCr) in full development.
The proposed plant will constitute 6 x 60 MVA semi-closed SAFs designed to
operate with maximum chromite ore briquettes in the charge (80% briquette and
20% lump chrome ore).

Ferro-manganese: The proposed capacity of the ferro-manganese plant will be

50,000 t/yr in phase-I and 100,000 t/yr in full development adjacent to the steel
melting shop. The ferro-manganese will be produced from two numbers of semi-
closed type submerged arc furnaces of 27.6 MVA each.

Silico-manganese: The proposed capacity of the silico-manganese plant will be

50,000t/yr in Phase-I and 100,000 t/yr in full development adjacent to the steel
melting shop. The silico-manganese will be produced from four numbers of
semi-closed type submerged arc furnaces of 27.6 MVA each in full development.

Technological parameters of briquetting and ferro-chrome plant

Briquetting plant : The technological parameters of the proposed briquetting

plant for the Ferro-chrome plant are given in table -2.5.

Table-2.5
Technological parameters of the briquetting plant

Sl. Parameter Unit Value/ feature

No.
1 Briquette production t/yr 978,300
2 No. of briquetting press no. 3
3 Production capacity of briquetting t/h 60
press
4 Press availability d/yr 330

Submerged arc furnaces

The technological parameters of the submerged arc furnaces for ferro-alloy

plants are given in table 2.6.

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Table-2.6

Technological parameters of the submerged arc furnaces

Sl. Parameter Unit Value / feature
No. Fe-Cr Fe-Mn Si-Mn
1 Ferro-alloy production t/yr 450,000 100,000 100,000
2 No. of submerged arc - 6 2 4
furnaces
3 Capacity of each furnace t/yr 75,000 50,000 25,000
4 No of tappings per - 12 12 12
furnace per day
5 Average tap weight t 18.94 12.6 6.3
6 Average tap-to-tap time of min 120 120 120
each furnace
7 Availability per furnace d/yr 330 330 330
8 Transformer rating of MVA 1x 60 27.6 27.6
each furnace
9 Type of shell - Water Water Water
cooled cooled cooled
10 Type of fume cleaning - Bag house Bag Bag
system house house
11 Type of electrode - Soderberg Soderber Soderber
g g
12 Electrode diameter mm 1,900 1,000 1,000
(approx)
13 Pitch circle diameter mm 4,500 3,000 3,000
(approx)
14 Type of lining :
- Working - Carbon Carbon Carbon
- Backup - Magnesite

Steelmaking And Continuous Casting Plant

The steelmaking and continuous casting plant has been designed to produce
824,700 t/yr of liquid stainless steel in Phase-I and 1,649,400t/yr of liquid
stainless steel in full development and cast the same into 800,000 t/yr and
1,600,000t/yr continuously cast slab respectively.

The stainless steel production will involve the following major steps.

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Production of ‘unalloyed’ liquid steel in electric arc furnace using double ‘D’
treated hot metal and purchased DRI in both phases. The ‘unalloyed’ liquid steel
will be subsequently charged into the AOD converter.

Production of chromium premelt based on liquid and solid HC ferro-chrome and

return stainless steel scrap in chromium pre-melter and its subsequent
processing in the AOD converter.

The ‘unalloyed’ liquid steel along with chromium premelt (from Cr-premelter) will
be blown in the AOD converter to achieve preferential decarburisation of the
liquid melt in presence of high Cr level for the production of stainless steel. A
ladle furnace has also been provided as a buffer between AOD converter and
caster and for homogenisation of temperature and composition of liquid stainless
steel prior to casting.

Production programme of the steelmaking and continuous casting shop

Sl. No. Facility Annual quantity, t Product
1 EAF 976,200 Unalloyed liquid steel

2 Chromium- 520,800 Chromium-premelt

premelter
3 AOD 1,649,400 Liquid stainless steel
converter
3 Ladle 1,649,400 Liquid stainless steel
furnace
4 Slab caster 1,600,000 Cast stainless steel slabs

The annual requirements of major raw materials and consumables for

steelmaking are indicated in table 2.7.

Table- 2.7
Requirement of major raw materials and consumables for steelmaking and
continuous casting (net & dry)

Sl. Item Annual requirement, t

No.
1 Return stainless steel scrap 129,600
2 Hot metal 943,800
3 Lime 267,400
4 Fluorspaar 8,300
5 Burnt dolomite 106,400
6 Refractory and fettling materials 25,000

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

7 Electrodes and nipples 1,450 (if required)

8* Refractories 7,200
9* Insulating compound 1,600
10* Casting powder 1,150
11* Copper plates for moulds 110
* For continuous casting plant

Major technological parameters of EAF

Sl. Parameter Unit Value / feature
No.
1 Liquid steel production t/yr 976,200
2 Furnace capacity, nominal t 2 x 100 t
3 Average tap-to-tap time min 60 approx
4 Heats / day no. 22 average (due to caster)
5 EAF availability d/ yr 320
6 Transformer rating MV 40 – 50
A
7 Furnace charge (average) - 87% hot metal & 13% coal
based DRI
8 Oxygen lancing - Mechanised top blowing
9 Level of automation - Computer controlled
operation (Level-II)
10 Steel refining - In AOD and LF (VOD
provision in future)
11 Fume collection and - Water cooled elbow, cooling
cleaning duct followed by bag house
system and chimney ;
secondary
emission control by canopy,
common system for EAF and
LF

Major technological parameters of AOD converter

Sl. Parameter Unit Value / feature

No
1 Liquid stainless steel t/yr 1,649,400
production
2 No. of converter no. Two operating with two
spare shells each
3 Converter capacity t 120
(nominal)

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Sl. Parameter Unit Value / feature

No
4 Specific volume, approx. m3 /t 0.5
of
liquid
steel
5 Type of converter - Combined blowing,
removable shell design with
detachable cone
6 Tilt drive - Electro-mechanical with air
motor for emergency tilting
7 Top lance movement - Hydraulic lifting / lowering
drive mounted on
hydraulically swivelling
hood; hydraulic power pack
8 Level of automation - Computer controlled
operation (Level-II)
9 Additive charging system - Mechanised with the
system of bunkers, vibro-
feeders, weigh-hoppers,
conveyors, etc.
10 Fume collection and - Hydraulically swivelling
cleaning water cooled collection
hood , gas cooler, bag
house system & chimney;
secondary emission control
by canopy on shop roof
11 Average tap-to-tap time min 60
12 Heats to be treated no. /d 22 average
13 Converter availability d/yr 320
14 Type of working lining - Dolomite lining
15 Steel grades - Stainless steel grades such
as J4, AISI-304, AISI-430

Major technological parameters of ladle furnace

Sl. Parameter Unit Value/feature
No.
1 Liquid stainless steel t/yr 1,649,400
to be treated
2 Furnace capacity, t 120
nominal
3 Treatment time min 48

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

4 Heats to be treated no./d 22 average

5 LF availability d/yr 320
6 Transformer rating MVA 25
7 Heating rate, average - 4 deg.C/min
8 Type of ladle furnace - Ladle on transfer car, roof lift
and lower, water cooled roof
9 Method of charging of - Mechanised with the system of
additives bunkers, vibro-feeders, weigh
hoppers, conveyors
10 Stirring of melt - Porous plug at ladle bottom with
argon purging
11 Fume collection and - Fume chamber above electrode
cleaning ports, ducting connected to EAF
bag house for fume cleaning
12 Automation - Computer controlled operation
(Level II)
13 Main functions of ladle - Alloying, heating, homogen-
furnace isation of chemistry and
temperature, deep desulphu-
risation, inclusion control & steel
cleanliness, holding of liquid
steel in case of emergency, etc
14 Steel grades - Stainless steel such as J4, AISI-
304, AISI-430

Technological parameters of continuous slab casting machine

Sl. Paramter Unit Value
No.
1 No. of machine no. 2 x 1 strand
2 Type of machine - Radial curved mould
3 Base radius of machine m 10.5
4 Section size mmxmm 150-200 x 1,000-1,600
5 Nominal heat Size t 120
6 Casting time min 60 (to match heat
delivery cycle)
7 Casting speed m/min 1.2-1.8
8 Casting practice - Sequence casting
9 No. of heats/sequence no. 10 (with flying tundish)
10 Preparation time min 45
11 No. of heats / day / caster no. 22
12 Caster availability d/yr 320

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

Sl. Paramter Unit Value

No.
13 Liquid steel to be cast t/yr 1,649,400
14 Yield from I.S. to cast slab % 97
15 Production of slabs t/yr 1,600,000

Rolling Mill Complex

Hot rolling mill facilities

It is envisaged to install a two-stand reversing steckel mill for production of about

1,000,000 t/yr of stainless steel hot rolled (HR) coils which will be converted to
100,000 t/yr of stainless steel HR annealed and pickled plates and 100,000 t/yr
of black coils by rolling the cast slabs in the mill. Balance HR coils will be
further processed in the cold rolling mill complex for production of cold rolled
(CR) products.

The hot rolling mill will mainly comprise of the following major technological
equipment :-

• Two slab grinding machines

• Two 110 t/h capacity walking beam type slab reheating furnace
• One primary descaling station
• One 4-high reversing roughing mill with vertical edger
• One crop shear
• Finishing descaling unit
• One 4-Hi finishing steckel mill with coiling furnace at entry and delivery side,
thickness gauge, entry side guides, pinch rolls and other associated equipment
• Runout roller table and strip cooling system
• One down coiler with coil handling facilities
• Mill auxiliaries consisting of lub. oil system, morgoil system, high pressure
hydraulic system, roll balancing system, hydraulic descaling system, roll cooling
system, air control system and grease system, etc.
• Roll grinding and bearing inspection facilities
• Mill electrics, controls and automation system
• Plate finishing facilities consisting of in line shearing, roller hearth annealing
furnace, batch pickling facilities, stretcher / roller leveller, resquaring shear, spot
grinding machine, etc.

Cold rolling mill facilities

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 Jindal Stainless Limited
EIA & EMP FOR THE MODIFICATION-CUM-EXPANSION OF
STAINLESS STEEL PLANT AT KALINGA NAGAR (ORISSA)

It is envisaged to install a cold roling mill (CRM) facilities of 800,000 t/yr for the
production of CR stainless steel sheets and coils.

The CRM facilities will comprise the following technological equipment

• One DRAP line comprising of two uncoiling units, edge trimming and cropping
units, one mechanical /chemical strip processing section, three nos. Z-high mills,
annealing furnace, scale breaker shot blast or pickling section, skin pass mill
and recoiler unit.
• One coil repair/grinding line
• Two (2) CR slitting lines with automatic packaging machine
• Two (2) cut to length lines with automatic packaging machine
• Necessary roll grinding and bearing inspection facility
• Necessary electrics, auxiliary and services facilities

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