Update : Kannappan Iron & Steel Plans To Set Up Sponge Iron Plant with Captive Power..
Industrial Directory Of India
RELEASED : ISSUE MARCH 25 /12
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Kannappan Iron & Steel Plans To Set UP
Sponge Iron Plant with Captive Power
(Update : Refer our earlier Report dtd.24.09.2011)
Kannappan Iron and Steel Company Ltd. plans to set up a Sponge Iron Plant having Capacity of 5000 Tons/ month and along with along with a 12 MW Cpative Power Plant at Karadivavi Village in Tiruppur District, Tamil Nadu.
Capacity :
1. Sponge Iron Plant : 5000 Tons/month
2. Captive Power Plant : 12 MW
Using WHRB & FBC.
Location :
Karadivavi Village, Palladam Taluk
Tiruppur District, Tamil Nadu
( Exact Location :15 km away from Tiruppur )
As 0n March 28, 2012 : The Project is in planning stage.
The project unit is coming up on 29.3 Acres of Land.
Out of this 8.1 Acres of Land will be developed as Green Belt.
IMPORTANT: As per the discussion we had last on 26.03.2012 with of Kannappan Iron and Steel Company Ltd. the Project is under planning stage.
The company is still waiting to obtain Environment clerance and the“NOC” from from State Pollution Control Authority.
The project is delayed by about 9 Months.
The Civil work is likely to start from
November/ December,2012.
The Project is Scheduled to be Completed
in October,2013 .
So, this is the RIGHT TIME to contact and Follow Up at following address obtain the detailed Enquiry of each product in time and to submit your quotation subsequently.
The Main Scope of Supply includes:
Captive Power Plant : 12 MW
Using WHRB & FBC.
1.Waste Heat Recovery Boilers:
Boilers : 10 TPH - 2 Nos.
The hot flue gases from DRI kilns will pass through waste heat recovery Boilers to recover the heat and to generate electricity. The gases after heat recovery will pass through ESPs and then discharged through chimneys into the atmosphere for effective dispersion of emissions into the atmosphere.
2.Fluidized Bed Combustion (FBC) Boiler:
Boilers : 36 TPH - 1 No.
Fuel : Coal and Char
ESP : 1 No, Chimney – 1 No.
Stack : Height- 60 Meter,
Dia : TOD- 1400 mm , BOD – 2300mm
Total dolochar generated will be used in FBC Boiler along with coal to generate electricity. The flue-gases will be treated in high efficiency ESP and then discharged through stack into the atmosphere.
.
Heat Exchangers, Air Pre-heater/Economiser) to be included both type of Boilers.
1. DRI Klin (2 Nos) : 2 X 95 TPD
2. Steam Turbine (1 No ): 12 MW
The plant will require one no 12 MW Steam Turbine and have uncontrolled extraction connected to one constant pressure deaerator normally working at 125DegC feed water temperature.
3. Iron Ore Crusher
4. Coal crusher
5. Coal/Char Preparing & Handling Plant
SPONGE IRON (DRI) Unit
Coal based DRI process
The coal-based method of producing sponge iron involves reducing iron ore
(lumps/pellets) with a carbonaceous material like coal or lignite. The reduction process is carried out in a Rotary Kiln (which is inclined and rotatesat a pre-determined range of speeds) at a stipulated temperature (850oC –1050oC). The inclination & the rotary motion of the kiln ensure that the rawmaterials move from feed-end to the discharge-end of the kiln and it isduring this movement that the actual reduction of iron ore to iron takesplace. The material discharged from the kiln is taken to a rotary cooler forcooling and the cooled product, after being discharged from the cooler moveson to the next step in the production process viz. product separation and handling system.
At this stage the product is a mixture of sponge iron and non-magnetic
matter such as char and with the aid of magnetic separators, the final
product, sponge iron is separated and stored in bins meant for the purpose.
Raw Materials
1. Raw Material for the Power plant :
a. Coal (50%) : 3480 Ton/month
b. Charcoal (50%) : 1920 Ton/month
2. Raw Material for the Power plant :
a. Coal : 6000 Ton/month
b. Iron Ore : 12000 Ton/month
b. Dolomite : 200 Ton/month
Air Pollution Control Equipment :
Electrostatic Precipitators/ Bag Filters
Particulate emissions from the plant will be controlled within 50 mg/Nm3.
The plant shall be provided with Electrostatic Precipitators
having high efficiency (above 99.98%) for collection of the fly ash that would
be produced from the Process of coal combustion in Boiler Furnace.
An Electro Static Precipitator would be provided for the cleaning / detarring of the Producer gas and the flue gases.
Stack of adequate height will be provided at the respective units. Water sprinkling will be done along the haul roads to control dust arising from vehicular movement. Dry quenching of coke shall be explored.
Coal from the coal yard will be crushed in a Crusher and conveyed to coal storage bunkers of Boilers through a system of Conveyor Belts, Crusher and Vibrating Screens and is fed to the furnace.
ESP, Dust Extraction systems for Conveyor Transfer Points, Crusher and Screen house with Hoods, Bag filter and Fans will be provided.
De-mineralised water from the storage tank will be pumped to the boiler with the
aid of Boiler Feed Pump. The boiler feed water through an Economizer will
the Steam drum and water walls where it is heated and converted to
saturated steam.
The steam from the main steam header will be taken to the
Turbo–Generators. After rotating the turbinethe exhaust steam is
condensed in the Air Cooled Condensers and the
condensed water is pumped to the De-Aerator and fed back to the boilers.
Cooling Tower : 1 No.
One induced draft RCC counter flow Cooling Tower with three cells of adequate capacity to meet the design operating point of the proposed CPP to be installed.
DG Set : . 1 No.
D.G. set : 750 KVA will be installed for stand by arrangement..
a stack 0f 15 Meter Height and 250 Dia.
Silencer (Acoustic enclosures) to be provided to D.G.
Material Handling Equipment
Conveyor
Crusher
Vibrating Screens
Pneumatic Conveying system
Other Systems
- Fuel handling system
- Ash handling system
- Air Cooled Condenser
- Fuel system
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Centralized Control System
One centralized Control System will be installed for the operation of major equipment (Boiler, STG, CW System) in the plant and other auxiliary systems (Compressors and DM plant) shall be operated from their relay based local control panels/stations.
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The following air pollution control systems/ measures are proposed in the Plant
1. All Conveyors will be completely covered with G.I. sheets to control fugitive
dust.
2. All bins will be totally packed and covered so that there will not be any chance
for dust leakage.
3. All the Dust Prone Points Material Handling systems to be connected with
de-dusting system with bag filters.
4. All Discharge Points and Feed points, wherever the possibility of dust
generation is there a de-dusting suction point will be provided to collect the dust.
5. The collected Dust from the Bag house of Steel Melting to be taken to a dust storage bin through a Pneumatic Conveying system.
Water Treatment Plant :
Oxdisation Chamber, Filter, D.M. Plant, Tube Settler
Pumps Valves, Custom Pipeline Work
D.M .Plant : 5 m3/ hr – 1 No.
1 x 5 m3/hr rated flow capacity Single Stream fully manual operated
outdoor type DM plant
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The total consumption of water for the Sponge Iron
and Power units will be 735 KLD.
Source Of Water :
The requirement of water for these units will be met from Pilur water scheme and Private water supply.
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The plant will be designed as a zero discharge plant. The entire treated waste water will be recycled for various purposes inside the plant. The water will be recirculated through cooling and treatment.
This includes Make-up water for DRI,Power plant and Domestic water.
Waste Water Generation
Boiler Blowdown, Cooling Tower Blowdown & DM Plant regeneration will be the sources of effluent generation from the power plant.
Details of Waster Water Generation
From Sponge Iron & Power Plant
1. Wet scrapper (below DSC) : 1 m3/ day
2. Boiler blow down : 4 m3/ day
3. Cooling Tower blow down : 46 m3/ day
4. R.O/ rejection : 74 m3/ day
5. Sewage : 27 m3/ day
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Total 152 m3/day
Effluent Treatment Plant:
pH of the boiler blowdown will be between 9.5 to 10.5. Hence a neutralization tank will be constructed for neutralizing the Boiler Blow Down. DM plant Regeneration water will be neutralized in a neutralization tank. After neutralization these two effluent streams will be mixedwith Cooling Tower blowdown in a Central Monitoring Basin (CMB).
Iron Ore Tailing generated from Iron Ore Beneficiation plant will be disposed off for land filling. The fly ash generated from Captive Power Plant will be sold as a raw material for cement and brick manufacturing. Dolo-char from the DRI units will be used in AFBC boiler. BF slag will be sold as a raw material in cement plants.
The treated effluent will be utilized for Dust Suppression, Ash conditioning and for Green belt development. No effluent will be let out of the plant premises. Hence Zero discharge concept will be implemented. Sanitary waste water will be treated in Septic tank followed by soak pit.
Other Equipments :
Material Handling Equipment : Conveyor, Hydraulic Equipment/Cranes,
DG Set, Air Compressor. Gear Box, Insulation, Valves, Pipes & Tubes, Cables, Automatic Weighing Machines for Bulk & Liquid Materials. Pressure Filler, Storage Tank, Cooling Tower/ Plant, Air Conditioning Plant,
Complete Laboratory Equipments etc
Fire Fighting System shall be as per the TAC Norms.
8.1 Acres of Greenbelt will be Developed and a scheme for Rainwater Harvesting have to be put in place.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, Factory Shed- Boiler House, Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Kannappan Iron and Steel Company Ltd.
9/110, Kalidas Road
Ramnagar, Coimbatore - 641 009, India
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Tel : +91- 422- 2231433, 2231533, 2231633
Fax : +91- 422- 2233126
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Email : enq...@kiscol.com
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