Nachiketa Power & Steel Plans for Integrated Steel Plant Along With Captive Power
Industrial Directory Of India
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Nachiketa Power Plans for Integrated
Steel Plant Along With Captive Power
Nachiketa Power & Steel Pvt. Ltd. plans to set up an Integrated Steel Plant having an Iron Ore Beneficiation and Pelletization Plant : 3,00,000 TPA, Sponge Iron Plant : 90,000 TPA, Steel Ingots and Billets Plant (through Induction Furnace with Concast) : 90,000 TPA,Ferro Alloys Plant : 30,000 TPA, Manufacturing of Structural items (through Rolling Mill): 90,000 TPA along along with a 21 MW (WHRB : 6 MW + FBC : 15 MW) Cpative Power Plant
at Silpahari Industrial Area at Silpahari Village in Bilaspur District, Chhattisgarh.
Capacity :
1. Iron Ore Beneficiation and Pelletization Plant : 3,00,000 TPA
2. Sponge Iron Plant : 90,000 TPA
3. Steel Ingots and Billets Plant : 90,000 TPA
(through Induction Furnace with Concast)
4. Ferro Alloys Plant : 30,000 TPA
5. Structural items(through Rolling Mill) : 90,000 TPA
11. Captive Power Plant : 21 MW
a. WHRB : 6 MW
b. FBC : 1X15 MW
Location :
Silpahari Industrial Area, Silpahari Village
Bilaspur District, Chhattisgarh.
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As 0n August 14, 2013 : The Project is in planning stage.
The project will come up on 39 Acres (15.822 Ha.) of Land.
Out of this 33% land ie. 13 acres shall be developed as Greenbelt.
IMPORTANT: As per the discussion we had last on 07.08.2013 with of Nachiketa Power & Steel Pvt. Ltd. the Project is under planning stage.
The company is waiting for Environment Clearances.
The project work is likely to start from
February/March 2014.
The Project is Scheduled to be Completed
By September,2015.
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So, this is the RIGHT TIME to contact and Follow Up at following address to obtain the detailed Enquiry of each product in time and to submit your quotation subsequently.
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The Main Scope of Supply includes:
Captive Power Plant : 21 MW
(WHRB: 6 MW + FBC : 15 MW)
1.Waste Heat Recovery Boiler:
DRI Kiln gas shall be used in WHRB.
The hot flue gases from above will pass through waste heat recovery Boilers to recover the heat and to generate
6 MW(3 X 2MW) electricity.
ie, the company will install 3 x 2 MW Waste Heat Recovery Boilers
based power plant utilizing waste heat coming from DRI kilns to generate nother 6 MW Power.
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:
In this section high pressure steam is produced using pressurized
boilers, which are fed to turbines for generating electricity.
The Boiler to be designed to take 100% ‘E or F’ grade coal as well as Char & Washery rejects as fuel.
Total dolochar generated will be used in FBC Boiler along with coal to generate 15 MW
(1 X 15 MW) 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.
3. DRI Klin(Sponge Iron Plant): 3 x 100 TPD
4. Heat Induction Furnace(Steel Ingot / Billet Plant): 2 x 15 Tons
5. Submerged Arc Furnace(Ferro-Alloy plant): 2 x 9 MVA
Manufacturing Process :
Sponge Iron Plant:
Crushed raw materials (Iron ore, coal & dolomite) will be fed to the kiln.
Coal will be providing the source of heat and also acts as reducing material to turn iron ore into iron. Sponge iron produced will be separated from waste materials in magnetic separator, screened and sent to steel making shop.
For the direct reduction of iron ore, the main furnace used is Rotary Kiln.
Iron ore, Coal, Dolomite/ Limestone will be fed in the weighed quantity and the kiln is rotated at the speed of about 0.5 rpm. A temperature between 1000 Deg C to 1050 Deg C will be maintained in about 70% of the kiln length towards discharge and side for required reaction. After the reaction, the product will be taken into an indirect cooling drum cooler. The product will be cooled to 100 Deg C and taken for product separation.
Details of manufacturing Process:
1. Iron Ore Preparation
Lower sized crushed ore shall be procured.
Sized ore is taken to the iron ore storage bins.
2. Coal Preparation
Similarly on coking steam coal of less than 150mm sizes as received from coal India shall be fed to
the vibrating feeder with Screen. The 6 mm shall be screened out, 6 to 25 mm
shall be sent to the storage bin and more than 25mm size shall be taken to further crushing into the crusher. After crushing the crushed coal again come back to the screen.
It is hence a closed loop circuit. After crushing and screening the sized coal is being stored in the bins.
3. Kiln Feeding
The weigh, feeders discharge the raw material on common Belt Conveyers, which discharge the
material into the kiln via a feeder.
4. Rotary Kiln
It is a refractory lined cylindrical vessel, having blowers and air pipes mounted on it to provide
combustion air to kiln. To heat up the rotary kiln an oil fired burner is used at the discharge end
of the kiln. Once the desired temperature is reached iron ore, coal and lime stone/dolomite fed
from the kiln feed end and also 6 mm fine coal is blown from the kiln discharge end. Hereafter
coal maintains the desired temperature for reduction process. Since the kiln is having a
downward slop from feed end side to discharge end side, it rotation causes the feed mix to travel
through the system. The kiln is also a reaction vessel. The reduction from oxide to metal occurs
by a gradual removal of oxygen, giving rise to various intermediate oxides. T
The final reduction from FeO to Fe is 67% and occurs in the last parts of the kiln before
discharging. So the maximum energy requirement is at last part of the kiln
5. Coal Blowing System
The fine coal shall be blown inside the kiln from discharge end. The coal blowing system
eliminates any requirement of liquid hydrocarbons from heating or reduction and enables the
process to be 100% coal based.
6. Rotary Cooler
A cylindrical vessel that rotates around it’s long axis and have slope towards discharge end. Hot
sponge iron from kiln at 1000 Deg C to 1050 Deg C discharge through the kiln discharge housing to the
rotary cooler. Water shall be sprayed over the entire length of rotary cooler for indirect cooling
of sponge iron. Some water shall also be sprayed inside the cooler for suppression of dust and for
cooling. The cooler has a tapered feed and an arrangement to divert oversize material to oversize
chute.
7. Product Handling
Sponge iron and char at 100 Deg C to 120 Deg C will be discharged through the cooler discharge chute to conveyor. The main conveyor belt will carry the product to product screen.
The final product of
sponge iron 3mm to 25mm fraction, -3mm to 3 mm fraction of char is being taken to separate
bins for storage.
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.
Other Equipments:
MELTING DIVISION - EQUIPMENTS/SYSTEM
1. Induction Melting Furnace
2. Circuit Breaker with CT’s & PT’s, Trivector Meter
3. Furnace Transformer
4. Auxiliary Transformer
6. EOT Cranes : 40/ 15 Ton
7. EOT Cranes 15/10 Ton
8 Cooling Tower
9 DM water Plant
10. Softener Plant
11. Round Magnets with CRD, Control panels & cables
12. Emergency Tank
13. Heat Exchanger
14. Ladles
15. Ladle Refractories
16. Lifting Bail Arms
17. Ladle Preheater
18. Scrap Charging Bucket
19. Slide Gate System
20. Water Pumps and Motors
21. Weigh Bridge
22. Air Compressor and Receiver
23. Temperature Measuring Equipments
24. Pollution Control Equipments
25. HT & LT Cables and Cable Trays
26. Battery & Battery Charges
27. Power Distribution Panels
28. Pipes and Fittings
29. Tubes, Valves, Flanges & Filters
30. Refractories
31. Laboratory Equipments & Apparatus
CASTING DIVISION - EQUIPMENTS/SYSTEM
1. Continuous Casting Machine
2. Air Compressor and Receiver
3. Cooling Tower
4. Softener Plant
5. Pumps
6. Motors
7. Tundish Refractories
8. C.I Slag Pot
9. L.T Cables & Cable Trays
10. MCC & PCC Panels
11. Pipes & Fittings
12. Tubes, Valves, Flanges & Filters
13. Safety Equipments
14. Gas cutting machine
15. Man Coolers
16. Chains & Slings
17. Lubrication system
18. EOT Crane : 10/ 5 Ton
19. Rectangular Magnet with CRD, Control panels & cables
ROLLING MILL DIVISION - EQUIPMENT/SYSTEM
1. Reheating Furnace
2. Billet table & charging system
3. Cooling bed
4. Conveyer tables, Repeaters, loppers & Guiding equipments
5. Rolling Mill accessories
6. Oil lubrication system
7. T.M.T system with instrumentation & pumps
8. Various Shearing machines
9. Water treatment & cooling system
10. EOT cranes
11. Mobile Crane
12. Square Magnet (5 ton)
13. Quality control & physical lab equipments
14. Transformers
15. L.T Cables & Cable Trays
16. MCC & PCC Panels
17. Pipes & Fittings
18. Maintenance Equipments, Tools & Tackles
19. Tubes, Valves, Flanges & Filters
20. Safety Equipments
21. Gas cutting machine
22. Man coolers
23. Chains & Slings
22. Pumps
24. Motors
25. Air Compressor and Receiver & Pneumatic system
26. Cooling Tower
27. Softener Plant
28. Lubrication system
29. Mechanical work shop equipments
Cooling Tower
DG Sets (as stand by during Power Failure)
Air Conditioning Plant
Material Handling Equipment
Conveyor
Crusher
Vibrating Screens
Dewatering Screen
Pneumatic Conveying system
Other Systems
- Fuel handling system
- Ash handling system
- Air Cooled Condenser
- Fuel system
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
Total water requirement for the proposed project is 3475 m3/day which will be supplied by CSIDC.
This includes Make-up water for DRI, SMS, Rolling Mill, Power plant and Domestic water.
Waste Water Generation
Domestic waste water generated will be treated in septic tank followed by soak pit.
Effluent Treatment Plant:
There will be no effluent generation in the DRI plant, SMS and Rolling mill as closed circuit cooling
system will be adopted.
Initially the acidic and alkaline effluent streams coming from cation and anion units of DM plant will be neutralized in a neutralization tank .
pH of Boiler blow down will be in between 9.5 and 10.5. Hence this effluent stream shall be
neutralized in another neutralization tank before mixing with other effluent streams.
All these effluent streams will be mixed in a central Effluent Monitoring Basin along with cooling
tower blow down.
Part of the treated effluent will be recycled into the DRI plant & Rolling mill make-up water for
cooling and the remaining treated effluent will be used for ash conditioning, dust suppression
and for greenbelt development.
The sanitary wastewater will be treated in septic tank followed by soak pit
Solid Wastes: Pellets generated from the plant will be given to Ceramic Industry and other end users.
Dolochar from Sponge Iron Plant will be used as fuel in FBC based power plant.
Slag is generated from the induction furnace will be utilized for road embankment as well as for
filling low lying areas within the plant premises, while the mill scales from rolling mill will be
recycled into SMS. Ash generated from the Power plant will be given to Brick manufacturers/
cement plants...
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.
13 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.
Companies/ General Industries/ Contractors/ Sub Contractors/ Manufacturers of Boiler, Material Handling Equipment , Water Treatment Plant, Effluent Treatment Plant, Air Pollution Control Equipments, Cooling Tower, Blowers, Cranes, Hydraulic Equipments, Water line Valve, Pump, Pipeline etc. related to Power Plant may Contact for Specified Enquiry at :
Nachiketa Power & Steel Pvt. Ltd.
C/o. Nidhi Pipes Limited
SCO. 44, 1st Floor Sector- 26, Madhya Marg
Chandigarh- 160 019, India
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Tel : + 91- 1762-280179/280479
Fax : + 91- 1762-282179
Email : in...@nidhipipes.com/ nidhi...@hotmail.com
Website : www.nidhipipes.com
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