substitution of natural gas by coke oven gas for existing

SUBSTITUTION OF NATURAL GAS BY COKE OVEN GAS

FOR EXISTING SPONGE IRON PLANT

At Salav, Dist. Raigad, Maharashtra

Project Report

Welspun Maxsteel Ltd. Mumbai

June 2014

Welspun Maxsteel Limited

Maharashtra Substitution of Natural Gas by Coke Oven Gas for Existing Sponge Iron Plant

Project Report

CONTENTS

Chapter No. Title Page Nos.

From To

01 Introduction 1-1 1-3

02 Major Technological Facilities 2-1 2-14

03 Raw Materials & Finished Products 3-1 3-4

04 Proposed Site 4-1 4-3

05 Services, Utilities & Manpower Requirement 5-1 5-4

06 Environmental Management 6-1 6-2

07 Project Implementation 7-1 7-1

08 Block Capital Cost 8-1 8-1

DRAWINGS

Sl. No. Description Drawing No.

01 Location Map WML/MH/PR/001

02 Regional Map WML/MH/PR/002

03 Road Linkage WML/MH/PR/003

04 Process Flow Sheet WML/MH/PR/004

05 General Layout WML/MH/PR/005

06 Implementation Schedule WML/MH/PR/006



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01 Introduction

01.01 Preamble

The US$ 3.5 billion Welspun Group is one of India’s fastest

growing conglomerates having registered a CAGR of 30% over the

last decade. It has a presence across five business verticals --

Pipes, Plates & Coils; Home Textiles; Steel; Infrastructure; and

Energy. In the first two verticals, it is a fully integrated player.

Welspun is also among the recognised world leaders in the fields

of Line Pipes and Home Textiles. The Group has a strong foothold

in more than 50 Countries, employs over 24,000 people and has

as many as 100,000 shareholders.

The Group has business dealings with companies across the

globe, including a number of marquee clients, covering most of

the Fortune 100 companies in the Oil & Gas and Retail sectors.

Among the group’s subsidiaries is Welspun USA, Welspun Tubular

LLC, Welspun Middle East and Welspun UK.

In the Line Pipe sector, Welspun has to its credit some of the

most prestigious projects including the world’s deepest pipeline

project in the Gulf of Mexico, heaviest pipeline project in the

Persian Gulf, highest LNG pipeline project in Peru and longest

pipeline project from Canada to the US.

Welspun Maxsteel Ltd. was formed on 22nd May, 2009 after

Welspun Steel Ltd. completed the acquisition of Vikram Ispat, the

Sponge Iron division Business of Grasim Industries Ltd. The

facility was set up with design capacity of 0.75 million tons of

Sponge Iron in the form of HBI (Hot Briquetted Iron).



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Welspun Maxsteel Ltd. takes pride in being the first and the only

one of its kind in the world to produce both HBI and DRI (Direct

Reduced Iron) from the same Reactor" using state of the art

technology “HYL III” from HYLSA of MEXICO and engineering

expertise of Davy Dravo of USA.

Welspun Power and Steel Ltd. signed a MOU with Government of

Maharashtra on 18th August 2009 to invest Rs. 6000 crores for

setting up an Integrated Steel Plant along with a 660 MW Captive

power plant through a Special Purpose Vehicle viz. Welspun

Maxsteel Ltd. at Salav, Taluka Murud, Dist. Raigad falling in C

zone under the package Scheme of Incentives (PSI) 2007 and to

provide direct and indirect employment to 5000 persons in

conformity with the state government’s policy regarding

employment of local persons.

The plant is based on usage of natural gas based process to

produce Sponge Iron. The availability of Natural Gas is becoming

very scarce in India & the prices are also increasing. It is

apprehended that it may no longer be viable to operate this plant

with Natural Gas leading to closure of the plant and loss of

employment of people. Welspun takes pride in serving the

community and hence it is proposed to substitute the Natural Gas

by Coke Oven Gas for producing Sponge Iron from the plant. This

technology is now being developed in steel plants and is becoming

viable for usage in production of Sponge Iron.

Welspun Maxsteel Limited (WML) intends to install a recovery type

coke oven plant for the generation of required Gas for the

production of Sponge Iron. The by-products like coke, benzol,



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sulphur, BTX shall be recovered and disposed off suitably in the

market.

For this purpose, it is proposed to install a 3 million tons per

annum coke oven plant which will generate about 154,000 Nm3/hr

of coke oven gas having total energy 662 Gcal/hr. Out of 662

Gcal/hr energy about 40% (265 Gcal/hr) would be used internally

in the coke oven plant for battery heating & ammonia cracking

and remaining 60% (397 Gcal/hr) would be used for production of

Sponge Iron/DRI.

MoEF GOI has already granted Environmental Clearance

after following the due processes including Public Hearing

for expanding the plant from 0.75 MTPA to 1.75 MTPA,

with integrated facility of Pellet Plant (4 MTPA), Steel

Plant (1.5 MTPA), Captive Power Plant (330 MW) at

Village Salav, P.O. Revdanda, District Raigad, Maharashtra

vide MOEF letter No. F.No.J-11011/183/2008-IA.II (I)

dated 27th January 2011.

Since this application is for substitution of Natural Gas by

Coke Oven Gas only, it is requested that fresh public

hearing may not be mandated.

The capital investment for the proposed gas generation coke oven

plant will be about Rs. 3000 crores.

The project has been envisaged keeping in view the substitution

of scarce & inconsistently available Natural Gas by Coke Oven gas.

The proposed plant shall have positive impact on socio-economic

development of the area along with further employment of people

by expanding the plant operation.



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02 Major Technological Facilities 02.01 General

The project envisages installation of a 3.0 Mt/yr coke oven plant

to generate 154,000 Nm3/hr of coke oven gas along with coke and

by-products at Salav village in Raigad district of Maharashtra. The

process flow sheet and general layout of proposed project is

shown in Drg. No. WML/MH/PR/004 & WML/MH/PR/005

respectively.

02.02 Process Chemistry

The Sponge Iron/DRI process converts iron oxide lump ore,

pellets, or pellet/lump mixtures into highly metalized Iron in the

form of direct reduced iron which is an ideal feed material for high

quality steel making.

02.02.01 Iron Oxide Reduction

Most naturally occurring iron oxide has the chemical composition

of haematite, Fe2O3 and contains about 30 percent oxygen by

weight. In this process, the chemically bonded oxygen in the iron

ore is removed by high temperature reduction reactions with CO

and H2 to produce metallic Fe. The CO2 and H2O are byproducts

produced by the iron ore reduction reactions. The overall

reduction reactions are :

Fe2O3 + 3H2 = 2Fe + 3H2O

Fe2O3 + 3CO = 2Fe + 3CO2



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An important property of the reduction gas is the reductant

/Oxidant ratio or “gas quality”. The gas quality is a measure of

potential for the gas to reduce iron oxide. The gas quality is

defined as the ratio of reductants to oxidants contained in the gas :

Gas quality = reductant / oxidant ratio

= (%H2 + %CO) / (%H2O + %CO2)

It is found that the optimum gas quality for hot reducing gas

entering the shaft furnace should be 9 or higher. Also, to obtain

essentially complete reduction, the quality of the spent reducing

gas exiting the shaft furnace should be at least 2.

Another important property of the reducing gas is the H2/CO ratio.

Control of the H2/CO ratio results in thermally balanced reduction

reactions since reduction with CO is exothermic, and reduction

with H2 is endothermic. That is, the heat required by the H2

reaction is balanced by the heat supplied by the CO reaction. So,

proper reduction temperatures are easily maintained.

The incoming COG (Coke Oven Gas) contains the reductant (CO

and H2) source of the reduction reactions in the shaft furnace.

Besides containing the reductants, COG also contains

approximately 25% CH4. In order to eliminate the impurities in the

COG and reform CH4 into additional reductants, the COG is

injected into the Thermal Reactor System (TRS) to create a

syngas which contains approximately 1% CH4.

Spent reducing gas exiting the shaft furnace is cleaned,

compressed, mixed with the TRS syngas system and cooled in the

process gas aftercooler to remove excess heat and water vapour.



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The gas stream, called rich process gas continues on to the CO2

removal system which strips the CO2 and H2S. The gas exiting the

CO2 removal system is called the lean process gas. The lean gas

and the bypass stream of the TRS syngas are mixed together and

sent to the feed gas mist eliminator for mist removal to achieve

minimum H2S levels to inhibit metal dusting. With this, the

majority of the sulphur compounds in the syngas is stripped in the

CO2 removal system and is not absorbed by DRI. The feed gas

stream from the feed gas mist eliminator contains 3-4% CH4. CH4

content in the reducing gas stream is an important control

parameter in this process. After heating in the reducing gas

heater, a small amount of O2 is added in the reducing gas stream

inducing a exothermic reaction to obtain the proper energy for the

reactions in the furnace.

The specific reducing gas consumption and gas quality also affect

the DRI metallization. The degree of metallization is a

quantitative means of determining the amount of O2 removed

from the iron oxide during the reduction reactions.

% Metallization = (% Metallic Fe / % Total Fe) x 100

The plant production capacity is based on the degree of

metallization and is about 93 - 94%.

The clean Coke oven gas proposed to be used in the production of

DRI plant shall have the below composition –



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Constituents Unit Value

H2 % vol 56-60

CO % vol 5-8

CH4 % vol 23-27

CO2 % vol 1.5-3

O2 % vol 0.3-0.8

N2 % vol 3-7

H2O % vol 0

Tar g/Nm3 Trace

Benzol g/Nm3 3.0

Naphthalene g/Nm3 0.4 max

H2S g/Nm3 0.3 max

HCN g/Nm3 0.28 max

Nominal pressure Bar (g) 0.1

Nominal Temp. °C 25

Net Heating Value Kcal / Nm3 4500

The syngas as produced to be used for DRI production shall have

the following composition –

Constituents Unit Value

H2 % vol 55.5 +/- 2%

CO % vol 24.5 +/- 1%

CH4 % vol 0.9 +/-0.5%

CO2 % vol 1.7 +/- 0.5%

O2 % vol 0

N2 % vol 4.9 +/- 2%

H2O % vol 12.5 +/-1%



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Tar g/Nm3 0

BTX g/Nm3 0

Naphthalene g/Nm3 0

H2S ppmv 150 – 300

Soot g/Nm3 0.02 max

The DRI plant has the following technological facilities –

1) Iron oxide material handling system

2) Reduction shaft furnace

3) Cooling gas system

4) Process gas circuit

5) Reformer / reducing gas heater

6) Heat recovery system

7) Thermal Reactor System (replacing the existing reformer)

8) Oxygen Injection

9) Seal gas and purge gas system

10) Water System

11) Dust collection system

12) Electrical and Automation system

02.03 The following are the technological facilities for the coke

oven generating the required 154,000 Nm3/hr of COG -

The following technological facilities have been envisaged for

proper and smooth operation of the plant.

1. Coal Preparation Plant

2. Coke Making Plant, Quenching & Screening

3. Gas cooling and cleaning system

4. Desulphurization and sulfur recovery

5. Benzol Recovery



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6. Ammonia scrubbing and distillation

7. Ammonia cracking unit

8. De-dusting

9. Gas holder & Booster station

10. Effluent treatment plant

02.04 Coal Preparation Plant

The coal preparation plant has been envisaged to cater to a daily

average wet coal through put of about 11900 t/day.

The coking coals from the overseas sources will be imported and

will be transported upto the captive jetty by barges. The coals

unloaded at the jetty will be transferred to plant coal storage yard

by belt conveying systems.

Coal storage yard at the coke oven plant has been envisaged for

storage of incoming coking coals. Coal received through conveyor

will transfer the coal to a stacker cum reclaimer machine for

forming stock piles according to the grades of coal. Different

grades of coal will be stored separately. Transfer of coking coal to

the stockpiles will be done by a rail mounted wheel-on-boom

stacker cum reclaimer. The stacking operation, if necessary, can

be performed in all three shift to match the coal receipt pattern at

the plant site.

The coal preparation unit will consist of coal crushing and

blending facilities.

Reclaimed coals of size ≤ 80 mm from the storage yard will be

crushed to < 3 mm not less than 80 %, in the primary crusher,



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delivered to the coal silos, one variety at a time, through a system

of conveyors. 12 Nos. bins with each capacity of 1000 tons and 4

Nos. coal surge bins with each capacity of 1000 tons will be

provided near the storage yard for storing of different types of

coals. Each constituent of the blend will be drawn in requisite

proportion from different bunkers to the secondary coal crushing

station.

In the secondary crushing station, blended coal will be crushed to

90% below 3 mm in reversible compact jump hammer crushers.

Coals after crushing will be conveyed to the mixer for full mixing

of different coals in order to ensure the complete mixing of each

type of blended coal to enhance the coke quality.

After the mixing section the coal blend is fed to coal blend

bunkers. Each concrete bunker has capacity to sustain 8 hours of

operation of coke oven batteries. Proportioning of coal blend from

both bunkers is performed by continuous action proportioning

devices. The adjustment for the preset capacity and capacity

control of the proportioning devices is performed by the coal

handling plant operator from the control room.

Downstream of the coal blend bunkers, there are conveyor

systems for coal blend supply to the stamping machine.

02.05 Coke Making Plant

4x62 nos. of stamp charged recovery type coke ovens will be

constructed with a total annual dry coke production, of around

3,000,000 tonnes.



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Coal from the coal preparation workshop is conveyed to the coal

stamping machine through the belt conveyor. The coal delivered

by the conveyors is sent from the feeding system of Stamping

Charging Pushing (SCP) machine into the coal hopper which is

located on the SCP machine. The coal is then delivered into

stamping box via plate type feeders, and stamped by the

stamping machines into coal cake. The stamped coal cake is

charged into the coking chamber from the coal side. The coal cake

is carbonized at a certain temperature, and after ~24 hours coke

is pushed into the bucket car by coke pusher via the coke guiding

gate. The bucket car then takes the hot coke to CDQ for dry

quenching. Afterwards the cooled coke will be discharged into belt

conveyor which goes to the coke screening system. In case of wet

quenching, the coke will be taken by the coke quenching car to

the coke-cooling wharf wherein it is discharged by the coke

scraper onto the belt conveyor and then taken to the coke

handling system.

The raw coke oven gas produced during carbonization goes

through the top of coking chamber, the ascending pipe, and the

bridge pipe, to the gas collecting main. The gas is cooled by

spraying liquor ammonia at ~78 under ~0.3MPa pressure at the

bridge pipe and gas collector, so that it is cooled from ~700 to

~84 ; then, it is sucked through the suction elbow and suction

pipe to the condensing/blowing unit. The tar and ammonia

condensed in the gas collecting main flow via the tar box and

suction main to the condensing/blowing unit.



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The heating gas (mixture of coke oven gas and blast furnace gas)

is sent through the external pipe to the coke oven. The combined

gas goes into the regeneration chamber and at the same time the

air goes into regeneration chamber via waste gas shut-on-off

device for air. After being pre-heated, the gas combined with air

goes into the vertical flue of combustion chamber. The flame is

elongated by the circulation of partial waste gas which makes the

heating in the top more even. The standard heating temperature

is 1300~1320 .

The waste gas, after combustion, goes runs through the top of

the vertical flue and then into the vertical flue with downward air

flow, via the regeneration chamber for partial heat recovery and

finally is discharged into the atmosphere from the chimney.

During coal charging, the possibly collapsed coal cake at the coal

side will be cleaned into the belt conveyor located under the

operation platform, and then delivered into the coal bin for

storage and transported by vehicles.

The fumes and dust which is produced during coal charging will

go via the gas transfer car into the adjacent coking chamber. The

dust collecting hood as well as gas collecting main will be set up

above the oven door on the coal side, which will capture the fume

dust escaping from the oven door during the coal charging and

send them into the ground de-dusting station. The fume and dust

generated from coke pushing will be guided via the coke guiding

car and dust collecting main into the ground de-dusting station for

treatment and discharging.



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The major structural dimensions and process indexes of the coke

oven are given below:

(1) The major structural dimensions of coke oven are as follows:

Total length of coking chamber: 17000 mm

Effective length of coking chamber: 16140 mm

Total height of coking chamber: 6300 mm

Effective height of coking chamber 5900 mm

Average width of coking chamber: 525 mm

Center distance of coking chamber: 1450 mm

Taper of coking chamber: 30 mm

Center distance of vertical flue: 480 mm

Number of vertical flues: 34

Thickness of combustion chamber wall: 100mm

(2) Major technical indexes of coking process:

Number of coke oven ports: 4×62 ovens

Dimensions of coal cake: L×W×H 16150/15950×480×5900 mm

Density of coal cake (Dry) 1.00 t/m3

Dry coal capacity of coking chamber 45.45 t

Cycle time of coke oven 24 hr

Yield ratio of dry CO gas 315 Nm3/t (dry coal)

Annual consumption of dry coal 4,285,000 t

Annual yield of dry coke 3,000,000 t

Temperature of raw coke oven gas from gas collector:~84°C

Pressure of raw coke oven gas from gas collector: 80~120Pa

02.06 Gas cooling and cleaning system

The section includes coal gas condensing, cooling, and pressurized

convey, separation, storage and convey of tar, ammonia, and tar



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slag, precipitation of tar fog drops and naphthalene in coal gas,

and cleaning of tail gas.

The mixture of tar, ammonia, and coal gas from coking section

enters into the gas-liquid separators at about 80°C, where the tar

and ammonia are separated from the coal gas. The raw coal gas

enters into the transverse pipe PGCs where coal gas is cooled.

The cooled coal gas enters into the electro tar precipitators to

precipitate tar fog drops and naphthalene from the coal gas; after

electric tar precipitation, the coal gas enters into the centrifugal

exhauster and is pressurized, and then sent to the

desulphurization section.

02.07 Desulphurization and sulfur recovery

Coke oven gas (at 45 ) coming from condensing-blowing section

first enters final cooling tower. The gas in final cooling tower is in

counter-current contact with the circulating cooling water sprayed

from the tower top and is cooled to 23 , then enters H2S

washing tower to remove H2S. The cooling water flowing out from

bottom of final cooling tower is pumped to the final cooling water

heat-exchanger and cooled to 210C and enters final cooling tower

for circulating and spray.

The cooled gas is cleaned of most of the H2S by passing through

the H2S washing tower with ammonia water. The clean gas is

discharged from the top of H2S washing tower and enters the

bottom of ammonia washing tower for ammonia removing.



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The gas entering from the bottom of the ammonia washing tower

is cleaned out of the ammonia and some hydrogen sulfide with

semi rich ammonia water from second ammonia washing tower.

The gas is then discharged from the top of the first ammonia

washing tower and then enters alkaline washing section at the

bottom of the second ammonia washing tower. At the alkaline

washing section, the gas is washed by NaOH solution to remove

most of the H2S.

The distilled Coke Oven gas is led from top of the de-acidification

tower to Claus Furnace for sulfur recovery.

The ammonia from ammonia distilling tower, enters ammonia

cracking furnace where it is cracked into N2 and H2.

About 1100 high temperature tail gas produced from ammonia

decomposition furnace is cooled to 300 though waste heat

boiler and 0.5MPa (G) steam is produced, and then the tail gas

passes through the boiler water per-heater again and cracker gas

cooler to be cooled to 80 .

The high temperature process gas discharged from bottom of

Claus Furnace is cooled through waste heat boiler, and the heat

recovered from the waste heat boiler is used to produce the

0.7MPa saturated steam. The process gas existing the waste heat

boiler still has H2S and SO2, and then conversion reaction is

carried out further in Claus Furnace. This process consists of

reactor with two sections and after each section of the reactor

there is set up the sulfur condenser and molten sulfur catcher. The

molten sulfur flows into the molten sulfur sealing tank and then



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into the molten sulfur storage tank. The tail gas is directed to the

chimney.

The molten sulfur stored in sulfur pool is pumped regularly with

submerged pump to sulfur slicer and cooled, formed and packed.

02.08 Benzol Recovery

This unit recovers Benzol from the coke oven gas. It includes two

section viz. benzol scrubbing and benzol recovery.

Benzol scrubbing uses scrubbing oil (either wash oil or Solar oil) to

absorb the benzol in the coke oven gas, and afterward the gas is

sent to the consumers. After benzol scrubbing, the benzol

contents in gas reduces to 2～5 g/Nm3.

The Benzol Recovery Plant will consists of three sections -

1. Cooling section

2. Benzol scrubbing

3. Benzol recovery

Benzol Hydro-Refining Unit

Benzol-hydro-refining unit will utilize the crude benzol as raw

material and remove the harmful impurities such as hydrocarbon,

hydrogen sulfide, ammonia and water etc containing the sulfur,

nitrogen, oxygen through chemical and physic methods, in order

to get high pure benzene, toluene, xylene.

The following are the process unit steps –

1. Deoctaniser

2. Hydrogenation

3. Stabiliser

4. Deheptaniser



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5. Recycle gas treating

6. Absorption section

7. Aromatic extraction

8. Aromatic Post fractionation

9. Hydrogen production unit

02.09 De-dusting system

“U” type gas transferring is arranged with high pressure ammonia

liquid spraying for the charging de-dusting, and the ground de-

dusing station is arranged for de-dusting purpose.

02.10 Gas holder & Booster station

The gas holder in this section is a 50000 m3 dry gas holder for gas

buffering and storage; the gas is boostered with Roots blowers.

The main purpose of the section is to even out the fluctuations in

production of gas and uneven gas consumption. The gas stored in

the gas holder is also used as a buffer to handle short-time

operation break-downs.



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03 Raw Materials & Finished Products 03.01 Raw Materials

The coke making facilities are planned to generate 154,000

Nm3/hr of coke oven gas to be used for Sponge Iron/DRI

production along with by-products viz 3,000,000 tonnes of gross

coke per year & chemicals. It is proposed to use 100% imported

coal, of different qualities and blend it suitably.

The proposed coke oven plant is designed based on use of low

ash imported coal in the coal blend to produce about 3,000,000

tonnes of gross coke per year. For the purpose of this report

following blend composition has been assumed by the technology

supplier

Coal Blend

- Coking coal - 70%

- Semi-soft coal - 10%

- Medium coal - 20%

The net and dry annual requirements of various raw materials and

their sources are given in table-03.01 for 3.0 Mtpa Coke Oven

Plant.

Table-03.01

Annual raw material (net and dry basis) Requirements:

Sl. No. Raw material Unit Quantity t/yr

Source

1 Imported Coking Coal t/yr 4,285,000 Imported

2 42% NaOH t/yr 6,272 Local



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3. Ni Catalyst m3/3-yr 90 Local

4. Wash Oil t/yr 3079 Local

03.01.01 Coal Availability of low ash coking coal of desired quality in this country

is limited. Hence, it has been envisaged that total requirement of

metallurgical coal 4,285,000 t/yr for the proposed coke oven plant

will be met through imports, as given in Table 03.02 and 03.03..

Table-03.02

Tentative quality of imported coal blend:

Sl. No. Quality parameters Unit Value 1 Size mm 0 to 50 2 Ash % 9.0 – 9.5 (max.) 3 VM % 24 to 26 4 Moisture % 8 to 10 5 Sulphur % 1.2 (max.) 6 Phosphorous % 0.06 (max.) 7 Grey king coke type - G 5 (min.) 8 Crucible swelling No. 6.5 (min.) 9 Mean max. reflectance (R0 max) - 1.10 to 1.30 10 Gieseler fluidity ddpm 600-2000

03.01.02 Sodium Hydroxide (NaOH)

It is proposed to use Sodium Hydroxide (42% NaOH) alkali

solution in the ammonia distillation tower. The requirement of

Sodium Hydroxide is about 6,272 t/yr. The typical quality is given

below :

Description Value

Sodium hydroxide (NaOH) % 42



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Sodium carbonate (NaCO3) % 1.5

Sodium chloride (NaCl) % 1

Fe2O3 % 0.02

03.01.04 Ni Catalyst It is proposed to use Ni Catalyst in the Ammonia cracking unit for

cracking of ammonia into Nitrogen and Hydrogen. The

requirement of Ni Catalyst is about 90 m3 for 3 years and it has

been proposed to procure it from local sources.

03.01.05 Wash Oil

The requirement of wash oil is about 3,079 t/yr and it is proposed

to procure it from local sources.

03.02 Finished Products The details of the finished products from the Coke Oven Plant are

given below.

Sl.No. Description Unit Output

1. Coke gas (dry) Nm3/yr 1350 ×106

1.1 Used for oven heating Nm3/yr 540 ×106

1.2 Available gas for DRI Plant Nm3/yr 810 ×106

2. Gross coke(dry) t/yr 3,000,000

80~25mm t/yr 2,790,000

-25+10mm t/yr 75,000

<10 mm t/yr 135,000

3. Tar (4% water) t/yr 135,000



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Sl.No. Description Unit Output

4. Sulphur t/yr 9,200

5. Crude Benzol t/yr 42,000

6. Benzene t/yr 29,500

7. Toluene t/yr 5,500

8. Xylene t/yr 1,500

9. Raffinates t/yr 5,500

03.02.01 Product Quality

Cleaned Coke Oven gas

Impurities Unit Quantity

Ammonia g/Nm3 0.05

Hydrogen sulphide g/Nm3 0.5

HCN g/Nm3 0.3

Benzol g/Nm3 2-5

Naphthalene g/Nm3 0.2

tar g/Nm3 0.01

Coke

Coke specifications (Tentative)

Sl. No. Quality parameters Value 1 Ash 12 % (max.) 2 VM 1.0 % (max.) 3 M10 8.0 (max.) 4 CSR 64 (min.) 5 Moisture 4 % (max.)



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04 Proposed Site

04.01 Site Location The 3.0 Mtpa Coke Oven Plant is proposed to be set up within the

existing sponge iron plant of M/s Welspun Maxsteel Ltd. The

existing sponge iron plant is situated in Salav village of Raigad

district in the state of Maharashtra. The site is at a distance of 150

km from Mumbai, and about 45 km from Roha by Road. The

location map and the regional map of the proposed site have been

shown in the drawing no. WML/MH/PR/001 and drawing no.

WML/MH/PR/002 respectively.

The indicative coordinates of the proposed site are given below:

Latitudes : 18°31’1” - 18°32’2.5” N Longitudes : 72°56’39” - 72°57’54” E

04.02 Area Requirement

04.02.01 General

The area requirement for the proposed plant has been estimated

based on the following factors:

Area requirements of individual technological and service

facilities

Smooth and uninterrupted flow of incoming and outgoing materials with minimum counterflow for different technological facilities.

Logistics in location of technological units as well as services

facilities.

Safety requirements and statutory provisions.



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Adequate green belt all around the plant.

Optimum lead for service lines.

Maximum utilization of the land.

Logistic approach in location of technological units as well as services with assumption that area is flat.

Space for storage of incoming coking coal of three varieties.

04.02.02 Estimated area

The area requirement for the proposed plant has been minimized

since the infrastructure and auxiliary facilities are already existing.

Special attention has been made to provide connectivity to the

existing facilities viz. utilities, raw material corridors, finished

product corridors etc.

The total area required is estimated to be approximately 80 acres.

04.03 Proposed Site

The company already has land in its possession for its existing

sponge iron plant complex. The proposed coke oven plant is

proposed to be setup within the existing area and no additional

land is to be acquired.

04.04 Logistics

The total coking coal required for the coke Oven Complex are

imported and would be handled by the existing port.

04.04.01 Road

The National Highway NH-17 (Mumbai-Goa) passes on the east

side about 50 km from the plant. State Highway also passes on



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the west side of the plant. The Mumbai city is located at about

150 km on the North-West side of the plant.

The Road linkage of the proposed site is shown in Drg. No.

WML/MH/PR/003.

04.04.02 Railways

The nearest railway station Roha is about 50 km from the plant

site and is located in the east on the Konkan Railway Mumbai -

Mangalore main line. Rail linkage from plant site has to be

strengthen.

04.04.04 Air Connectivity

The nearest Mumbai airport is 150 km away from site connected

through major road. The proposed Navi Mumbai International

airport is 90 km away from plant site.

04.05 Water

The make up water requirement for the proposed plant

generating 154,000 Nm3/hr gas at 3 million tons per year coke

production level, as estimated, will be about 690 cum/hour (16.5

MLD).

04.06 Power

The estimated power requirement of the coke oven plant will be

about 45 MW.



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05 Services, Utilities and Manpower Requirement 05.01 General

The estimated power requirement of the recovery type coke oven

plant will be about 45 MW and will be sourced from captive

sources. The nearest grid of Maharashtra State Electricity Board

may be utilised in case of short fall.

05.02 Power

The estimated power requirement is about 45 MW.

05.03 Water System

The fresh water requirement for the proposed coke oven project

shall be about 690 m3/hr (16.5 MLD).

Water supply is classified into domestic water supply system,

production and fire fighting water supply system, multi-use water

system and circulating water system.

05.04 Compressed Air Station

A captive compressed air station would be established for the

proposed plant.

05.05 Plant Automation

The controlling system is proposed to be of distributed controlling

type. The system generally is based on EIC integrated structure in

which the PLC and DCS is taken as controlling core functioning

with data collecting, procedure controlling, process controlling,

parameter indicating, over-limit alarming, equipment running

status display, data storage, production data printout, which



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combines production management with process control thus

constitute a safe, high efficient and opened controlling system.

One PLC is additionally arranged for pressure regulating of gas

collecting main, while the PLC each for coke oven machinery

control, oven machinery auto-positioning system, hydraulic

exchange system and ground de-dusting station is supplied

together the mechanical equipment. Level 1 system adopts Client-

Based network structure and provides the interfacing provision

with Level 2 system in the future.

05.06 Communication System

Telephone system will be provided for communication inside as

well as outside the plant. Telephone system shall comprise one

Electronics Private Automation Branch Exchange (EPABX) of

required line capacity and associated cable network along with

Press-to-talk system, CCTV, VHF wireless system as required.

05.07 Repair And Maintenance Facilities

The existing sponge iron plant repair and maintenance facilities

will take care of routine repair and periodical maintenance work of

the coke oven plant. Major repairing works involving machining,

fabrication and assembly of heavy and critical jobs of specialized

nature are envisaged to be contracted to outside agencies.

05.08 Warehouse

A existing central warehouse will keep spares of equipment, hard-

wares and consumables of the proposed coke oven project.



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For storing various refractories, separate buildings have been

envisaged. Refractories will be received in pallets and in bags.

05.09 Ancillary Facilities

Necessary ancillary facilities such as administrative building,

canteen, car park, cycle and scooter stand, first-aid station etc.

shall be provided based on the manpower requirement for the

plant.

05.10 Drainage And Sewerage System

Open type drain has been envisaged for the plant storm water

drainage. The drains will be laid generally by the side of the

roads. Storm water run-off, collected through arterial and trunk

drain, will be discharged suitably for minimum pollution.

Plant drainage

This drainage system is classified into domestic & Production

drainage system and production clean sewage drainage system.

The effluent from the sewage treatment plant will be utilized for

the development and maintenance of greenery.

05.11 Roads

Adequate plant road system will be provided. The road system will

be integrated with the existing roads.

05.12 Manpower Requirement

The proposed plant will not only require management and

executive manpower but also, skilled, semi-skilled, unskilled and



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clerical manpower. However, a number of jobs like major repair

and maintenance, cleaning, transportation and loading/unloading

of bulk materials, etc. will be done by engaging out side agencies.

The total manpower requirement is estimated at 450 persons.



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06 Environmental Management

06.01 The proposed plant would result in air, water and land pollution of

varying nature and degree. This chapter briefly outlines the nature

and sources of pollution and also suggests broad environmental

protection measures to be adopted for limiting pollution within

permissible levels.

06.01 Nature of Pollution

The inputs to the above facilities will comprise raw materials/in-

process materials along with water, fuel and power. These would

therefore lead to release of emissions to the air, generation of

wastewater and solid wastes. The sources of pollution from the

proposed project and the types of environmental pollution likely to

occur are summarized in Table-06.01.

Table-06.01

Sources and Nature of Pollution

Facility/Department Pollutants released Type of pollution

Coke Oven PM, CO2, NOx, SO2, PAH, heat

Air pollution

PM, VOC Work zone air pollution

Oil & grease, phenol, cyanide

Water pollution

Suspended scales, Traces of oil & grease

Water pollution

06.02 Pollution Prevention and Control Measures

In consideration of the above stated pollution potential of the

plant, suitable mitigation schemes are envisaged in order to



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control environmental pollution within the permissible norms and

keep the environment fairly clean.

06.03 Design Targets

The proposed pollution control measures for the entire plant

operation would be designed on the basis of the following criteria:

a. Characteristics of treated waste water to be discharged to plant drain

Temperature shall not exceed 5oC above ambient TSS < 100 mg/l Oil & grease < 10 mg/l BOD < 30 mg/l at 27oC for 3 daysCOD < 250 mg/l.

b. Stack emissions PM < 50 mg/N m3 c. Work zone noise (Leq)

(Time weighted average of 8 hrs)

85 dB (A)

Routine environmental monitoring of stack emission, ambient air

quality, work zone air quality, noise level and waste water

receiving pond and surface water stream will have to be carried

out. The monitored data would be recorded and necessary

corrective measures implemented to ensure that design targets

are maintained and avoid any non-compliance of Statutory

Regulations. The guidelines & environment protection rules laid

down by MoEF shall be adhered to for the plant facilities.



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07 Project Implementation 07.01 General

Implementation of a modern Coke Oven Plant which generates

coke oven gas is a challenging task and calls for meticulous

planning, scheduling and monitoring to realize the project goals in

budgeted time frame. The time schedule for installation of Coke

Oven Plant will depend to a large extent upon completion of pre-

project activities; methodology adopted in procurement of plant &

equipment, engineering, construction and erection activities at

site. The extent of import component of plant & equipment,

availability of infrastructural facilities at site as well as efficient

project management and monitoring also play an important role in

determining the time frame requirement for the project.

07.02 Schedule

The implementation schedule for installation of the proposed Plant

is indicated in the form of bar chart in the drawing no.

WML/MH/PR/006. The overall schedule shows that from the date

of start of the project (Zero date), the first pushing of the coke

oven plant will be commissioned in 22 months and the

commissioning of By-Product plant will be in 25 months. The

schedule as presented is based upon conventional project

implementation logics for coke oven plant, preliminary vendor

information available and in-house analysis.

07.03 Zero Date

The date of start of project activities has been assumed as “zero

date” for installation of the proposed plant.



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08 Block Capital Cost

The estimated block capital cost outlay for the project is about Rs.

3,000 crores.

SL. ACTIVITIES DURATION OF NO. ACTIVITY

1 Project Approval 0 Month

2 Basic Engineering 3 Months

3 Detailed Engineering 17 Months

4 Tendering, Scrutiny and order placement 10 Months

5 Planning & construction of Infrastructure facilities 16 Months

6 Civil works 13 Months

7 Fabrication & Erection of Structures 13 Months

8 Delivery of Equipment 13 Months

9 Erection of Equipment 22 Months

10 Testing & Commissioning 7 Months

11 Production to commence -CO PLANT BY-PRODUCT PLANT

3 5 7 27 3723

SUBSTITUTION OF NATURAL GAS BY COKE OVEN GAS FOR EXISTING SPONGE IRON PLANTPROJECT IMPLEMENTATION SCHEDULE

D U R A T I O N I N M O N T H S33 35251 319 11

DRG. NO. WML/MH/PR/006

13 15 2917 19 21

Documents

substitution of natural gas by coke oven gas for existing