VSL STEELS LTD.

Plant Layout

VSL Steels Ltd.

VSL Steels Ltd is Flagship Company of VSL Group ( V S Lad &

Sons), the pioneer in Iron ore mining and one of the oldest mining

companies in the State of Karnataka. VSL Group, in its endeavour

to expand its business, is delighted to be part of the Core Iron &

Steel Industry.

We have established a Pig Iron Plant in the name of V.S.L. Steels

Ltd. in Paramenahally Village, Hiriyur Taluk, Chitradurga District,

Karnataka State capable of producing about 1.5 Lakh (0.15

Million) M.T. of Pig Iron per annum. V.S.L. Steels has a Mini

Blast Furnace of 262 M3 capacity, designed / technology by

MECON Ltd. The commercial production was started in January,

2007.

Major Facilities

Blast Furnace

262 M3

( Useful Volume) with

2 Nos. of PCM & SGP

Power Plant

( B F Gas Based)4 MW

Coke Oven Plant 100 MT / Day

Sinter Plant

(Under Construction)33 M2

BLAST FURNACE OF 262 CUBIC METERS

TAP HOLE DRILLING TO TAKE OUT HOT METAL

LANCING OF TAP HOLE

SHIFTING OF HOT METAL BY LRS CRANE

HOT METAL POURED IN TO THE PIG CASTING

MACHINE TO PRODUCE PIG IRON

CLOSING OF TAP HOLE BY MUD GUN MACHINE

BLAST FURNACE DETAILS :

Description Unit Value

Blast Furnace No 1

Volume M3 262

Productivity T/M3 ~ 2.0

HM Production Tons / Day 500

Coke Rate Kg/thm 650

Slag Rate Kg/thm 250

Slag Basicity CaO/SiO2 0.95

Hot Blast Temp. Centigrade 1000

Highlights of Blast Furnace Performance

Highest Hot Metal

Production519 MT (12th Feb 2010)

Lowest Coke Rate

( Net & Dry )593 Kg/THM ( 2nd Jul 2009 )

Highest Monthly Hot Metal

Production14,684 MT ( Jan – 2010 )

Highest Productivity 2.26 T/M3

Sl.

No.Material

No of

Bins

Effective

Volume

(cum)

Total Storage

Capacity in

Hours

1 Coke 2 140 12

2 Iron Ore 2 140 20

3 Nut Coke 1 110 80

4 Limestone 1 35 25

5 Dolomite 1 35 40

6 Quartzite 1 35 60

7 Manganese Ore 1 35 150

No. of Stoves 3 Nos.

Shell Height 28 M

Shell Diameter 5.3 M

Dome

Temperature1250 Deg. Cent.

Checker hole

diameter40 mm

Burner type Ceramic

Cold Blast

pressure1.5 Kg/cm2

Waste gas

Temperature350 Deg. Cent.

Hot Blast

Temperature1000 Deg. Cent.

HOT BLAST STOVE DETAILS

GAS CLEANING PLANT-THERMAX LTD

Gas volume at inlet 64000 nm3/hr

Gas pressure

at inlet4000 mmwc

Gas Inlet

Temperature300Deg

Gas out let

Temperature50 Deg mm

Dust content at

inlet10 gm/m3

Dust content at

outlet5 mg/m3

Water requirement

(Circulation)150 m3/hr

StagePressure

( mmwc )

Volume

( m3/sec )

1st 2300 8.25

2nd 4945 9.29

3rd 7985 10.5

4th 11425 11.99

5th 15275 13.57

SLAG GRANULATION PLANT

Slag Tapped per

day125 MT Approx.

Slag Flow Rate 1.5 – 3.0 T / min

Water Flow

( Circulation )450 m3/hr

Water Pressure 3.0 kg /Cm2

Special Features of Blast Furnace

1.RTDs:Resistance temperature detectors (RTDs) fixed in all tuyers inlet and outlet for quick judgment of performance of tuyers.

2. Thermocouples( Below the Tuyers):

Total 10 thermocouples fixed below each of the tuyers(to know the condition of the tuyers)

PACKAGE BOILER DETAILS

Make Thermax

Capacity 3 TPH

Working

Pressure15 kg/Cm2

TypeFire Tube

Boiler

CRANE & PCM Details

LRS Cranes Details:

1. M/s. Mukand Ltd.,

Capacity: 50/20 T

2. M/s. Globe Engineering

Capacity: 50/20 T

PCM Details:

1. M/s. METCO EngineeringCapacity: 500 T/Day No. of Moulds: 250Chain Length: 35 MtrSpeed: 6 – 12 Mtr/Min

2. M/s. METCO EngineeringCapacity: 500 T/Day No. of Moulds: 250Chain Length: 35 MtrSpeed: 6 – 12 Mtr / Min

With Ladle Hydraulic Tilting Device

CAPTIVE POWER PLANT - 4 MW

BOILER

MakeThermax

Babcock Wilcox

TypeBF Gas & Oil

Fired

Capacity 22 T/hr

Hydraulic test pressure

79.5 kg/cm2

Steam outlet pressure

44 kg/cm2

Steam outlet temperature

440 Deg. Cent.

TURBINE DETAILS

Make Triveni

Year of Mfg 2006

Power 4500 kw

Turbine gear boxTriveniGears

Gear ratio 5.519

Make BHEL

TypeSynchronous

Generator

Voltage 3.3 KV

RPM 1500

Capacity 4 .0 MW

ALTERNATOR

Air Cooled Condenser

Make Paharpur Ltd

Type Air Cooled

Fan Diameter

9.14 Mtr

Fan Speed 114 RPM

DG SET DETAILS

1. MAN B & W DG Set

Alternator

AVK Make, 11 KV, 750

RPM, 3.8 MW

2. Pilistick DG Set

Alternator

TDPS Make, 3.3 KV,

500 RPM, 2.5 MW

100 MT PER DAY COKE OVEN PLANT

SINTER PLANT

Capacity - 33 M2

Supplier – SSIT (China)

Type - Circular

Production/hr. - 59.40 T/hr.

Productivity - 1.80 T/M2/hr.

SINTER PLANT UNDER CONSTRUCTION

SINTER PLANT UNDER CONSTRUCTION

WATER RESERVOIR

We have created artificial lake in an area of about 25 Acres for

Rain Water Harvesting and recharging of Bore wells.

WATER RESERVOIR

Quality Assurance Lab

VSL Steels has setup a Quality Assurance Lab with modern

equipment along with well qualified staff. Raw materials are

checked to ensure their quality by the applicable Indian Standards

(IS) Methods. The Pig Iron produced is checked for its quality by an

Optical Emission Spectrometer. As the analysis reports are given

instantaneously by Spectrometer, it helps the Operation department

to take immediate corrective actions so as to control the quality of

Pig Iron being produced. The quality of Process Water and CPP

Water is checked by HATCH instrument.

VSL Steels Limited has been awarded ISO 9001:2008 & ISO

14001:2004 certificates by Perry Johnson Registers, INC.

Spectrometer

Quality Lab

Marketing

VSL Steels produces various grades of Pig Iron which are utilized by the foundry industry to produce

superior grade and high quality precision castings. We are catering to the needs of foundry industry

throughout India from Tamil Nadu to Punjab. Our quality is well accepted because of the consistency of

specification of the Pig Iron supplied.

Product Despatch:

Pig iron is analyzed by Spectrometer. Pig iron is heaped in batches according to the Heat Numbers

produced. Test certificates will be issued to every Heat produced indicating the grades of pig iron. Care is

taken to ensure that there is no mix-up of heaps.

We are moving our product by road and by rail. For Rail transhipment, the Pig Iron is first moved to

Chitradurga Railway Station, which is 55 Km, from our plant and there on to Customer destinations

through container rakes.

Pig Iron Specification:

The chart below depicts the various types of Pig Iron produced and their chemical composition. In addition

to standard specifications, VSL Steels can produce pig iron with chemical composition according to

customer needs.

PIG IRON LOADING INTO THE CONTAINER AT

RAILWAY STATION

VSL Steels Ltd plant location:

Nearest Town : Hiriyur - 10 Kms

Nearest Railway Station : Chitradurga - 55 Kms

Nearest Sea Port : New Mangalore Port – 325 Kms

Nearest Airport : Bangalore International AirPort – 170 Kms

Nearest State Highway : SH 19 – 1Kms

Nearest National Highway : NH 4 – 10Kms

Karnataka Industrial Areas Development Board (KIADB) Land : 99 Acres and 5 Guntas(Paramenehalli & Doddaghata Village,Hiriyur Taluk,Chitradurga)

Power Sanction : 5000 KVA from 66 KV State Grid (Hindusghatta Sub -Station,Hiriyur Taluk)

Water : Permission to use ground water of 1260 Cubic Meters per day and to draw 1 Lakh Cubic Meters per of water from Vedavathi River bed per annum.

Present Water consumption including domestic is 600 M3 / Day.

OTHER DETAILS RELATED TO PLANT

WATER SOURCES

1. Ground Water : a. Borewells within the Plant Area – 12 Nos,

( We can draw approx 500 M3/Day)b. Borewells in Farm House – 11 Nos,

( We can draw approx 800 M3/Day)

2. River Bed:We have permission to draw 1,00,000 M3 / Annum.

3. Rain Water Harvesting (Artificial Lake) 25 Acres Area:Presently we can collect and store 2,00,000 M3 of Runoff water during rainy season from catchment area of 900 acres. Holding / storage of water can be increased upto 4,00,000 M3 with further excavation

MAP SHOWING LOCATION OF BOREWELLS

Water Pipeline Route

Iron ore:a) Chitradurga District Mines (Sesa Goa,Mineral Enterprises ,R.Praveenchandra ) .These mines are about 60 Kms from the plant.

b) Tumkur District Mines (Balaji Produce, Tumkur Minerals etc) .These mines are about 50 to 70 Kms form the plant.

c) Bellary District Mines (NMDC ,SMIORE,Mysore Minerals Ltd,B.Kumar Gowda,MSPL,VESCO,SKME,Tiffins Baryets , etc . These mines are about 150 to 170 Kms from the plant.

LAM Coke: Import: Nearest Sea port: New Mangalore -325 Kms from the plant.

Domestic:Sl.No. Plant Name & Place Prod. Capacity ( MT/Monthly)Approx. Dist. From Plant1 Sathavana Ispat Pvt. Ltd., Bellary 30000 175 KM2 Gujarat NRE Coke, Dharwad 20000 300 KM3 Basudha Udyog Pvt. Ltd., Chennai 10000 550 KM4 Bhatia Coke Pvt. Ltd., Chennai 12000 550 KM5 SESA ( Sterlite ) Goa, Goa 50000 450 KM6 S F L, Mundra / Porbander, Gujarat 100000 1700 KM

All other flux (Lime Stone,Dolomite,Quartz & Manganese)

All the flux are available in Chitradurga & Tumkur district and the distance from the plant to the source is about 50 to 80 Kms.

RAW MATERIAL SOURCE

Land Details

❖ KIADB land : 99-05 Acres (Paramanahalli &

Doddaghatta Village,

Hiriyur Taluk, Chitradurga)

❖ Agriculture land adjacent to plant : 45-24 Acres (DoddaghattaVillage, Hiriyur

Taluk, Chitradurga)

❖ Agriculture land adjacent to SH-19 : 15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga)

UDUVALLI - GUEST HOUSE

15-37 Acres (Uduvalli Village, Hiriyur Taluk, Chitradurga)

VSL Steels Ltd

(Details of Water, Land ,Railway Line and

Iron ore for expansion)

Water :

Details of Upper Bhadra Project,Karnataka.

29.90 TMC of Water to District of Chikkamagalore,Tumukr,Davangere & Chitrdurga Districts for irrigation ofabout 2,25 Lakhs Hectares..

According to the proposal, the Upper Bhadra lift Irrigation Scheme envisages lifting of 17.40 TMC of waterin Stage-I from Tunga river to existing Bhadra reservoir and lifting of 29.90 TMC of water in Stage-II fromBhadra reservoir to tunnel near Ajjampura in Tungabhadra sub-basin of Krishna basin. After tunnel, throughChitradurga Branch Canal and Tumkur Branch Canal, it is planned to irrigate 2,25,515 ha area by dripirrigation in the districts of Chikkamagalur, Chitradurga, Tumkur and Davanagere. This water would also fillup 367 tanks (157 through Chitradurga Branch Canal and 131 throughTumukurubranch).

Out of 29.90 TMC of water, 19.04 TMC of water is earmarked for irrigation and remaining 10.86 TMC isallocated for filling of 367 minor irrigation tanks. The entire water distribution will be automated andcontrolled by SCADA system. About 787 villages are likely to be benefitted under this project. The proposedproject requires 2,114 ha area land for construction of main canal and delivery chambers.

The project as per plan will have to complete by December 2017 and we expect about 6 months delay incompleting the project.

29.90 TMC of water to 4 Districts (Chikkamoagalore,Chitradurga ,Tumkur and Davangere ) out 4 DistrictChitradurga will get maximum share 11.96 TMC (Chitradurga Branch Canal) and 2 TMC for feeding water toVani Vilas Sagar Dam.

The Vani Vilas Sagar Dam is about 8 Kms from our plant and the Dam has capacity of hold 30 TMC of waterbut due to number of check dam & lakes in the catchment area few TMC of water reaches Dam at present(about 2 TMC) once Upper Badhra Project is commissioned directly 2 TMC water will be feed to V V S Damand also additional water reaches Dam due to filling of water body (check dam/lakes) totally about 5 to 6 TMCwater will be available.,

Land for Expansion:

Adjacent to the existing plant/land we have identified additional land of about 153 Acres- 28 Guntas.

Part- I (Government land)

a) Sy No 33 Doddaghata Village : 52 Acres 05 Guntas

b) Sy No 36 Doddaghata Village : 33 Acres 03 Guntas

c) Sy No 37 Doddaghata Village : 06 Acres 19 Guntas

d) Sy No 27 (part ) at Paramanahalli Village : 13 Acres 17 Guntas

Total : 105 Acres 04 Guntas

Part-II (Private land )

a)Sy No 34 & 35 (Doddaghata Village) - : 45 Acres 24 Guntas

b)Sy No 198 Paramanahalli Village : 03 Acres

Total : 48 Acres 24 Guntas

Grand Total : 153 Acres 28 Guntas

Note : 40 Guntas is 1 Acre.

Railway Line :At present the nearest Railway line is about 55 Kms (Chitradurga City Station for Pig Iron loading)and 80 Kms (Amruthapura Station for Raw Material).

The proposed new Railway Line will be at about 8 Kms from the plant.

List of working mines

Permissible Production (MMT)

Sl. No Name of the Mining Lease Category ML. no Revised MPAP

1 VESCO A 2296 1.100

2 B. Kumara Gouda A 2516 1.260

3 SMIORE A 2580 1.600

4 Zeenath Transport Company A 2547 0.480

5 P. Balasubbasetty & Sons A 2502 0.480

6 V.N.K Menon A 2543 0.100

7 Lakshmi Minerals A 2551 0.066

8 Tiffin Barytes A 2293 0.560

9 Nadeem Minerals A 2526 0.410

10 Allum Prasanth A 2352 0.046

11 Sri GaviSiddeshwara A 2552 0.260

12 R.B.S.S.N A-1 2682 0.1013

13 Allum Prashant A-1 2289 0.090

14 VIOM (MSPL) B 2416 1.800

15 Hanumantha Rao B 2505 0.100

16 Iyli Gurunath Iron Ore Mine (RMML) B 2593 0.320

17 Chowgule & CO B 2546 0.380

Sl. No Name of the Mining Lease Category ML. no Revised MPAP

18 G G Bros B 2522 0.140

19 H R Gaviyappa B 2483 0.105

20 H.N Premkumar B 2538 0.070

21 Jaisingpur Iron Ore Mine ( Ashwathnarayan Singh)

B 2531 0.120

22 S.V Srinivasulu B 2604 0.100

23 Zeenath Trasport Company B 2239 0.180

24 GG Bros B 2586 0.036

25 Narayanpur Manganese & Iron Ore Mine B 1602 0.626

26 H.G Rangan Goud B 2549 0.114

27 SKME B 2141 0.426

28 NMDC-KIOM A 1111 6.000

28 NMDC-DIOM A 2396 6.000

30 MML - TIOM A 2605 0.650

31 MML - SIOM B 2629 0.410

Total (Bellary Dist.) 24.1303

32 Sri R. Praveen Chandra A 2294 0.750

33 Mineral Enterprises A 2346 0.570

34 Garudadhri Impex Pvt Ltd., B 2583 0.008

35 Sesa Goa B 2677 2.29

Total (Chitradurga & Tumkur Dist. ) 3.618

GRAND TOTAL 27.7483

Note : Revised Iron ore production permissible limit as on November 2017

Iron Ore production permissible limit

Hon'ble Supreme Court has allowed total of 35 Million MT per annum Iron ore

extraction from State of Karnataka.

a) Bellary District : 28 Million MT

b) Chitradurga & Tumkur District : 07 Million MT

PROPOSED EXPANSION PLANVSL Steels Ltd has expansion plan to produce 0.3 Million MT finished steel.

Proposed Expansion Plan:

a) Modernizing existing Blast Furnace to increase the volume from 262 M3 to 325 M3, by retro fitting modern

facilities such as installation of Stave coolers, Bell Less top, Pulverized Coal Injection, Oxygen Enrichment

of Hot Blast, Preheating of Gas, Etc.

b) Setting up Steel Plant to Produce 0.3 MTPA Finished Steel (Flats,Bars & Rods)

In order to sustain the viability of the industry in the present competitive market, VSL Steels Ltd managementis of the view that we have to expand our existing Pig Iron plant into 0.3 Million MT Steels plant bymodernization of Blast Furnace and adding Steel making and Rolling facilities at the present existing facilitiesat Paramenahally and Doddaghatta Village, Hiriyur Taluk, Chitradurga District in the land adjacent to existingfacilities.

Additional Investment (Project Cost) : Rs. 393.25 Crs

Additional Land for expansion : 153 Acres-28 Guntas

Additional Water source : 0.034 TMC from Vani Vilas Sagara Dam

Additional Power : 20.00 MW