Steel Plant Layout: Civil Engineering perspective
Dr. B.V.K.
Lalith Kumar1Civil Engineering
1NMDC Nagarnar, C.G, India ***
Abstract - Steel is used in most of the infrastructure projects, bridges, dams, transmission lines, pipe lines, machine tools, automobiles, defense, commercial and residential buildings. Any country industrialization depends on metal consumption. Nation economic success depends on steel industry. India stands second position in world steel production. Steel is being used in civil engineering as major material all structural and civil infrastructure projects. The properties of steel such as light weight in nature, easy for fabrication, shipping, erection, high durability draws attention of engineers to design various structures and which saves times in completion of projects.
Key Words: Steel Plant Layout, Major Packages, Construction Schedule, Major Item Quantities
1.INTRODUCTION
InGlobalscenariotheworldcrudesteelproductionforthe year2021was1911milliontons(mt).Chinahadproduced crude steel at 1032 mt and India produced 126 mt in the year2022.
In India, there about 3647 units of steel production units ranging from small mini steel plants with smaller blast furnaces,spongeironunits,inductionunitsandrollingmills.
The upcoming steel projects and their various details of capacities, project costs and land details are listed below. Some companies are taken over by MNC players in steel industry.
1. NMDC 3MTPA Iron and steel plant with an investmentofRs15525crinitialprojectcostwith landof1934acres.
2. TataSteel,Capacity6.0MTPAGreenFieldProject, Orissawithprojectcostof6500Crin3040acres.
3. TataSteelCapacity12MTPAJharkhand,
4. ESSAR Projects in Orissa in Paradeep, Capacity 3.2MTPA in Chhattisgarh, Essar Steels, BellaryThese projects are under new company Arcellor MittalNipponSteel
5. JSPL,Angul,Orissa,Capacity6MTPAexpansionwith aninvestmentofRs23000crin4332acres
6. JSPL,Jharkhand,GreenfieldProjectof5MTPAwith aninvestmentof20000Cr
7. IspatIndustries,Capacity2.8MTPA,Jharkhandwith aninvestmentof10000Cr
8. Electrosteel,Jharkhand,Capacity2.2MTPAwithan investmentof7300Cr
9. Visa Steel, Kalinganagar, Jajpur, Orissa, Capacity 1.5MTPA,withaninvestmentofRs2808Crin1200 Acres
10. VisaSteel,plansforsettingup2.5MTPA,inRaigarh Chhattisgarh
11. VisaSteel,plansforsettingup1.5MTPA,inMadhya Pradesh
12. JSW Steel, Vijayanagar, Karnataka with an expansion, 16 MTPA to 18MTPA, with an investmentofRs.15000Cr
13. POSCOSteel,Orissa,12MTPA,withaninvestmentof 51000Cr in 4000 Acres and POSCO has cold rold plantsinMaharashtra.
14. JSWUtkalSteelPlant,13.2MTPAgreenfieldproject withaninvestmentofRs65000Cr
15. JSW plans to setup pellet plant in Jagatsinghpur, OrissawithaninvestmentofRs9000Cr
Theprivatesteelcompaniesplayingmajorroleincrudesteel production as well as sponge iron. The percentage of contributionbyprivateplayersis89%inoverallproduction.
2.SteelProcessingMethodology
Steel processing technology involves removing impurities from iron ore and alloying other elements to produce differentgradesofsteel.
Modernsteelindustriesuse recycledmaterialaswell as traditional raw materials iron ore, coal and limestone. Two process methodology generally used in making steel suchasbasicoxygensteelmakingandelectricarcfurnace.
2.1SteelPlantLayout
Inthispapersteelplantlayouthasbeenpresentedbasedon process technology and some site specific projects listed withavailableprefeasibilitystudies.
Thereareseveralmethodsusedfordesignofplantlayout(i) SLP systematic layout plan (ii) Algorithm (iii) Arena simulationmethod.TheSLPmethodiswidelyusedforsteel plant layouts. The overall layout of steel plant based on material inflow and outflow of manufactured products by Satyendra,Ispatguruconsidered.
The principles considered in designing layout of iron and steelplantis(a)minimumtraveltime(b)sequenceofflowof materials or flow of materials (c) usage of materials (d) compactness of plant (e) consideration safety and satisfaction(f)flexibility(g)interdependencies(h)minimum investmentsandrecoveries(j)environmentalaspects
Although plant layout is often studied by metallurgical, mechanicalstreams,itisessentialtounderstandbasiclayout and material inflow and outflow of finished products in layoutdesignpointofviewbycivilengineering.
Themajorandimportantfacilitiesconsideredinplantlayout are raw material shed, covered shed for coke storage, wagon tippler, by-product plant, sinter plant, fuel andfluxscreening,limecalciningsystem,blastfurnace,steel meltingshop,primarygasandsecondarygascleaningplant, thinslabcaster,rollingmill,compressedairstation,water reservoir, treated water supply, BF slag storage, air separation,mainreceivingsub-station,plantoxygensystem, propane storage, power plant, sewage treatment plant, central stores and electrical shops, area shop buildings, railwaynetworkandweighbridges,roadnetworkandweigh bridges,administrationoffice,timeoffice,materialdispatch system, fire brigade, telephone exchange, medical health systemandlabs.
2.2Cokeoven Sizeofcokeoven
For1MTPASteelplantneed50to100cokeovensofeach length15to20mwidth0.4to0.5mtandheight4to6m.In Coke Oven plant consists of gas treatment units (b) absorptiontower(c)coolingandcondensationunits(d)gas scrubberand(e)pumpsandcompressorsandfans.
The size of coke oven complex is approximately 600 mt x 200 mt and height of 30 m for 3 MTPA plan with a constructionperiodof36months
2.3By-productplant
Byproduct plant plays important role in steel process. It removestoxicgasesandvariousresiduesgeneratedduring process of coke oven and these will be sent to byproduct.
The residues will be reused and some residues have commercial values. As per capacities of steel plant, the approximatearearequiredfor1MTPA1000to2000sqm,for 2MTPA1500to3000sqmand3MTPA2000to4000sqm.
2.4SteelMeltingShop
The process in SMS is briefed as after treatment in ladle furnace,liquidsteelwillbesenttoturretofthinslabcaster. The liquid steel will be cast through two thin slab casters with hot strip mill. The shop will be equipped with continuous casting machines and auxiliary facilities for productionof2milliontonneHRcoilsin3MTPAplants.
Gasesgeneratedduringsteelmeltingintheconvertorshall undergocollectionandcleaning.Thecleanedconvertorgas storesforuseasfuel.
Thesizeofplantdependsonproductionprocess–electrical arc furnace(EOF) or basic oxygen furnace(BOF). The approximateareafor1MTPA2000-4000sqmforEOF,3000 to5000sqmforBOF,2MTPA4000-8000sqmforEOF,6000 to10000forBOFand3MTPA6000-10000sqmforEOF,8000 to15000forBOF.
2.5ThinSlabCasterandRollingMills
Therollingmill equipmentin3MPTAhastwonumbers of tunneltypetemperatureequalizingcumholdingfurnaces, onependulumtypeslabandcableshear,onehighpressure de-scalingstation,coilcoolingsystem.Floorcoilsystemand coilstoragesystemanddispatchingthroughrailwaylines.
The size of plant depends on production process –size of Thin slab caster for 1MTPA 3000 to 5000 sqm and mills 10000to15000sqm,sizeofthinslabcasterfor2MTPA5000 to8000sqmandmills15000to20000sqm,andsizeofthin slabcasterfor3MTPA8000to12000sqmandmills20000 to25000sqm.
2.6OxygenPlant
Oxygen plant is required in any steel plant for oxygen enrichmentintheblastfurnace,blowinginBOF,heatingof BOF lining, secondary refining in RH – OB and general purposeuseinvariousunitsofthesteelplant.
2.7wasteheatandEnergyRecovery
The excess blast furnace BF gas, CO gas and BOF gas available from various units will be utilized in mixed gas firedboilertogenerateHPhighpressuresteam.Thesteam generated from the gas fired boilers in addition with HP steam coming from CDCP (Coke oven) will be utilized in steam turbines of turbo blowers and steal turbines to generatepower,incaseof3MTPA2x40MWpowercan be generated.
Other units are not covered above are given in individual structurewisequantitiesinsection3.
3. Major civil items in a Steel Plant
Themajorquantitiesof1Mtpasteelareexcavationquantity 10,00,000cum, Concrete quantity is 10,00,000 cum, structuralsteelisabout100,000tonsandcladding500000 sqm. The quantities may vary based on site specific and otherfactorsandconditions.
Individual package wise quantities of civil and structural steelaregivenasfollows
1. Raw material handling system concrete 170000cum,structuralsteel70000MT,
2. Coke oven concrete 86000cum, structural steel 20000MT; Byproduct concrete 45000 cum, structuralsteel5000MT;
3. Sinter plant concrete 51000 cum, structural steel 15000MT
4. Blastfurnaceconcrete113000cum,structuralsteel 31000MT
5. Steelmeltingshopconcrete152000cum,structural steel31000MT
6. Thin slab caster and mills concrete 260000cum, structuralsteel35000MT
7. Turboblowerconcrete1700cum,structuralsteel 1500MT
8. Compressed air station concrete 3500 cum, structuralsteel275MT
9. Piping system concrete 7900cum, structural steel 3800MT
10. Centralfireandtelenetworkconcrete2700cum,
11. Powersupplyotherstructuresconcrete33000cum
12. MRSconcrete6700cum
The other important items cabling, pipe supply and electricalsarenotcovered,theyarebeyondscopepresent paper.
period of steel plant depends on several facto such as availability of resources, regulatory approvals, weather conditions.Thepointswhichinfluenceingreenfieldproject issummarizedbelow
a) Prefeasibility study – (8 to 12 months) study the feasibility of project considering geographical features, availability of ores and connectivity, environmentalimpactstudies.Thisphasecantake severalmonthstoayear.Thisphasealsoknownas pre construction phase. Pre-construction phase –finalize project plans, obtain land clearances and environmentimpactstudiesprocureequipmentand materials
b) DesignEngineering–(1to2years)designinglayout facilities, process flow diagrams, structural and mechanical design,electrical andinstrumentation plans,Thisphasemaytake1to2years.
c) Procurementofequipmentandmaterials(1year)–acquiring all machinery and equipment, understandingsupplyprocedures.
d) Site preparation – (4 months to 1 year) -area clearance, establishing temporary construction facilities and access roads. It can take several monthstoyear
e) Construction Phase (2 years to 5 years)construction of various civil works of essential componentsofsteelplants.Structuralconstruction works which is a part of main construction work. The structural work consists of fabrication and structural components of raw material handling, coke oven, byproduct structures, blast furnace, sinter plant, steel melting shop, mill structures, piping, lime calcining units, junction towers and galleriesandtheirerection,itcantake8monthsto 2years.
f) Installationandcommissioning(8monthsto1year) – This phase covers installation of various equipment of individual packages and commissioning.Itcantakeseveralmonthstoayear.
g) Trailrunsandfinetuning(4to8months)–Before fullscaleproduction.Itisessentialtoruntrialruns andfinetuning.Thisphasetakesfewmonths.
h) Full scale production – Once full operational, productionphasecommences.
4. Construction Period of a Steel Plant
Therevariousimportantpointstobeconsideredinsetting up greenfield iron and steel plant. The total construction
Thetotalconstructionperiodrangesfrom3to7years.The totalconstructionperioddependsoncontinuousmonitoring, financial cash flows, obtaining regulatory approvals and miscellaneousfactors.
5. Conclusion
Inthispaperanattempthasbeenmadetopresentpointsto be considered in designing layout of steel point and construction aspects of various capacities of plant. Integrated steel point is a seamless integration of various branchesofengineeringandwithcarefulinvestments.The existence of steel plant will improve socio economic improvement of any region. The paper covers few points onlyasitconsideredcivilengineeringperspectiveviewand constructionmethodology.Theschedulesoftheprojectare crucialinnatureasthereislotofinterferencesofdifferent technical aspects. The effective plant layout depends on
materialinflowandoutflowofdownstreamplants,suchas endproductsofsteelplants,flatsteels,rolledsectionsand wiresetc.
ACKNOWLEDGEMENT
Author would like to submit the technical information presented in this paper is for information purpose only. Authorsubmitacknowledgementstolibrarycongressand various steel producing companies in India. The technologicalprocessandfeasibilitystudiesareavailablein printandelectronicmedia.
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