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Neelachal Ispat Nigam Limited

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NEELACHAL ISPAT NIGAM LIMITED (NINL) (Click to view the website)

 

Neelachal Ispat Nigam Limited (NINL), a Company promoted by MMTC Limited, Industrial Promotion and Investment Corporation of Orissa Limited (IPICOL) has set up an Integrated 1.1 Million ton capacity Iron and Steel Plant at Kalinga Nagar Industrial complex, Duburi, District Jajpur, Orissa. Presently the main products are pig iron and BF coke along with nut coke, coke breeze, crude tar, ammonium sulphate and granulated slag. Steel making facility having Basic Oxygen Furnace (BOF) and Continuous Casting machine along with Oxygen Plant, Lime and Dolomite Calcination Plant is in advance stage of construction and will be producing steel billets from early 2013. Other Products including bars and rods will be produced subsequently.

NINL, has become India's largest producer and exporter of saleable pig iron. Pig iron produced by NINL has established its acceptance in domestic as well as in international markets because of its high quality. Company is widely catering to demands of eastern, central and northern regions of India for Pig iron apart from exports. Similarly the BF coke produced by NINL is of high quality and is being supplied to almost all units of Steel Authority of India Ltd. and Vishakhapatanam Steel Plant. The "KAMDHENU" fertilizer (Ammonium Sulphate) produced is in high demand in nearby areas. Crude tar is being despatched to down stream industries for further processing. BF Slag is being supplied to cement plants for further processing to manufacture cement.

NINL is having 62.5 MW captive power plant to meet the power requirements. Apart from meeting own requirement NINL is presently exporting substantial quantity of power to GRIDCO, Orissa. The steel making facilities under Phase-II expansion are Basic Oxygen Furnace (BOF) alongwith a six strand Billet Caster, Oxygen Plant, Lime & Dolomite plant and auxiliary unit. Presently, almost all equipment erection with respect to BOF & Continuous Casting Plant (CCP) are completed and Lime & Dolomite plant is under commissioning. NINL has been allotted Iron Ore Mine at Koira in the districts of Sundergarh and Koenjhar having capacity of 110 million tonnes reserves.  Forest clearance of these iron ore mines is still awaited and are expected to be operational by March’2013.

Over the years MMTC has become the acknowledged market leaders in facilitating export of Indian Iron Ore. Today, MMTC is India’s one of the largest exporters of minerals and ores, handling large quantity of iron ore through various ports like Vizag, Paradeep, Goa, etc across the country. Neelachal Ispat Nigam Limited (NINL) form part of MMTC’s strategic initiative of creating synergy between its minerals and metal trading activities. Neelachal Ispat Nigam Limited represents a major investment by MMTC for enhancing exports and increasing domestic trading activities and at the same time realizing greater value addition for Orissa’s vast mineral wealth.

MMTC’s contribution as the main promoter starts with procurement of raw materials like iron ore and coking coal, to closely monitor the eventual manufacturing and supply of finished products that meet the diverse requirements of end users for quality products.

It will be our endeavour to work in tandem with consumer industries to provide them with a market savvy, innovative and flexible product mix and be in virtual control of the entire value addition chain. 


LOCATION

The Steel Plant is located in district Jajpur about 100 km from Bhubaneswar. It has proximity to Iron Ore Mines, Sea Port, Railway Network and Express Highway. It is located at a distance of:

  1. 5 Km from Paradeep Daitari Expressway
  2. 15 Km from Jajpur Railway Station
  3. 30 Km from existing Iron Ore Mines at Daitari of Orissa Mining Corporation
  4. 45 Km from National Highway Madras, Kolkata
  5. 120 Km from Paradeep Sea Port

 

PRODUCTS

Description
Presently manufactured

Annual capacity (t)

Pig Iron

855000 (conversion capacity)

LAM coke

811000

Nut coke

28000

Breeze coke

42500

Gross sinter

1710000

Granulated slag

305000

Crude tar

35800

Ammonium sulphate

12750


Steel products in Phase – 2 (under implementation) and will be operational from early 2013.

Billets (for sale, 100x100 mm, 150x150 mm)

897000 tpa.

Pig Iron production after implementation of Phase –II will be

152960 tpa.

MAJOR FACILITIES

Unit

-

Nos.

-

Technical specification

Blast Furnace

-

One

-

1915 Cubic Meter Useful Volume with slag granulation unit.

Sinter Plant

-

One

-

180 Sq. Meter grate area

Coke Oven

-

Single battery with 67 ovens

-

7m tall, state of art technology, with dry quenching with by-product plant.

Power Plant

-

STG- 2 nos.

GTG- 1 no.

-

Gas based captive power plant with total capacity of 62.5 MW

Basic Oxygen Furnace*

-

One

-

110 Ton

Continuous Casting Plant*

-

One

-

6 Strand Billet Caster

Oxygen Plant*

-

One

-

418 tons/day


TECHNOLOGICAL UNITS

RAW MATERIAL HANDLING SYSTEM (RMHS)

Designed to handle 2.50 million tons/year of various raw materials such as Iron Ore, Dolomite, Limestone, Quartzite, Manganese Ore, Coke etc., Major material handling Equipment are Wagon Tippler and side Arm Charger, Stacker-cum-Reclaimer, Twin Boom Stacker, Blender Reclaimer, Transfer Car, Belt conveyors of various widths and lengths. The entire operation is automated and operated from a Central Control Room to provide consistent quality of raw materials to Blast furnace and Sinter Plant. The raw materials will be brought by rail transport to the wagon tippling yard.

 

 

 

 

 

Stacker cum Reclaimer in RMHS yard :BLAST FURNACE COMPLEX

Blast Furnace to produce 1.1 million tons of Hot Metal/year is in operation. The Furnace has useful volume of 1,915 cubic meters with Hot Blast Stoves for supplying pre-heated blast with 1,100 C hot blast temperature. Improved distribution techniques for raw material charging using the Paul Wurth bell less top have increased productivity and lowered fuel rate. Improved stave cooling and design features of Blast Furnace will contribute to longer campaign life.

 

Blast Furnace with four hot blast stoves

 

PIG CASTING MACHINE

 

 

 

 

 

 

 

2 Units of Pig Casting Machine for casting pigs. Capacity of each machine is 200 tons/hour are in operations.

 

 

Sinter Plant

One Sinter Machine of 180 square mt sintering area with rotating circular cooler.13 Nos. of bunkers for storage of various raw materials like Iron ore fines, nut/breeze Coke, Dolomite, Quartzite etc., and a mixing drum of 3.8 m dia x 16 m length for mixing of raw materials. Sinter Plant has circular cooler and facilities to despatch sinter through conveyor system direct to Blast Furnace bunkers.


 

 

 

 

POWER PLANT

 

Power Plant of 62.50 MW capacities with 2 Steam Turbo Generator (S.T.G.) of 19.25 MW each and Gas Turbo Generator (G.T.G.) of 24 MW with Heat Recovery Steam Generator, Full utilization of surplus fuel Gas such as Blast Furnace Gas and Coke oven Gas. Power Plant is already in operation and excess power is exported to GRID.

The power plant has been designed on the concept of full utilization of surplus fuel gases such as blast furnace gas, converter gas and coke oven gas. No external fuel is used for steam generation. LDO is used for flame stabilization. NINL is self sufficient in power and is exporting substantial quantity of power.

Power Plant having two steam generators

 


Coke Oven:

7-meter tall, state of art technology, one battery with 67 ovens with chamber volume of 41.6 cum and a capacity of 31.6 t dry coal charge is in operation and having 100 % dry quenching (CDCP) with by-product plant. CDCP consists of three cooling chambers with individual hoist, lifting shaft, waste heat boiler, dust catching arrangement and smoke fan. It has three chambers, each having a capacity of 52-56 tons/hr.

By-Product plant is designed for cleaning raw coke oven gas and to recover crude tar, remove ammonia as ammonium sulphate and extract naphthalene by absorbing in solar oil. By-product Plant capacity is to treat gases 42,300 cum/hr. BOD Plant is designed for treatment of effluent water containing ammonia, cyanide, phenol etc.


 Coke Oven Battery having 67 ovens 7 m tall 

 

 

Steel Melting Shop :

Continuous Casting Plant-6 Strand Billet CasterA Steel Melting Shop of 0.9 million ton capacity comprising of Hot Metal Mixer, Basic Oxygen Furnace (LD Converter), Ladle Refining Furnace, 6 strand Billet Caster, Lime Calcinations Plant, Dolomite Plant and an Oxygen Plant apart from other auxiliary facilities like Water, Gas, Compressed Air etc. are being set up under phase-II expansion plan. 

The steel making facilities having Basic Oxygen Furnace (BOF), Continuous Casting machine with Oxygen Plant, Lime Plant, and Dolomite Calcination Plant are currently in advance stage of installation and production of billets is targeted by early 2013.

 

 

Continuous Casting Plant-6 Strand Billet Caster

 

 

Presently, MMTC is marketing Pig Iron in Domestic as well as Export markets and LAM Coke in the domestic market from its Coke & Iron marking facility at NINL Plant. On commissioning of Steel making and Continuous Casting facility consisting of Basic Oxygen Furnace for steel making and 6 strand Continuous Casting Machine for casting of billets, supply of quality steel billets being produced using state of art technology will be made available to the market.

The commissioning of SMS will increase its product portfolio having various qualities & sizes of steel billets & finished steel (rods/ rounds) etc. and will further boost the top line of the company by way of better product mix and higher realisation due to value addition.


QUALITY CONTROL

Quality control from raw materials through hot metal to pig iron, slag, sinter, coke comprises complete sequence of test utilizing the latest physical and chemical techniques.

 

TECHNICAL SPECIFICATION

 

PIG IRON

Grade

C

( %)

Si

( %)

Mn, % (max)

S, % (Max.)

P, % (Max.)

Weight

per Piece (Kg)

N-1(Steel grade) 

3.6-4.3

Up to 1.24

<1

0.05

0.15

15-20

N-2(Foundry grade) 

3.6-4.3

1.25 to 1.79

<1

0.05

0.15

15-20

N-3(Foundry grade) 

3.6–4.3

1.80 to 2.20

<1

0.05

0.15

15-20

The product is confirming to IS: 13502-1992. Orders for materials as per Customer's Specification and tolerances are also accepted

BF Coke

MC(% Max)

Ash(% Max)

VM
(% max)

S           (% Max)

M-40       (% Max)

M-10      (% Max)

CRI         (% Max)

CSR      (%)

1

12.5

1

0.55

82

6

22-23

<63.5

 

STEEL GRADE FOR BILLET :

Steel Group

Steel Grade

1.  Low carbon structural steel &   

     electrode quality wire

AISI 1006, 1008, 1010, 1012, 1015

2.  Plain carbon steel for  

    automobiles and machine parts

C-12, C-20, Cq-15, EN-3B, EN-3D, EN-328

 

S.N.

Steel Grade

%C

%Si

%Mn

%S

%P

%AI

1.

AISI 1006

0.08(max)

0.03

0.25-0.40

0.4

0.05

0.02

2.

AISI 1008

0.10(max)

0.15

0.30-0.50

0.4

0.05

0.02

3.

AISI 1010

0.08-0.13

0.15

0.30-0.60

0.04

0.05

0.02

4.

AISI 1012

0.10-0.15

0.15

0.30-0.60

0.04

0.05

0.02

5.

AISI 1015

0.13-0.18

0.15

0.30-0.60

0.04

0.05

0.02

6.

C-12







7.

C-20

0.14-0.21

0.10-0.40

0.05-0.8

0.04

0.05

0.02

8.

Cq-15







9.

EN-3B

0.25%(max)

0.35(max)

1.00(max)

0.06

0.06

0.02

10

EN-3D

0.18-0.23

0.35(max)

0.70-1.00

0.050

0.04

0.02

11

EN-32B

0.10-0.18

0.15-0.35

0.60-1.00

0.035

0.035

0.02

 

Dimension of Billet to be cast are as follows:

  1. 100 mm X 100 mm
  2. 150 mm X 150 mm

Crude tar

Pitch (%)

Moisture, % (Max)

Sp.Gravity

52-55

5

1.15-1.2

 

Ammonium sulphate

N2

Moisture

Colour

20.5 % min

< 1%

Off white

 

GRANULATED SLAG

The product is meeting IS: 12089-1987

CaO (%)

Al2O3 (%)

SiO2 (%)

FeO

MgO

Basicity

33-34

15-17

33-34

0.7-0.8

9-10

0.95-1.0

 

 

MARKETING OF PRODUCTS

The principal users of NINL Products, both main and by-products, are steel plants including mini steel plants, casting and foundry units, however, steel billets and bars & rods will be used by forging & rolling mills, wire drawing industries, fabrication and manufacturing units e.g. wire ropes, electrodes etc., construction and house building, cement plant, chemical industries and other such allied sectors.

Our marketing and production teams in MMTC and NINL will aim through a face to face and a personalized approach, to stay in tune with our customers perspectives and give them comprehensive customer support in their businesses. At the same time, it is our commitment to work closely with society to sustain the environment and to provide environment friendly products, by adopting cleaner technologies and recycling waste so as to ensure green and pollution free environment around the vicinity of  the NINL plant.


PLACEMENT OF ORDERS

Orders may be sent to MMTC's Corporate Office at New Delhi directly or to MMTC's Kolkata, Bhubaneswar, Chennai, Mumbai & Ahmedabad offices. On broad basis, the normal lead time for delivery is 30 days. In certain cases, material can be supplied within 7-10 days.



Visitor Number : 0007338375
Last Updated on 23-03-2017