A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
An alloy is a mixture or solid solution composed of metals. Similarly, Ferroalloys are the mixture of Iron with high proportion of other elements like manganese, aluminium or silicon. Alloying improves the physical properties like density, reactivity, Young’s modulus, electrical and thermal conductivity etc.
The main demand of ferroalloys, nowadays is continuously increasing as the major use of such products are in the field of civil construction; decorative items; automobile; steel industry; electronic appliances.
Tags
Book on Ferroalloys, Business consultancy, Business consultant, Business Plan for Ferroalloys manufacturing plant, Ferro Alloy Industries Consultant, Ferro alloy industry in India, Ferro Alloy Projects, Ferro alloys industry, Ferro alloys industry about Ferro alloys, Ferro alloys manufacturers, Ferro alloys manufacturing Process, Ferro alloys plant, Ferro Alloys Process, Ferro alloys Production Industry in India, Ferro alloys Production processes, Ferro alloys production technology, Ferro alloys uses, Ferro Alloys, Ferro Manganese, Ferro Molybdenum, Ferro Niobium, Ferro Boron, Ferro Titanium, Ferro Tungsten, Ferro Silicon, Ferro Nickel, Ferro Chrome, Ferroalloy production, Ferroalloys & Alloying Additives, Ferroalloys Based Projects, Ferroalloys Business Manufacturing, Ferroalloys manufacturing, Ferroalloys manufacturing Business, Ferroalloys production line, Ferroalloys Theory and Technology, Ferrous metals and ferroalloys processing, Great Opportunity for Startup, High Carbon Ferro Alloys, How to Start a Ferroalloys Production Business, How to start a successful Ferroalloys manufacturing business, How to Start Ferro alloys Production Industry in India, Ideas in Ferroalloys processing industry, Indian Ferro alloy industry, Indian Ferro alloy industry - present status and future outlook, Indian Ferro alloys industry: a review, Indian Ferro alloys producers, India's Ferro Alloys Industries, Industrial Project Report, Integrated Ferro Alloys, Manufacture in India of Ferroalloys used in alloy steel, Most Profitable Ferro alloys manufacturing Business Ideas, Niir, NPCS, On the role of ferroalloys in steelmaking, Pollution Control in Ferroalloy Production, Process technology books, Production of Ferro Boron, Production of Ferro Molybdenum, Production of Ferro Nickel, Production of Ferro Niobium, Production of Ferro Titanium, Production of Ferro Tungsten, Production of Ferroalloys, Production of Manganese Ferroalloys, Production Process of Ferro Chrome, Production Process of Ferro Silicon, Production Techniques of Ferroalloys, Profitable Ferroalloys manufacturing Industry, Project consultancy, Project consultant, Proposed Ferro Alloys & Integrated Steel Plant
A PROJECT REPORT ON
“Eliminating corner gap in sc mould at LD2 SNC”.
During the internship the following research is evaluated and being verified by the authorized TATA steel employee.
An alloy is a mixture or solid solution composed of metals. Similarly, Ferroalloys are the mixture of Iron with high proportion of other elements like manganese, aluminium or silicon. Alloying improves the physical properties like density, reactivity, Young’s modulus, electrical and thermal conductivity etc.
The main demand of ferroalloys, nowadays is continuously increasing as the major use of such products are in the field of civil construction; decorative items; automobile; steel industry; electronic appliances.
Tags
Book on Ferroalloys, Business consultancy, Business consultant, Business Plan for Ferroalloys manufacturing plant, Ferro Alloy Industries Consultant, Ferro alloy industry in India, Ferro Alloy Projects, Ferro alloys industry, Ferro alloys industry about Ferro alloys, Ferro alloys manufacturers, Ferro alloys manufacturing Process, Ferro alloys plant, Ferro Alloys Process, Ferro alloys Production Industry in India, Ferro alloys Production processes, Ferro alloys production technology, Ferro alloys uses, Ferro Alloys, Ferro Manganese, Ferro Molybdenum, Ferro Niobium, Ferro Boron, Ferro Titanium, Ferro Tungsten, Ferro Silicon, Ferro Nickel, Ferro Chrome, Ferroalloy production, Ferroalloys & Alloying Additives, Ferroalloys Based Projects, Ferroalloys Business Manufacturing, Ferroalloys manufacturing, Ferroalloys manufacturing Business, Ferroalloys production line, Ferroalloys Theory and Technology, Ferrous metals and ferroalloys processing, Great Opportunity for Startup, High Carbon Ferro Alloys, How to Start a Ferroalloys Production Business, How to start a successful Ferroalloys manufacturing business, How to Start Ferro alloys Production Industry in India, Ideas in Ferroalloys processing industry, Indian Ferro alloy industry, Indian Ferro alloy industry - present status and future outlook, Indian Ferro alloys industry: a review, Indian Ferro alloys producers, India's Ferro Alloys Industries, Industrial Project Report, Integrated Ferro Alloys, Manufacture in India of Ferroalloys used in alloy steel, Most Profitable Ferro alloys manufacturing Business Ideas, Niir, NPCS, On the role of ferroalloys in steelmaking, Pollution Control in Ferroalloy Production, Process technology books, Production of Ferro Boron, Production of Ferro Molybdenum, Production of Ferro Nickel, Production of Ferro Niobium, Production of Ferro Titanium, Production of Ferro Tungsten, Production of Ferroalloys, Production of Manganese Ferroalloys, Production Process of Ferro Chrome, Production Process of Ferro Silicon, Production Techniques of Ferroalloys, Profitable Ferroalloys manufacturing Industry, Project consultancy, Project consultant, Proposed Ferro Alloys & Integrated Steel Plant
Ferrosilicon productiion and submerged arc furnace (1)Nasser Harby
Ferroalloys, by definition, are alloys of two or more metals, of which one is Iron. The U.S. Bureau of Mines defines ferroalloy as an alloy of iron with at least one other element except for carbon.
The main indicator of the quality of a ferroalloy is its chemical composition and, above all, the content of the leading element. It is important to have Consistency in alloying element amounts in ferroalloys from heat to heat, allowing the manufacture of standard products
The smelting of ferroalloys is commonly performed in electric arc furnaces.
Although ferromanganese can be produced in a blast furnace in a manner similar to iron, the reduction of chromium and silicon from their oxides requires higher Process temperatures and lower oxygen potentials than can be achieved in a blast furnace
Raw materials are perhaps the most important factor for obtaining good furnace operation the first step towards improvements is to reduce the variations
The aim of this course is to present the basic principles for the production of ferrosilicon alloys processes, and a simple preview for submerged arc furnaces.
It is attended for Engineers working in this field, and students or metallurgists maybe find answers for their questions, because at the end of this course you will figure out that you have a preview for this manufacture and the main problems and solutions for the ferrosilicon production process. And having an overview for submerged arc furnaces design and operations.
.
The paper to be published as the lead article in the Metals & Minerals Review – Ferroalloy Special – January 2013 issue makes a case that while there are many positives for the ferroalloy industry in India, viz. scalability, location near high growth markets, cost advantages of labour, technical manpower domestically available ore and reducing price of reductant blend; the growth in ferroalloy production is stymied by inadequate infrastructure, rising cost & availability issues in thermal coal, fear of getting saddled with old technology, and lack of capital.
The global slowing of demand for ferroalloys, the re-emergence of China as a major exporter and the threat of imports are other factors that the Indian ferroalloy industry would need to tackle.
Therefore it is very difficult to predict if the ferroalloy industry in India can repeat the spectacular double digit growth of the last five years. The only certainty is of ferroalloy prices; which have been volatile and unpredictable in the past – they will remain volatile and unpredictable in the future: some things will never change!!
Ferrosilicon productiion and submerged arc furnace (1)Nasser Harby
Ferroalloys, by definition, are alloys of two or more metals, of which one is Iron. The U.S. Bureau of Mines defines ferroalloy as an alloy of iron with at least one other element except for carbon.
The main indicator of the quality of a ferroalloy is its chemical composition and, above all, the content of the leading element. It is important to have Consistency in alloying element amounts in ferroalloys from heat to heat, allowing the manufacture of standard products
The smelting of ferroalloys is commonly performed in electric arc furnaces.
Although ferromanganese can be produced in a blast furnace in a manner similar to iron, the reduction of chromium and silicon from their oxides requires higher Process temperatures and lower oxygen potentials than can be achieved in a blast furnace
Raw materials are perhaps the most important factor for obtaining good furnace operation the first step towards improvements is to reduce the variations
The aim of this course is to present the basic principles for the production of ferrosilicon alloys processes, and a simple preview for submerged arc furnaces.
It is attended for Engineers working in this field, and students or metallurgists maybe find answers for their questions, because at the end of this course you will figure out that you have a preview for this manufacture and the main problems and solutions for the ferrosilicon production process. And having an overview for submerged arc furnaces design and operations.
.
The paper to be published as the lead article in the Metals & Minerals Review – Ferroalloy Special – January 2013 issue makes a case that while there are many positives for the ferroalloy industry in India, viz. scalability, location near high growth markets, cost advantages of labour, technical manpower domestically available ore and reducing price of reductant blend; the growth in ferroalloy production is stymied by inadequate infrastructure, rising cost & availability issues in thermal coal, fear of getting saddled with old technology, and lack of capital.
The global slowing of demand for ferroalloys, the re-emergence of China as a major exporter and the threat of imports are other factors that the Indian ferroalloy industry would need to tackle.
Therefore it is very difficult to predict if the ferroalloy industry in India can repeat the spectacular double digit growth of the last five years. The only certainty is of ferroalloy prices; which have been volatile and unpredictable in the past – they will remain volatile and unpredictable in the future: some things will never change!!
Low Carbon Ferromanganese Production. Manufacturing Project of Low Carbon Ferromanganese. Production of Ferroalloys
Low Carbon Ferro Manganese is widely used to manufacture tool steel and structural steel products. Low carbon ferro manganese required where carbon control in steel is strictly necessary 7% C and 74 - 78 % Mn is a standard ferro manganese used for the purpose allowing and deoxidation.
Ferro Manganese Low Carbon is also a major constituent of Mild Steel Welding Electrodes (E6013) and other electrodes.
Ferromanganese is a ferroalloy that has high content of manganese; it is manufactured by heating mixture of oxides Fe2O3 and MnO2 along with carbon, which is usually coke and coal in an electric arc furnace or blast furnace. In the furnace, the oxides go through carbothermal reduction, hence, producing ferromanganese which is used as deoxidizer for steel. Main producing countries of Ferro Manganese are India, South Africa, Korea & Europe.
Manganese is largely used for creation of iron and steel alloys for building purposes, ceramics, bricks, catalyst and many more. Ferro Manganese is used in welding flux industry, in steel industry as a deoxidizer for steel and many other uses. Low Carbon Ferro Manganese that is widely acclaimed for its optimum quality and accurate composition.
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Niir Project Consultancy Services
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Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
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Low Carbon Ferromanganese, Manufacture of Low-Carbon Ferromanganese, Ferro Manganese Low Carbon, Ferro Manganese Manufacture, Low Carbon Ferro Manganese Manufacturing Process, Low Carbon Ferro Manganese Manufacture in India, Ferro Alloys Manufacturing, Manufacturing of Low Carbon Ferro Alloys, Low Carbon Ferromanganese Manufacturing Plant, Low Carbon Ferro Manganese (Medium Grade), Low Carbon Ferro Manganese Manufacture, Ferro Alloys, Production of Low-Carbon Ferromanganese, Project Report on Low Carbon Ferromanganese Manufacturing Industry, Detailed Project Report on Low Carbon Ferromanganese Manufacturing, Project Report on Low Carbon Ferromanganese Manufacturing, Pre-Investment Feasibility Study on Low Carbon Ferromanganese Manufacturing, Techno-Economic feasibility study on Low Carbon Ferromanganese Manufacturing, Feasibility report on Low Carbon Ferromanganese Manufacturing, Free Project Profile on Low Carbon Ferromanganese Manufacturing, Project profile on Low Carbon Ferromanganese Manufacturing, Download free project profile on Ferro Alloys Manufacturing, Production of Manganese Ferroalloys, Ferro Alloy Plant, Manganese Ferroalloys Industry, Manufacturing Process of Ferro Manganese, Opportunities in Ferroalloy Sector,
InterfaceIndian Ferro Alloy Industry –An Outlook
Steel Industry Snap Shot
Ferro Alloy Industry
Demand Drivers
Industry Structure
Capacity, Production, Exports & Imports
Raw Materials and Inputs
Manganese
Chrome
Power
Demand of Steel
Ferro Alloy Capacity Utilisation
Capacity Addition
Infrastructure
India’s Competitiveness
Conclusions
Steelmaking and Iron Products (Cast Iron, Compacted Graphite Irons, Ductile I...Ajjay Kumar Gupta
The iron and steel industry is one of the most important industries in India. Most iron and steel in India is produced from iron ore. The Indian Ministry of Steel is concerned with: the coordination and planning of the growth and development of the iron and steel industry in the country, both in the public and private sectors; formulation of policies with respect to production, pricing, distribution, import and export of iron and steel, Ferro alloys and refractories; and the development of input industries relating to iron ore, manganese ore, chrome ore and refractories etc., required mainly by the steel industry.
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Cast Iron Production, Development of iron and steel industry in India, Foundry process of cast iron, Grey cast iron, How iron is made, How is iron manufactured?, How is iron produced?, How is Steel Produced, How to Start a Steel Business, How to Start a Steel Production Business, How to start a successful Steel iron business, How to Start an Iron & Steel Business, How to Start an Iron Business, How to Start an Iron Production Business, How to Start Iron Business, How to Start Iron making Industry in India, How to start steel factory, How to Start Steelmaking Industry in India, Indian Iron Industry, Indian Steel Industry, Iron & Steel Business ideas and Opportunities, Iron and steel industry in India, Iron and Steel Manufacturing, Iron and steel manufacturing process, Iron and Steel Production, Iron and Steel, Iron Based Profitable Projects, Iron business in India, Iron industry in India, Iron making Industry in India, Iron making process, Iron making Projects, Iron Production Process, Ironmaking and Steelmaking, Major Iron and Steel Plants of India, Malleable cast iron, Manufacture of steel, Manufacturing Process for Iron and Steel, Modern steel making technology, Most Profitable Steel Iron Business Ideas, New small scale ideas in Iron making industry, New small scale ideas in Steelmaking industry, Process of making steel from iron ore, Process of steelmaking, Production of compacted graphite irons, Production of ductile iron, Profitable Iron & Steel Business Ideas, Profitable Small Scale Steel iron manufacturing, Raw Materials for Steelmaking, Setting up a Steel Factory Business in India, Setting up and opening your Steel iron Business, Small scale Commercial Steel iron making, Small scale Steel iron production line, Starting a Steel Business, Starting a Steelmaking Business, Starting an Iron Business, Starting an Iron making Business, Starting Steel Mini Mill Startup Business, Start-up Business Plan for Iron and Steel, Steel and iron Business, Steel and iron industry, Steel and iron production, Steel business plan, Steel Industry in India, Steel iron making machine factory, Steel iron Making Small Business Manufacturing, Steel making process in detail, Steel making process steps, Steel making Projects, Steel manufacturing process
60 not out - sixty successful years of continuous ferro alloy making at jodaPRABHASH GOKARN
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The Ferro Alloy sector globally, and especially in India, is notoriously short-lived for reasons detailed in the paper. It also elaborates the reasons for the longetivity of FAP Joda.
Presentation titled "Chrome Business India – China Yesterday, Today and Tomorrow" seeks to explore the changing relationship between two Asian giants in face of a over 25% growth in SS production in China which propelled it to the #1 producer of stainless steel in the world and pressures posed by India\'s own impressive double digit growth in SS Production.
Production of Ferro Molybdenum. Opportunities in Ferromolybdenum, Ferroalloys Industry
Ferromolybdenum is an alloy formed by combining iron and molybdenum. It is an extremely versatile alloy used primarily in high-strength low alloys and stainless steels. It has numerous beneficial properties and can be used even in cast irons, some high-speed tool steels, and superalloy applications. Adding ferromolybdenum to a material helps to improve weldability, corrosion and wear resistance as well to increase ferrite strength.
Applications
The largest application area of ferromolybdenum is in the manufacture of ferrous alloys. Based on the range of molybdenum content, ferromolybdenum can be applied in the manufacture of machine tools and equipment, military hardware, refinery tubing, load-bearing parts and rotary drills.
Ferromolybdenum is also used in cars, trucks, locomotives and ships. Ferromolybdenum is added to stainless and heat-resisting steels that are used in synthetic fuel and chemical plants, heat exchangers, power generators, oil-refining equipment, pumps, turbine tubing, ship propellers, plastics and inside acid storage containers.
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Tel: +91-11-23843955, 23845654, 23845886, 8800733955
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Ferro Molybdenum, Ferromolybdenum, Ferromolybdenum Production, Production of Ferromolybdenum, Process for Production of Ferromolybdenum, Ferromolybdenum Manufacturing Process, Ferroalloys Production, Ferro Molybdenum Production Process, Molybdenum Manufacture, Molybdenum and Ferromolybdenum Production, Ferro Molybdenum Manufacturing, Molybdenum Processing, How to Start Production of Ferroalloys, Process for Producing Ferromolybdenum, Ferro Molybdenum Manufacture in India, Ferro Molybdenum Uses, Project Report on Ferromolybdenum Manufacturing Industry, Detailed Project Report on Ferromolybdenum Manufacturing, Project Report on Ferromolybdenum Manufacturing, Pre-Investment Feasibility Study on Ferro Molybdenum Production, Techno-Economic feasibility study on Ferromolybdenum Manufacturing, Feasibility report on Ferromolybdenum Manufacturing, Free Project Profile on Ferro Molybdenum Production, Project profile on Ferro Molybdenum Production, Download free project profile on Ferro Molybdenum Production
October 2014 Edition of BEACON, A Monthly Newsletter by SIMCON.
Inside this issue:
INDUSTRY ANALYSIS : Metal
COMPANY ANALYSIS : Tata Steel
Events Report
Concept of the Month
Quiz
Did You Know?
Exploratory Data Analysis Example - Credit Risk Analysis (Second Attempt)PRABHASH GOKARN
An attempt to analyze Bank Data on loans and find patterns in the data that are predictors of loan defaults. This will ensure that future loan decisions are made more logically and reduce possible defaults. The analysis has been done using Python.
Magnetic Separation of Metallics from Ferrochrome SlagPRABHASH GOKARN
At a Ferroalloy Plant producing High Carbon Ferro Chrome, the slag co-produced is granulated. The separation between slag and metal is not perfect and the granulated slag contains ~1% to 3% of entrapped ferrochrome. Apart from being a loss of valuable Ferro Chrome, local miscreants climb the unstable slag heaps to manually recover and steal the carry over Ferro Chrome granules, which is both a security and safety risk. We have successfully implemented a magnetic separation method for the recovery of metallics from the slag.
On 20th April 2018, Tata Steel’s Ferro Alloy Plant at Joda turned sixty. It is India’s oldest continuously operating ferroalloy plant, and one of the oldest continuously operating ferroalloy plants in the world. The plant was set up as a wholly owned subsidiary(Joda Ferro Alloy Pvt Ltd). It was the first assignment of M/s M N Dastur and completed eight months ahead of schedule. This is a booklet published by M/s MN Dastur on the occasion.
SEWAGE AND ITS TREATMENT - Experience from setting up Sewage Treatment Plants PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for freshwater coupled with increased contamination from untreated wastewater. Along with steps taken to clean our polluted rivers and streams, laws for disposal of wastewater are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper discusses the major technologies for sewage treatment.
Sewage and its treatment - experience from setting up STPs PRABHASH GOKARN
Growing population has resulted in a steep increase in demand for fresh water coupled with increased contamination from untreated waste water. Along with steps taken to clean our polluted rivers and streams, laws for disposal of waste water are becoming stricter, resulting in an urgent need for setting up facilities for treatment of sewage. There are several treatment options, each with its own set of advantages and disadvantages. Drawing from our experience in setting up and running sewage treatment plants across various locations involving multiple technologies, this paper describes most of the popular technologies adopted for sewage treatment and the possible reasons for their selection.
Pre – fabricated buildings in mining - an environment friendly alternativePRABHASH GOKARN
Pre-fabricated buildings (or simply, pre-fabs), are buildings that are manufactured off-site in advance, usually in standard sections that can be easily shipped, and are assembled at site. There are many advantages of Pre-Fabricated buildings which make it especially suited to Mining Locations. With the improvement in the materials used in making pre-fab buildings, the rising cost of labour, safety & quality concerns, and environmental concerns of construction waste disposal; pre-fab buildings are poised to increase in popularity. This article discusses the experience in making a pre-fabricated office building at a mining location.
Safety Challenges in the Construction of a Large Water Recovery PlantPRABHASH GOKARN
The Ferro Alloy Plant at Joda was commissioned in 1958 and is in continuous operation since. It currently produces 50,000 MTPA of HC Ferro Manganese in two Submerged Arc Furnaces.
Gas Cleaning Plant (GCP) slurry generated in wet venture scrubbers is collected in slurry pits inside the plant for drying and subsequent disposal. Because of space constraints, and in order to recycle the water used in the wet venture scrubbers, Tata Steel is upgrading its GCP slurry handling process by the installation of a GCP slurry dewatering plant.
Construction of large structures within an operating plant, without affecting operations is always a challenge. The job is even more challenging, since the plant is 58 years old, with many unmarked structures, pipes, and cables lying underneath.
This paper discusses how new and unexpected challenges are tackled during the construction of the Slurry Dewatering Plant without compromising on safe working.
Constructing on of India's largest single location Effluent Treatment PlantsPRABHASH GOKARN
Tata Steel operates one of the largest chromite mines in India at the Sukinda Valley in Odisha. The chrome ore produced is subsequently converted it to Ferro Chrome and sold to customers across the world, making Tata Steel one of the top ten Chrome players in the world. A large quantity of water, generated during mining and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent chromium oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.05 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel has set up an Effluent Treatment Plant at Sukinda with a capacity of ~108 million litres/day, the largest in the region, and possibly one of the largest single location ETPs in India. This paper discusses how the challenges faced during construction of this Effluent Treatment Plant were successfully tackled.
Brazil's Mining Tragedy : Lessons for the Mining IndustryPRABHASH GOKARN
The Brazilian mining tragedy was an eye-opener for the mining fraternity to introspect on the existing tailing management processes, identify gaps, complete hazard identification and risk assessments, and modify or develop safe operating procedures and emergency preparedness plans in line with the guidelines issued by Statutory Authorities from time to time. This is necessary to avert the occurrence of similar incidents in the future.
Presentation at the 9th WORLD AQUA CONGRESS on 26th-27th Nov 15PRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Improving Water Quality by Constructing an Effluent Treatment PlantPRABHASH GOKARN
Tata Steel operates chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, pumped out from the mining pit and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an additional state of art effluent treatment plant at Sukinda with a capacity of 108 million litres/day; one of the largest in the region; which will be completed by Sept 2015. This paper discusses how the technology for the Effluent Treatment Plant was chosen amongst various alternatives, how the capacity of the plant was decided, the challenges during construction of the said Effluent Treatment Plant that were faced, and how these were successfully tackled. The paper also describes how, because the outlet water is of a better quality than the water from the local water body, the outlet water will be used as the input to the Water Treatment Plant, aiding water consumption and lowering operating cost.
Project Management Challenges in an Effluent Treatment Plant Construction PRABHASH GOKARN
Tata Steel operates India’s largest chromite mines at the Sukinda Valley in Odisha producing chrome ore which is subsequently converted it to Ferro Chrome and sold to customers across the world. A large quantity of water, generated during mining and due to rainfall, needs to be handled during the mining operations. Chrome Ore mainly contains tri-valent Chromic oxide and a very small fraction of hexavalent di-chromate. Water coming in contact with chromium ore preferentially leaches out soluble hexavalent chromium from the ore body, as a result, water from the mine contains 0.2 – 4 mg/l of hexavalent chromium against a safe limit of 0.005 mg/l for human consumption; requiring all water to be treated before its release from the mines. Thus, Tata Steel is setting up an effluent plant at Sukinda with a capacity of 108 million litres/day; perhaps one of the largest in the region; which will be complete by end June 2015.
Sustainable Development in the Mining Industry - presentation at QCFI BhilaiPRABHASH GOKARN
Mining is the primary method of extraction of minerals needed by man.
The main constraint to sustainability in mining stems from the increasing pollution generated by the extraction process and the large consumption of resources (mostly energy and water) needed in refining of the minerals.
Mining operations are associated with a range of environmental and social impacts, as well as the non-renewable nature of many mined resources. Thus the sustainability of this industry and the efficient use of its resources for development remain crucial.
There is a growing realization globally of the importance of strong and effective legal and regulatory frameworks, policies and practices for the mining sector that deliver economic and social benefits.
It is possible for mining to contribute to sustainable development through:
• Enhancing the benefits while mitigating the negative impacts both when mining is taking place and subsequently as well (by scientific mine closure)
• Improving stakeholder participation in the management of the resources including local and indigenous communities
• Addressing the environmental, economic, health and social impacts and benefits of mining throughout their life cycle, including workers' health and safety.
There must be a balance between contrasting claims of sustainability for the future versus current economic benefit from mining. We must :
• Stay within the capacity of ecosystems to absorb change.
• Provide an adequate standard of living for those in the area of influence.
• Create wealth for development of society & provide for the development of advanced technology.
• Develop systems of governance which promote and sustain these goals.
Sustainable Development in the Mining Industry - presentation at QCFI Bhilai
The Indian Ferro Alloy Industry
1. The Indian Ferro Alloy Industry
- Prabhash Gokarn & TS Sunderesan,
Indian Ferro Alloy Producers Association
About IFAPA
Indian Ferro Alloy Producers Association (IFAPA) is committed to the growth of the
ferro alloy industry in India. It represents the Indian Ferro Alloy Industry with almost
all ferro alloy producers being members of the association.
IFAPA imbued with the philosophy that while individual initiative, enterprise and
efforts are the foundation of a nation’s progress, a co-operative and complementary
functioning of the ferro alloy industry is needed for consensus in all its interfacing
activities with various outside agencies, like the government and other industry bodies
to avoid confrontational and conflicting facets.
IFAPA is the sole industrial body that interfaces with government, trade and other
industry bodies, educational and R&D institutions on — legal, tenurial, fiscal,
regulatory, forests and environmental — all matters connected with the functioning of
the ferro alloy industry on a continuing basis.
2. INTRODUCTION:
What are Ferro Alloys
Ferro Alloys are vital inputs for the production of all steel : carbon, low alloy
and high alloy steels, including stainless steel. Ferro Alloys are used during the
production of steel, as deoxidants, to make clean steels and as alloying agents.
Ferro Alloys are classified into two categories, based on the nature of
manufacture and useage pattern, namely :
1. Bulk Ferro Alloys viz., High Carbon Ferro Manganese, Silico Manganese,
Ferro Silicon, High Carbon Ferro Chrome etc., usually manufactured by
carbo-thermic reduction using submerged electric arc furnaces and,
2. Noble Ferro Alloys viz., Ferro Molybdenum, Ferro Vanadium, Ferro
Tungsten, Ferro Silico Magnesium, Ferro Titanium, Ferro Boron, etc.,
usually manufactured by alumino-thermic reduction in the Thermite
process.
The requirement of Ferro Alloys, both type and quantity, depends upon the
process of steel making and the type of steel being made. For instance, the
quantity of silico manganese and ferro silicon, traditionally used to make
killed and semi-killed steels and for aiding desulphurization had reduced as
steel plants adopted newer technologies (like Basic Oxygen Steelmaking,
external desulphurization using cored wire injection, and vacuum degassing).
However, with the steep increase in the demand for alloy steels, the specific
consumption of ferro alloys is on the increase.
Steel is alloyed to increases its resistance to Corrosion and Oxidation, to
improves its Hardenability and Tensile Strength, its High Temperature
Strength & Creep Resistance, to increase Wear and Abrasion resistance and
modify the nature of inclusions in steel, that decreases the tendency of steel to
crack during processing or during service.
3. The Indian Ferro Alloy Industry – the genesis
The Indian Ferro Alloy Industry in the organized Sector came into production
in mid sixties, at the behest of the Planning Commission, which thought it
proper that instead of raw materials abundantly available in the country being
exported at throw away prices, the country could build up the infrastructure
where it could use the natural resources of Ores like Manganese Ore, Chrome
Ore, Titanium Ore and produce value added products like Ferro Alloys.
In the Second Five Year Plan, the Planning Commission formulated a Policy
and suggested licensing units based on 50% of the production capacity for
exports, besides meeting the local requirements.
Initially, the Ferro Alloy Units came up in what are now the states of Orissa,
Karnataka, Maharashtra, and Andhra Pradesh mainly due to availability and
proximity of raw material & power. Ferro Manganese plants came up at Joda
in Orissa, Dandeli in Karnataka, Tumsar in Maharashtra and near Vizag, A.P.
Today the Ferro Manganese plant at Joda is the one of oldest continuously
operating Ferro Alloy plants.
The first phase of expansion of the industry took place between the late sixties
and seventies and 14 furnaces with capacity addition of 178 MVA undertook
bulk production of Ferro Silicon and Ferro Chrome.
The second phase of expansion was during the eighties on product
diversification, assimilation and advance technology and setting up of Export
Oriented Units to earn substantial foreign exchange for the country. This
resulted in addition of 12 more furnaces and the capacity addition during the
eighties was about 308 MVA.
The Ferro Alloy Industry was thrown open and liberalized during 1991-92. As
a result, a number of Small and Medium Units having transformer rating of 2.5
MVA to 10-12 MVA emerged in production of Bulk Ferro Alloys, particularly in
the State of Madhya Pradesh, West Bengal, Kerala, Pondicherry, Goa,
Jharkhand, Chhattisgarh, Jammu and Meghalaya.
4. The Indian Ferro Alloy Industry Today
Since liberalization, the Indian Ferro Alloy industry has truly become global.
The ferro alloy industry in India has grown far in excess of the growth in the
steel industry and the estimated production capacity of ferro alloys in India is
more than double the domestic demand, with a significant proportion (upto
50% in some years) of the ferroalloys being exported. Despite this, the ferro
alloy industry operates at an average 65% capacity utilization.
The estimated production capacity has crossed 2200 MVA and fresh capacity
of around 500 MVA is coming up, mostly in Manganese ferro alloys to feed the
proposed steel expansion.
Table 1 : The Indian Ferro Alloy Industry
Capacity,
Current Capacity Units Furnaces MVA
mill MT
Manganese Alloys 76 161 1182 2.1
Ferro Silicon 29 38 266 0.2
Chrome Alloys 28 53 803 1.3
Noble Ferro Alloys 37 - - 0.04
TOTAL 170 25 2 2251 3.64
5. Contribution of the Indian Ferro Alloy Industry to the Indian Economy
Like the software industry that propelled India to global fame and made India
the hub for software development, properly nurtured, the Indian Ferro Alloy
industry has the potential to make India the hub for ferroalloys to the world.
Already, the Indian Ferro Alloy industry is :
a. A Valuable Foreign Exchange Earner
India is a major ferro alloy exporter and Ferro alloy exports are a major
Foreign Export earner.
Foreign Exchange Earned from Ferro Alloy Exports in Million USD
1800
1547 548*
1600
1400
1200 1118 *in 3 Qtrs ,
Apr-Dec’09
1000
800
600
364
400 266 266
200
0
2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
Of this over 60%-70% is earned by export of HC Ferro Chrome.
b) Earnings from Export of Ferro Alloys ploughed back to society :
The earnings from the total sales of Ferro Chrome the Industry has re-
invested in the Industry by setting up Captive Power Plants, acquiring
Coal Mines, Ore Mines and spending a huge amount on Society by
setting up Residential complexes, Schools, Colleges and Hospitals, etc.,
which has created additional jobs for the people. Ferro Alloy industries
are located in remote areas creating islands of prosperity in states of
Orissa, Karnataka, West Bengal, Chattisgarh, Kerela & Andhra Pradesh.
6. c) Electricity generation
Electricity generation by the Ferro Chrome Industry through Captive
Power Plants is also supplied to the grid, thus increasing availability of
power in India.
Also, although generation costs for power is not high, the industry pays
a high tariff due to cross subsidization to Agriculture, Low Plant Load
factor and high T & D losses. The Units have to maintain a minimum
demand of 85 % of Power in their operation. This clearly shows that the
Industry has paid much more than the normal power tariff applicable
for this Industry, which has earned substantial revenue to the State and
Central Governments
d) Industrialization of the eastern region –
particularly Orissa, West Bengal and Andhra Pradesh
e) Employment to people :
It is estimated that a 50k/MT Ferro Alloy plant supports around 750
families around the plant(ie a total of about 60,000 families by the ferro
alloy industry in India), and these plants are located in remote areas
where there is no other source of employment.
The steep increase in power tariff in South Africa and China coupled with
increases in freight, labour, and regulatory costs in China has made the Indian
Industry highly competitive. Decreased Chinese competitiveness has resulted
in a sharp reduction in ferroalloy exports from China, which has turned into a
net ferroalloy importer since 2009.
This presents an opportunity for the Indian Ferro Alloy industry to
consolidate its position as a leading Ferro Alloy exporter to the world.
As stated earlier, due to the low capacity utilization of existing capacities and
with new facilities coming up, India has the unique ability to immediately
scale up production of ferro alloys.
India enjoys a freight advantage in markets such as China, Korea & Japan,
which are large consumption centres. China, in particular has shown a nearly
25% growth in steel production and is still growing.
Other advantages include comparable power, labour & inland freight costs to
major ferroalloy production regions like China and domestic availability of
ore.
7. However, there are some bottlenecks that need to be resolved if India is to
claim its position, namely:
1. Infrastructural Bottlenecks
Inadequate roads, railway network capacity & ports for handling large
scale ore imports & ferroalloy exports. The Government action on
encouraging investments for rapid infrastructure development; creation of
special economic zones and special freight corridors is a step in the right
direction and action needs to be speeded up.
2. Transport Bottlenecks & Problem of Transport Union
Transportation has been the bane of the ferroalloy industry, due to high
cost of transportation, low reliability and frequent disruptions. In many
major ferroalloy manufacturing regions, the transport sector is in the
clutches of powerful transport unions who do not allow outside trucks in
the sector. Consequently transport rates in some sectors are amongst the
highest in the world. It is necessary for the industry and the local
authorities to jointly tackle.
3. Power Availability & Cost
Indian average power tariffs are at similar level to China, after steep
increase in power tariffs in China recently, which has made the Indian
Industry competitive. Also, power sector reforms - allowing for Captive
Power Plants & Power Wheeling has made the industry somewhat inured
to grid power. However, as small captive power plants are not energy
efficient, there is an urgent need to increase grid power generation to
support ferroalloy industry growth. Recent power shortages in summer in
Eastern India (the hub of Ferro Alloy production) and South India, is also a
matter of concern.
4. Regulatory Framework
The industry needs a regulatory framework that encourages ferroalloy
exports for India to consolidate its position as major ferroalloy exporter.
Incentives to ferroalloy export hubs by way of priority power allocation,
rake availability, and tax structure will help boost ferro alloy exports
further.
In conclusion, the ferroalloy industry in India is all set to further consolidate
its position as the major source of ferroalloys to the world, if the above
bottlenecks are resolved.
10. Sized Ferro Alloy ready for Packing
Automation of Submerged Electric Arc furnace for Ferro Alloy making
11. Quality Control during Ferro Alloy Making
Casting of tapped liquid ferro alloys into cast pans before sizing
12. The strategic advantage of the ferro alloy industry in India stems from India’s
resource base in terms of manganese & chrome ores
A fully mechanized Manganese ore mine
13. A mechanised Chrome Ore Mine in Orissa
A mechanized Manganese ore mine in Orissa