Index

Techno
Steel Distribution
Power & Coal
Flow Sheet
CCD Plan
Major Raw Matl.
R M Sourcewise
Coke Balance
Scrap Balance
SPP
Furnacewise HM
IPT

MAJOR TECHNO ECONOMIC PARAMETERS

ITEM

UNIT

Hard Coke yield

% dry coal
Hard Coke yield
T/oven
% Imported coal in blend
%
Coke rate in BF
Kg/THM
Nut Coke rate
Kg/THM
CDI
Kg/THM
CTF
Kg/THM
Fuel Rate
Kg/THM
BF Productivity on W V
T/m3/day
SMS-I :
Hot Metal
Kg/TCS
Scrap Kg/TCS
Total Metallic Input Kg/TCS
SMS-II :
Hot Metal
Kg/TCS
Scrap Kg/TCS
Total Metallic Input Kg/TCS
* CDI & *CTF - May start from Oct'11

2011-12
Target
65.25
10.30
75.00
528
26
4*
1*
554
1.52
1070
80
1150
1045
90
1135

ITEM
Sinter Usage
Yield from mills:
PM PLATE
HR COIL
CR COIL
GP/GC
E T P (own)
E R W PIPES
S W PIPES (own)
CRNO
Energy consumption
Electricity consumption

PARAMETERS

COAL CHEMICALS DEPARTMENT PRODUCTION PLAN FOR THE Y

UNIT
%
%
%
%
%
%
%
%
%
G.Cal/TCS
KWH/TSS

2010-11
Target
72.0
92.7
97.7
94.3
88.0
78.6
91.5
93.0
88.5
510

Item
Oven pushing
Production Plan:
Crude Tar Prodn
EHP Prodn
Road Tar Production
Anthracene Oil
LCO-II
Napthalene
Carbolic Oil
Light Oil
Amm Liquor
Press Oil
Amm Sulphate Prodn
Sulphuric Acid Prodn
Availability for external sales:
Crude Tar
Anthracene Oil
LCO-II
H P Napthalene
Carbolic Oil
Light Oil
Amm Sulphate
Consumption Plan:
Sulphur requirement
Ratios:
Crude Tar yield % of DCC
Amm Sulphate Yield % of DCC
Sulphur consumption per ton of Acid
Acid consumption per ton of sulphate

Unit
2011-12
Nos/day
355
Ton
Ton
Ton
Ton
Ton
Ton
Ton
Ton
Ton
Ton
Ton
Ton

65693
11219
840
3156
2930
906
406
225
1352
529
16834
16200

Ton
Ton
Ton
Ton
Ton
Ton
Ton

34530
3156
2930
906
406
225
16834

Ton

5994

3.2
0.82
0.37
0.785

CTION PLAN FOR THE YEAR 2011-2012

Basis:
Production Days
Dry Coal Charge per oven (T)
%PBCC
Battery 1,2
Battery 4 & 5 (from Oct-10)

366
15.8
15%
15%

Internal Consumption:
Crude Tar:
PBCC
BF
Pitch and Road Tar
Total

(T)
4658
3965
22540
31163

Extra Hard Pitch:

PBCC
BF
LDBP
Total

(T)
10869
0
350
11219

Sulphuric Acid:
For Amm. Sulphate
At CRM
At CPP-1
Total

(T)
13214
6000
360
19574

Acid to be procured by CRM

3374

SCRAP BALANCE : 2011 - 12

UNIT

INPUT

OUTPUT

YIELD

CCM-I

424.37

418.00

98.50%

ITEMS

DIFF
6.37

Crop end
Tundish Skull (Gr-I)
Scale Loss
TOTAL
CCM-II

1861.65

1830.00

98.30%

31.65
Crop end & Process Slab
Steel Skull (Gr-I)
Tundish Skull (Gr-II)
Scale Loss

TOTAL
PM
(own)

535.00

TOTAL
PM
(ext)

6.16

TOTAL
HSM

496.00

92.7%

39.00
Crop End/ Plate Cutting
Scale Loss

4.00

64.9%

2.16
Crop End/ Plate Cutting
Scale Loss

1713.00

1674.00

97.7%

39.00
Crop End
HR Coil End
Scale Loss

TOTAL
HR Plate

326.50

320.00

98.0%

6.50
Crop End/ Plate Cutting

TOTAL
HRCS

689.90

683.00

99.0%

6.90
Crop End/ Plate Cutting

TOTAL
CRC

233.30

220.00

94.3%

13.30
HR gas cut
HR sheet cutting
CR Coil End
CR Cutflat end
CR sheet cutting
CR gas cut

TOTAL
GALV

193.20

170.00

88.0%

23.20
HR gas cut
HR Sheet Cutting
CR Cutflat end
CR Coil End
CR sheet cutting
CR gas cut
Zinc Dross

TOTAL
ETP
(own)

23.80

18.72

78.6%

5.08
BP Coil end

Tin Plate scrap

CR Coil End
CR Sheet Cutting
Bales
TOTAL
ETP
(ext)
TOTAL
ERW

18.00

17.28

96.0%

0.72
BP Coil end

67.80

62.00

91.5%

5.80
Scrap Pipes/ PEC
Melting Scrap

TOTAL
SWPP
(own)

49.00

TOTAL
SWPP
(ext)

15.00

TOTAL
CRNO

45.60

93.0%

3.40
Scrap Pipes + PEC
Melting Scrap

14.40

96.0%

0.60
Scrap Pipes + PEC
Melting Scrap

96.00

85.00

88.5%

11.00
HR Hi Si sheet cutting
Hi Si HR Coil end
Hi Si CR Coil end
Hi Si CR sheet cutting
HR sheet with weld joints

TOTAL
GRAND
TOTAL

6252.67

6058.00

194.67

SCRAP GENERATION:
SMS

Roll Mills
BF
SSD

Crop End/ Process Slab

Tundish Skull (Gr-I)
Steel Skull (Gr-II)
Light Scrap
C.I.Scrap
Wear / Maint Scrap
TOTAL SCRAP GENERATION

SCRAP REQUIREMENT:
UNIT
CCM - I
CCM - II
TOTAL

TARGET
418
1830
2248

PLANT SALES OF SCRAP:

UNIT
PM

ITEMS
Crop End/ Plate Cutting

Kg/T
80
90

(ext)
CRM

SSM

ERWP
SWPP
GALV

Jackal Slab End Cutting (Ingot Route)

HR gas cut
HR sheet cutting
CR Coil End
CR Cutflat end
CR sheet Cutting
CR gas cut
BP Coil end
Tin Plate Scrap
HR (Hi-Si) Sheet Cutting
Hi-Si HR Coil end
Hi-Si CR Coil end
Hi-Si CR sheet Cutting
HR Sheet cutting with welding joints
End Cutting Scrap
End Cutting Scrap
Zinc Dross
TOTAL SCRAP

(' 000 T)
% GEN

TOTAL
GEN.

SCRAP FOR
CONSN.
SALE

0.5%
0.8%
0.2%
1.5%

2.12
3.39
0.85
6.37

2.12
3.39

0.2%
0.6%
0.8%
0.1%
1.7%

3.72
11.17
14.89
1.86
31.65

3.72
11.17
14.89

6.7%
0.6%
7.3%

35.85
3.16
39.00

35.85

19.0%
16.1%
35.1%

1.17
0.99
2.16

1.4%
0.3%
0.6%
2.3%

23.98
5.14
9.88
39.00

23.98
5.14

2.0%
2.0%

5.52

29.79

35.85

LOSS

0.00

0.85
0.85

0.00

1.86
1.86

0.00

3.16
3.16

1.17
1.17

0.99
0.99

29.12

0.00

9.88
9.88

6.50
6.50

6.50
6.50

0.00

0.00

1.0%
1.0%

6.90
6.90

6.90
6.90

0.00

0.00

0.15%
0.15%
4.95%
0.15%
0.15%
0.2%
5.7%

0.35
0.35
11.55
0.35
0.35
0.35
13.30

0.35
0.35
11.55
0.35
0.35
0.35
12.60

0.00

1.0%
1.0%
0.9%
6.6%
1.0%
1.0%
0.5%
12.0%

1.93
1.93
1.74
12.75
1.93
1.98
0.94
23.20

1.93
1.93
1.74
12.75
1.93
1.98
0.94
19.34

0.00

8.0%

1.90

0.00

0.70

3.86

1.90

0.4%
5.0%
0.9%
7.1%
21.4%

0.10
1.19
0.21
1.68
5.08

4.0%
4.0%

0.10
1.19
0.21
1.68
1.68

3.40

0.00

0.72
0.72

0.00

0.72
0.72

0.00

2.5%
6.0%
8.5%

1.70
4.11
5.80

4.11
4.11

2.5%
4.5%
7.0%

1.23
2.18
3.40

2.18
2.18

1.5%
2.5%
4.0%

0.23
0.38
0.60

2.3%
2.0%
6.6%
0.3%
0.3%
11.5%

2.21
1.92
6.34
0.29
0.25
11.00
194.67

1.70
1.70
1.23
1.23

(' 000 T)

REQD
33.44
164.70 Shortage
198.14 37.45

(' 000 T)

SALE
1.17

0.00

0.23
0.38
0.38

0.23

0.00

6.34
0.29
0.25
6.87
47.25

0.00
16.73

2.21
1.92

4.13
130.69

(' 000 T)

5.85
14.56
14.89
95.39
6.00
24.00
160.69

0.00

0.40
0.00
0.00
25.49
2.09
2.50
2.33
2.62
0.10
0.00
0.00
6.34
0.29
0.25
1.70
1.45
0.94
47.65

Distribution of Steel produced in SMS-I & SMS-II between PM & HSM

Power Generation & Drawal

MW

Furnacewise HM Plan

CPP-I

47.0

Hot Metal

SMS-I

SMS-II

Slab Stock

CPP-II

111.38

BF-1

497

418000

1830000

Drawal
Export

28.98
0.5

BF-2
BF-3

509
509

PM
135000

Total
CPP-I Boiler Coal (T)

186.86
655,837

BF-4
Total

845
2360

400000

CPP-II Boiler Coal (T)

978,362

IPT / External Purchase

('000 T)

IPT

INTER PLANT TRANSFER REQUIRED FOR SPP ROLLING (2011-12)

('000 T)

Product
Jackal Plate (Ingot Route)
Jackal Plate (CC- Route)
Spade Plate (CC Route)
IPT Requirement

6159
Total:

541159

TMBP-BSL
SWPP-BSL
HSM

Total:

Hard Coke

1713000

978350000
111378.643

IPT FOR NAVY GRADE STEEL :

Product
DMR 249 A
DMR 249 B

6.159
26

Qty (T)
175
600

Taking 300 days of cutting/year. Slab tonnage from SMS-I for PM

300x100x4.5 = 135000 T

SPECIAL PLATE PLANT

Material Flow

PRODUCTION PLAN: 2011-2012

Hot Metal
2360000

ITEM
Jackal Anld.Plate

81.4%

HM Cons.

HM Cons.

(Kg/T)

(Kg/T)

Slab Stock
0

1070

1045

Tot. HM

Mixer

1912400

2359700

300

CCM-I
Output

CCM-II
Output

Spade Anld.Plate

1830000
Total
Cr. Steel
2248000

SPP
Input
6159
Output
4000

PM Plates
Input 541159
Yield
92.4%
Output 500000

Jackal Heat Treated Plate

447300

418000

HR Plates
Input
326500
Yield
98.0%
Output
320000

Yield
75%
75%

Slab Rolling at PM
SPP Output

Basis: Average 100 Slabs cut everyday at CCM-I for PM

18.6%

Yield
55%
60%
65%
Slab
Slab

Total IPT for Spade & Jackal

18
15

SPP (Spade/Jackal/DMR)

283000
1430000

Qty. (T)
220
800
2205
Jackal CC
Spade CC
Total

Hot Strip Mill

Input
Yield
Output

1713000
97.70%
1674000

Plate Mill
Input
Input SPP
Total Input

HRC(Sale)
Input 689900
Yield 99.0%
Output 683000

535000
6159
541159

Yield
92.7%
64.9%
Total Output

CRS/C
Input
233300
Yield
94.3%
Output
220000

Output
496000
4000
500000

GP/GC
Input 187200
Yield 88.0%
Output 170000
Zinc Gross Kg/T
35
Zinc Net Kg/T
29.5
Zinc Input MT 6000
Dross in MT
935
Dross Kg/T
5.5

463500

ETP(OWN)
Input 23800
Yield 78.6%
Output 18720
ETP(BSL)
Input 18000
Yield
96%
Output 17280
Total Input 41800
Total Output 36000

ERWP
Input 67800
Yield 91.5%
Output 62000

SWP
Input 49000
Yield 93.0%
Output 45600
SWP (BSL) Coil
Input 15000
Yield
96%
Output 14400
Total Input 64000
Total Output 60000

CRNO
Input
96000
Yield
88.5%
Output
85000
Own Coil Input
Coil Stock
Total Saleable Steel

1,674,000
2,136,000

462,000

PROD.(T)
250
770
0

Spade Heat Treated Plate

Total Defence Product
Navy Grade DMR - (249 A & B )

2205
3225
775

Grand Total

4000

Slab Reqd.(T)
Yield
Ingot Reqd.(T)
400
50%
800
1333
3392
1333
Jackal Ingot
800
3392
Spade Ingot
0
4726
Total
800
Jackal
2133
Spade
3392

Slab Reqd.
233
800
6159
4000

Remarks
Through BSP Slab Route
Through ASP Slab Route

MAJOR RAW MATERIAL REQUIREMENT

ITEM

DAYS IN A YEAR
COKING COAL
Pushing (No/Day)
PCC
MCC
Imported (Hard)
Imported (Soft)
Total Coking Coal
BLAST FURNACE
Iron Ore (L)
Quartzite

PRODN
PLAN

RATE
Kg/T

TOTAL
CONSM
('000 T)

UNDER SIZE
AT OBBP
%
TONS

CONS
Kg/T

HNDL
LOSS
%

('000 T)
RAW
MATERIAL
REQD

366
355
15.00%
10.00%
68.00%
7.00%

15.8

2360
2360

476
10.0

1123
24

B/mix:
78.2%
30%
70%

1607
1256.28
57.8
134.9

821
83
153

4.3%
6.2%
B/mix:
78.2%
30%
70%

69.1
99.6
2006
1568.3
72.2
168.5

821
44
162

2.0%
1.4%
5.6%

40.1
28.1
112.3

Total Sinter Reqd.

3440
SINTER PLANT - I:
1530
Iron Ore (fines)
Lime Stone(% of 12% flux)
Dolo(Lump)(% of 12% flux)
Trimming Addition
Lime Stone
Dolo(fines)
SINTER PLANT - II:
1910
Iron Ore (fines)
Lime Stone(% of 12% flux)
Dolo(Lump)(% of 12% flux)
Trimming Addition
Flux
Lime (Calcined from CP-II)
Dolo(fines)
TOTAL SINTER PLANT REQUIREMENT
Iron Ore (fines)
Lime Stone
Dolo (Lumps)
Dolo (fines)
Total Crude Steel
2248
LDBP (STEEL MELTING SHOP - I)
Lime Stone (30-60 mm)
418
Raw Dolomite (SMS-I)
418
CP-II (STEEL MELTING SHOP - II)
Lime Stone (30-60 mm)
1830
Dolomite (SMS-II)
1830
TOTAL SMS FLUX
Lime Stone
Dolomite

MOIST
8.0%
8.0%
8.0%
8.0%

308
205
1396
144
2053
30.0%

481.4

697
10.0

Sinter Usage %
Iron Ore Usage %
Fe in Hot Metal
Fe in Sinter
Fe in Iron Ore
HM Production ('000 T)

0.72
0.28
0.95
0.53
0.63
2360

1.0%
1.0%
1.0%
1.0%

338
225
1533
158
2254

Requirement for 1 MT of HM
Iron Ore + Sinter (MT)
Sinter in Kg / T of HM
Iron Ore in Kg / T of HM

1.70
1225
476

2.5%

1646
23.6

Sinter Requirement ('000 T)

Screen Loss %
Gross Sinter Required ('000 T)

2891
16%
3440

Base Mix Blend in Sinter Plants

Iron Ore (Fines)
Coke Breeze
LD SLAG
FLUX (Lime Stone + Dolo)

%
78.2
5.2
3.6
13

Major Raw Material Reuirement

Iron Ore (Lumps)
Iron Ore (fines)
Quartzite
Lime Stone (BF Grade)
Dolo (Lumps) BF Grade
Dolo (fines)

15

2824.58
211.1
303.4
240.0

-481.4
-46.3

2.5%
1.25%
1.25%
1.25%

2403
167
307
205

151
10

1.25%

72
4.2

172
103

1.75%

314.0
189

-37.1

151
10

63.3
4.2

12.0%

151
81

276.3
148.2

12.0%
20.0%

8.6

37.7
37.1

386
193

Lime Stone (SMS Grade)

Dolo (Lumps) SMS Grade

('000 T)
1646
2403
24
167
307
205
386
193

680.4

0.8698703
0.9550619

Raw Material Linkage 2010-11

UNIT: ('000T)
RSP
HM PROD
2360
SINTER
3440
DESP : IRON ORE LUMP QUANTITY
REQMT
1646
KIOM
50
MIOM
50
BOLANI
0
BARSUA
800
KALTA
296
GUA
0
CHIRIA
450
TOTAL
1646
Bhilai/Pellet
TOTAL
1646
Purchase
0
DESP : IRON ORE FINES QUANTITY
REQMT
2403
KIOM
380
MIOM
430
BOLANI
100
BARSUA
1243
KALTA
150
GUA
0
CHIRIA
100
TOTAL
2403
Purchase
0
DESP : LIMESTONE (BF Grade)
REQMT
167
KUTESHWAR
167
BHAWANATHPUR
0
TULSIDAMAR
0
TOTAL
187
Purchase
-20

External Coke Requirement

SAIL / RSP

ITEM

UNIT

2011 - 12
PLAN
366

No/Day
' 000 Tonnes
' 000 Tonnes
' 000 Tonnes
' 000 Tonnes

355
2360
1530
1910
3440

T/Oven

15.8

Hard Coke
Nut Coke
Mixed Breeze Coke
Gross Coke

Tons/Oven
Tons/Oven
Tons/Oven
Tons/Oven

10.31
0.24
1.50
12.05

Hard Coke
Nut Coke
Mixed Breeze Coke
Gross Coke

Yield (%)
Yield (%)
Yield (%)
Yield (%)
Kg/THM
%
Kg/T of Sinter
Kg/T of Sinter
%
Tonnes
Tonnes

65.25
1.50
9.50
76.25
528
8.7%
66.00
66.00
5.8%
2052894
1565396

Tonnes
Tonnes
Tonnes
Tonnes
Tonnes
Tonnes

1339578
1245490
1364173
-24595
-26000
26,000

Tonnes
Tonnes
Tonnes

195025
118683
-30567

Total Days in the Year

PRODUCTION PLAN
Oven Pushing
Hot Metal
Sinter Plant # 1
Sinter Plant # 2
Total Sinter
BASIS FOR CALCULATION
Dry Coal Charge
Coke Fraction

Coke Rate
Coke Screen Loss
MBC Consumption at Sint.Plant # 1
MBC Consumption at Sint.Plant # 2
Coke Moisture
Total Dry Coal Charge
Gross Coke Production
HARD COKE BALANCE
Hard Coke Production
Skip Coke Required
Conveyor Coke Required
Hard Coke +/- (Dry)
Hard Coke +/- (Wet)
Purchased Hard Coke +/- (Wet) (Rounded)
MIXED BREEZE COKE BALANCE
Mixed Breeze Coke Production
At Coke Ovens
Mixed Breeze Generation at BF
NC from MBC at OBBP by screening

Total Mixed Breeze Coke Available

Total MBC Required for Total Sinter
Total MBC Required for BF
Mixed Breeze Coke +/- (Dry)
NUT COKE BALANCE
Nut Coke Production
NC from Screening at OBBP
Total Nut Coke Available
NC addition with avaiable Nut coke
COAL TO HOT METAL RATIO
ITEM

Conveyor Hard Coke Required (Dry)

Equivalent Coal(Dry)
Coal Moisture
Equivalent Coal(Wet)
Hot Metal production
Ratio

Tonnes
Tonnes
Tonnes
Tonnes

283141
227040
12000
44101

Tonnes
Tonnes
Tonnes
Kg/THM

30793
30567
61360
26

Unit
Tonnes
Tonnes
%
Tonnes
Tonnes

Qty.
1364173
2090585
8.0%
2272375
2360000
0.963

ENERGY BALANCE
Days

366

Hours

8784

( Budget Year 2011-2012)

EMD/SAIL/RSP
Form No.:
Unit

Quantit
y

Energy
Value
Mcal/Unit

Coking coal excluding Tar&Pitch

103 T

2053

6500

Boiler Coal - CPP I

103 T

629.6

2800

Purchased Coke

103 T

26.0

6200

Furnace oil

103 T

0.45

9800

Diesel consumption

103 T

4.0

10000

Sl.
No.
A

Particulars
Energy Input:

Purchased power 103 MWH 1118.7

Cr.Tar Purchased

103 T

0.0

2400
8800

Total A:
B

ENERGY CREDITS
Power in township,FP & Constn. 103 MWH 250.344

2400

BF coke
Sold

103 T

Stock

103 T

Sold

103 T

Stock

103 T

Sold

103 T

Stock

0.0

6200

103 T

44.10

6200

Tar products

10 T

76.912

8800

Granulated Slag sold

103 T

920.4

1070

10000

103 T

1720

103 T

0.0

6000

Pearl coke

Mixed coke

Benzole products 10 KL
3

Slab sold/stock
TOTAL (B)
C
D

NET ENERGY INPUT (A-B):

Less : Energy for
Pig iron (equivalent HM)

External inputs :
BSM Ingots

103 T

Slabs

103 T

6.159

2400

HR coils for CRM

10 T

HR coils for SWPP

103 T

15

1350

TMBP Coils

10 T

15

1350

Total (D)
E

Crude steel production

F
G

Energy for crude steel

Specific energy consumption

Date:31.01.2011

103 T
GCal/TCS

Gas Generation
Budget year 2011-2012
EMD/SAIL/RSP
328
Energy
Million
GCal

Form:

330

Unit

Quantity

Tonnes

2052894

Nm /TDC

320

103 Kcal/ Nm3

4.2

Sl. No.
1
CO Gas
Dry coal charge

13.344
1.763

CO Gas yield

0.161

Calorific value

0.004

Total CO Gas

10 Kcal

2759.090

0.040

Losses

109 Kcal

18.446

2.685

Net Gas available for con.

10 Kcal

2740.643

BF Gas
Coke rate

Kg/THM

528

Hot metal production

10 T

2360

BF Coke consumption

103 T

1245.490

Nm /TSC

2920

103 Kcal/ Nm3

0.840

Total BF Gas

10 Kcal

3054.938

Losses

109 Kcal

14.757

Available for consumption

10 Kcal

3040.181

Available from LD Gas

109 Kcal

0.000
17.997

BF Gas Yield

0.601

Calorific value
0.000

Overall CV (composite BFG)

0.000

Net available for cons.

0.273

10 Kcal/ Nm
3

89.597
3

0.853

109 Kcal

3129.778

103 T

1830

LD Converter gas

0.677

SMS-II production

0.985

LD Converter gas yield

0.000

Calorific value

0.000

Total LD Converter Gas

109 Kcal

263.520

2.536

Losses

10 Kcal

0.000

Net available for con.

109 Kcal

263.520

CO Gas available for con.

109 Kcal

2740.643

CO Gas to Coke Ovens

109 Kcal

492.695

Nm3/TCS
10 Kcal/ Nm
3

80
3

1.8

15.461

4
0.000

Mixed Gas

CO Gas to CCD

109 Kcal

36.893

0.000

Net CO available for mixed gas

10 Kcal

2211.056

0.015

BF Gas for mixed gas

109 Kcal

37.465

0.000

LD Gas for mixed gas

10 Kcal

173.923

0.020

Total mixed gas make

109 Kcal

0.020

Calorific value of mixed gas

10 Kcal/ Nm
3

0.055
###
15.406
6.8532

Modified on date: 21.01.2011

2422.444
3

3.632

Gas Balancing
EMD/SAIL/RSP

Budget year: 2011-2012

Pushing:

Th.
Nm3/hr

Sl.
No.

355

Heat
Cons.
Quantit
3 Require
Norms 10
y 103 T.
d 103
Kcal/T
Gcal

Unit

Coke Ovens

2065.654

600

Sintering Plant-I

1530

42

64.260

Sintering Plant-II

1910

22

42.020

Blast Furnace

2360

530

1250.800

74.787

Pit sides, Mixers, SMS-I

418

170

71.060

0.500

CCM-I

418

75

31.350

74.287

SMS-II, CCM-II

1830

80

146.400

Plate Mill

541.159

365

197.523

Normalising furnace

10

Hot Strip Mill

1713

345

590.985

11

Cold rolling Mill

275.1

320

88.032

12

CRGO

3000

0.000

13

CRNO

85

275

23.375

14

Galvanising Lines

170

475

80.750

15

Lime Plants

414.029
2.000

300.000

412.029

17

To Mixing

5.667

18

Others

19

Total

20

Available for Boilers

21

Furnace oil required

417.696

CV

0.600

Comp.BF Gas

0.853

Mixed Gas

3.632

Fce.Oil

9.800

BF Gas

0.840

CO Gas

1239.392 39.753

32.000

16 Coal Chemicals Department

/day

Gas consumption
ratio

1.000
59.932
5.000
11.000
75.932

Gas consumption
ratio

Form No.:

Gas Consumption 109 Kcal

331

Available from fuels

BF Gas
Nm3/hr

BF Gas

CO Gas

60.247

492.695 746.698

0.000

BF Gas Mixed Gas 109Kcal

0.000

Item

Quantity
99.653

64.260

0.000

42.020
100.000

2.014
1.317

1250.800

166.930

0.000

71.060

2.227

31.350

0.983

146.400

4.589

197.523

6.191

32.000

1.003

590.495

0.49

F.oil

50

18.509

88.032

2.759

0.000

0.000

23.375

0.733

80.750

2.531

300.000

9.404

36.893

0.000

2211.056 37.465
14.757

425.247

2740.643 2034.963 2092.512

0.000

Mixed
Gas
Nm3/hr

1094.815

329.932

3.92
4.41

2740.643 3129.778 2422.444

F.oil

400

5.000

0.000

2.000

13.329

271.583

65.590

146.112

10.342

417.696

75.932

450

EMD/SAIL/RSP

Steam generation and consumption

For the Budgeted year 2011-2012
FORM NO.:

Sl. No.

Item

Unit

T/MWH

H.P.Steam-I

M.P.Steam

Norm.

Prod.n Steam 103T Norm.

4.600

47.000

TURBO GENERATOR

TURBO BLOWER

PROCESS STEAM

103 T

219.600

OTHERS & LOSSES

103 T

263.520

TOTAL STEAM REQUIRED

103 T

3479.621

LESS : AVAILABLE FROM

Prod.n

1899.101

Kg/THM 465.000 2360.000 1097.400

MP Steam:

103 T

HP Steam:

103 T

3479.621
3479.621

NET STEAM REQUIRED

10 T

HEAT REQUIRED/T OF STEAM

GCal/T

TOTAL HEAT REQUIRED

103 GCal

2574.919

10

LESS AVAILABLE FROM :

Gas 103 GCal

1424.747

0.740

0.780

Fuel Oil
QUANTITY:

400.000

CALORIFIC VALUE: GCal/T

9.800

ENERGY: 103 GCal

TOTAL (10):

3.920

103 GCal

1428.667

11 Heat Reqd. from Boiler coal (9-10):

103 GCal

1146.253

12

CV of Boiler coal

GCal/T

2.800

13

Boiler Coal Required

103 T

409.376

14

Handling & Moisture Losses

15

Gross Boiler Coal Required

103 T

4.000

4.000
426.433
Total boiler coal required:
Gross boiler coal required:

Date:

31.01.2011

333

M.P.Steam
Steam 103T

1124.352

219.600
904.752

705.707

705.707
220.228

229.404
629.604
655.837