At NMDC Steel Ltd., our integrated steel plant is designed with state-of-the-art facilities to ensure efficient production, sustainability, and innovation. The key units of the plant include:
Raw Materials Handling System (RMHS)
The Raw Materials Handling System (RMHS) at NMDC Steel Ltd. is designed to manage 10.75 million tons (MT) of raw materials annually to support the operations of the 3 MT steel plant. The system features an extensive 33 km conveyor network for efficient material transport. Key components include:
- 4 wagon tipplers for unloading raw materials seamlessly.
- 7 stackers cum reclaimers for efficient stacking and reclaiming operations.
- 1 slew stacker and 2 bridge-type barrel reclaimers to ensure uninterrupted handling of various raw materials.
This advanced system ensures a smooth and continuous supply of raw materials, optimizing plant operations and productivity.
Coke Oven
The Coke Oven Plant at NMDC Steel Ltd. is designed to convert metallurgical coal into coke, which serves as a crucial reducing agent for the Blast Furnace. The facility is equipped with two batteries, each comprising 67 ovens with a height of 7 meters, ensuring high-capacity production.
To enhance efficiency and environmental sustainability, the plant features two Coke Dry Cooling Plants for dry quenching. The combined annual production capacity of the two batteries is approximately 1.76 million tons (MT) of coke.
By-Product Plant
The By-Product Plant at NMDC Steel Ltd. is equipped to process 86,400 Nm³/hour of raw coke oven gas, enabling the recovery of essential by-products critical for industrial applications. Key outputs include:
- Crude Tar: Production capacity of up to 90,000 tons per year.
- Elemental Sulphur: Production capacity of up to 2,500 tons per year.
- Naphthalene: Production capacity of up to 380 tons per year.
This facility plays a crucial role in maximizing resource utilization and supporting sustainable operations by converting raw coke oven gas into valuable by-products.
Sinter Plant
The Sinter Plant at NMDC Steel Ltd. is equipped with a cutting-edge sinter machine featuring a 460 m² grate area, complemented by advanced service facilities to ensure seamless operations. This facility is designed to agglomerate iron ore fines, coal fines, fluxes, and other fine materials at high temperatures, resulting in a single porous mass known as sinter. The sinter serves as a vital feedstock for the Blast Furnace, playing a critical role in the steelmaking process.
With a gross production capacity of 4.73 million tons per annum (MTPA), the Sinter Plant ensures a reliable and efficient supply of high-quality sinter to support consistent steel production.
Blast Furnace
The Blast Furnace at NMDC Steel Ltd. is among the largest in India, with an impressive useful volume of 4,506 m³ and a production capacity of 3.32 million tons per annum (MTPA). It is a critical unit in the steelmaking process, where hot metal is produced through the reduction of raw materials, including iron ore, sinter, coke, and fluxes such as limestone and quartzite, at high temperatures.
The hot metal produced is directed to the pig casting machine for pig iron production or sent to the Steel Melting Shop (SMS) for further refinement into steel. Subsequently, the steel undergoes additional processing to produce high-quality Hot Rolled Coils (HRC), catering to diverse industrial requirements.
Steel Melting Shop (SMS)
The Steel Melting Shop (SMS) at NMDC Steel Ltd. is designed to produce 3 million tons per annum (MTPA) of liquid steel, equipped with advanced facilities to ensure high efficiency and precision in steelmaking. Key features of the SMS include:
- 2 x 175 t Hot Metal Desulphurization (HMD) units for sulfur removal from hot metal.
- 2 x 175 t Basic Oxygen Furnaces (BOFs) for primary steelmaking.
- 2 x 175 t Ladle Furnaces (LF) for refining steel and achieving precise chemical composition.
- 1 x 175 t RH-OB Degasser unit for degassing and producing high-grade steel products.
The SMS receives hot metal from the Blast Furnace via torpedo ladles and processes it into various grades of steel, catering to diverse industrial and customer requirements.
Thin Slab Caster (TSC)-Tunnel Furnace (TF) and Hot Strip Mill (HSM)
The Thin Slab Caster (TSC) at NMDC Steel Ltd. receives liquid steel from the Steel Melting Shop (SMS) and converts it into thin slabs through precision casting. The slabs have widths ranging from 900 mm to 1650 mm and thicknesses of 50 mm, 70 mm, and 90 mm.
Following the casting process, the slabs are fed into the Tunnel Furnace (TF), which serves a dual purpose:
- Heating the slabs to a uniform rolling temperature.
- Conveying the hot slabs to the Hot Strip Mill (HSM).
The HSM rolls the heated slabs into coils with thicknesses ranging from 1 mm to 16 mm, tailored to meet specific customer requirements. Additionally, the HSM is equipped with a shearing line capable of processing 400,000 tons per year, ensuring flexibility and high productivity.
Oxygen Plant
The Oxygen Plant at NMDC Steel Ltd. is equipped with advanced facilities to generate oxygen, nitrogen, and argon, essential for various operations within the steel plant. To meet these requirements efficiently, the plant features two air separation units, each with an oxygen production capacity of 1250 tons per day (t/d).
Power Blowing Station (PBS) & Turbo Blower
The Power Blowing Station (PBS) at NMDC Steel Ltd. is equipped with an in-house power generation unit to meet emergency power requirements. Key facilities include:
- 3 x 160 Tonne per Hour (TPH) multi-fuel gas-fired boilers for reliable and efficient power generation.
- 2 x 40 MW Steam Turbo Generators to ensure a steady and sufficient power supply during critical operations.
Water Intake System
The plant’s water requirements, estimated at 5,160 m³/hour, are met through an advanced water intake system. Raw water is sourced from the Sabari River, located approximately 33 km from the plant. The system includes:
- Two raw water storage reservoirs with a total capacity of 5 million m³, ensuring consistent supply.
- A design based on the principle of Zero Liquid Discharge (ZLD), incorporating water recycling to minimize environmental impact.
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