KSL 2.6.1 Utility Data R4

Kalyani Steels Ltd.
Media Consumption List - preliminary Date: 2014-14-08
Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH
Pressure: Heat
Medium: Oxygen Class: O2 at TOP1
1.60 MPa Quality 99.60 %
Size
60 t Steel Grade:
peak: Consumption for pipe dimension and buffer tank calculation daily avg: Consumption over 24 hours a day. TOP1: Next Column to consumer including connection to the manifolds
Dedinitions:
(consumer is 100% in operation) For generation plant calculation nearby of all consumers
Item tap to tap Heats Consumption TOP1 SMSD Process Department

No. Plant Media consumer time per Specific peak 1) daily avg.2) Dept Revision
Remarks P&ID No.
[minutes] day [Nm³/t] [Nm³/h] [Nm³/h] DN column level Name No. Date
1x BOF O2 Injection 40 36 49.4 14,400 4,446
1x AOD O2 Injection 69.5 20 7,200 1,700
2x LF Platform service 100 10
1x RH Oxygen Blowing 800 50
Multifunction lance 650 100

Vessel preheater 650 500
Total Platform Service -

420 150
General Purpose
1xBOF Included above - -
1xAOD Included above - -
2xLF Included above - -
1xRH Included above - -
Total: Oxygen 0.0 24,220 6,956
KSL_02_06_01_Utility_Data_R4_14082015 Page 1 of 14 The data provided above is confidential, preliminary and are subject to change during basic engineering.
Kalyani Steels Ltd.
Pressure: Heat
Medium: Nitrogen Class: N2 at TOP1
Size
60 t Steel Grade: 0
Dedinitions:

Remarks P&ID No.
40 36
1 x BOF Bottom purging 0.85 288 77
slag splashing 14,400 1,080 240 Nm3/min for 3 minutes
Slag Retaining Device 500 75 220 Nm3/min for 2 secs
MHS DRI Bin Fluidization 500 150
1 xAOD Nitrogen injection 69.5 20 3,600 1,212
2 x LF 4 x Ladle transer Car 250 140
1x RH Flooding 800 Supply to Buffer tank

Hydris 1
Lance Purging 120
1xGCP Expansion Tank 200 First fill - 200 Nm3/hr for filling
Emergency Flushing of Flare Stack 1 24,300 Consumption per emergency purging
200 Nm3 in 30 secs
HMD General service 1,500
Total: Nitrogen 46,459 2,734
Kalyani Steels Ltd.
Pressure: Heat
Medium: Nitrogen Class: N2 at TOP1
Size
60 t Steel Grade: 0
Dedinitions:

Remarks P&ID No.
1 x BOF Bottom Stirring valve station

Valve Station Lance 4,265 1,020
Lance dome, Chute sealing, Radar etc
1 X GCP Switch Over Station 2,220 1,000
Electrostatic Precipitator
Flow measurement behind ESP
ID Fan Shaft Sealing
1 x GCP Coarse dust disposal system 2,750 1,900
Fine dust disposal system
Ignition Device Control Cabinet
Make up water tank
1 x GRS Gas Cooler -1 400 400
Gas Holder Proper

1 x GCP 1,500 1,500
Common Gas Duct
Gas Export Station Gas Export Net work 1,500 400
Secondary Ventilation MHS (DRI) Cyclone Fluidisation 120 90
Total: Nitrogen 12,755 6,310
Kalyani Steels Ltd.

Pressure: Heat
Medium: Argon Class: AR at TOP1
Size
60 t Steel Grade: 0
Dedinitions:

Remarks P&ID No.
1 x BOF 40 36 0.80 288 77
1 xAOD 3,600 513
2 xLF 4 x Ladle transer Car 250 140
1x RH Lift gas 80 30
Lance purging 120
HMD Dry back up supply 100 For carbide safety
Total: Argon 4,438 760
Kalyani Steels Ltd.

Pressure: Atmos. dew point -40°C quality: as "Instrument Air"
Medium: Dry Compressed Air (IA) Class: CA at TOP1
0.60 MPa oil content < 20 ppm dust and oil free
peak: Consumption for pipe dimension calculation (consumer is 100% in daily avg: Consumption over 24 hours a day. TOP1: Next Column to consumer including connection to the manifolds
Dedinitions:
operation) For generation plant calculation nearby of all consumers

Remarks P&ID No.
40 36
1 x BOF Slag Retaining Device 45 9 1
Flaps & Gates, Bin vibrators, Actuator

MHS 190 55
valves etc
1 xAOD Service 100 40
2xLF Shrouding, cylinders, actuators 400 100

Service 100 40
Electrode nippling stand 100 10
1x RH Actuating Media 20 2
1 x HMD Actuating Media 20 2
For pneumaticaly actuated valves,

1 x GCP 10 10
dampers
Bag Filter Cleaning

Secondary Emission Silo Fludisation
Vent Silo BF Cleaning 3,700 2,450
Control System
Pneumatic Conveying System
Total: Dry Compressed Air (IA) 0.0 4,685 2,718
Kalyani Steels Ltd.

Pressure: Pressure. dew point 6°C quality: as "Instrument Air"
Medium: Compressed Air (plant Grade) Class: CA at TOP1
0.60 MPa oil content < 0,1mg/Nm³ dust and oil free
Dedinitions:

Remarks P&ID No.
40 36
1 x BOF CCTV, Camera Cooling/Purging 70 70 1
Ladle Gunning Machine
Converter Gunning Machine
Taphole drilling/ Converter Break out
1,110 38 KSL to check from the manufacturer
machine
Ladle Break out Machine
PSTS
1 X GCP Purging of Recovery duct

1,700 Only for Maintenance purpose
Gas Cooler outlet duct purging
Ladle Preparation Area

Converter Area
Charging Aisle
260 100
Desulphurisation Area
Slag yard Area
Lime Coating Facility
Total: Compressed Air (Plant Grade) 0.0 3,140 208
Kalyani Steels Ltd.
Pressure: net calorific

Medium: Steam Class: at TOP1
1.20 MPa
value
dry saturated
Dedinitions:

Remarks P&ID No.
[minutes] day [ t / h] [t/h] DN column level Name No. Date
40 36
1x RH Vacuum System 12.5 5
1 X GCP Gas Conditioning Tower Spray Nozzle

1.7 1
Cleaning of Ignition Burner Piping
Various purging points for Mixed Gas for

2.0
Ladle pre-heaters etc
Total: Steam 0.0 16 6
Kalyani Steels Ltd.

Medium: Coke Oven/Mixed Gas Class: at TOP1
0.12 bar
value
4000 Kcal/Nm3 Tar Content & Moisture<20ppm
Dedinitions:

Remarks P&ID No.
[minutes] day [ t / h] [t/h] DN column level Name No. Date
40 36
1 x GCP Flare Stack-1 ignition device (support fuel) 40 20
Ladle heater/dryer (Support fuel) 4,500 1,900 This data has to be checked
by KSL from the manufacturer
of Ladle Pre-heaters
Total: Coke Oven/Mixed Gas 0.0 4,540 1,920
Kalyani Steels Ltd.

Medium: LPG/Propane Class: Prop at TOP1
0.15 MPa
value
21000 kcal/Nm³ 0t
Dedinitions:

Remarks P&ID No.
[minutes] day [m³/h] [Nm³/h] DN column level Name No. Date
1 x GCP Flare Stack-1 ignition device (pilot burner) 40 20
Ladle Repair Area Major consumer will be the Ladle heaters.KSL

to check the consumption figures & required
Deslagging area pressure from the heater manufacturers.
Lance repair Area
General Purpose 500 170
Scrap Boxes & Transfer
Ladle heater/dryer for pilot ignition
BOF-1
1x RH Multifunction lance 100 15

Vessel preheater 100 77
Total: 0.0 740 282
Kalyani Steels Ltd.

Pressure:
Medium: DCW (Direct Cooling Water) Class: IW at TOP1
0,4 Mpa Quality IW "Industrial water Quality"
Dedinitions:

Remarks P&ID No.
6.15.2.6 [minutes] day [m³/t] [m³/h] [m³/h] DN column level Name No. Date
40 36
Lance Cooling Sec Circuit CT 16.0 6.0 The make up water requirement for the
Slag Cooling secondary circuit as indicated is tentative.
1 x BOF
Lime Coating 50.0 30 KSL to check this with the PHE Supplier and
IR Camera CT supplier
1 X GCP Gas Conditioning Tower-1 22.0 8
Gas Recovery Make up water to Cooling Tower for Gas 7.5 3 The make up water requirement for the
Cooler secondary circuit as indicated is tentative.
KSL to check this with the PHE Supplier and
CT supplier
Gas Holder Gas Holder Area 10.0 10
Gas Export Station Gas Export Station Network 30.0 20
Twin HMDS Service points to be fixed at a later stage
1x RH Condenser Water 600
Total: Direct Cooling Water 0.0 136 77.1
Kalyani Steels Ltd.

Pressure:
Medium: Soft Water Class: SO at TOP1
0,6 Mpa Quality SO "softened water Quality"
Dedinitions:

Remarks P&ID No.
40 36
1 X BOF Lance Cooling 10.0 3.75 Recirculation water -160 m3/hr ,CLS
Leakage / evaporation loss is very less and
Make up water requirement is less than 2
m3/hr. However, the peak quanity has been provi
initial filling purpose.
1 X GCP Skirt Hydraulic Cooling Recirculation water -800 m3/hr ,CLS
ID Fan Bearing Cooling 26.0 8.0 Peak flow is required for initial filling and
Hood & GCT top cone cooling evaporation losses due to steam formation
Gas Export Station 30.0 5.0

69.5 20
1 x AOD Lance cooling 5.0 1 Recirculation water -50 m3/hr ,CLS
Hood and Water Cooled duct cooling 25.0 14 Recirculation water -1350 m3/hr ,CLS
2 x LF Roof 4 Recirculation water -400 m3/hr ,CLS

Transformer 1 Recirculation water -60 m3/hr ,CLS
50
Live parts 2 Recirculation water -150 m3/hr ,CLS
Hydraulics 1 Recirculation water -70 m3/hr ,CLS
Emergency 400 - Emergency water -200 m3 ,CLS
1x RH Machine Cooling water 150

Emergency 80
1 x HMD Hydraulic cooling 20
Total: Soft Water 0.0 480 251
Kalyani Steels Ltd.

Pressure:
Medium: Service Water Class: SW at TOP1
Dedinitions:

Remarks P&ID No.
1 x BOF Service points To be fixed at a later stage
1 x AOD Service points To be fixed at a later stage
2 x LF Service points To be fixed at a later stage
1x RH Service points to be fixed at a later stage
1 x HMD Service points to be fixed at a later stage
Total: Service Water 0.0 0 0
Kalyani Steels Ltd.

Pressure:
Medium: Potable Water Class: PW at TOP1
0,5 Mpa Quality Drinking water
Dedinitions:

No. Plant Media consumer time per peak 1) daily avg.2) Dept Revision
Remarks P&ID No.
[minutes] day [m³/h] [m³/h] DN column level Name No. Date
1 x BOF
2xLF Emergency shower 3.0

Control room 1.0
1x RH Control room 0.5
Workshops, misc. 10
1 x HMD Control room 0.5
Total: Potable Water 0.0 15 0
Kalyani Steels Ltd.

Pressure:
Medium: Fire Fighting Water Class: IW at TOP1
Dedinitions:

Remarks P&ID No.
[minutes] day [m³/t] [m³/h] [m³/h] DN column level Name No. Date
Different places in SMP
Total: Fire Fighting Water 0.0

KSL 2.6.1 Utility Data R4

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Kalyani Steels Ltd.

Media Consumption List - preliminary Date: 2014-14-08

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1x BOF O2 Injection 40 36 49.4 14,400 4,446

1x AOD O2 Injection 69.5 20 7,200 1,700

2x LF Platform service 100 10

1x RH Oxygen Blowing 800 50

Multifunction lance 650 100

Total Platform Service -

Total: Oxygen 0.0 24,220 6,956

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

MHS DRI Bin Fluidization 500 150

1 xAOD Nitrogen injection 69.5 20 3,600 1,212

2 x LF 4 x Ladle transer Car 250 140

1x RH Flooding 800 Supply to Buffer tank

Total: Nitrogen 46,459 2,734

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1 x BOF Bottom Stirring valve station

1 X GCP Switch Over Station 2,220 1,000

1 x GRS Gas Cooler -1 400 400

Gas Holder Proper

Gas Export Station Gas Export Net work 1,500 400

Secondary Ventilation MHS (DRI) Cyclone Fluidisation 120 90

Total: Nitrogen 12,755 6,310

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1 x BOF 40 36 0.80 288 77

1 xAOD 3,600 513

2 xLF 4 x Ladle transer Car 250 140

HMD Dry back up supply 100 For carbide safety

Total: Argon 4,438 760

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

Flaps & Gates, Bin vibrators, Actuator

1 xAOD Service 100 40

2xLF Shrouding, cylinders, actuators 400 100

1 x HMD Actuating Media 20 2

For pneumaticaly actuated valves,

Bag Filter Cleaning

Total: Dry Compressed Air (IA) 0.0 4,685 2,718

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1 X GCP Purging of Recovery duct

Ladle Preparation Area

Total: Compressed Air (Plant Grade) 0.0 3,140 208

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Pressure: net calorific

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1x RH Vacuum System 12.5 5

1 X GCP Gas Conditioning Tower Spray Nozzle

Various purging points for Mixed Gas for

Total: Steam 0.0 16 6

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Pressure: net calorific

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1 x GCP Flare Stack-1 ignition device (support fuel) 40 20

Total: Coke Oven/Mixed Gas 0.0 4,540 1,920

Hospet, Karnataka Process Route: 1 BOF - 1 AOD - 2 LF - 1 RH

Item tap to tap Heats Consumption TOP1 SMSD Process Department

1 x GCP Flare Stack-1 ignition device (pilot burner) 40 20

Ladle Repair Area Major consumer will be the Ladle heaters.KSL