FERRO ELECTRICITY

Based in the eastern State of Orissa well known for its rich natural resources, IMFA is India's largest, fully integrated producer of Ferro Alloys with 157 MVA installed furnace capacity, a 108 MW coal-based Captive Power Plant and extensive Chrome Ore mining tracts. In October 2006, Indian Charge Chrome Ltd (ICCL; Estd: 1983) merged with IMFA to create a leader in the field of Ferro Alloys. Today, IMFA produces Ferro Chrome, Ferro Silicon, High Purity Ferro Silicon, and Ferro Silicon Magnesium for the domestic market as well as major international markets. IMFA is unique from a quality perspective in that it has multi-product & multi-location ISO 9001 certification covering the entire range of its activities. How it all began...

Therubali, in the erstwhile undivided Koraput district of Orissa was as remote a location as can be imagined. Other than a cluster of mud huts there was little else on offer for the local population which consisted almost exclusively of Adivasis (indigenous tribals). There was no infrastructure worth speaking off - even the most basic facilities such as potable water & electricity were not to be found and people watched trains whiz by since there was no traffic. While Orissa provided a steady stream of raw materials to industries based in neighbouring States and indeed all over the world there was very little that it received in return by way of employment generation or development. It all changed in 1962 when Dr Bansidhar Panda, an American educated research scientist, chose this remote area to be the cornerstone of his dream of an industrialised Orissa. Ably supported by his wife, the late Mrs Ila Panda, the dream has since turned into reality. Today's Therubali in the newly carved out Rayagada district is the envy of many who look to the bustling township with modern infrastructure and amenities as leading the drive for value addition and employment generation within the State.

IMFA's 108 MW coal-based Captive Power Plant is located in Choudwar across the banks of the Mahanadi river from the millennium city of Cuttack, Orissa's second largest city and erstwhile capital. The Power Plant not only meets the entire electricity requirements of IMFA's but also supplies to the state grid. By virtue of the Captive Power Plant, this foray also provided IMFA with a vital aspect of its much desired integration. Given the high cost of electricity prevalent today in India, one of IMFA's major strengths is the Captive Power Plant. The complex is also a self-contained township with residential colonies, schools, hospital, temple and gas station etc. Fact Sheet Manufacturing facilities:

108 MW coal-based power plant Products: Electricity Electricity is generated at 11 KV through two turbo alternating generator sets each of 54 MW capacity. Each turbine consists of a high pressure and a low pressure module coupled on either side of the generator through epicyclic gears. Steam required to drive the turbines is derived through a boiler plant comprising of 5 stoker fired boilers. Each boiler has a capacity of 97 tonnes/hour steam at a pressure of 68 kg/cm2 and temperature of 513 centigrade. An incremental expansion of power generating capacity by way of a 30 MW dual-fuel power plant has been finalised next to the existing power plant at Choudwar. The unit will operate on coal / coalwashery rejects besides utilising the furnace gas from the 48 MVA ferro chrome furnace which is presently being flared. Thus, the power which will be generated will be both cost-effective as well as environment friendly. Work is currently underway and the unit is expected to be commissioned by March 2010. IMFA has also firmed up plans to set up an additional 120 MW coal-based power plant (CPP) at Choudwar on land already available at its manufacturing complex. Financial closure has been achieved and the EPC contract has been awarded. As such, commercial operation is expected in the first quarter of 2012.

FERRO CHROME
IMFA's operation is located in Choudwar across the banks of the Mahanadi river from the millennium city of Cuttack, Orissa's second largest city and erstwhile capital. It houses a 48 MVA furnace dedicated in producing Ferro Chrome. This modern unit came about as a result of IMFA's major thrust on becoming a leading producer of Ferro Chrome which is a vital input in stainless steel production. The complex spread over 270 acres is also a self-contained township with residential colonies, schools, hospital, temple and gas station etc.

Fact Sheet Manufacturing facilities: 1 x 48 MVA submerged electric arc furnace Products: Ferro Chrome

Ferro Chrome is extensively used in the manufacture of superior alloys and stainless steel. In fact, it is the addition of chromium which gives essential characteristics to steel such as resistance to heat and corrosion. It is a strong carbide forming element and as such it is an important alloying element in tool and die steels including high speed steel. Ferro Chrome is produced by reducing Chrome Ore lumps and agglomerated fines known as briquettes in a submerged electric arc furnace by using carbonaceous reductants such as coke. The burden also comprises of fluxing material such as bauxite and quartz. The molten Ferro Chrome along with slag is tapped at certain regular intervals from the furnace hearth and is then cast into a casting bay. After it has cooled down the cakes are crushed, sized, screened and then stored in specific lots ready for despatch. Customers in the domestic and international markets include most of the well known names. The normal specifications are: 57 - 63% 4% max. 8% max. 0.03% max. 0.05% max. 0.04% max. 0.05% max. 10-100 mm 10-150 mm 90% min. 90% min.

Chromium (Cr) Silicon (Si) Carbon (C) Phosphorous (P) Sulphur (S) Size

(Bulk orders with other specifications as per customer's requirements can also be considered)