Mideast Integrated Steels Limited (MISL) was originally planned as an integrated steel plant of 1.5 million tonnes per annum of finished steel to be completed in discreet phases. MISL has two, 389 cubic meters blast furnaces supported by commensurate raw material handling system, power plant and blower house, power distribution system, plant water system and associated essential services have since been commissioned. The blast furnaces are operating on all ore burden with purchased coke producing about 1200 tonnes per day of hot metal (about 2.5% Si).
MISL estimates an output of about 700,000 tonnes of basic grade low silicon hot metal per year, from the two blast furnaces with 70 per cent sinter with balance sized ore feed in the burden.
Raw Materials Handling System
All raw materials are brought to the plant by road and unloaded either manually in designated areas in the open raw materials stock yard, or by a truck tippler installed at tail end of one of the yard conveyors. Two wagon tipplers were proposed to unload the incoming raw materials brought by rail, unfinished foundations of which exist. A mechanized raw material yard was planned with three stockpiles and two stacker-cum-reclaimers to store the incoming raw materials (both by rail and by road) and reclaim and distribute them to consuming units by belt conveyor. One stacker-cum-reclaimer with one yard conveyor is now in service to stack the material unloaded by truck tippler. Conveyor systems exist to transport raw materials from raw material yard to the stock houses of both the blast furnaces.
Iron Making
The plant has two operating blast furnaces of useful volumes 389 cubic meters each. The furnaces produce about 1,200 tonnes of hot metal per day operating with all ore burden and purchased coke. The output is sold as pig. Two 100 tph pig casting machines support the system. The blast furnaces are designed for 0.5 MPa top pressure. The stoves provided in each furnace are capable of delivering hot blast at 10000C. Gas cleaning is by adjustable venturi washer. Material charging is by skip car. Facilities for screening of sinter, coke and weighing of the feed materials are provided.
Plant Power Distribution
Power is received over 132 kV double circuit line from Old Duburi sub-station of OPTCL and terminated at MISL switchyard with double bus arrangement. The power limitation for each circuit is 80 MVA. Only one bus is in operation at present. MISL can import upto 3 MVA power from the grid as per present power purchase agreement.
Main HT power distribution in the plant is at 6.6 kV with Main Step Down Substation (MSDS) located adjacent to the 132 kV switchyard. 6.6 kV MSDS is having two bus sections, each feeding various plant local sub-stations. MISL generates about 3 NW power in its own BF gas based 2 x 4.5 MW captive power plant (CPP) and imports about 1.5 MW power from the grid. Existing CPP comprises three 50 tph boilers with BF gas heating and liquid fuel support for generation of steam to run Turbo-Blowers TB-1, TB-2 and TB-3 (one standby) and 4.5 MW Turbo-Generators TG-1 and TG-2 (one of the generators serve as standby at present). The Turbo-Generators (TG-1 and TG-2) feed the 6.6 kV CPP sub-station which in turn is connected to the MSDS.
Plant Water System
Raw make-up water is presently available at plant site through the existing 800 mm diameter, 17 Km long, 1600 m3 per hour capacity cross-country line from IDCO intake pump house on river Brahmani. The plant raw water reservoir capacity is about 120,000 m3. The plant water system comprises raw water treatment plant, water systems pertaining to BF-1 and BF-2, water system for slag granulation for BF-1 and BF-2, water system for CPP and drinking water system. One 150 m3 per day demin plant is also in operation.
Auxiliary facilities
The plant has adequate covered space for central stores, central maintenance shop and laboratory to cater to its existing requirement.
Roads and Drainage
The plant has a regular network of roads, partly metalled. The plant drainage system is partly in place.
Rail Yard
MISL have already obtained approval from railways for an in-plant railway yard along with its connection with the east coast railway track near Sukinda Road. This yard will be connected with the east coast railway between Jakhapura and Sukinda Road stations, near the south eastern boundary of the plant. This would enable the plant to receive majority of the raw materials by rail.
