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ACNielsen ORG-MARG
Situation Analysis for SME
Sector
Submitted to TERI
By
Orissa Cluster
ACNielsen ORG-MARG
SUMMARY OF FINDINGS
• There are approximately 45 units in this cluster who are engaged in manufacturing
of Sponge Iron.
➢ PRODUCTION:
Annual Production (In Tonnes)
7
9 9
5 5
6
2
3
4
3
4
3
6
4
1
8
1011
0
2
4
6
8
10
12
2005-06 2006-07 2007-08
Upto 20000 Tonnes 20000 to 40000 Tonnes 40000 to 60000 Tonnes
60000 to 80000 Tonnes 80000 to 100000 Tonnes 100000 to 150000 Tonnes
Above 150000 Tonnes
ACNielsen ORG-MARG
➢ ENERGY REQUIREMENTS
• CUMULATIVE FUEL USAGE
Qty consumer per
annum
Number of Units using
the fuel
Electricity 40038000 Units 41
Coal / Hard Coke 3781560 Tonnes 43
HSD 644000 Liters 39
• USAGE OF ELECTRICITY (IN UNITS CONSUMED PER ANNUM)
Usage of Electricity (In Units consumed per annum)
15%
12%
20%
26%
15%
12% Upto 100000 Units
100000 to 500000 Units
500000 to 1000000 Units
1000000 to 1500000 Units
1500000 to 2000000 Units
Above 2000000 Units
• USAGE OF COAL (IN TONNES PER ANNUM)
ACNielsen ORG-MARG
Usage of Coal (In Tonnes per annum)
12%
5%
9%
37%
14%
9%
14%
Upto 10000 Tonnes
10000 to 25000 Tonnes
25000 to 50000 Tonnes
50000 to 75000 Tonnes
75000 to 100000 Tonnes
100000 to 200000 Tonnes
Above 200000 Tonnes
• USAGE OF HSD (IN LITERS PER ANNUM)
Usage of HSD (In Liters per annum)
30%
18%
26%
13%
13%
Upto 5000 Liters
5000 to 10000 Liters
10000 to 20000 Liters
20000 to 30000 Liters
Above 30000 Liters
ACNielsen ORG-MARG
➢ RAW MATERIAL REQUIREMENT
• CUMULATIVE RAW MATERIAL USAGE
ACNielsen ORG-MARG
Qty consumer per
annum
Number of Units using the raw
material
Iron Ore 3837000 Tonnes 26
• USAGE OF IRON ORE (IN TONNES PER ANNUM)
Usage of Iron Ore (In Tonnes per annum)
4%
19%
23%
12%19%
23%
Upto 50000 Tonnes
50000 to 100000 Tonnes
100000 to 150000 Tonnes
150000 to 200000 Tonnes
200000 to 300000 Tonnes
Above 300000 Tonnes
ACNielsen ORG-MARG
FIELD OBSERVATIONS
✓ As per the field findings this cluster is not an SME cluster as the plant & machinery
cost is more than Rs. 20 crs.
✓ In Mayurbhanj, Keonjhar and Sundergarh around 130 sponge iron
factories were functioning, of which over 50% were illegal. Many are operating
even without NOCs. Clearnance procedures and Public hearings are unheard of
here and inspite of this in the past two years people have managed to get almost 6
plants to withdraw or stop construction in Sundergarh. The main reason cited by
the people for opposition has been the large-scale air and water pollution, which
had started affecting not only their health but also that of their livestock, agriculture
and land.
✓ Sponge iron also known as direct reduced iron is extracted from iron ore
and is used in the making of steel
✓ In Orissa the most affected district is Sundergarh where almost 50 of these
plants are situated. The district inspite of being a Schedule V area is facing a
situation where land is being transferred to these companies without NoCs from
the Gram Sabha
✓ These units are dependant on National Mineral Development Corporation
(NMDC) and private miners for iron ore
✓ Sponge iron is used for making long steel products such as ingots and
billets.
✓ In sundergar district 16 nos, In Keonjhar district 14 nos, Jharsuguda District
11 nos & in Jajpur district 4 nos.
✓ All the sponge iron units are mechanized in nature and are in operation
since last 7/8 years, there are some units, which have started very recently - 2
years back.
✓ The units are using technology sourced from Lurgi.
✓ All the units are running continuously for 3 shifts and are sourcing power
from the grid @ 3.90/- per unit, having HT connections. Some units have CPP.
✓ If a plant has a total annual production capacity of 6.9 million ton, it requires
about 17 million-ton iron ore and 13 million ton of coal.
✓ The sponge iron units have an high energy cost of 30 to 35% and the raw
material cost is 60%t of total production cost
ACNielsen ORG-MARG
Electricity
❖ Electricity supply by North Eastern Electricity supply company of Orissa ltd,
Corporate office, Januganj, Balasore,Ph- 06782-269864
❖ Western Electricity supply company of Orissa Ltd, corporate office- Burla,
Sambalpur, Orissa, Ph-0663-2430892, 2430895
❖ Power getting from grid, duration of electricity20 to 22 hr regularly
Equipments
➢ Induction furnace – 15 ton
➢ Crusher (Coal crusher, iron crusher & slag crusher)
➢ Sponge iron kiln – 350 to 400 tpd
➢ Motor
➢ Conveyors
Process
• Fe2O3 Fe3O4 FeO Fe
Raw material mixed (Iron ore, Dolomite & limestone + coal)
Magnetic separator
Screen Cooling to
atmospheric
condition
Feeding in Kiln Induction furnace (Temp required 750oC to 1050oC) & prs of 1 to 2 bars.
Waste through
conveyor
ACNielsen ORG-MARG
• For rolling process temperature required 900oC to 1100oC & Prs
required 7 kg to 14 kg CM2
Final
Product
ACNielsen ORG-MARG
ACNielsen ORG-MARG
Mines
Iron OreYard
ACNielsen ORG-MARG
Coal yard
Sponge iron plant
ACNielsen ORG-MARG
Kiln
Sponge iron
ACNielsen ORG-MARG
SERVICE PROVIDER
Raw material supplier (Coal)
❖ Mahanadi Coal field ltd, Brajraj nagar, Orissa
❖ Basundhara Coal Field ltd, Talcher, Orissa
❖ Global Coal & Mining pvt. Ltd, Belpahar
❖ Bhatia International Ltd, Belpahar
Raw material supplier ( Iron ore)
❖ Rungta Mines, Barbil, Orissa
❖ Sirajudhin Minerals, Barbil, Orissa
❖ Essel Pvt. Ltd, Joda, Orissa
❖ East India Pvt. Ltd, Orissa
❖ S.Lal & co ltd, Barbil
HSD (Indian Oil, Bharat Petrolium)
Equipment suppler
Hari Machines Ltd
Rajgangpur,
Orissa,
Ph-06624-220141/161
B.K. Engineering
Bhilai,
Chhatisgarh
Venus Control, Noida (U.P)
Ucan, Mumbai
Elgpa Eng. Ltd, Hyderabad
ACNielsen ORG-MARG
Ashok Technologies
A – 15, Maypuri Industrial Area,Phase – 1, New Delhi – 110064,
Ph-011-28115308, 228116570
Association
Orissa Sponge Iron Manufacturers’ Association.
Palash Palli,
Bhubaneswar-751020
Ph-0674-2594875 (Mr. G.S. Agarwal)
ACNielsen ORG-MARG
Bankers
✓ All the units are associated with the baks for CC limits.
o IDBI
o State bank of India, Jajpur road, Orissa
o Canara bank, Jajpur, Orissa
o United bank of India
o Bank of Baroda, KEONJHAR,ORISSA-758001
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