form-1environmentclearance.nic.in/writereaddata/...1a&2c, redifice signature, no 6, hospital...
Post on 05-Aug-2020
7 Views
Preview:
TRANSCRIPT
FORM-1
On
PROPOSED EXPANSION OF EXISTING FERRO ALLOYPLANT TO 1.0 MTPA INTEGRATED STEEL PLANT COMPRIS-ING OF SINTER PLANT, BLAST FURNACE, PIG CASTING MA-
CHINE, COKE OVEN PLANT, ROLLING REBAR MILL , OXY-GEN PLANT & WHRB
OF
M/s. THE SANDUR MANGANESE & IRON ORES LTD.AT DANAPUR, DANAYAKANKERE & HANUMANHALLI
VILLAGES, HOSPET, BELLARY DISTRICT, KARNATAKA
Prepared by:- DECEMBER 2016
VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)
Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594
E-mail-visiontekin@yahoo.co.in , visiontekin@gmail.comVisit us at - www.vcspl.org
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 1Visiontek Consultancy Services Private Limited
APPLICATION FORM-1(AS PER EIA NOTIFICATION 2006 & REVISIONS THEREOF)
(I) Basic Information
SerialNumber
Item Details
1. Name of the project/s
Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA
Integrated Steel Plant in 3 Phases comprising of Sinter Plant, Blast
Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen
Plant and WHRB.
2. Sl. No. in the schedule 3(a)
3. Proposedcapacity/area/length/tonnage to behandled/commandarea/lease area/numberof wells to be drilled
Proposed production:
1.0 MTPA Steel
Plant Area: 320.79 acres (129.81 Ha.).
The expansion is within the existing plant premises.
Proposed configuration:
Sl.No.
Plant/Unit Name
ConfigurationFinal
AnnualProduct
ion
FinalCapac
ityin
MTPA
Phase-I Phase-II
PhaseIII
1Blast
Furnace
1x0.4MTP
A BF( Size350-
400m3 )~
1212.12TPD
-
1x0.4MTPA BF( Size350-
400m3)~
1212.12 TPD
2 x400000
TPA
0.800
PigCastingMachine
1212.12TPD
- -1 x
400,000TPA
0.400
2
CokeOven
Plant andWHRB
0.4MTPA~
1212.12TPD
- -1 x
400,000TPA
0.400
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 2Visiontek Consultancy Services Private Limited
WHRB-
130TPH
SteamGenerat
ion
3SinterPlant
1 x 50m²
~1600TPD
-
1 x 50m²
~1600TPD
2 x528,000
TPA
1.056
4
EnergyOptimiza
tionFurnace(EOF)
-
1 X50 T
~1602
TPD
1 X 50T
~1602TPD
2 x528,710
TPA
1.057
5
LadleRefiningFurnace (LRF) &VacuumDegasser
(VD)
-
1 X50 T~160
2TPD
1 X 50T
~1602TPD
2 x528,710
TPA
1.057
6
Continuous
Castingmachine(CCM)
-
1 X4
Strand
9/16m
radius
~1570
TPD
1 X 4Strand9/16 mradius~1570TPD
2 x518,135
TPA
1.036
7Rolling(RebarMill)
-
1 X100TPH~151
5TPD
1 X100TPH
~1515TPD
2 x500,000
TPA
1.0
8Oxygen
Plant1 X 100
TPD
1 X350TPD
--
1 x33000
TPA + 1X
-
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 3Visiontek Consultancy Services Private Limited
115500TPA
Maximum No. of Working Days considered for all units - 330
4.New/Expansion/Modernization
Expansion units will be installed in the existing Ferro Alloy Plant
5.Existing capacity/areaetc.
Sl. No. Description Existing capacity(MTPA)
1
Ferro AlloyPlant havingthree submergedarc furnaces
55 MVA(20MVA-02No’s., 15MVA-01No.)
2 Sinter plant 1.5 MT
3coal basedcaptive powerplant
32 MW
4Manganese OreBeneficiationPlant
2 tph
6. Category of the projecti.e. ‘A’ or ‘B’
A
7.Does it attract thegeneral condition? Ifyes, please specify.
No.
8.Does it attract thespecific condition? Ifyes, please specify.
No.
9.
Location
Plot/Survey/KhasraNo.
SurveyNos.2/1C/2,2/1C/3,3/3B,4/2C/2,65,Partsof66(A,A2,A3&B),72,73,74,75,76,77,78,79,80,81,144,145,146,147,148,411/A1/a-15,411/1A/a16,415/E/2,417/A/1,563,564,565,567,590, 591&592 of Danapurvillage546,547,548,549,552&552A/1of Danayakanakere village
Village Danapur & Danayakanakere villages
TehsilDanapur Panchayath, MMHalli , Hobli, HospetTaluk
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 4Visiontek Consultancy Services Private Limited
District Bellary
State Karnataka
10.Nearest railwaystation/airport alongwith distance in kms.
Vyasankere–3.6KmsVyasaColonyCrossOverStation–300m-E HubliAirport(Operational)–150Kms
11.
Nearest town, city,District Headquartersalong with distance inKms.
Hospet-7.1km–N(15Kmbyroad) Bellary -58km–E(75Kmbyroad)
12.
Village Panchayats,Zilla Parishad,Municipal Corporation,Local body (completepostal address withtelephone nos. to begiven)
Danapur Panchayath, MMHalli, Hobli, HospetTaluk, Bellary District
13. Name of the applicant M/s.The Sandur Manganese & Iron Ores Limited
14. Registered AddressLakshmipur, Sandur, Bellary District, Pin–583119,KarnatakaState
15.
Address forcorrespondence:
Name ShriA.G.Suresh
Designation(Owner/Partner/CEO)
Director(Projects)
Address
1A&2C, Redifice Signature, No 6 , Hosp i t a lRoa d , Sh iva j i Na ga r , Bengaluru, Karnataka.
Pin Code 560001
E-mail suresh@sandurgroup.com
Telephone No. (080)41520176-80
Fax No. (080)41520182
16.
Details of AlternativeSites examined, if any.
Location of these sitesshould be shown on atopo sheet.
Coke plant will be within the existing Plant premises. All otherunits shall be installed adjacent area to the existing plant
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 5Visiontek Consultancy Services Private Limited
17. Interlinked Projects No.
18.
Whether separateapplication ofinterlinked project hasbeen submitted?
Not Applicable
19.If yes, date ofsubmission
Not Applicable
20. If no, reason. Not Applicable
21.
Whether the proposalinvolves approval/clearance under: ifyes, details of the sameand their status to begiven.
(a) The forest(Conservation)Act, 1980?
(b) The wildlife(Protection)Act, 1972?
(c) The C.R.Z.Notification,1991?
Not Applicable
22.
Whether there is anyGovernmentOrder/Policy relevant/relating to the site?
No
23.Forest land involved(hectares). No
24.
Whether there is anylitigation pendingagainst the projectand/or land in whichthe project is proposedto be set up?
(a) Name of theCourt
No
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 6Visiontek Consultancy Services Private Limited
(b) Case No.(c) Orders/directio
ns of the Court,if any and itsrelevance withthe proposedproject.
25. Expected Project Cost Rs.5300 Crore
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions,which willcause physical changes in the locality (topography, land use, changes in water bodies, etc.)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities /rates,wherever possible) with source of information data
1.1 Permanent ortemporary change inland use, land cover ortopography includingincrease in intensityof land use (withrespect to local landuse plan).
No. Land Use of the Project Site:
The land proposed to be utilized for the Expansion is underthe premises and complete land of 320.79 acres (129.81Ha.) is Industrial Land.
Land utilization pattern of the proposed site is given below:
Area of 33% land out of 320.79 Acres (129.81 Ha.) isdedicated for Green Belt development.
1.2 Clearance of existingland, vegetation andbuildings?
No Existing clearing of vegetation shall be kept to minimumwhile planning the layout.
1.3 Creation of new landuses?
Yes Industrial setup for 1.0 MTPA Integrated Steel Plant alongwith other auxiliary facilities.
1.4 Pre-constructioninvestigations e.g.bore holes, soiltesting?
Yes Soil testing shall be carried out for design of civil structuresat adequate locations within the proposed site. This shall becarried out at the time of detailed engineering on receipt ofenvironment clearance.
1.5 Construction works? Yes Required for erection of the plant & machinery duringinstallation process, roads, storage sheds etc.
1.6 Demolition works? No No demolition work is envisaged.
1.7 Temporary sites usedfor construction worksorhousing ofconstruction workers?
No All the workers will be engaged from the nearby villages.
Executive and technical staff shall be accommodated in theexisting guest house of SMIORE.
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 7Visiontek Consultancy Services Private Limited
1.8 Above groundbuildings, structuresorearthworksincluding linearstructures, cut and fillor excavations
Yes Most of the structures shall be located above the ground.
1.9 Underground worksincluding mining ortunneling?
Yes An underpass shall be constructed to cross the
existing railway line.
1.10 Reclamation works? No Not Applicable
1.11 Dredging? No Not Applicable
1.12 Offshore structures? No Not Applicable
1.13 Production andmanufacturingprocesses?
The process steps
1. Blast Furnace (BF)
- Iron ore, coke and limestone are charged by a skip ordirectly through conveyor from top of the furnaceusing devices like two bell system with or withoutmovable throat armour or bell less top for burdendistribution.
- Preheated air is blown from near the bottom throughtuyers close to the junction of the hearth and bosh.Combustion of coke in front of tuyers generates heat andreducing gases. The ascending gases carry thisthermal energy and transfer the same to the descendingburden resulting in reduction of iron ore to iron. The ironin liquid state with nearly four percent (4%) carbon iscollected at the bottom of furnace.
2. Sinter Plant
- The process starts from receiving of fuel, flux and iron-bearing material to finished sintering ore out of the plant,including raw material and fuel receiving, fuel crushing,flux crushing and screening, proportioning, mixing,balling, distributing, igniting, sintering, hot orecrushing, screening and cooling as well as transferringof finished sinter ore out of the plant.
- Returned sinter and dust during production is sent back tothe process directly in order to protect environment frompollution. Furthermore, facilities of exhausting,dedusting, dust discharging and silencing, can makeenvironment well protected.
3. Cooking process
- This process production facilities consist of coalpreparation plant, coke making plant, coke screening
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 8Visiontek Consultancy Services Private Limited
plant and boiler & desulphurization plant and powergeneration unit.
- The coking plant consists of 2 batteries with 56ovenseach. Its coke yield will be 0.4MTPA
4. Power Plant
- Blast furnace exhaust gas and flue gases from cokeovens are fed to waste heat recovery boiler wherethe hot gases convert the water in the circulatingtubes into super-heated steam at high pressure. Thissuper-heated high pressure steam is sent to turbineswhereby the turbine is rotated and power is generated.
- Coal based power plant is based on Rankinecycle.
1.14 Facilities for storageof goods or materials?
Yes Iron Ore lumps, Iron Ore Fines, Coke or Coking Coal andFluxes (Limestone & Dolomite) will be stored in sheds
1.15 Facilities fortreatment or disposalof solid waste orliquid effluents?
Yes
Solid WasteSource Quantity
(TPA)Disposal
Blast furnaceslag
Will be sold to cementplant
SMS slag Used as road ballast orgeneral land fill material
Waste water generated from the different areas of the plantwill be treated to the desired extent in suitable treatmentfacilities and recycled back to the process, as far aspracticable.
NOT REQUIRED AS THERE IS NO BY PRODUCTPLANT
1.16 Facilities for longterm housing ofoperational workers?
Yes A self contained township to house the employees and theirfamilies of the proposed plant is envisaged outside theplant boundary. Development will be ensuring thehigh qualities of functionality and attractiveness, throughthe fulfillment of needs of the users with safety andamenity.
As per man power requirement of the plant, thecategorized manpower on payroll shall be 898.Considering 100% satisfaction level for housing provision898 families in different categories will be housed inthe proposed township. Housing density of 75 families /hectare has been considered according to “GroupHousing” norm of “UDPFI Guidelines”. Thus the landrequirement shall be 12 hectares.
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 9Visiontek Consultancy Services Private Limited
1.17 New road, rail or seatraffic duringconstruction oroperation?
No Existing facility shall be utilized.
1.18 New road, rail, airwaterborne or othertransportinfrastructureincluding new oraltered routes andstations, ports, airportsetc?
No. Not applicable.
1.19 Closure or diversionof existing transportroutes or infrastructureleading to changes intraffic movements?
No. Not applicable.
1.20 New or divertedtransmission lines orpipelines?
No. Not applicable.
1.21 Impoundment,damming, culverting,realignment or otherchanges to thehydrology ofwatercourses oraquifers?
No. Not applicable.
1.22 Stream crossings? No. Not applicable.
1.23 Abstraction ortransfers of waterform ground orsurface waters?
Yes Requirement for the proposed plant shall be 685 cu m perhour out of which 25 cu m shall be soft water. Thus, rawwater at the rate of 685 cu m per hour shall have to bedrawn from Tungabhadra dam & bore wells.
Tungabhadra (TB) division Munirabad has sanctionedpumping of 185 m3/hr raw water from Tungabhadrareservoir. SMIORE’s application for enhancement of400 m3/hr is under active consideration. Also, withdrawalfrom bore wells of 208 m3/hr has been assured. Hence,from both the water sources a total of 600 m3/hr raw waterwill be made available for the proposed plant.
1.24 Changes in waterbodies or the landsurface affecting
No Not applicable.
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 10Visiontek Consultancy Services Private Limited
2. Use of Natural resources for construction or operation of the Project (such as land, water,materials or energy, especially any resources which are non-renewable or in short supply):
Sl.No. Information/checklistconfirmation
Yes/No Details thereof (with approximate quantities /rates,wherever possible) with source of information data
2.1 Land especiallyundeveloped oragricultural land (ha)
Yes The whole land is of Industrial type, with mostlyundeveloped barren nature.
2.2 Water (expected source& competing users) unit:KLD
Yes Water requirement for integrated steel plant andcaptive power plant is estimated to be about 16440KLD. This requirement will be met from water
drainage or run-off?
1.25 Transport ofpersonnel ormaterials forconstruction,operation ordecommissioning?
Yes Transportation of personnel and materials will be inevitableduring construction and operation phase of the project.
Transportation of personnel will be done through officevehicles and materials will be carried out by closedcontainerized trucks.
The finished product will be transported by road/rail.
1.26 Long-termdismantling ordecommissioning orrestoration works?
No Not applicable.
1.27 Ongoing activityduringdecommissioningwhich could have animpact on theenvironment?
No Not applicable.
1.28 Influx of people toan area in eithertemporarily orpermanently?
Yes Workers will be employed from the local area only.
1.29 Introduction of alienspecies?
No Not applicable.
1.30 Loss of native speciesor genetic diversity?
No Not applicable.
1.31 Any other actions? No Not applicable.
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 11Visiontek Consultancy Services Private Limited
allocated from Tungabhadra Reservoir by TB DivisionMunirabad.
2.3 Minerals (MT) Yes Iron ore, limestone, dolomite, manganese Forproduction of hot metal
2.4 Construction material –stone, aggregates, sand /soil (expected source –
MT)
Yes Civil construction materials like stone, cement,concrete, sand, iron rods etc. shall be required and itwill be estimated during the detailed engineering andshall be procured from local area.
2.5 Forests and timber(source – MT)
No Not Applicable
2.6 Energy including elec-tricity & fuels (source,competing users) Unit:fuel (MT), energy (MW)
Yes The Total power requirement for the proposed 1.00MTPA Integrated steel plant comprising of CokeOvens, Sinter Plant, Blast Furnace, Steel Melt Shopand Continuous Caster as the main units is estimated tobe about 92 MW.
Sources :
Sent out power from Coal based Power
Plant - 32 MW
Balance to be drawn from Karnataka Powertransmission Corporation Limited (KPTCL).
2.7 Any other naturalresources (useappropriate standardunits)
No Not Applicable.
3. Use, storage, transport, handling or production of substances or materials, which could beharmful to human health or the environment or raise concerns about actual or perceivedrisks to human health.
S.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data
3.1 Use of substances or materials,which are hazardous (as perMSIHC rules) to human health
No Not Applicable
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 12Visiontek Consultancy Services Private Limited
or the environment (flora,fauna, andwater supplies)
3.2 Changes in occurrence ofdisease or affect diseasevectors (e.g. insect or waterborne diseases)
No Not Applicable.
3.3 Affect the welfare of peoplee.g. by changing livingconditions?
Yes. Direct and indirect benefits for the localpeople will have better bearing on the livingcondition of people.
3.4 Vulnerable groups of peoplewho could be affected by theproject e.g. hospital patients,children, the elderly etc.
No Not envisaged.
3.5 Any other causes No Not envisaged
4. Production of solid wastes during construction or operation or decommissioning(MT/month)
Sl.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data
4.1 Soil, overburden or minewastes
Yes. The solid by-products produced due to theproposed plant will be BF-slag, steel meltshop (SMS) slag, flue dusts, effluenttreatment plant sludge, caster scrap, fly ash,bottom ash and mill scales etc. Flue dust,product fines, raw material fines etc will beutilized in the process, i.e. in the sinter plant.Mill scale would be utilized in sinter plantafter de-oiling the same to prevent damage toESPs in the sinter plant and to minimizegeneration of PCDD/F.
BF slag would be granulated and sold tocement plants. The SMS slag will beprocessed for metal recovery for partrecycling in the Sinter Plant, BOF and BF.Fly ash collected from ESP hoppers of thecaptive power plant shall be collected in drycondition for supply to cement and brickmanufacturers or used for land filling.
An additional land of 149 acres outside theplant vicinity (falling under the jurisdiction of
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 13Visiontek Consultancy Services Private Limited
Danayakankere village) is being procured fordumping slag.
Bottom ash would be collected for future usein land reclamation, road construction etc
4.2 Municipal waste (domesticand or commercial wastes)
Yes A fully fledged Sewage treatment plant willbe provided for treating wastewatergenerated from the plant and township
4.3 Hazardous wastes (as perHazardous Waste ManagementRules)
Yes During Construction Phase
Recyclable
Used batteries
Waste metal from welding and cuttingDuring Operation Phase
Recyclable
Used Batteries
Containers of hazardous materials (viz. oildrums, chemical drums)
4.4 Other industrial process wastes Yes Blast furnace flue gas, Hot gases from BOFetc.
4.5 Surplus product No No surplus product is envisaged.
4.6 Sewage sludge or other sludgefrom effluent treatment
Yes A fully fledged Sewage treatment plant willbe provided for treating wastewater generatedfrom the plant and township. Sludgegenerated will be dried and used as manure.Sludge resulting from neutralization of boilerblow down, Water treatment plant back washshall be disposed as per KSPCB guidelinesappropriately.
4.7 Construction or demolitionwastes
Yes Negligible quantity of top soil will beexcavated for construction, which shall beutilized for greenbelt development. Wastesteel – shall be sold to recyclers. Wastecement plaster & waste cement concrete– shall be used for making base layer forroads within premises.
4.8 Redundant machinery orequipment
No Not Applicable
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 14Visiontek Consultancy Services Private Limited
4.9 Contaminated soils or othermaterials
No Not Applicable
4.10 Agricultural wastes No Not Applicable.
4.11 Other solid wastes Yes Organic waste generated from canteen shallbe composted and will be used as manure.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data
5.1 Emissions from combustionof fossil fuels fromstationary or mobile sources
Yes Source PollutantsCoke Oven plant SO2,NOx,COBOF, EAF and ladleFurnace
SO2, NOx, CO
5.2 Emissions from productionprocesses
Yes Particulate matter, SO2 and NOx, CO,Iron Oxide, etc
5.3 Emissions from materialshandling including storageor transport
Yes Fugitive Dust
5.4 Emissions from constructionactivities including plant andequipment
Yes From all combined sources in plant, theambient air quality (24 hrs) will be asfollows:
o PM10< 100 µg/m3
o PM2.5< 60 µg/m3
o SO2< 80 µg/m3
o NOx < 80 µg/m3
5.5 Dust or odours fromhandling of materialsincluding constructionmaterials, sewage and waste
No Fugitive dust
5.6 Emissions from incinerationof waste
No No Incineration of waste is involved
5.7 Emissions from burning ofwaste in open air (e.g. slashmaterials, constructiondebris)
No Not Applicable
5.8 Emissions from any othersources
No Dust will rise during demolition.
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 15Visiontek Consultancy Services Private Limited
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data with source ofinformation data
6.1 From operation of equipmente.g. engines, ventilation plant,crushers
Yes Cumulative noise shall be < 75 dB(A)within the project boundary and
Heat shall be emitted near the tap holearea of SMS, during tapping, which willbe taken care providing heat resistantaprons and working hours of theworkers will be inter-changed.
6.2 From industrial or similarprocesses
Yes Cumulative noise shall be <75 dB (A) at theboundary of the plant.
6.3 From construction ordemolition
Yes Maximum cumulative noise shall vary from70 to 75 dB(A) at the construction site.
6.4 From blasting or piling No There is no blasting or piling activity relatedto the erection & commissioning of Plant.
6.5 From construction oroperational traffic
Yes Noise levels from constructionequipment for very short duration.
6.6 From lighting or coolingsystems
No Not applicable
6.7 From any other sources No Not applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or intosewers, surface waters, groundwater, coastal waters or the sea:
S.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible)with source of information data
7.1 From handling, storage, use orspillage of hazardous materials
No Not Applicable
7.2 From discharge of sewage or othereffluents to water or the land(expected mode and place ofdischarge)
No Not Applicable
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 16Visiontek Consultancy Services Private Limited
7.3 By deposition of pollutants emittedto air into the land or into water
Yes Air emissions shall be maintainedwithin the standard stipulated byKSPCB.
7.4 From any other sources No Not applicable.
7.5 Is there a risk of long term build upof pollutants in the environmentfrom these sources?
No Proper management plan shall beimplemented to maintain the risk at theminimum.
8. Risk of accidents during construction or operation of the Project, which could affect humanhealth or the environment
Sl.No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data
8.1 From explosions, spillages,fires etc. from storage,handling, use or production ofhazardous substances
Yes Risk assessment and appropriate safety measureswill be taken as per OSHA Standards, incongruence with Inspector of Factory & BoilersGuidelines.
8.2 From any other causes Yes Due to mishandling ofmachinery/equipment and falling fromheight during construction and operationphase.
Heat exposure around furnace area. Electrical hazards
8.3 Could the project be affectedby natural disasters causingenvironmental damage (e.g.Floods, earthquakes,landslides, cloudburst etc)?
No Not applicable
9. Factors which should be considered (such as consequential development) which could leadto environmental effects or the potential for cumulative impacts with other existing orplanned activities in the locality
Sl. No. Information/Checklistconfirmation
Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data
9.1 Lead to development ofsupporting facilities, ancillarydevelopment ordevelopmentstimulated by theproject which could haveimpact on the environment
Yes
Shall be carried out to fulfill the requirementof project, if any and facilities shall beextended to public to the possible extent.Proposed project shall provide direct andindirect employment and businessopportunities to locals. This in turn shall
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 17Visiontek Consultancy Services Private Limited
e.g.:• Supporting infrastructure(roads, power supply, wasteor waste water treatment,etc.)• housing development• extractive industries• supply industries• other
increase per capita income.
9.2 Lead to after-use of the site,which could havean impacton the environment
Yes An aesthetic, pleasant environment withlush greenery and greenbelt will bedeveloped in the plant.
9.3 Set a precedent for laterdevelopments
Yes Implementation of Proposed projectshall support the other industrial &social developments in the region.
Proposed project shall provide directand indirect employment and businessopportunities to locals.
9.4 Have cumulative effects dueto proximity to other existingor planned projects withsimilar effects.
No None
(III) Environmental SensitivityThe 15km radius topographical location map is enclosed as Annexure-I.
Sl.No.
Areas Name/Identity
Aerial distance (within 15km.)Proposed project locationboundary
1 Areas protected underinternational conventions,national or local legislation fortheir ecological, landscape,cultural or other related value
Not applicable Notapplicable
2 Areas which are important orsensitive for ecological reasons– Wetlands, watercourses orother water bodies, coastalzone, biospheres, mountains,forests
Back water ofTungabhadra (TB)dam
2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance
3 Areas used by protected, Not applicable Not applicable
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 18Visiontek Consultancy Services Private Limited
Sl.No.
Areas Name/Identity
Aerial distance (within 15km.)Proposed project locationboundary
important or sensitive speciesof flora or fauna for breeding,nesting, foraging, resting, overwintering, migration
4 Inland, coastal, marine orunderground waters
Back water ofTB dam
2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance
5 State, National boundaries None Not applicable6 Routes or facilities used by the
public for access to recreationor other tourist, pilgrim areas
NationalHighwayNo.13Hospet Railway station
500m from the proposedexpansion activities7.2Km(Aerial)away from thePlant/15Kmsbyroad
7 Defence installations No Not applicable8 Densely populated or built-up
areaHospet 7.2Km(Aerial)away from the
Plant/15Kmsbyroad9 Areas occupied by sensitive
man-made land uses (hospitals,schools, places of workshop,community facilities)
Yes Hospitals situated in Hospetsituated at 7.2 Kms(Aerial)away from the Plant/15Kmsby road. Schools/ facilitiesrun by SMIORE adjacent toexisting ferro alloy plantpremises.
10 Areas containing important,high quality or scarce resources(ground water resources,surface resources, forestry,agriculture, fisheries, tourism,minerals)
Back water ofTungabhadra DamIron Ore Mines
2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance4KmsfromSiteGunda RF-adjacent to thePlant site towards NorthSandurRF-7.0km–ERamgadRF-3.1km–SEHospetRF-3.6km-NE
11 Areas already subjected topollution or environmentaldamage (those where existinglegal environmental standardsare exceeded)
No Not applicable
12 Areas susceptible to naturalhazard which could cause theproject to present environ-mental problems (earthquakes,subsidence, landslides, erosion,flooding or extreme or adverseclimatic conditions)
No Not applicable
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 19Visiontek Consultancy Services Private Limited
(IV) Proposed Terms of Reference for EIA studies
The following are the terms of reference for EIA studies:
1. Baseline data will be generated as per the stipulated guidelines in EIA manual prescribed byMoEF in the study area of 10 km radius around the proposed site for the following:
1. Description of Environment
Ambient Air Quality
Ambient air quality monitoring will be carried out at adequate stations representing the study area asper guidelines of MoEF.
Meteorology
Meteorological parameters such as wind speed, wind direction, temperature, relative humidity, cloudcover and rainfall will be generated at one station on hourly basis for 24 hours during the studyperiod.
Noise level
Measurement of noise levels within the study will be carried out at adequate locations at regularintervals for 24 hours during the study period.
Traffic Volume Counts
Traffic volume counts will be carried out at adequate locations within the study area on hourly basisfor 24 hours, once in each month during the monitoring period.
Water Quality
Adequate water samples (surface water and ground water) will be collected as per standardguidelines. The samples will be analyzed for essential parameters as per CPCB standard.
Soil Quality
Testing of soil samples will be carried out from adequate locations within the study area for physicaland chemical parameters.
Flora & Fauna
Survey will be carried out in the study area as per the guidelines of MoEF. Species of flora will belisted in detail with local name, scientific name and species including endangered species, whilefaunal species will be identified as per the Wildlife Protection Act, 1972 and as amendedsubsequently and shall be listed as endangered, endemic, migratory and aquatic.
Remote Sensing Study
This study will be carried out based on the satellite imagery of the study area to assess the land usepattern.
Socio-economic Survey
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 20Visiontek Consultancy Services Private Limited
Socio-economic survey in the study area will be carried out to assess the status of demographicpattern, employment pattern and general amenities available based on the Census 2011, secondaryinformation available with different government agencies and Survey.
2. Impact Assessment
Impacts shall be identified based on the actual and foreseeable events, including operational events
and typical events of the proposed project activities. Processes that may create risks to the natural
environment and socio economic environment shall be considered in terms of key potential
environmental impacts.
3. Environment Management Plan
Mitigation measures to be adopted under EMP for all specified significant environmental impactslikely to result out during the construction and subsequently during operation shallalso be a part ofthe EIA/EMP report. The likely identified impacts and recommended mitigation measures shall bebased on the following:
Various applicable environment laws/acts/standards/guidelines;
Project information provided by project proponent;
Baseline information and reconnaissance survey of the study area;
Past experience in similar type of projects; and
Standard National/International environmental management guidelines/practices.
“I hereby give an undertaking that the data and information given in the application and enclosures
are true to the best of my knowledge and I am aware that if any part of the data and information
submitted is found to be false or misleading at any stage, the project will be rejected and clearance
given, if any to the project, will be revoked at our risk and cost.”
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 20Visiontek Consultancy Services Private Limited
Socio-economic survey in the study area will be carried out to assess the status of demographicpattern, employment pattern and general amenities available based on the Census 2011, secondaryinformation available with different government agencies and Survey.
2. Impact Assessment
Impacts shall be identified based on the actual and foreseeable events, including operational events
and typical events of the proposed project activities. Processes that may create risks to the natural
environment and socio economic environment shall be considered in terms of key potential
environmental impacts.
3. Environment Management Plan
Mitigation measures to be adopted under EMP for all specified significant environmental impactslikely to result out during the construction and subsequently during operation shallalso be a part ofthe EIA/EMP report. The likely identified impacts and recommended mitigation measures shall bebased on the following:
Various applicable environment laws/acts/standards/guidelines;
Project information provided by project proponent;
Baseline information and reconnaissance survey of the study area;
Past experience in similar type of projects; and
Standard National/International environmental management guidelines/practices.
“I hereby give an undertaking that the data and information given in the application and enclosures
are true to the best of my knowledge and I am aware that if any part of the data and information
submitted is found to be false or misleading at any stage, the project will be rejected and clearance
given, if any to the project, will be revoked at our risk and cost.”
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 20Visiontek Consultancy Services Private Limited
Socio-economic survey in the study area will be carried out to assess the status of demographicpattern, employment pattern and general amenities available based on the Census 2011, secondaryinformation available with different government agencies and Survey.
2. Impact Assessment
Impacts shall be identified based on the actual and foreseeable events, including operational events
and typical events of the proposed project activities. Processes that may create risks to the natural
environment and socio economic environment shall be considered in terms of key potential
environmental impacts.
3. Environment Management Plan
Mitigation measures to be adopted under EMP for all specified significant environmental impactslikely to result out during the construction and subsequently during operation shallalso be a part ofthe EIA/EMP report. The likely identified impacts and recommended mitigation measures shall bebased on the following:
Various applicable environment laws/acts/standards/guidelines;
Project information provided by project proponent;
Baseline information and reconnaissance survey of the study area;
Past experience in similar type of projects; and
Standard National/International environmental management guidelines/practices.
“I hereby give an undertaking that the data and information given in the application and enclosures
are true to the best of my knowledge and I am aware that if any part of the data and information
submitted is found to be false or misleading at any stage, the project will be rejected and clearance
given, if any to the project, will be revoked at our risk and cost.”
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 21Visiontek Consultancy Services Private Limited
Annexure-ITopo Map
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 22Visiontek Consultancy Services Private Limited
Annexure-II
Baseline data collection is under process for the period December2016 to February 2017 as perthe ToR letter vide letter no. F. No. J-11011/205/2014-IA-II (I) dated 07.04.2015.
AIR SAMPLING LOCATIONS
NOISE SAMPLING LOCATIONS
Sl.No.
Locations StationCode
Aerial Distance fromplant site (Km)
Directionfrom plant
siteType of Area
1.SMIORE PlantPremises
A1 -- -- Industrial Area
2. Rajapura A2 3.8 Km N Industrial/ Mines Aea
3. Hanumanhall A3 1.9 Km S Residential Area
4. Munirabad A4 9.5 KmNW
DownwindResidential Area
5. Vyasankere A5 3.0 Km WNear Reservoir(Residential Area)
6. Venkatagiri A6 6.5 Km E Industrial Area
7. Hospet A7 7.8 Km SSW Residential Area
8. Ramgard A8 7.0 Km SE Near Reserve Forest
Sl.No. Locations
StationCode
Aerial Distance fromplant site (Km)
Directionfrom plant
siteType of Area
1.SMIORE PlantPremises
N1 -- -- Industrial Area
2. Rajapura N2 3.8 Km N Industrial/ Mines Aea
3. Hanumanhall N3 1.9 Km S Residential Area
4. Munirabad N4 9.5 KmNW
DownwindResidential Area
5. Vyasankere N5 3.0 Km WNear Reservoir(Residential Area)
6. Venkatagiri N6 6.5 Km E Industrial Area
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 23Visiontek Consultancy Services Private Limited
7. Hospet N7 7.8 Km SSW Residential Area
8. Ramgard N8 7.0 Km SE Near Reserve Forest
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 24Visiontek Consultancy Services Private Limited
.7TOPOSHEET – SHOWING THE AAQ & NOISE MONITORING LOCATIONS
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 24Visiontek Consultancy Services Private Limited
.7TOPOSHEET – SHOWING THE AAQ & NOISE MONITORING LOCATIONS
M/s. THE SANDUR MANGANESE & IRON LIMITED
Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant
comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant
and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary
District, Karnataka
Page 24Visiontek Consultancy Services Private Limited
.7TOPOSHEET – SHOWING THE AAQ & NOISE MONITORING LOCATIONS
Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)
Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : visiontekin@gmail.com, visiontekin@yahoo.co.in, Visit us at : www.vcspl.org
Committed For Better Environment
PRE – FEASIBILITY REPORT
On
PROPOSED EXPANSION OF EXISTING FERRO ALLOYPLANT TO 1.0 MTPA INTEGRATED STEEL PLANT COMPRIS-ING OF SINTER PLANT, BLAST FURNACE, PIG CASTING MA-
CHINE, COKE OVEN PLANT, ROLLING REBAR MILL , OXY-GEN PLANT & WHRB
OF
M/s. THE SANDUR MANGANESE & IRON ORES LTD.AT DANAPUR, DANAYAKANKERE & HANUMANHALLI
VILLAGES, HOSPET, BELLARY DISTRICT, KARNATAKA
Prepared by:- DECEMBER 2016
VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)
Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594
E-mail-visiontekin@yahoo.co.in , visiontekin@gmail.comVisit us at - www.vcspl.org
TABLE OF CONTENT
SR. NO DESCRIPTION PAGENO
1.0 INTRODUCTION 42.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 52.1 Need for the project & its importance to the country or Region 62.2 Employment Generation 73.0 PROJECT DESCRIPTION 73.1 Location 73.2 Site Selection 73.3 Technology Selection 73.4 Project Description 83.5 Raw material Requirement 83.6 Water and Power Requirement 93.7 Waste Generation and Management 94.0 SITE ANALYSIS 94.1 Connectivity 94.2 Present Landuse 104.3 Existing Infrastructure 104.4 Climate data from secondary sources 115.0 PLANNING BRIEFF 115.1 Planning concept 115.2 Landuse Planning 116.0 PROPOSED INFRASTRUCTURE 116.1 Industrial and Residential area 116.2 Green Belt 126.3 Others 127.0 REHABILITATION AND RESETTLEMENT (R&R)PLAN 128.0 PROJECT SCHEDULE AND COST ESTIMATES 128.1 Project Schedule 128.2 Project Cost 139.0 ANALYSIS OF PROPOSAL 132.0 INTRODUCTION2.1 Identification of project and project proponent 142.2 Description of Nature of the project 142.3 Need of the Project and its Importance to the Country and/or Region 172.4 Supply- Demand Gap 182.5 Major Steel Consuming Sectors 242.6 Alloy & Special Steel Sector 262.7 Employment generation (Direct & Indirect) due to the project 283.0 PROJECT DESCRIPTION3.1 Type of project 303.2 Location 313.2.1 Plant Location 31
3.2.2 Alternative Sites Examined 343.2.3 Land Requirement 343.2.4 Plant Layout 343.3 Site Selection 363.5 Process Description 513.6 Raw Materials Requirements 723.7 Water & Power Requirement with its Source 733.8 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for
their Management/Disposal73
3.8.1 Waste Water Generation and Treatment 753.8.2 Solid Waste Generation and Utilization 763.8.3 Noise Levels 773.8.4 Green Belt Development 774.0 SITE ANALYSIS
4.1 General 784.2 Connectivity 784.2.1 Topography 784.2.2 Existing Land Use Pattern 794.4 Climate Data 795.0 PLANNING BRIEF5.1 Planning Concept 805.1.1 Technical Concept 805.2 Land Use Planning 806.0 PROPOSED INFRASTRUCTURE6.1 Industrial and Residential Area 816.2 Green Belt 816.3 Others 817.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN8.0 PROJECT SCHEDULE & COST ESTIMATES8.1 Project Schedule 838.2 Project Cost 859.0 ANALYSIS OF PROPOSAL9.1 Financial and Social Benefits 869.1.1 Improvements in the Physical Infrastructure 869.1.2 Improvements in the Social Infrastructure 869.1.3 Employment 869.1.4 Other Benefits 86
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 1
CHAPTER – 01
EXECUTIVE SUMMARY
1 Name of theproject
Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPAIntegrated Steel Plant in 3 Phases comprising of Sinter Plant, BlastFurnace, Coke Oven Plant, Rebar Mill, Oxygen Plant and WHRB byM/s The Sandur Manganese & Iron Ores Limited.
2 S.No in theschedule
Activity 3(a)
3 RegisteredOffice
M/s The Sandur Manganese & Iron Ores LimitedLakshmipur, Sandur , Bellary District, Pin – 583119, Karnataka
4 Name of theApplicant
M/s The Sandur Manganese & Iron Ores Limited.
5 Area ofplant
320.79 acres (129.81 Ha.). (Existing)
6 Topo SheetNo
57 A/8
7 LatitudeLongitude
Latitude: 15° 11' 47" NLongitude: 76° 22' 50"E
8 Proposedcapacity
The proposed expansion is comprising of the following:
Sl.No.
Plant/UnitName
ConfigurationFinal
AnnualProductio
n
FinalCapacit
yin
MTPA
Phase-IPhase
-IIPhase
III
1Blast
Furnace
1x0.4MTP
A BF( Size350-
400m3 )~
1212.12TPD
-
1x0.4MTP
A BF( Size350-
400m3 )~
1212.12TPD
2 x400000
TPA
0.800
Pig CastingMachine
1212.12TPD
- -1 x
400,000TPA
0.400
2Coke OvenPlant andWHRB
0.4MTPA~
1212.12TPD
WHRB -130TPHSteam
Generation
- -1 x
400,000TPA
0.400
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 2
3SinterPlant
1 x 50 m²~1600TPD
-
1 x 50m²
~1600TPD
2 x528,000
TPA
1.056
4
EnergyOptimization Furnace
(EOF)
-
1 X50 T
~1602
TPD
1 X 50T
~1602TPD
2 x528,710
TPA
1.057
5
LadleRefiningFurnace (LRF) &VacuumDegasser
(VD)
-
1 X50 T~160
2TPD
1 X 50T
~1602TPD
2 x528,710
TPA
1.057
6
ContinuousCastingmachine(CCM)
-
1 X 4Stran
d9/16
mradius~157
0TPD
1 X 4Strand9/16 mradius~1570TPD
2 x518,135
TPA
1.036
7Rolling(RebarMill)
-
1 X100TPH~151
5TPD
1 X 100TPH
~1515TPD
2 x500,000
TPA
1.0
8Oxygen
Plant1 X 70TPD
1 X200TPD
-
1 x 23100TPA +
1 x 66000TPA
-
Maximum No. of Working Days considered for all units - 330
9 Cost ofProject
Rs. 5300.00 Cr.
10
Man powerRequirement
898
11
WaterRequirement
685 m³/Hr will be sourced from Tungabhadra Dam & Bore wells.
12
PowerRequiremen
92 MW (32 MW will be sourced from existing Coal based CPP andbalance will be sourced from Karnataka Power Transmission Corporation
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 3
t Limited.
13
Nearestrailwaystation/airport alongwithdistance inkms
Nearest Railway Station: Tungabhadra R.S- 7.8 Km NWHospet R.S- 9.8 Km NE
Nearest Airport: Vidyanagar – 26 km. E
14
NearestTown, City,DistrictHeadquartersalong withdistance inkms.
Hospet-7.1km–N(15Km byroad)Bellary -58km–E(75Kmbyroad)
15
Villagepenchants,Parishad,Municipalcorporation,localtelephonenos to begiven) body(completepostaladdresseswithtelephoneno.s to begiven)
Village- Danapur & Danayakankere & HanumanhalliPanchyat- DanapurTaluk- HospetDist-BellaryKarnataka
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 4
1.0 INTRODUCTION
M/s The Sandur Manganese & Iron Ores Limited (Here after SMIORE) currently
operating a Ferro Alloy plant ( 3 Submerged Arc Furnaces with total capacity 55 MVA, 1
Sintering plant of 1.5 MT, Manganese Ore Beneficiation Plant 2 t/Hr input and 32 MW Coal
based CPP) at Hanumanhalli village, Danapur Mandal, Hospet Taluk, Bellary District of
Karnataka State. Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant
to 1.0 MTPA Integrated Steel Plant in 3 phases comprising of following units:-
Table 1.1 Proposed Configurations (Expansion)
Sl.No.
Plant/UnitName
Configuration FinalAnnual
Production
FinalCapacityin MTPAPhase-I Phase-II Phase III
1 Blast Furnace
1x 0.4MTPABF
( Size 350-400m3 )
~ 1212.12TPD
-
1x0.4MTPA
BF( Size 350-
400m3 )~ 1212.12
TPD
2 x 400000TPA
0.800
Pig CastingMachine
1212.12 TPD - -1 x 400,000
TPA 0.400
2Coke Oven Plant
and WHRB
0.4MTPA~ 1212.12
TPDWHRB -130TPHSteam
Generation
- -1 x 400,000
TPA 0.400
3 Sinter Plant1 x 50 m²
~1600 TPD-
1 x 50 m²~1600 TPD
2 x 528,000TPA
1.056
4Energy
OptimizationFurnace (EOF)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
5
Ladle RefiningFurnace ( LRF)
& VacuumDegasser (VD)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
6Continuous
Casting machine(CCM)
-
1 X 4Strand9/16 mradius~1570TPD
1 X 4 Strand9/16 mradius
~1570 TPD
2 x 518,135TPA
1.036
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 5
7Rolling (Rebar
Mill)-
1 X 100TPH
~1515TPD
1 X 100TPH
~1515 TPD
2 x 500,000TPA
1.0
8 Oxygen Plant 1 X 70 TPD1 X 200
TPD-
1 x 23100TPA +
1 x 66000TPA
-
Maximum No. of Working Days considered for all units - 330
2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
The project is being promoted by the Sandur Manganese & Iron Ores Limited
(SMIORE) having their registered office at
Sandur Mangenese & Iron Ore Ltd.
Lakshmipur,
Hospet District - 583119 (Karnataka).
And
The Project Division Office at;
First & Second Floor
Redifice Signature
No.6, Hospital Road, Shivajinagar
Bangalore- 560 001
Karnataka
The Sandur Manganese & Iron Ores Limited is Flagship Company of the reputed Sandur
Group of Karnataka. SMIORE was founded in 1954 by the former ruler of the Princely
State of Sandur Mr. Yeshwanthrao Hindurao Ghorpade.
Associated with the management of the Company from its inception, Mr. M.Y.
Ghorpade with a Master’s Degree in Economics from Cambridge nurtured and
developed SMIORE into one of the finest professionally managed companies in India,
doing business in the fields of manganese ore, ferroalloys and electronics. Mr. M.Y.
Ghorpade is known world-wide for his black and white wildlife photography. His rich
experience as Karnataka's Minister for Finance in the 1970s and later for Rural Development,
and his sustained effort of socio-economic reconstruction and service at Sandur over the
years set the tone for the company's progressive growth.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 6
Sandur was once described by Mahatma Gandhi as an oasis and is renowned for its
sylvan beauty and abundant resources of manganese and iron ores. The Sandur mines are
situated in the picturesque and historic valley of Sandur in Hospet district of Karnataka at
an elevation of about 1,000 metres and extending over an area of about 20 sq. kms.
The mines are estimated to contain reserves in the region of 25 million tons of the low
grade, low phosphorous manganese ore and about 50-60 million tons of low grade iron
ore. SMIORE produces about 2.2 million tonnes of manganese and iron ores per annum.
Presently, the major activities of SMIORE are mining of low grade, low phosphorous,
manganese and iron ores, facility for production of ferroalloys and management of
hydro-electric power generation. The group also owns facilities to produce resistor
networks and copper clad laminates. The Ferro-alloy plant has two working submerged
arc furnaces. The first furnace is a 15 MVA furnace and the second furnace is 20MVA
furnace both furnaces are producing 24,000 tpy of Silico- manganese.
2.1 Need for the project & its importance to the country or Region
Steel consumption in India is closely associated with manufacturing, housing and
infrastructure sectors. Being a developing country, most of the industries are far away from
their maturity which kept the steel consumption rate intact in domestic market even during
the testing times of recession.
The scope for raising the total consumption of steel is huge, given that per capita steel
consumption is only 73.3 kg – compared to 210 kg across the world.
Carbon steel products are currently dominating steel consumption in the country. Fast
infrastructural developments and consumer durables industries have fueled the demand. The
government has also supported the steel industry with the announcement of massive
investment in railways, airport and power sectors.
Keeping in view the rate of growth of economics and with India becoming a sourcing hub for
auto components of auto companies’ word wide, demand projection for the alloy steels, it
will be necessary to create additional capacities in order to meet the projected requirements
during the post 2016-17 period. It is estimated that around 3.8 million tonnes per annum of
additional capacities would need to be created during the next 5-year period in order to meet
the requirements projected by the year 2021-22.
The trends indicate that the country's steel imports are gaining significant momentum to meet
the strong demand. We anticipate that this trend will see an upward growth trajectory in
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 7
coming years on the back of some concrete industry attributes analyzed thoroughly in the
report.
2.2 Employment Generation
Direct and indirect employment will be generated to the local population. The total man
power requirement during construction for the project will be 898.
3.0 PROJCET DESCRIPTION
The proposed project is an expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated
Steel plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill &
Oxygen Plant.
3.1 Location
The proposed facilities of the 1.0 MTPA Integrated Steel Plant comprising of Sinter
Plant, Mini Blast Furnace, Pig Casting Machine, Steel Melt Shop, Continuous Casting
Machine, Rebar Mill and WHRBower Plant will be installed at Vyasanakere, near
Hospet in the State of Karnataka in the land owned by SMIORE to South and South
East of their existing/ adjoining Ferro Alloy Plant complex. The proposed location of
steel plant site bears the following coordinates. The proposed site falls under the Survey of
India Toposheet No. 57A/8 and the buffer zone falls under the Survey of India Toposheet 57
A/7. The Latitude and Longitude of the proposed site is 15°11'47"N and 76° 22'50"E
respectively.
3.2 Site Selection
The total project land area including existing & Expansion is 320.79Acre (129.81 Ha.).. The
site has following facilities:
Proximity to the sources of base raw material,
Availability of common Infrastructure facilities / utilities (water / power etc.),
Availability of land, approach roads & accessibility
Topography of land and geological aspects
Nearness to rail head, transport logistics
3.3 Technology Selection
Technology selection involves an analysis of past achievements, present status and future
prospects of each technology under consideration keeping in view the following criteria.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 8
Availability of project plant capacity/module.
Suiting to selected product mix & raw materials
Conservation of scarce inputs such as power & water.
Considerations of capital cost & maintenance cost.
Delivery schedule
Operational flexibility
3.4 Project Description
Following are the steps involved in production process:
i. Raw Materials to Metallics;
ii. Metallics to Liquid Steel;
iii. Liquid Steel to Refined Liquid Steel; and
iv. Refined Liquid Steel to Semis, i.e. Billets & Blooms.
3.5 Raw Material Requirement
Following are raw material required for the cement production along with their sources
Table.1.1 Raw Materials Requirement
Sl. No. Raw material Quantity in TPACoke oven
1 Hard Coal 3,78,0002 Soft Coal 1,62,000
Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven
Plant0Blast furnace
1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000
Energy Optimization Furnace1 Scrap 2,35,0002 Flux 12,6883 LimeStone & Dolomite 1,00,453
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 9
3.6 Water and Power Requirement
Water requirement for the project is as follows:
Table 1.2 Water RequirementSl.No.
Plant Unit Water Requirement in m3/HrFresh Water Soft Water DM Water Total in
m3
1 Sinter Plant 10 10 -- 202 BF Shop 95 100 -- 195
3
Pig Casting Machine(Considering 10%Utilization of PCM thewater requirement)
20 -- -- 20
4
EOF +LRF +VD(Transformer, Reactor &H.C. Cable Cooling)
64 60 26 150
5 Coke Oven Plant 70 -- -- 706 WHRB --7 CCM 50 -- -- 508 Rebar Mill 130 -- -- 1309 Oxygen Plant 20 -- -- 20
10Green belt & DustSuppression 20
-- -- 20
11 Miscellaneous Use 10 -- -- 10Total 489 170 26 685
Source of Water
The water requirement will be sourced from Tungabhadra Dam & Bore wells.Power Requirement
The total connected power of the plant is expected to be about 92 MW.
3.7 Waste Generation and Management
Waste water generated from the different areas of the plant will be treated to the
desired extent in suitable treatment facilities and recycled back to the process, as far
as practicable, facilitating adequate reuse of water and economizing on the make-up
water requirement. The treated effluent water will be collected in a sump located in a low
lying area. The water thus collected shall be used for dust suppression at raw material
handling system, slag cooling in SMS and road sprinkling etc.
4.0 SITE ANALYSIS
4.1 Connectivity
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 10
The site is at 7.1 km West away from nearest town Hospet. National Highway [NH-13] is
550 m towards West and South Western Railway Hospet – Kottur broad gauge railway
line of South Western Railway passes close to the east side boundary of the existing Ferro
Alloy Plant.
The suitability of the project site has been assessed in the report. As the proposed
project shall be located in the existing well developed unit, there shall be minimal
cutting and filling activity. Easy access to raw material.
The following factors were considered while selecting the subject site:
a. Availability of adequate land free from extensive cultivation and forest for locating
the power plant with provision for future expansion.
b. Suitability of land from topography and geological aspects.
c. Location with respect to fuel sources and road/rail linkage.
d. Availability of adequate supply of water to meet condenser cooling water and other
service water requirements.
e. Facilities for ash disposal.
f. Ease of transportation of imported coal from the port
g. Facility for transportation of power plant equipment and construction materials to site.
h. Power Evacuation facilities.
i. Proximity to major load centres in the power system
j. Environmental aspects
4.2 Present land use
The present land is gently undulating and suitable for industrial development.
Topography and Existing Land use Pattern
The topography of the land is gently undulating and well suited for development of industrial
projects. Land for the proposed project is industrial land & Plant is not coming under the
dense forest category land. This area also does not form part of any National Park, Wild Life
Sanctuary and Natural/Biosphere reserve.
4.3 Existing Infrastructure
a. Ferro Alloy Plant having three submerged arc furnaces with a total capacity of 35 MVA
(20 MVA-01 No., 15 MVA-01 No.) & sintering plant of 1.5 MT.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 11
b. 32 MW coal based captive power plant (CPP) belonging to Star Metallics & Power
Private Limited (Subsidiary of SMIORE).
c. 32 MW CPP (existing CPP) is coal based with fluidized bed combustion technology.
Power from the CPP is used to run Ferro alloy plant and the surplus power if any is being
exported to the grid.
4.4 Climate Data from secondary sources
May month is usually the hottest with daily maximum of 38 ⁰C and December is the coldest
month with mean daily minimum of 17.2 ºC. The average annual rainfall of the area is 529
mm.
5.0 PLANNING BRIEF
5.1 Planning Concept
Technical Concept
The Sandur Manganese & Iron Ores Limited proposes to setup an Integrated Steel Facility for
the production of 1.00 MTPA Steel with finished product of 5.5 to 20 mm diameter wire
rods at Vyasanakere, Near Hospet in the State of Karnataka. The captive power
generation will be to utilize the waste heat from the Coke Ovens and waste gases of Blast
Furnace.
Human Resources
Human Resource is the most valuable asset in any industry. The accelerating pace of
technology advancement and fierce competition in the market has led to the increasing
importance of human resources. Continuous skill updating of the existing human resources
and generating new talents in consonance with the needs of the industry are vital for the
progress of the industry.
5.2 Land Use Planning
Total land required for the plant including existing & expansion is 320.79 Acre (129.81 Ha.).
Total land has already been acquired.
6.0 PROPOSED INFRASTRUCTURE6.1 Industrial and Residential Area
The setting up of the 1.0 MTPA integrated steel plant comprising of Sinter Plant, Mini Blast
Furnace, Coke Oven Plant, Rebar Mill, WHRB & Oxygen Plant along with existing ferro
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 12
alloys plant requires 320.79 Acre (129.81 Ha.) of land. Coke plant will be within the existing
Plant premises. All other units shall be installed adjacent area to the existing plant.
6.2 Green Belt
A greenbelt development plan will be prepared and implemented along with the project. Total
green belt area shall be of 33% of total area and will be developed in the plant.
Green belt Development plan
Green belt of 33 Acre will be developed in the plant premises as per CPCBguidelines.
10m wide greenbelt will be developed all around the plant.
The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind
firm, deep rooted. A three tire plantation is proposed comprising of an outer most belt of
taller trees which will act as barrier, middle core acting as air cleaner and the innermost core
which will act as barrier.
6.3 Others
A garland drain around the plant is envisaged to collect surface run-off during rainy
season.
Drinking water facilities will be provided for employees as well as nearby villagers.
Existing road and rail network will be utilized for raw material and final products
transportation.
7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN
The proposed project is an expansion of the existing ferro alloys plant and will be
build in existing available land, hence there will be no displacement of residents.
Local people will be engaged for construction and operation activities. Surrounding
area have all the infrastructure facilities, hence no housing colony/township is
envisaged.
8.0 PROJECT SCHEDULE AND COST ESTIMATES
8.1 Project Schedule
The commissioning of the plant is 24 months from ordering of main machinery. The external
agencies such as consultant, machinery suppliers, contractors of civil construction and
equipment will be selected carefully well in advance.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 13
An effective project team shall be formulated with an experienced Project Manager as its
leader.
8.2 Project Cost
An estimated capital cost of the proposed expansion is 5300.00 Cr. including the Pre-
operative expanses, contingency and interest during construction.
9.0 ANALYSIS OF PROPOSAL
The benefits of the proposed unit shall be as follows,
Improving and building road network in the adjoining villages.
Strengthening local school buildings with playgrounds.
Improvement in social awareness programme such as sanitation and hygiene, HIV
Prevention Program.
Adult education and female education programmes will be provided to the illiterate
adults and backward females of the villages in the project surrounding area.
Long term employment of up to 898 people in the operation of the proposed plant
apart from contract labourers.
Generation of additional jobs by local business in the supply of raw materials,
finished products and services. Development of the local area in terms of an enlarged
market will provide the farmers with a good outlet of their agricultural products to
enjoy the price effect. Thus, the proposed project will usher in the social and
economic upliftment of the persons living in the vicinity of the Project i.e. of society
at large.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 14
CHAPTER – 02
INTRODUCTION
2.1 Identification of Project and Project Proponent
The project is being promoted by the Sandur Manganese & Iron Ores Limited
(SMIORE) having their registered office at
Sandur Mangenese & Iron Ore Ltd.
Lakshmipur,
Hospet District - 583119 (Karnataka).
And
The Project Division Office at;
First & Second Floor
Redifice Signature
No.6, Hospital Road, Shivajinagar
Bangalore- 560 001
Karnataka
The Sandur Manganese & Iron Ores Limited is Flagship Company of the reputed Sandur
Group of Karnataka. SMIORE was founded in 1954 by the former ruler of the Princely
State of Sandur Mr. Yeshwanthrao Hindurao Ghorpade.
Associated with the management of the Company from its inception, Mr. M.Y.
Ghorpade with a Master’s Degree in Economics from Cambridge nurtured and
developed SMIORE into one of the finest professionally managed companies in India,
doing business in the fields of manganese ore, ferroalloys and electronics. Mr. M.Y.
Ghorpade is known world-wide for his black and white wildlife photography. His rich
experience as Karnataka's Minister for Finance in the 1970s and later for Rural Development,
and his sustained effort of socio-economic reconstruction and service at Sandur over the
years set the tone for the company's progressive growth.
Sandur was once described by Mahatma Gandhi as an oasis and is renowned for its
sylvan beauty and abundant resources of manganese and iron ores. The Sandur mines are
situated in the picturesque and historic valley of Sandur in Hospet district of Karnataka at
an elevation of about 1,000 metres and extending over an area of about 20 sq. kms.
The mines are estimated to contain reserves in the region of 25 million tons of the low
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 15
grade, low phosphorous manganese ore and about 50-60 million tons of low grade iron
ore. SMIORE produces about 2.2 million tonnes of manganese and iron ores per annum.
Presently, the major activities of SMIORE are mining of low grade, low phosphorous,
manganese and iron ores, facility for production of ferroalloys and management of
hydro-electric power generation. The group also owns facilities to produce resistor
networks and copper clad laminates. The Ferro-alloy plant has two working submerged
arc furnaces. The first furnace is a 15 MVA furnace and the second furnace is 20MVA
furnace both furnaces are producing 24,000 tpy of Silico- manganese.
2.2 Description of Nature of the project
M/s The Sandur Manganese & Iron Ores Limited (Here after SMIORE) currently
operating a Ferro Alloy plant ( 3 Submerged Arc Furnaces with total capacity 55 MVA, 1
Sintering plant of 1.5 MT, Manganese Ore Beneficiation Plant 2 t/Hr input and 32 MW Coal
based CPP) at Hanumanhalli village, Danapur Mandal, Hospet Taluk, Bellary District of
Karnataka State.
Table 2.1 Plant Configuration (Existing)
Sl.No. Description Existing capacity (MTPA)
1Ferro Alloy Plant having threesubmerged arc furnaces
55MVA(20MVA-02No’s.,15MVA-01No.)
2 Sinter plant 1.5 MT
3 coal based captive power plant 32 MW
Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant to 1.0 MTPA
Integrated Steel Plant in 3 phases comprising of following units:-
Table.2.2 Plant Configuration (Expansion)
Sl.No.
Plant/UnitName
Configuration FinalAnnual
Production
FinalCapacityin MTPAPhase-I Phase-II Phase III
1 Blast Furnace
1x 0.4MTPABF
( Size 350-400m3 )
~ 1212.12TPD
-
1x0.4MTPA
BF( Size 350-
400m3 )~ 1212.12
TPD
2 x 400000TPA
0.800
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 16
Pig CastingMachine
1212.12 TPD - -1 x 400,000
TPA 0.400
2Coke Oven Plant
and WHRB
0.4MTPA~ 1212.12
TPDWHRB -130TPHSteam
Generation
- -1 x 400,000
TPA 0.400
3 Sinter Plant1 x 50 m²
~1600 TPD-
1 x 50 m²~1600 TPD
2 x 528,000TPA
1.056
4Energy
OptimizationFurnace (EOF)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
5
Ladle RefiningFurnace ( LRF)
& VacuumDegasser (VD)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
6Continuous
Casting machine(CCM)
-
1 X 4Strand9/16 mradius~1570TPD
1 X 4 Strand9/16 mradius
~1570 TPD
2 x 518,135TPA
1.036
7Rolling (Rebar
Mill)-
1 X 100TPH
~1515TPD
1 X 100TPH
~1515 TPD
2 x 500,000TPA
1.0
8 Oxygen Plant 1 X 70 TPD1 X 200
TPD-
1 x 23100TPA +
1 x 66000TPA
-
Maximum No. of Working Days considered for all units - 330
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 17
Table.2.2 Raw Material
Sl. No. Raw material Quantity in TPACoke oven
1 Hard Coal 3,78,0002 Soft Coal 1,62,000
Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven
Plant0Blast furnace
1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000
Energy Optimization Furnace1 Scrap 2,35,0002 Flux 12,6883 LimeStone & Dolomite 1,00,453
2.3 Need of the Project and its Importance to the Country and/or Region
Steel is traditionally considered the backbone of national economic development. It is a major
input into sectors which support economic growth such as infrastructure, machinery, power
and railways, as well as being important for fast growing sectors, in particular automobiles
and consumer durables. In 2013 global crude steel output reached 1,607 million tonnes up by
3.5% as compared to 2012. Table 2.1 shows the year-wise global crude steel production since
year 2005.
Table 2.3 Year Wise crude Steel Production
S. No. Year Steel Production ‘000 tonnes YOY Change %1. 2005 1,146,686 7.32. 2006 1,251,196 9.13. 2007 1,351,289 8.04. 2008 1,307,339 -3.35. 2009 1,219,715 -6.76. 2010 1,395,000 14.27. 2011 1,527,000 6.88. 2012 1,559,200 3.19. 2013 1,607,200 3.5
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 18
As suggested by Brief report on Iron & Steel Industry in India March, 2013 by Corporate
Catalyst India, the demand for steel in India is expected to rise about 7 percent in this
financial year as compared to the last financial year. The overall outlook for the steel sector is
positive and the demand is likely to pick up on the back of revival in economic growth and
the government’s measures to ease infrastructure investment rules.
India is currently the World’s fourth largest producer of crude steel after China, Japan and
US. India is expected to leave behind USA and Japan in a couple of years. The steel
production is expected to reach 300 million tones by 2025 as compared to 81 million tones
recorded last year.
Table 2.4 Top Ten Steel Producing Countries, production in million T (Source – World
Steel Association)
Country Rank 2010 2011 2012 2013 % 13/12China 1 638.7 695.5 724.7 779.0 7.5Japan 2 109.6 107.6 107.2 110.6 3.1UnitedStates
3 80.5 86.2 88.7 87.0 -2.0
India 4 68.3 72.2 77.3 81.2 5.1Russia 5 66.9 68.7 70.4 69.4 -1.5SouthKorea
6 58.9 68.5 69.1 66.0 -4.4
Germany 7 43.8 44.3 42.7 42.6 0.0Turkey 8 29.1 34.1 35.9 34.7 -3.4Brazil 9 32.9 35.2 34.5 34.2 -1.0Ukraine 10 33.4 35.3 33.0 32.8 -0.5As seen from this Table, India is ranked 4th in world steel production and is amongst the
three nations that had a positive growth in 2013 in comparison to 2012 against 7-countries
reporting negative change.
2.4 Supply-Demand Gap
2.4.1 Global Steel Scenario:
The increase of 3.5% in World crude steel production over 2012 is mainly from Asia and
Middle East, while the crude steel production in all other regions decreased in the same
period.
Steel production had declined in nearly all the major steel producing countries and regions
including the EU, North America, South America and the CIS. However, Asia, in particular
China and India, and the Middle East showed positive growth. The region’s share of world
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 19
steel production increased slightly from 65.7% in 2012 to 67.3% in 2013. China’s crude steel
production in 2013 reached 779.0Mt an increase of 7.5% on 2012. China’s share of world
crude steel production increased from 46.7% in 2012 to 48.5% in 2013 and apart from China
it can also be seen that Taiwan was up by 8%, India was up by 5% and Japan increased by
3% with South Korea the only major Asian producing country to show a decline, down by
4%. Other notable increases were Iran, up by 7% and Mexico, up by 2%. Apart from
Mexico, the NAFTA countries did not fare well with Canada down 8% and the US falling by
2%. Indeed, if the current rates continue, it will not be long before India overtakes the US as
the world’s 2nd largest steel producing region. It should also be noted that despite the well
documented problems with Europe, crude steel production only fell by 2% year on year.
The world steel industry is now firmly set on a path to recovery. The recovery is not only like
earlier times, but also stronger than expected. It was driven in large part by government
stimulus packages and recent inventory re-stocking. The Steel Demand across the world is
clearly on a rising trend and the same is shown in figure-2.1 below.
Figure 2.1 (Source – World Steel Association)
2.4.2 Indian Steel Scenario:
The Indian steel industry has witnessed an impressive performance in recent years and had
achieved growth rate of 5%. With production of 81.2 million tonnes of steel, India has
maintained 4th position and is expected to become the 2nd largest producer of crude steel in
the world. India also maintained its lead position as the world's largest producer of direct
reduced iron (DRI) or sponge iron.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 20
Afric
a
Fran
ce
EU(1
5)
EU(2
7)
Othe
rEu
rope
Russ
ia
C.I.
S
The worldwide meltdown beginning mid-2008 had put a question mark on future of all
segments of economy including manufacturing, automobile and construction. Nevertheless,
the fiscal measures being taken by the Govt. of India assured that the growth in economy will
be sustained through emphasis on infrastructure development and employment
generation.
The steel industry in India is expected to grow at around 7% p.a. feel experts. This is higher
than the rate at which it has grown in the last financial year. The recent reforms announced by
the Government as well as the expected monetary policy easing to be announced by the RBI
may play the accelerator for growth in the steel industry. The lifting of the iron ore ban down
south will also help in this regard.
Another positive factor for steel industry is the very low per capita steel consumption of India
as shown in figure-2.2 below.
Figure 2.2 (Source – 2012 Steel Industry Outlook, BOC International)
India’s steel consumption grew 3.3%, lowest in three years, to 73.3 million tonne in 2012-13
on subdued demand due to slackening economy and high interest rates. It grew by 5.5% in
2011-12 and 9.9% in 2010-11.
Indian economy grew by 4.9% last fiscal. The government expects it to clock 5.6% growth in
2014-15.
Broadly, steel consumption of an economy grows by 1.2 times of the GDP. Though it did not
happen for India in last fiscal, government officials believe it could actually happen this time
around.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 21
India’s per capita steel consumption is just around 60 kg, as against the world average of over
210 kg, and 460 kg in China.
In this respect, one of the major initiatives that need to be taken is to focus on increasing the
consumption of steel in the rural areas of India. The potential for the growth of consumption
of steel in the rural areas of India for purposes like rural housing, rural infrastructure, etc is
high which needs to be tapped efficiently. The growing involvement of private sector in
steel production would lead to adoption of innovative marketing techniques to boost steel
demand. This falls in line with the objectives and intentions of the Ministry of Steel as part of
the National Steel Policy.
2.4.3 Projection of Demand and Capacity
Steel demand has been forecast based on a projected growth path of the GDP as growth in
steel demand is closely linked to the growth in GDP and the intensity of steel use in the
economy.
Taking into account the recent developments around the world and the Indian economy and
observing the general pattern of growth in other middle income and emerging economies,
steel demand has been projected under two likely scenarios of 7% and 8% GDP growth rates
per annum. (Table–2.3) Also, another scenario of 6.0% GDP growth rate, however unlikely
this may be, has also been drawn up to assess the critical minimum requirement of the
economy in the worst case scenario.
Table 2.5 Estimated Steel Demand and Required Crude Steel Capacity, 2011-12 to 2025-26.Growth Scenario Projected Demand for Finished Steel (MT)
2011-12(Actual)
2025-26 CAGR (%) Implicit GDPElasticity
GDP Growth at 7%
70.92 202 7.8% 1.11
GDP Growth at 8%
70.92 233 8.9% 1.11
GDP Growth at 6%
70.92 175 6.7% 1.11
Crude Steelcapacity Requiredto SustainProjected Demandin the Base case
88.40 244
The basic assumptions of the steel demand forecast adopted here are as follows.
a) GDP growth is sustained around 7–8 percent per annum with perceptible improvements in
basic structural strength of the economy so that the projected growth rates can be sustained
over a long term. Projections made here, however, assume that no drastic structural change of
the economy will take place involving major parameters such as savings and investment.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 22
b) The projections of demand has been made on the assumption of zero trade balance in
steel e.g., imports and exports of steel balance out.
2.4.4 Outlook for Steel Demand and Steel Supply
(a) Domestic Demand
(i) Demand for steel is closely linked with production activities in various sectors of the
economy. Being the basic material for development of economic and social infrastructure,
steel is used for producing capital goods as well as final consumption goods. As a result one
may establish a direct relationship between economic growth as measured by Gross Domestic
Product (GDP), Gross Fixed Capital Formation (GFCF) & Index for Industrial Production
(IIP) and demand for steel. The same methodology based on the estimated relationship
between GDP and steel demand was adopted while making the projections of steel
demand for the 11th Plan period and it did give a fairly accurate assessment.
(b) Export Demand
(i) India has enormous potential, necessary resources and capabilities to become a global
supplier of quality steel. Also there exists ample market opportunities in the neighbouring
regions of Asia, Africa and the Middle East. The policy framework while according top
priority to meet domestic demand should also take into account the large export possibilities.
Table 2.6 Estimated Demand and Capacity CreationCategory Explanatory
Variable(CAGR during
2005-06 to2010-11)
Growth Rate
assumed for 12th
Plan (%)
Projection based onassumed growth rate
(2016-17)-MT
Long ProductsBars &Rods
Construction(8.3%)
11.0 44.1
Structural Construction(8.3%)
9.5 9.4
Rly.Material
Construction(8.3%)
5.0 1.4
Total Non-Flat 10.5 54.9Flat Products
Plates Consumption ofOil & Gas(8.9%), GDFCin Plant &machinery 8.9%)
7.5 7.3
HRCoils/Sheet/Skelps
IIP inmanufacturing(9.7%)
9.0 23.8
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 23
Cr Coils/Sheet
IIp in transportequipment(12.8%),consumption ofpetrol (4.3%)
11.0 11.8
CoatedSheets
10.8 8.8
ElectricalSheets
InstalledCapacity inPower (6.6%)
8.0 0.8
Tin Plates GDFC inPlant &machinery(8.9%)
8.0 0.6
Pipes GDFC inPlant &machinery(8.9%)
12.0 2.9
Total Flat 11 56.0Total Carbon Steel 110.9Demand for Alloy/StainlessSteel
5.0
Total Domestic Demand forSteel
115.9
Total Requirement of crudesteel
139.9
Likely Capacity of CrudeSteel
140.0
Source: Development and Growth scenario for Steel Industry in India by SAIL2.5 Major Steel Consuming Sectors
There are four major drivers of steel consumption: Auto sector, Construction, Capital goods
and Consumer durables.
Among these the “Construction” has close to 50% share as per analysis of the World Steel
Association (formerly International Iron & Steel Institute-IISI) for the year. In context of
India this is expected to be still higher in view of the need for housing and the vast potential
of infrastructure development in the form of Roads, Bridges, Ports, Railways etc. Steel has
emerged as an ideal construction material. With suitable composition and thermal treatment,
steel exhibits a wide range of properties: a very high strength for use as load bearing member,
and toughness for use in extreme temperatures, etc.
2.5.1 Sector-Wise Projected Consumption
Developed countries have higher per capita consumption as these countries have higher
consumption of flat products which is used to produce consumer oriented products. In
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 24
comparison, the developing countries require more of long products for the development of
infrastructural facilities of the nation.
In Indian scenario the scope of consuming steel has long way to go. The potential is mainly in
the constructional industry which is expected to move from concrete-intensive construction to
steel- intensive construction.
The four major drivers of steel consumption are:
Auto Sector, Construction, Capital Goods, Consumer Durables.
Figure 2.3 below gives the future consumption pattern in various sectors.
Figure 2.3 Future ConsumptionThe usage of steel in construction has increased due to tremendous change in construction
technology namely Composite Construction, Light Steel Framing and Modular
Construction etc.
2.5.2 Rebars Production & ConsumptionAt present Rebar market is dominated by regional players due to high logistics expenses.
Eastern and Western Regions have the largest concentration of small re-rolling mills for steel
rebars. There are about 1800 small producers and the market is highly fragmented and un-
organized. Also these producers produce Induction Furnace based steel having quality
problems. Thus there is great scope for development of quality producers going through Blast
Furnace / Electric Arc Furnace route. The break-up of rebars by various producers is
presented in the bar chart below. As can be clearly seen the unorganized sector
accounts for over 74% of the total rebar production in 2012-13.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 25
The annual consumption of Rebar from 2008-09 to 2013-14 and future forecast of demand
from 2015-16 to 2020-21 is shown in following chart. It will be seen the annual demand is
expected to grow from present level of 23.91 million ton to 41.82 million tons by 2020-21
giving a CAGR of 10.16%.
2.6 Alloy & Special Steel Sector
Alloy steel industry registered a rapid growth during the last two decades. Many existing
alloy steel manufacturers undertook expansion and modernization programmes to update the
technology, improve productivity, reduce costs, conserve energy and achieve better quality.
Currently, there are 24 recognized alloy and special steel manufacturers in the
country with an installed capacity of almost 6.5 million tonnes per annum. The product range
of the industry is quite comprehensive as it covers nearly 250 grades of alloy and special
steels. The capacity of individual units lies in the range of 24 to 800 thousand tonnes per
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 26
annum. 13 manufacturers produce Alloy Steels from scrap, whereas 11 manufacturers have
Ore based units.
Imports constituted a significant share of the overall availability of alloy and special steels in
the country during early 80's. Imports have since come down with improved availability from
indigenous manufacturers. Other than certain specialty products for critical applications,
imports are resorted to by a few consumers based only on price preference. Major imports in
the field comprise CHQ (Cold Heading Quality) wire rods for the high tension fastener
industry; blooms for seamless pipe industry and tool & die steels. Currently, aggregate import
of alloy and special steels in the country is of the order of 100 thousand tonnes per annum,
comprising CHQ wire rods, forging quality steels and seamless pipe quality blooms. Exports
of alloy and special steels have been varying over the years and have been quite erratic. From
time-to-time, certain categories of alloy steels have been exported either through MMTC - the
canalizing agency or through manufacturers directly. Currently direct exports of alloy and
special steels from India are estimated at around 50 thousand tones per annum. Additionally,
substantial quantities of alloy and special steels are being exported indirectly from India in
the form of semi-finished / finished products. Taking into account the domestic production,
imports and exports, apparent domestic consumption of alloy and special steels during the
year 2012-13 works out at around 4.3 million tones.
The Indian alloy and special steel industry registered an ACGR of 10.3 percent per annum
during the period 2003-04 to 2007-08. During the year 2008-09, the industry witnessed a
negative growth of 21 percent as a result of global melt down, following the Lehman
Brothers crisis. Thereafter, the industry registered an ACGR of 12 percent till the year 2012-
13. Based on the past performance, current status and future outlook for the industry, the
domestic alloy and special steel industry is likely to register an ACGR of around 9 percent
per annum till the year 2021-22.
Table 2.7 Past & Projected Demand: 2003-04 to 2021-22
Year Demand (Th. Tonnes) ACGR (%)2003-04 2,300 10.32007-08 3,410 --2008-09 2,700 (-)21.02012-13 4,250 12.02021-22 9,230 9.0
Based on the above, the domestic consumption of alloy & special steels is likely to increase
from 4.3 million tonnes in 2012-13 to almost 9.2 million tonnes per annum by the year 2021-
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 27
22. Currently, there is over capacity in the country for the manufacture of alloy &: special
steels. At an average growth in domestic consumption of around 9 percent per annum from
2012-13 onwards, the existing capacities would be adequate to meet the emerging demand
only till the year 2016-17. It will be necessary to create additional capacities in order to meet
the projected requirements during the post 2016-17 period. It is estimated that around 3.8
million tonnes per annum of additional capacities would need to be created during the next 5-
year period in order to meet the requirements projected by the year 2021-22.
Table 2.8 Need for Additional Capacity: 2012-13 & 2021-22(Th. Tonnes)Year Demand Potential
DomesticAvailability
Surplus/Gap Additional CapacityRequirement
2012-13 4,250 4,250 -- --2021-22 9,230 5,850 3,380 3,750
2.7 Employment Generation (Direct and Indirect) Due to the Project
The organizational structure that would be required for the Plant operations has been given
due consideration. The total man power requirement for the project during operation will be
898. The manpower requirement has been planned keeping in view the following:
Smooth & efficient running of the plant with optimum manpower.
Capacity utilization with optimum energy consumption.
Effective coordination
Rational distribution of responsibilities
The organizational development would be started from the project phase itself as
those involved with the project would also be trained for Operations.
The total manpower requirement for the Plant and Administration has been estimated on
the basis of functional requirement of a modern plant. For loading of packed cement in
trucks and for housekeeping, contract / casual labour have been considered.
Table 2.9 Manpower Requirement during operation
Sl. No Category Proposed Manpower
1 Managerial Staff 602 Executives 803 Skilled 1354 Unskilled 4505 Office staff 73
Total 898
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 28
Training of Personnel
Training of the required manpower for the proposed project shall be planned, well in
advance. The key personnel shall be selected and trained suitably. The training shall be
carried out in the following manner:
Onsite training during the construction phase of the Project
On job training during the commissioning phase of the project.
On job training during operation of the plant immediately after commissioning.
The training of the key engineering personnel such as Process Engineer, Mechanical
Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the
facets.
The training of the key operating personnel such as cement mill operator, Packer
operator, mechanic, welder, fitter and electrician shall be suitably carried out during the
construction, erection and operation phases.
The training program shall include the following aspects among others so as to impart
knowledge and training to the key personnel in relevant aspects of the plant design, operation
and maintenance:
Understanding the functions of various units.
Understanding the equipment in respective sections.
Important parts and control in each equipment.
The hazards in respective sections and precautions to be taken for safety of the
equipment & personnel.
Inspection, preparation and start up of equipment in respective sections.
Routine operation of respective sections.
Shut down procedures for respective sections.
Procedure for attending to emergency stoppage due to failure of power, water and
air supply.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 29
CHAPTER - 3
PROJECT DESCRIPTION
3.1 Type of Project
M/s The Sandur Manganese & Iron Ores Limited (Here after SMIORE) currently
operating a Ferro Alloy plant ( 3 Submerged Arc Furnaces with total capacity 55 MVA, 1
Sintering plant of 1.5 MT, Manganese Ore Beneficiation Plant 2 t/Hr input and 32 MW Coal
based CPP) at Hanumanhalli village, Danapur Mandal, Hospet Taluk, Bellary District of
Karnataka State. Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant
to 1.0 MTPA Integrated Steel Plant in 3 phases comprising of following units:-
Table 3.1 Proposed Configurations (Expansion)
Sl.No.
Plant/UnitName
Configuration FinalAnnual
Production
FinalCapacityin MTPAPhase-I Phase-II Phase III
1 Blast Furnace
1x 0.4MTPABF
( Size 350-400m3 )
~ 1212.12TPD
-
1x0.4MTPA
BF( Size 350-
400m3 )~ 1212.12
TPD
2 x 400000TPA
0.800
Pig CastingMachine
1212.12TPD
- -1 x 400,000
TPA 0.400
2Coke OvenPlant andWHRB
0.4MTPA~ 1212.12
TPDWHRB -130TPHSteam
Generation
- -1 x 400,000
TPA 0.400
3 Sinter Plant1 x 50 m²
~1600 TPD-
1 x 50 m²~1600 TPD
2 x 528,000TPA
1.056
4Energy
OptimizationFurnace (EOF)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
5
Ladle RefiningFurnace ( LRF)
& VacuumDegasser (VD)
-1 X 50 T
~1602TPD
1 X 50 T~1602 TPD
2 x 528,710TPA
1.057
6Continuous
Casting machine(CCM)
-1 X 4Strand9/16 m
1 X 4Strand 9/16
m radius
2 x 518,135TPA
1.036
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 30
radius~1570TPD
~1570 TPD
7Rolling (Rebar
Mill)-
1 X 100TPH
~1515TPD
1 X 100TPH
~1515 TPD
2 x 500,000TPA
1.0
8 Oxygen Plant1 X 100
TPD1 X 350
TPD--
1 x 33000TPA + 1 X
115500 TPA -
Maximum No. of Working Days considered for all units - 330
3.2 Location
The proposed facilities of the 1.0 MTPA Integrated Steel Plant comprising of Sinter
Plant, Mini Blast Furnace, Pig Casting Machine, Steel Melt Shop, Continuous Casting
Machine, Rebar Mill and WHRB will be installed at Vyasanakere, near Hospet in the
State of Karnataka in the land owned by SMIORE to South and South East of their
existing/ adjoining Ferro Alloy Plant complex. The proposed location of steel plant site
bears the following coordinates. The proposed site falls under the Survey of India Toposheet
No. 57A/8 and the buffer zone falls under the Survey of India Toposheet 57 A/7. The
Latitude and Longitude of the proposed site is 15°11'47"N and 76° 22'50"E respectively.
3.2.1 Plant Location
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 31
Figure 3.1 Index Map
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated Steel Plant comprising of Sinter Plant, Mini BlastFurnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 32
Figure 3.2 Topo map- 10Km Radius
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 33
3.2.2 Alternative Sites Examined
As this is an expansion project proposed to be set up within the existing plant premises so no
alternative site has been considered.
3.2.3 Land Requirement
The requirement of total land including existing plant , proposed expansion and Green Belt is
320.79 Acre (129.81 Ha.). The proposed expansion shall be located within the existing plant
premises at- Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet
Taluk,Bellary District, Karnatak. The land has been already identified & acquired.
3.2.4 Plant Layout
The layout of the plant when developed will have the following features.
Process departments will be consolidated into comprehensive production units
requiring short conveying distances;
The major utilities and service facilities will be centrally located in respect to points
of high consumption;
Sufficient space will be provided for ease of operation and maintenance;
The lengths of power cables will be minimized by suitably locating load distribution
centres in respect of process departments;
Outward movements of materials from customers/suppliers will be segregated from
internal plant traffic
Sufficient space for storage of raw materials.
Adequate green belt & provision for future expansion.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated Steel Plant comprising of Sinter Plant, Mini BlastFurnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 34
Figure 3.3 Plant Layout
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 35
3.3 Site Selection
The site selected by SMIORE for setting up the Integrated Steel Plant has the following features
and infrastructure facilities:
The nearest railway station is Vyaspuri Colony about 200 meters from plant site on the
Hospet – Kottur broad gauge railway line of South Western Railway which passes close to
the east side boundary of the existing Ferro Alloy Plant of SMIORE and the proposed
Integrated Steel.
Railway culvert to connect the existing plant site of SMIORE to the proposed site is
proposed to be constructed under the railway line. Statuary approvals for the same are in
process.
Tungabhadra River Dam with perennial source of sweet water is running at distance of about
12 kms from the plant site.
The National Highway NH-13 passes on Western periphery of the plant site providing
excellent connectivity for road transport.
Hospet town is about 12 kms from the plant site facilitating residential needs of the
staff.
A 110 KV line supplies power to the Main Receiving Sub Station (MRSS) in the existing
plant facility of SMIORE.
3.4 Technology Selection
Correct selection of production technology is vital for the long term viability and sustainability
of the project. This requires an in-depth study of the technological developments with regard to
productivity, energy efficiency, environmental emissions and disposal of effluents etc. The
diagram showing different stages of the Production Process Flow and material balance on net &
dry basis for the proposed 500,000 tpa Integrated Steel making facility is attached as
Annexure-3.1. The project shall include Iron making facilities i.e. Sinter Plant, Blast Furnace &
Pig Casting machine. The Coke Producing unit along with WHRB for power generation and a
Blast furnace gas based power plant shall also be installed. The Steel Making & Rolling unit
shall be setup as down steam units of the project.
The Pig Iron manufacturing technologies related to Integrated Steel Plant can be divided into the
following broad Steps:
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 36
i. Raw Materials to Metallics;
ii. Metallics to Liquid Steel;
iii. Liquid Steel to Refined Liquid Steel; and
iv. Refined Liquid Steel to Semis, i.e. Billets & Blooms.
Raw Materials to Metallic
Basic raw materials for an integrated steel plant are Iron Ore Lumps, Iron Ore Fines, Coke or
Coking Coal and Fluxes – Limestone, Dolomite etc. Metallics can be defined as the intermediate
products which are then converted to steel. The metallics include intermediate products like
Molten Pig Iron called Hot Metal (HM), Direct Reduced Iron (DRI), Recycled Scrap and Cold
Pigs.
The three different methods that can be used for the production of iron from Iron ore are:
Coke-Ovens -Sinter-Blast Furnace (BF) Route, Direct Reduction Technique and Smelting
Reduction Technologies.
Hot metal as a metallic feed in steel making has the advantage of both thermal heat content of the
metal and the chemical energy of the charge in subsequent processing. The most popular process
route for production of hot metal is “Sinter Plant + Blast Furnace”.
3.4.1 Blast Furnace Process
In an integrated steel plant, Blast Furnace plays a vital role in controlling production and
economics of plant and it normally accounts for about 60 percent of the energy consumption for
production of one ton of steel.
Irrespective of the developments in iron making processes, Blast Furnace remains the
undisputed leader due to established technology. Even today more than 60% steel is
manufactured though the BF Route. Only disadvantage is the shortage of Coke worldwide. Coke
is produced by controlled combustion of coking quality coal in coke ovens. Due to this, cost of
coke is rising day by day and the route is becoming Costlier. Technologies are being developed
to reduce the consumption of coke in BF’s.
The technology of Iron making through blast furnace is one of the time tested metallurgical
processes which is continuing for many decades without any sign of being made obsolete by
modern developments. It is projected in the international scenario that this technology will
continue easily for the next fifty years without threat of obsolescence. The process is based
upon a moving bed reduction furnace which reduces iron ore with coke and limestone. The
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 37
blast furnace essentially works on the counter-current principle. The descending solid charge
meets a current of ascending gases and reduction of iron ore takes place along with its
progressive heating. The reduction of iron ore is the most important and most difficult one also.
Iron ore, Coke, Sinter and limestone are charged by a skip or directly through conveyor from the
top of the furnace. Mini and Medium Blast furnaces range around 4 to 6 m in hearth diameter
and are around 30 m tall. The furnace is basically a vertical shaft of circular cross-section and is
made of five main sections. Bottom-most part of the furnace is called hearth, where liquid metal
and slag is collected. This is surmounted by an inverted cone known as bosh. A short vertical
section, called bosh parallel connects the bosh to the truncated upright cone called stack, which
in turn support the throat.
Operating procedures comprise; charging of ore, sinter, coke and fluxes either by skip or
conveyor to the furnace top and using one of the devices like two bell systems with or without
movable throat armour or bell less top for burden distribution.
Preheated air is blown from near the bottom through tuyeres close to the junction of hearth and
bosh. Combustion of coke in front of tuyeres generates heat and reducing gases. The ascending
gases carry this thermal energy and transfer the same to the descending burden. Simultaneously,
the carbon monoxide (CO) rich gases when they leave the combustion zone partially reduce the
iron oxide present in the ore and sinter.
About 65% of oxygen in the iron bearing material is reduced by the gases, called indirect
reduction and the rest of oxygen and the metalloids (Mn, Si, P) are reduced directly by the
carbon (this is called direct reduction) at lower zone of blast furnace.
Coke carbon reacts with iron oxides in the furnace, releasing the iron and producing CO and
CO2 gas. The iron sinks to the furnace hearth whereas the impurities present in ore and sinter
called gangue material like SiO2, Al2O3 etc and the ash component of coke combines with
fluxes (CaO, MgO) to form a fluid slag. Being lighter, slag floats on the top of the molten iron.
The gas leaving from the top of the furnace, carries with it fine dust which is separated and
recovered through a gas cleaning plant. The combustible BF gas, after cleaning, is used for
heating of the stoves and for generating steam at boiler house. This BF gas can also find
application in Reheating furnaces of Rolling Mills.
The iron and slag are tapped by opening the tap hole at regular intervals. Iron is collected
in refractory lined ladles. The hot metal so produced is sent to the steel melting shop for steel
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 38
making. The slag is granulated in cast house by high pressure water and is generally used for
cement making or for construction related activities. Metallurgical coke suitable for BF is a
scarce commodity but still the BF route is preferred.
3.4.1.1 Smelting reduction technology
It is a is a coal-based iron making process and thus different from the conventional coke-based
conventional blast furnace. Most smelting reduction processes also avoid the agglomeration of
iron ore. Smelting reduction technology, as the name clearly suggests, involves both solid-state
reduction and smelting. Unlike Direct Reduction, SR produces liquid hot metal like a Blast
Furnace.
Smelting is melting involving chemical reduction reactions. Smelting reduction technology
exploits the principle that coal can be gasified in a bath of molten iron. Smelting reduction
technology is the only recent serious contender to replace the conventional energy- intensive
blast furnace that has been the dominant iron making technology for centuries.
Some of the important processes of SR technique are COREX, FINEX,
HISmelt, and Blast Furnace (to extend BF technology to small capacity) COREX has couple of
commercial plants in operation including one at JSW in India and FINEX has been
commercialized with the operation of first 1.5 Mtpa plant at POSCO, Pohang Works in Korea.
All these SR processes make use of non-coking coals. A brief introduction of some of these
processes is given below:
3.4.1.2 COREX Process
COREX is an industrially and commercially proven smelting-reduction process developed by
Siemens VAI for the cost-efficient and environmentally friendly production of hot metal from
iron ore and coal. The process differs from the conventional blast furnace route in that non-
coking coal can be directly used for ore reduction and melting work, eliminating the need for
coking plants.
The Corex process was developed in the late 1970s and its feasibility was confirmed during the
1980s. Following the first industrial application of a Corex C-1000 plant (nominal production of
1,000 tons of hot metal per day) at Iscor Pretoria, South Africa, four C-2000 plants (nominal
production of 2,000 tons of hot metal per day) were subsequently put into operation at
Posco/Korea, Mittal Steel/South Africa and at JSW Limited/India. In early November 2007, the
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 39
first Corex C-3000 plant was started up at Baosteel, China. It has a nominal production capacity
of 1.5 million tons of hot metal per year.
In the Corex Process all metallurgical work is carried out in two separate process reactors – the
reduction shaft and the melter gasifier. Lump ore, sinter, pellets or a mixture thereof are first
charged into a reduction shaft via a lock-hopper system where they are reduced to direct-reduced
iron (DRI) by a reduction gas moving in the counter-flow direction. Discharge screws convey the
DRI from the reduction shaft into the melter gasifier where final reduction and melting takes
place in addition to all other metallurgical and slag reactions. Hot metal and slag tapping are
carried out as in conventional blast furnace practice. The quality of the hot metal is equivalent to
that produced in a blast furnace.
Viewing the process from the coal-route perspective, non-metallurgical coal is directly charged
into the melter gasifier via a lock-hopper system. Due to the high temperatures predominating in
the dome of the melter gasifier (in excess of 1000 °C), a portion of the hydrocarbons released
from the coal during de-volatilization are immediately dissociated to carbon monoxide and
hydrogen. Undesirable by-products such as tars and phenols, etc. are destroyed and therefore
cannot be released to the atmosphere. Combustion with oxygen injected into the melter gasifier
results in the generation of a highly efficient reduction-gas.
The reduction gas exiting from the melter gasifier consists mainly of CO and H2 laden with fine
coal, ash and iron dust. This dust is largely removed from the gas stream in a hot-gas cyclone and
is then recycled to the process. Through the addition of a cooling gas, the reduction-gas
temperature is adjusted to its optimum working range. After leaving the hot-gas cyclone, the
reduction gas is then blown into the reduction shaft via a bustle, reducing the iron ores in counter
flow.
The top gas is subsequently cooled and cleaned in a scrubber, after which it is available as a
highly valuable export gas with a net calorific value of approximately 7,500 – 8000 kJ/m³ (STP).
This gas is suitable for use for a wide range of applications, including:
Power Generation
Production of DRI
Heating Purpose within the Iron & Steel Complex.
3.4.1.3 FINEX Process
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 40
FINEX process of iron making has been developed jointly by Siemens VAI and POSCO. It
makes use of iron ore fines and non-coking coal and a plant has been put in operation with
operating capacity of 1.5 million ton per annum in the year 2007-08. It is claimed that the
process can make use of low-grade ore and low-ranked coal, has flexible operation with
independent control of reduction & melting processes. The process is claimed to be
environmental friendly with relatively low emission of SOx, NOx & dust and scope of CO2
sequestration. It is claimed to be Cost Competitive with capital investments shown to be 80%
and operating cost 85% in comparison to BF route.
3.4.1.4 HIsmelt Process
HIsmelt Process was started by a consortium of Rio Tinto, Nucor Corporation, Mitsubishi
Corporation, and Shougang Corporation. The group has set up an 800,000 tpa plant in Kwinana,
Western Australia. The merchant pig iron facility has been designed and engineered with a 6-
metre hearth diameter Smelt Reduction Vessel. It is claimed that HIsmelt Technology can make
use of low grade iron ore and can be started, stopped or simply kept idle without any problem.
The HIsmelt Corporation has started marketing of the technology based on its success at the
Kwinana project.
3.4.1.5 Direct Reduction Processes for Iron Making
Electric arc furnace (EAF) route of steelmaking originated essentially to recycle the scrap steel.
Faster growth in the sector led to shortage of scrap and the direct reduced iron (DRI) or sponge
iron has served as an alternative feed stock that involves reduction of iron ore in solid state.
Besides replacement of scrap, DRI has additional advantage of being virgin feed for quality
steels where tramp elements accompanied with recycled scrap need be avoided or diluted to the
extent desirable.
The technology of Iron making through blast furnace is one of the time tested metallurgical
processes. Irrespective of the developments in iron making processes, Blast Furnace remains the
undisputed leader due to established technology. Even today more than 60% steel is
manufactured though the BF Route. It is projected in the international scenario that coal reserves
would be available for next fifty years and that this technology will continue easily without
threat of obsolescence. To reduce the consumption of coke Technologies like Pulverized Coal
Injection, Oxygen Enrichment of the Combustion air have been developed and adopted. On
analyzing the available technologies, BF is the best route and is recommended.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 41
3.4.2 Coke Oven
Coking coal contributes to approximately 50% of the cost of hot metal. Therefore, it is logical
that coke quality and price needs to be kept under control in the iron and steel industry to be
competitive. The two primary variables that influence the price and quality of BF coke are –
coke making technology and raw materials used. Some of the technological developments that
have improved performance of industry are:
Stamp Charging of Coal
Partial Briquetting of Coal Charge (PBCC)
Selective Crushing of Coals
Dry Coke Quenching
3.4.2.1 Types of Coke Oven Plants
The coke making process involves carbonization of coal to high temperatures (1100°C) in an
oxygen deficient atmosphere in order to concentrate the carbon. There are two commercial coke
making processes-
By-product Coke making
Majority of coke production in the world is from by-product coke oven batteries. The coke
making operation comprises of the following steps:
Coal from different mines is blended, pulverized, and oiled. The blended coal is charged into
a number of slot type ovens.
Coal carbonized in reducing atmosphere and the off-gas is collected and sent to the by-
product plant.
Non-Recovery/Heat Recovery Coke making.
Non-Recovery coke plants, originally referred to as beehive ovens, have large oven chambers.
The carbonization process takes place from the top by radiant heat transfer and from the bottom
by conduction.
Primary air for combustion is introduced into the oven chamber through several ports located
above the charge level in both pusher and coke side doors of the oven. Combusted gases exit
through common tunnel via a stack which creates natural draft. Since by-products are not
recovered, the process is called Non-Recovery Coke making.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 42
The waste gas is fed into a waste heat recovery boiler to convert waste heat into steam for power
generation; hence, the process is also called Heat Recovery Coke making.
The Non-Recovery Coke Ovens are considered eco-friendly in comparison to recovery type. It is
less capital intensive and has shorter construction periods as compared to recovery type Coke
Oven. Main features are:
Energy of carbonisation is supplied by burning the gaseous volatile products released from
the coal charge during carbonisation.
Heat generated by the combustion of the volatile matter, produces high temperature zone in
the free space above the coal charge. This radiates back into the coal charge downwards.
The products of combustion are drawn through the various points in the oven arch and passed
through side wall off-take flues into a series of sole flues located below the oven floor.
Application of heat takes place from above, sides and below the charge. Temperature at the
point where burning gases are drawn into the side off take ports is of the order of 1200 oC.
3.4.2.2 Selection of Oven Technology
Out of the two types of ovens – horizontal and vertical type, the later has been considered
technologically advantageous. Technical benefits of Vertical Type Coke Ovens are:-
Lower cost and higher yield: Coking and combustion chambers of vertical type heat recovery
ovens are completely apart from each other. The oven door is smaller, does not get deformed and
is easy to seal.
Since heating is carried out in the combustion chamber, air is kept out of contact with coal. Thus
burning up to ash in the final stage of coal-to- coke conversion is avoided reducing loss of
material.
In horizontal type heat recovery coke ovens, the air leakage around the oven door can occur as it
is difficult to have a perfect sealing. Correspondingly, inlet air increases leading to burning loss
in the range of ~ about 5%, which is a large waste.
Good utilization of heat energy, as the vertical type heat recovery coke ovens have theadvantages of modern recovery coke ovens.
3.4.3 Sintering Process
Sintering is one of the technologies for agglomeration of iron ore fines into useful BF burden
material. This technology was developed in the early 20th century for treatment of waste fines.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 43
Since then, sinter has been widely accepted and is the preferred BF burden material. Presently
more than 70% of hot metal in the world and about 50% in India is produced through sinter. The
major advantages of using sinter in BF are:
Facilitates use of fines of iron ore, lime, dolomite, coke breeze, and other metallurgical waste
for hot metal production;
It has better reducibility and other high temperature properties;
BF productivity is enhanced with improved quality of hot metal;
Facilitates reduction in coke rate;
3.4.3.1 Basic Technology
Raw materials for sinter are: iron ore fines (-8mm), coke breeze (-3 mm), limestone & dolomite
fines (-3 mm) and other metallurgical wastes. Proportioned raw materials are mixed and
moistened in a mixing drum. The mix is loaded on sinter machine through a feeder on to a
moving grate (pallet) and then rolled through a segregation plate so that coarse materials settle at
the bottom and fines on the top.
Top surface of mix is ignited through stationary burners at ~ 1000 °C. As pallets move forward,
air is sucked through wind boxes situated under the grate. A high temperature combustion zone
is created in the charge-bed with burning of solid fuel of the mix and regeneration of heat of
incandescent sinter and outgoing gases. Due to forward movement of the pallet, the sintering
process travels down.
Sinter is produced as a combined result of locally limited melting, grain boundary diffusion and
re-crystallization of iron oxide. On completion of the process, the sintered cake is cooled,
crushed and screened.
3.4.3.2 Main Features of the Sintering Machine
i. Sinter plant to have Irish mixer (High intensified mixer) to maximize usage of ultra fines
from the mines.
ii. Fuel preparation system adopts open-circuit crushing consisting of four- roller crushers to
ensure more than 85% fuel particle size 3-0 mm to reduce fuel consumption and achieve better
chemistry.
iii. Automated weighing dosing is employed to improve dosing accuracy, ensuring consistent
quality of sinter, reducing fuel consumption and achieving stable production.
iv. Deep-bed sintering for economical operation of the process
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 44
v. Circular Sintering Machine with Circular cooler has been considered for its high productivity
and compact Design. It has simple structure with ease of operation and maintenance.
vi. Electric dust removers are installed at machine head and tail end with dust removal efficiency
of more than 99 %.
vii. Standard air draft device adopted for high efficiency and low power consumption.
3.4.4 Metallics to Liquid Steel
The options available for conversion of Metallics to Liquid Steel are:
i. BOF/LD- Basic Oxygen Furnace/LD Convertor
ii. EAF- Electric Arc Furnace
iii. EOF- Energy Optimizing Furnace
iv. IF- Induction Furnace
3.4.4.1 Basic Oxygen Furnace (BOF)
Among various technologies for steelmaking, Basic Oxygen Furnace (BOF) or LD
Converter is the predominant steelmaking route accounting for over 55% or more of the
world steel production. It requires approximately 85-90% feed as hot metal with balance scrap as
coolant to take care of the thermal energy generated during oxygen blowing. The process is
very fast and suits capacities with various converter size. The infrastructural requirements
of the shed and pollution control arrangement make it capital intensive.
The process differs from the EAF in that it is autogenous, or self- sufficient in energy. The
primary raw materials for the LD Convertor are
80-85% liquid hot metal from the blast furnace and the balance is steel scrap. These are charged
into the Furnace vessel. Oxygen (>99.5% pure) is "blown" into the LD Convertor at
supersonic velocities. It oxidizes the carbon and silicon contained in the hot metal liberating
great quantities of heat which melts the scrap. There are lesser energy contributions from the
oxidation of iron, manganese, and phosphorus.
The product of the process is molten steel at 1600°C-1650°C with a specified chemical analysis.
From here it may undergo further refining in a secondary refining process or be sent directly to
the continuous caster where it is solidified into semi finished shapes: blooms, billets, or slabs.
Trends and Drivers in the BOF/ LD Convertor can be summarized as follows:
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 45
Advances in slag splashing that extend refractory life and use of post- combustion lances
have improved furnace availability.
Increasing demand for ultra-low-carbon (ULC) steels has made secondary processes more
important.
Hot metal desulfurization is usually done in the BOF transfer ladle.
Meanwhile, steelmakers constantly experiment with BOF oxygen lance configurations,
oxygen batching and flux additions practice.
Technological Challenges:
Life incompatibility of the lower hoods shorter than the furnace, and related maintenance
issues.
Environmental standards are getting tougher.
Furnace vessel shell distortion and destruction during a long campaign are a constant
challenge.
3.4.4.2 Electric Arc Furnace (EAF)
EAF offers an alternative method of bulk steel making. Unlike the BOF route, the Electric Arc
Furnace does not use 85-90% hot metal but can definitely work with 50-60% hot metal and
the remaining charge consists of material such as steel scrap or sponge iron. EAF requires
heavy pollution control equipment. Modern electric arc furnaces typically make up to 150 tonnes
of steel in each heat which takes around 70 minutes.
Due to principle of operation EAF’s require high short circuit levels and heavy transmission
lines for back up. This in itself is expensive equipment and adds to the cost of EAF
installation. Regular maintenance of electrical components is also an additional requirement.
In India the early 70’s and 80’s saw a massive growth of electric arc furnace (EAF) and
induction furnace (IF) based steelmaking units respectively. This had created a growing demand
for steel scrap, as a result of which the scrap was in short supply. Moreover, significant
improvements in steel plant yield, rolling technology and continuous casting processes have
decreased the amount of in-plant generation of scrap. This ultimately has resulted into the
shortage of scarp supply throughout the world and its fluctuating prices.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 46
Although steel scrap is rather a tailor made input material, problems faced by steelmakers are its
short supply, fluctuating prices, heterogeneous nature and above all higher content of tramp
elements (0.1 to 0.8%).
The non-availability of consistent quality scrap at a reasonable price necessitated the search for
an alternative to scrap for use in secondary steel sectors. This problem has been tackled using
direct reduced iron (DRI) or sponge iron which is not only a substitute for steel scrap as a feed
material in EAF but also a more suitable melting stock for the production of good quality steels.
Unlike scarp and pig iron, the DRI is characterized by a high porosity, low density, low thermal
conductivity, high specific surface area, relatively high oxygen content and intermediate carbon
percentages. DRI has uniform chemical and physical characteristics; it hardly contains any tramp
metallic elements (about 0.02%) and low sulphur content. This promotes the use of DRI in the
charge as a partial replacement to scrap which ultimately improves the mechanical and
metallurgical properties of the products. Advantages of using DRI as a feed material are reported
elsewhere. Thus DRI is particularly suitable for the production of quality steels. The DRI melting
in EAF is a well-established technology.
3.4.4.3 Energy Optimizing Furnace (EOF)
EOF is a melting and refining furnace using combined oxygen and air blow in bath consisting of
hot metal, pre-heated solid scrap and fluxes.
Submerged oxygen blow reacts with carbon from hot metal, generating CO bubbles, further
oxidized to CO2 by oxygen through atmospheric air injections by supersonic lances.
Sensible heat in the off gases is used for pre heating of scrap, located above the furnace roof.
Salient Features of EOF are summarized below:
i. No electrical energy is utilized for melting of charge.
ii. Maximum heat is utilized from the chemical reactions.
iii. Liquid steel produced is of highest purity with very low phosphorous and sulphur.
This is due to continuous flushing of slag during blowing and slag free tapping.
iv. Low tramp elements in steel due to virgin Liquid Metal route.
v. About a third of oxygen is used for blowing the bath and two thirds facilitates post-
combustion.
vi. Greater flexibility of metallic charge mix, solid addition of scrap up to 40% is possible.
However, DRI usage up to 5%. is possible.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 47
vii. Combined oxygen blowing as submerged and post combustion in atmosphere.
viii. The solid scrap is pre heated by outgoing waste gases.
ix. Especial submerged tuyeres for oxygen blowing with longer life.
x. Blowing time is about 30 minutes and tap-to-tap time less than an hour.
xi. The productivity of an EOF is similar to that for a state of the art EAF but it has relatively
low capital cost because of elimination of the electrical supply equipment.
xii. Efficient pollution control operation under slightly negative pressure, hence no
secondary dust emissions.
xiii. De-slagging and double slag practice possible during oxygen blowing
xiv. Highest productivity
3.4.4.4 Induction Furnace (IF)
The option of Induction Furnace (IF) based steel making is limited to relatively smaller
capacities with limitations of refining steel with slag as is possible in BOF, EOF and EAF
processes.
Among the four steelmaking processes, EOF is considered the most suitable. Major advantages
of EOF are:
i. There is no electrical energy required for melting. The entire operation consumes 30-35
KWH/T of electrical power.
ii. Maximum utilization of all reaction energy, outgoing flue gases
iii. Quality requirement of steel produced especially for low ‘P’ up to 0.025 (max) is best
achieved through EOF. The process is very effective because of de-slagging during oxygen
blowing.
iv. Cost of production is lowest as compared to any other process.
v. Pollution control equipments are cheaper and the route is environment friendly.
3.4.5 Liquid Steel to Refined Liquid Steel
Having manufactured Liquid Steel of the required composition from the LD Convertor, the next
step is to further refine this to the exact chemical composition and other metallurgical
requirements as per the required steel grades.
Technologies available for refining the liquid steel are;
i. Ladle Refining Furnace (LRF)
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 48
In the LRF, liquid steel in deoxidized and de-sulphurised with the help of slag metal reactions
and addition of fluxes. Argon in bubbled to facilitate reactions through stirring. Steel temperature
is raised by arcing with the help of three graphite electrodes. LRF performs the following
operation:-a
Raising the temperature to desired levels (1620oC for mild steel) with perfect soaking of
ladle shell and refractory.
Floatation of non-metallic inclusion making steel clean.
Homogenization of temperature and chemistry.
Presently, LRF is the only process available and hence recommended.
ii. Vacuum Degassing
Vacuum Degassing means removal of harmful dissolved gases from LM. This is a requirement
from end users like Automobiles industry. Depending on the selection of equipment, vacuum
degassing can be carried out in two ways;
Tank VD
In this process ladle with LM is placed inside a tank, the tank is covered and then subjected to
high vacuum. The Tank may be fixed or mounted on a moving car.
RH Degasser
This technology is an improvement over the tank degasser. In RHD, two snorkels of the
refractory lined vacuum vessel are lowered into the ladle with liquid metal. LM is sucked
through one snorkel and returned through the other. LM comes in intimate contact with vacuum.
Efficiency of this process in reaching low gas levels is better than tank degasser.
Both VD & RH degasser are desired for producing alloy steels & specialty steels. These are not
required in the present stage of the project.
RH degasser is suitable for heat sizes of 50 T or above. For smaller heat sizes, like this project,
tank degasser is the best choice and recommended.
3.4.6 Refined Liquid Steel to Semis3.4.6.1 Continuous Casting Machine (CCM)Continuous casting is the process to solidify molten steel into a semi finished billet, bloom, or
slab for subsequent processing. Prior to introduction of the continuous casting practice in
1950s, steel was poured into stationary molds to form ingots. But continuous casting has
substantially added to improved yield, quality, productivity and cost efficiency.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 49
Steel from the LD Convertor -LRF is tapped into a ladle and taken to the continuous casting
machine. The ladle is raised onto a turret that rotates the ladle into the casting position above the
tundish. Liquid steel flows out of the ladle into the tundish and then into water-cooled copper
mold. Solidification begins in the mold, and continues through the first zone and strand guide. In
this configuration, the strand is straightened, torch- cut and then discharged for intermediate
storage or hot charged for
finished rolling. The melting /casting/ rolling processes are linked while casting a shape that
substantially conforms to the finished product. The complete chain from liquid metal to finished
rolling can be achieved within two hours. End-use dictates quality, grade and shape of the cast
product (billet, bloom, slab, beam blank, and/or round).
To start a cast, the mold bottom is sealed with a dummy bar head attached to dummy bar. The
dummy bar is held in place hydraulically by Straightener Withdrawal units. This head prevents
liquid steel from flowing out of the mold. The steel poured into the mold is partially solidified,
producing a steel strand with a solid outer shell and a liquid core. In this primary cooling area,
once the steel shell has sufficient thickness, about 10–20 mm, the straightener withdrawal units
are started. The moving dummy bar starts to withdraw the partially solidified strand out of the
mold along with the dummy bar.
Liquid steel continues to pour into mold to replenish the withdrawn steel at an equal rate. The
withdrawal rate depends upon the cross-section, grade and quality of steel being produced, and
may vary widely depending upon section, quality and machine design parameters. Casting
times are typically matched with the EOF tap-to-tap time.
Upon exiting the mold, the strand enters a roller containment section and secondary cooling
chamber in which the solidifying strand is sprayed with water to promote solidification. This
area preserves cast shape integrity and product quality. Larger cross-sections require extended
roller containment. Once the strand is fully solidified and passed through the straightener
withdrawal units, the dummy bar is disconnected, removed and stored. Following the
Straightener, the strand is cut into individual pieces of required length and discharged for
further processing.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 50
3.5 Process DescriptionSandur Manganese & Iron Ores Limited is planning to setup an Integrated Steel Plant Facility for
production of about 8,00,000 tpa Pig Iron & about 1,00,000 Liquid Steel & further Rebars. Following
is the brief description of Technological Equipments being set up at Proposed Plant.
Proposed expansion comprises of following major units:
Blast furnace,
Pig Casting Machine,
Coke Oven plant and WHRB,
Sinter Plant,
Energy Optimization Furnace (EOF)
Ladle Refining Furnace (LRF) and Vacuum Degasser (VD)
Continuous Casting Machine (CCM)
Rolling (Rebar Mill)
Oxygen Plant
3.5.1 Blast Furnace
The size requirement of the 2 Mini Blast Furnace has to be decided based on the capacity requirement
of the finished product and has been worked out to be 350-400 m3. The furnace will conform to the
following main features:
3.5.1.1 Main Features of the BF Installation
The salient features of the BF installation are envisaged as enumerated below:
To ensure enhanced smelting rate in the furnace, the materials charged in the furnace will undergo
before charging: Screening, weighing and automatic balancing of weight for variation in
moisture to improve accuracy of input materials and fuels for stable blast furnace operation and
increased output.
High top pressure for enhanced output and coke saving through better heat exchange between
charged solid materials and the generated gases.
Energy saving and environmental protection: In blast furnace design, a series of energy saving &
environmental protection technologies are adopted, such as reclamation of used heat from the flue
gas of the hot blast stoves for preheating the combustion-supporting air.
BF with 350-400 m3 effective volume shall have one tap hole and 12-14 tuyeres. However the
vendor can decide the number of tuyeres based on the design considerations.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 51
Furnace Profile and dimensions shall be selected taking into consideration, the
characteristics of available raw materials and modern trends in Blast Furnace technology to give
high productivity, low energy consumption and longevity of the furnace.
The selection of refractory materials at various sections of BF will ensure a long campaign life
>10 years, keeping the investment cost at an appropriate and reasonable level.
An efficient BF cooling system shall be adopted to ensure longevity of the blast furnace at
optimum coal injection of 120-150 Kg/thm. In addition to the Stave Coolers of appropriate
design in various parts of BF body walls, the BF bottom shall also be water cooled.
Belt Conveyor Charging and Bell-Less top system shall be provided to ensure proper distribution
of charge inside the BF.
Three (3) nos. top combustion hot blast stoves will be provided to meet the high blast temperature
requirements of ~ 12000C. BF gas shall be used for all the stove burners along with combustion
air, both pre- heated to ~150-2000C in separate recuperators installed in exhaust flue duct of
stoves.
Dry Bag type gas cleaning is proposed to ensure higher cleaning quality of 5 mg/Nm3 and
achieve higher blast temperature in hot blast stores.
A hydraulic Mud-Gun and a tap hole Drill Machines of appropriate capacity shall be installed at
the cast house.
Slag Granulation Plant shall be of Filter Bed Type. The water supply system shall be of re-
circulation type. Granulated Slag shall be sold to cement factories.
BF gas shall be used for Hot Blast Stoves heating, Hot Metal Ladles Preheating, Sinter Plant and
surplus gas shall be utilized for electric power production.
Pig Casting Machine having a capacity of about 121.12 TPD is proposed to ensure production of
Pig Iron.
Sinter and Coke shall be screened before charging to BF. Charging shall be done through Weigh
Hoppers with load cell weighing system.
One (1) working + one (1) standby Electric Motor Driven Air Blowers with BPRT (BF gas
pressure recovery turbine) facility is not envisaged for this small furnace size. The electric supply
for these motors shall be at 11 KV, 50 c/s, 3-Phase. To utilize the available pressure and
temperature of BF gas. One gas turbine will be connected with electric blower through clutch
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 52
with this system about 40% power will be saved for normal running of electric blower. The BPRT
is not envisaged as the Power output of the unit is not viable w.r.t the investment made.
Pneumatic Pulse Jet Cleaning Bag Filter Type De-dusting unit shall be provided to cater to all
the dust generating points in material handling system.
EOT Cranes / Hoists shall be provided for maintenance of the various equipment.
Table 3.2 Technical parameters of Blast Furnace
No Name Unit Indicator Remarks
1. Blast furnace volume m3 350-400
2. B.F. working volume m3 295
3. Productivity t/m3/day >3.0
4. Coke ratio Kg/thm <450
5. Coal ratio Kg/thm ~120
6. Ore grade TFe % 61-63
7. Sinter usage % 75 * 25% Iron
Ore/Pellets8. Blast temperature °C ~ 1200
9. Top pressure MPa 0.03- 0.12
10. Slag volume Kg/thm 300-350
11. Oxygen enrichment rate % Upto 4
12. Steam Injection gm/m3 As required
13. Working days of BF days 330 Annual
14. Iron output of BF t/a >400,000 Annual
15. No. of Tuyers Nos. 12-14
16. Tap Hole Nos. One (1)
17. Charging System Type Belt conveyor
with Bell Less
Top
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 53
Table 3.3 Specific Consumption of Power & Utilities
NO. TYPE OF POWER UNIT REMARKS
1. Blast rate
1400 Nm3/thm
1250 Nm3/thmWith O2
Air volume infurnace without O2Air volume infurnace with O2
2. Steam 0.020 t/thm
3. Electricity 30 kWh/thmExcluding airblowers
4. Clear circulating water50 t/thm(Approx.)
As perRequirement
5.Turbid circulating waterFrom slag flushing
~3.5 t/thm(Approx.)
As perRequirement
6.Water supplemented forslag flushing
0.7t/thm(Approx.)
As perRequirement
7. Nitrogen ~20 Nm3/thmAs perRequirement
8. Oxygen ~42 Nm3/thmAs perRequirement
9. Compressed air ~10 Nm3/thmAs perRequirement
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 54
Figure 3.4 Process Flow Diagram of Blast furnace3.5.2 Pig Casting Machine
Design parameter
Type : : Continuous Double Strand Linear Pig Casting Machine
No. required : One Double Strand Pig Casting Machine
Capacity 1212.12 TPD
Speed 8-12 m/mm
Slope 11 degree (approx.)
No. of Pig 5 per Mould
Weight of each
pig
7.5 kg
Temp. of Liquid
Metal
1400 deg.Cel. at pouring point
Drive A.C>Motor
Lime Sprayer A.C.Motor
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 54
Figure 3.4 Process Flow Diagram of Blast furnace3.5.2 Pig Casting Machine
Design parameter
Type : : Continuous Double Strand Linear Pig Casting Machine
No. required : One Double Strand Pig Casting Machine
Capacity 1212.12 TPD
Speed 8-12 m/mm
Slope 11 degree (approx.)
No. of Pig 5 per Mould
Weight of each
pig
7.5 kg
Temp. of Liquid
Metal
1400 deg.Cel. at pouring point
Drive A.C>Motor
Lime Sprayer A.C.Motor
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 54
Figure 3.4 Process Flow Diagram of Blast furnace3.5.2 Pig Casting Machine
Design parameter
Type : : Continuous Double Strand Linear Pig Casting Machine
No. required : One Double Strand Pig Casting Machine
Capacity 1212.12 TPD
Speed 8-12 m/mm
Slope 11 degree (approx.)
No. of Pig 5 per Mould
Weight of each
pig
7.5 kg
Temp. of Liquid
Metal
1400 deg.Cel. at pouring point
Drive A.C>Motor
Lime Sprayer A.C.Motor
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 55
Control VVVF
Voltage 415 V +/- 10%, 60 Hz +/- 5%, 3 Phase
3.5.3 Coke Oven Plant
3.5.3.1 Introduction
In view of the plans to set up BF and the present world-wide coal/coke crisis and volatile prices of
Coke, it is necessary for the company to construct coke oven batteries to meet about 400,000 TPA
annual requirement of coke corresponding to 1.0 mtpa capacity planned in future. Availability of BF
coke is likely to remain difficult in future due to increased consumption of coke worldwide.
Developed countries, in general, do not produce coke for outside sale due to stringent pollution
control restrictions.
In the recent past various technologies for improving the quality of coke especially with respect to
strength of coke and environment control have been developed.
Among the various options for Coke oven batteries, it has been found that non-recovery (heat-
recovery) stamp charged type of coke ovens are most economical to build. In China construction of
this type of batteries is very common these days. In India also, several such batteries have been/ are
being installed by companies like Sesa Goa, JVSL, JSW, Neco- Jayswal, etc.
The desired quality parameters can be met by non-recovery type coke ovens. Accordingly, a non-
recovery type coke oven battery is proposed for project.
3.5.3.1 Coking Process
Coal is crushed and fines are conveyed to silos for storage & blending. Crushed coal blend from coal
tower is directly received in a hopper for charging in stamping machine. From the hopper coal is
evenly discharged into stamping box, where coal blend is stamped into coal cake. Bulk density of the
cake is between 1.05 – 1.1 t/ m3. The coal box with ready coal cake are together loaded in coal
charging car and taken to the oven which is ready for pushing. The coke pushing car pushes the coke
out of the oven and coke side is immediately closed. Thereafter, coal cake is pushed inside oven with
the help of charging mechanism and immediately pusher side door is also closed. The coking coal
cake is heated in oven and raw coke oven gas is separated out. Adjustable suction valve on the oven
roof and oven doors allow the introduction of primary air to combustible raw gas. The incomplete
combustible gas goes to coke side descend and then to fire channels on both sides of oven wall and
then goes into fire channel at the oven bottom. The oven bottom fire channels are four linked
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 56
arch type. Secondary air is introduced to burn with incomplete combustible gas. Thus, cake base is
heated through heat exchange with oven bottom bricks. Thermo-couples are provided to measure
temperature at the bottom.
After the raw gas is completely burnt in bottom fire channel, the flue gases flows into the ascendant
fire channel into the oven wall on other side and then into uptake at the centre of the oven roof.
All the gases evolved during the carbonization of coal charge including tar etc. are completely burnt
inside the oven. The flue gases from the oven at a temperature of about 900-1000oC pass through
waste heat flue ducts and led to WHRB .The sensible heat of waste gas is recovered in WHRB for
generation of power. The gas is cooled to less than 200°C before it is allowed to pass to exhaust
chimney.
Non recovery or heat recovery coke oven are of two types. One is similar to byproduct type having
vertical oven where heating of coking chamber is done from side wall and another type is horizontal
oven where heating of coking chamber is done from the top. The process of carbonization in oven is
under slightly negative pressure and this result in practically emission free operation of battery.
The company has planned to set up 0.4 MPTA non-recovery vertical type coke oven batteries as a
part of its expansion project to meet its captive requirement of coke for its blast furnace
operations. With power generation from Flue gases of coke oven, the net cost of power generation is
reduced substantially.
3.5.3.2 Coke Oven Complex
The proposed Coke Oven Complex will consist of non-recovery type of 2 Nos of 2 x 28 chamber
coke oven batteries, 1 coal tower in-between. A power plant utilizing the waste heat of flue gases
from coke ovens is also proposed to be built. The capacity of the Coke oven complex shall be more
than 400,000 tonnes /annum of gross coke. In this process, the coal to be charged in oven is first
converted into a cake through stamping process and then coke is charged into oven. The oven will be
provided with self adjusting suction pressure controller for individual oven as well as a changer
controller at chimney base in order to control thermal regime of Coke Oven Battery. The major
facilities envisaged are as under:
Coal Preparation and Proportioning Plant
Coke Oven Battery Proper
Coke Screening Plant
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 57
Gas Cleaning Heat Recovery System and Power Plant
Auxiliary production facilities like maintenance shop, laboratory, warehouse etc.
a. Coal Preparation & Proportioning Plant
The prime objective of a coal preparation plant is to feed consistent quality of coal to coke oven
batteries for production of required quality of BF coke. For coal for Coke Oven batteries, a separate
coal yard will be provided near the Coke oven battery. Coal will be received through rail wagons,
self-discharging trucks & tipper system. The capacity of the Coke oven complex shall be 400,000
tonnes/ annum of gross coke.
The unloading and loading system is designed to capacity of 100t/h, while the blending, crushing and
feeding system is designed to capacity of 100t/h.
The cleaned coal shall be fed into the coal hopper. Appropriate number of coal blending hoppers shall
be provided based on the coking coal types, and electronic belt scale shall be provide below the coal
blending hopper for measuring the coal blending proportion. The coal blending hoppers shall be
welded with steel, and electrical vibrator shall be provided on the outer wall to ensure no sticking or
blocking.
Two back-impact plate hammer crushers shall be selected for crushing of raw material coal.
Permanent magnetic iron remover shall be provided before raw materials enter the crusher.
The coal preparation plant is mainly composed of cleaned coal yard, coal receiving and blending
hopper, crusher room and cleaned coal belt corridor, for purpose of stripping, loading, coal
blending, crushing and other tasks so that blended coal of required grain size shall be delivered to the
coal tower of the coke oven.
The coal preparation plant shall be continuously operated to 365days every year and production
personnel shall be allocated to three-shift operations.
The major facilities envisaged are as under:
Supply of coals
3-4 grades of coal Imported are blended to make charge mix shall be mainly from Australia. In actual
practice, coal supply will depend upon actual over all receipt patterns and accordingly blend
composition is to be adjusted keeping in view the qualitative parameters of BF coke required. This
would also require laboratory tests for establishing the most optimum coal blend.
Requirement of coals
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 58
For production of 400,000 tpa yearly Gross coke (dry), the requirement of gross coal (including
moisture content & handling losses) is estimated at 540,000 tpa. Receiving coal is classified based on
chemical composition and coking index. Non coking coal and coking coal are stacked separately
.These coals are discharged on a conveyor in proportions based on blend composition and taken to
coal crushing unit. The coal is crushed to -3 mm (>90%) in two stages and transferred to fine coal silo
and from there to stamping machine.
b. Coke Oven Batteries Proper and Equipment
The proposed coke oven battery shall be non-recovery type. The installed capacity of plant will be 0.4
mtpa of the BF Coke. The Coke Oven will be provided with self-adjusting suction pressure controller
for individual oven as well as damper controller at chimney. The coke produced shall be screened in 3
sizes i.e. 20-60 mm (BF coke), 8-20 mm (nut coke) & below 0.8 mm (coke breeze).While the BF
coke and Nut coke will be used for Blast Furnace, coke breeze will be used in sinter making. A power
plant utilizing the waste heat from flue gas is proposed to be built.
c. Brief Description of Structure of Coke Ovens
This design will use Heat-Recycle Stamping Clean Coke Oven, with following main features:
Oven body Structure design:
Oven top: flat-top structure of mechanical coke oven.
Arrangement of coking chamber oven wall flue and bottom combustion flue: main wall thickness
100mm for coking chamber, uniform distribution of rectangular down flues and flame flues on the
oven wall.
There is flanged connection between the branch flue and the gas gathering flue to facilitate
integral replacement.
Coking chamber with small center distance and small wall thickness help to reduce refractories of
coke oven.
The waste heat boiler is provided against the emergency chimney in order to reduce length of the
main flue.
Oven body Material
The part from bottom of the coke oven combustion chamber to the coking chamber top shall be
made of silica brick, while other parts shall be made of common clay brick, diatomite brick or red
brick, etc. depending on the strength and temperature changes as well as insulation effects in such
parts.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 59
Process device
Iron parts for oven protection
Iron parts for oven protection include buckstay, tie rod in length and breadth, spring, oven door
and door frame.
Quenching
In the design, quenching tower is designed for purpose of quenching, which shall be provided
with powered coke setting pond of the quenching pump house, clean water tank, drainage pipe
network and other facilities.
Buttress Wall
Reinforced concrete buttress walls shall be provided on both ends of the coke oven to bear thrust
from individual parts of the coke oven.
Figure 3.5 Process Flow Diagram for Coke Oven Plant
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 59
Process device
Iron parts for oven protection
Iron parts for oven protection include buckstay, tie rod in length and breadth, spring, oven door
and door frame.
Quenching
In the design, quenching tower is designed for purpose of quenching, which shall be provided
with powered coke setting pond of the quenching pump house, clean water tank, drainage pipe
network and other facilities.
Buttress Wall
Reinforced concrete buttress walls shall be provided on both ends of the coke oven to bear thrust
from individual parts of the coke oven.
Figure 3.5 Process Flow Diagram for Coke Oven Plant
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 59
Process device
Iron parts for oven protection
Iron parts for oven protection include buckstay, tie rod in length and breadth, spring, oven door
and door frame.
Quenching
In the design, quenching tower is designed for purpose of quenching, which shall be provided
with powered coke setting pond of the quenching pump house, clean water tank, drainage pipe
network and other facilities.
Buttress Wall
Reinforced concrete buttress walls shall be provided on both ends of the coke oven to bear thrust
from individual parts of the coke oven.
Figure 3.5 Process Flow Diagram for Coke Oven Plant
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 60
3.5.4 Waste Heat Recovery Boiler
One no. waste heat recovery Boiler with BF combustion gas capability will be installed for heat
recovery from coke oven flue gas and BF gas firing. Total potential of gas generation from BF &
Coke Oven is 130 TPH. It will be sent to existing 32 MW Captive Power Plant for power generation
replacing coal.
3.5.4.1 Boiler & Auxillaries
One no. waste heat recovery boiler with BF combustion gas capability will be installed for heat
recovery from coke oven flue gas and BF gas firing boiler for generating steam at 140t/h and at a
temperature of ~520oC.
The boiler will consist of gas inlet pipe, super-heaters, economiser, air pre- heater, integral piping,
draft fans, deaerator and feed water system, boiler feed pumps, air ducts, flue gas duct work,
supporting structures, platforms and walkways etc.
The boiler will be provided with Blast furnace gas combustion firing system with required support.
Drum
The boiler will be provided with one (1) No. steam drum and one (1) No. water drum of fusion
welded construction. The drum will be provided with suitable dished ends with pressed steel,
manhole doors. All plates will be of boiler quality, constructed in accordance with IBR. The steam
drum of the boiler will be provided with suitable internal fittings to ensure steam purity with TDS less
than 0.1 ppm and silica content not exceeding 0.02 ppm.
Boiler Tubes and Manifolds
Heating surfaces of the boiler will comprise membrane water walls of combustion chamber
constructed from carbon steel seamless tubes. The water wall tubes will be arranged to cool the front,
roof, sides and rear walls of the combustion chamber.
Super heater
The boiler will be provided with one (1) super heater. The super heater elements would be divided
into two (2) sections viz. primary super heater and final super heater with an attemperator in between.
Attemperators
Spray type attemperating equipment would be provided for the boiler to control the final steam
temperature within a tolerance margin of + 50C
Blow down Tank
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 61
Water which is blown down periodically from the steam drum to maintain the quality of the feed
water in the drum will be collected in the blow down tank.
Chemical dosing System
Chemicals are dosed into the boiler water loop at appropriate points for control of boiler water
quality. Two types of dosing systems are present - the high pressure and the low pressure system.
Each system will contain tanks for solution preparation, pumps and agitators with motors.
De-aerator & Feed water storage tank
The de-aerator shall be of either horizontal or vertical, direct contact, spray cum tray type. The steam
for de-aerator will be drawn from the bleed of turbine during normal operation. Condensate from the
Air Cooled Condenser will be supplied to the de-aerator. The de-aerator will be a constant pressure
unit. The make-up requirement of de-aerator will be from de-mineralized storage tanks. The de-
aerator shall be mounted on a feed water storage tank of approximately 20 minutes hold up capacity.
Boiler feed pumps
It is proposed to install two (2) Nos. of 100% capacity, multistage, electric motor driven boiler feed
pumps, one working and one standby, for catering to boiler feed water requirements. The capacity of
these pumps will be suitable for 110% maximum continuous rating of the boiler output, including
spray water requirement of the attemperator. Feed water will be supplied to the boiler at temperature
of 105 0C.
Supporting Structure
The boilers are bottom supported and will be provided with suitable steel supporting structure of
bolted / welded construction from rolled steel sections and designed with adequate strength for the
loads imposed by the boiler and associated equipment. The supporting structure shall be provided
with mono- rail beams for floors.
3.5.6 Sinter Plant
3.5.6.1 Main desirable features of the sintering machines
i. Sinter plant to have Irish mixer (High intensified mixer) to maximize usage of ultra fines
from the mines.
ii. Fuel preparation system adopts open-circuit crushing consisting of four-roller crushers to ensure
more than 85% fuel particle of size 3-0 mm to reduce fuel consumption and achieve better chemistry.
Flux crushing is close circuit crushing through hammer mill.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 62
iii. Automated weighing dosing is employed to improve dosing accuracy, ensuring
consistent quality of sinter, reducing fuel consumption and achieving stable production.
iv. Linear- bed sintering for economical operation of the process.
v. Circular cooler is used for cooling sinter for its simple structure and ease of operation and
maintenance.
vi. Process gas and plant de-dusting system using dry ESP and bag house respectively.
vii. Sinter size stabilization using Sinter Crushing
viii. Standard air draft device adopted for high efficiency and low power consumption.
ix. Control system:
a. Instruments o f r e l i a b l e a n d a d v a n c e d performance are employed to display,
record, control and automatically adjust process parameters; product quality and energy.
b. Communication facilities like telephone, video display (television) etc are installed at
production, quality control, and dispatch for directive communication.
c. Computer control system is incorporated to monitor and manage the whole plan.
3.5.6.2 Technical Parameters
S.NO ITEM UNIT INDICATOR
1. Sintering machine Type Linear with circular cooler
a No of sintering machines Set 2
b Effective sintering area m2 50
2. Productivity machine t/m2/h > 1.5
3. Operation rate % 90
4. Annual working days day 330
5. Annual output of sinter tonnes >592,950
6. Energy consumption Kw/t <48
7. Coke breeze /ton sinter Kg/t ~65
8. Under-grate suction mm WC >1000
9. Sinter Quality Norms
a TFe % > 55-57
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 63
b FeO % 8±1.5
c CaO % ~ 10±0.5
d SiO2 % 5±0.5
e Al2O3 % < 2.5
f MgO % 1.1
g Basicity (CaO/SiO2) % 1.8±0.2
h Product Particle size mm +5 to -60 mm
10. Temperature of CooledSinter
0C Below 100
11. Dust Content of ExhaustGases at Stack
mg/Nm3<50
3.5.6.3 Main plant facilities
Sinter plant proper will consist of the following main technological units:
Receiving Bin Unit
Fuel and Flux Crushing Units
Flux Screening Unit
Proportioning Unit
Mixing and Nodulizing Units
Sintering Unit
Cooling Unit
Sinter Screening Unit
Head & Tail De-dusting Units
Main Exhaust Fan Unit
Plant De-dusting Units
The above units will be interconnected by conveyor galleries and junction houses for conveying sinter
mix. Finished sinter, hearth layer and sinter return fines.
3.5.7 Energy Optimizing Furnace (EOF)
3.5.7.1 Design Basis
No. of Units 2
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 64
Annual Liquid Steel Production capacity : 5,28,710 T each
Furnace working availability 330 days
Charge Composition
Hot metal 80 %
Scrap 20%
Tap to tap time 35-45 minute
Oxygen Consumption 50-70 Nm3/TLS
Oil Consumption (Heating of new Bottom)0.5 – 1.0 kg/ Ton
Refractory Consumption Bottom Repair ~ 4 kg/t
Heat/Campaign >700 heats
Bottom Exchange Within 12 hrs-16 hrs
3.5.7.2 Salient Design Features
The EOF proper consists of 2-units of shuttle-type Bottom cars. One bottom car supports the EOF
furnace in operation and the other one supports a second bottom at one or another side for relining.
Both cars are equipped with roll collar tracks to tilt the furnace for tapping or de- slagging. Tilting is
performed by high-speed hydraulic cylinders, allowing slag-free tapping.
Furnace is equipped with refractory lined bottom, split water cooled shell, water cooled roof and
sealing between the furnace and Scrap Pre-heater, hot metal launder, steel tapping launder,
submerged tuyeres, atmosphere injectors and supersonic lance for oxygen blowing, air-fuel burners
for heating-up new bottom.
Scrap Preheaters are placed immediately above the furnace, provided with water-cooled tilting fingers
to support the solid metallic charge which is heated by the furnace off-gas. At the moment of
charging, the fingers tilt, releasing the preheated scrap onto the bottom of the EOF.
EOF is also provided with water-cooled inclined pipe placed below the fingers for additions into the
furnace; air injectors for post-combustion of carbon monoxide; water sprays to control the off-gas
temperature before the scrap layer, off-gas uptake, water cooled sliding door and scrap charging
system, both placed at the Scrap Preheater top.
Submerged tuyeres are designed for optimizing oxygen flow rates to ensure effective bath agitation
and optimum reaction with carbon in the bath while avoiding ejection of hot metal from the furnace.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 65
In a special design of tuyeres, three concentric pipes, enable optimum cooling of the end section
projecting into the furnace. In this way, tuyeres burn-off is limited to less than 2.5 mm per heat.
Design and arrangement of scrap Preheater enables efficient preheating up to 850oC and allows rapid
furnace charging without stopping with no dust exhaust to the building atmosphere and little noise.
Water cooled roof and walls above bath reduce refractory consumption.
3.5.7.3 Brief Description of main equipment
Furnace Proper
- Launder for hot metal charging
- Detachable Bottom with spare
- Shell & Roof with cooling elements
- Burners, injectors and tapping system
- Instrumentation and control
Scrap Pre-heater
- Shell, Fingers, water cooled panels, movable roof, scrap bucket operating system.
Gas Cleaning System (Wet Type)
- Ducting
- Expansion Chamber
- Gas Cooling Tower
- Venturi Scrubber
- Thickener
- Control Valves, I D Fans with control damper
- Flow measurement system for stack
- Water circuit for cleaning including pumps and thickener etc.
Additive And Alloy System
- At EOF building
- Bins, weighed discharging system. Ducting in furnace & steel ladle for gas/fumeextraction.
Hydraulic system- The hydraulic system shall serve the following equipment:- Furnace tilting device, scrap bucket opening
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 66
- Fingers and movable roof movements etcCooling water system- Cooling towers, pipes and fittings, pumps, chemical treatment system etc.Gases and fluid system- Oxygen, N2, Fuels, handling system with piping and control panelsElectrical control & instrumentation- Main substation, transformer, switchgear, MCC, motors cables, PLC, software, distribution
substation & illumination.
3.5.7.4 Ladle Refining Furnace
As the specifications for steel are becoming more stringent, the conventional primary steel making
processes are finding it increasingly difficult to meet these requirements. Even if the existing EAFs,
BOFs or EOFs are able to meet these requirements they often do so at the expense of loss in
production or under-utilization of the steel making unit. The shortage and the high cost of energy as
well as the need to conserve it, demand that the remelting or the reheating of the steel be kept to the
unavoidable minimum and large number of processes have been developed to treat liquid steel
outside the primary steel making vessel.
The secondary steel making processes have, therefore, been developed in producing steels
conforming to stringent specifications.
Secondary steel making processes are adopted, primarily to meet requirements, in the following
areas:
1. To achieve extremely low levels of Sulphur, Oxygen, Nitrogen, Carbon, Phosphorus and
Hydrogen
2. Inclusion control to extremely low levels and control of morphology of inclusions
3. Temperature control particularly in case of continuous casting and especially for sequence
casting.
4. Alloying and analysis control for optimum utilization of ferroalloys to achieve desired
properties consistently
5. Improving the fluidity of liquid steel for easy teeming
6. Increased Production rates by decreasing furnace refining times
Basic principle behind secondary refining is to shift the major part of the lengthy refining, de-
oxidation, desulphurization and alloying operations outside the primary steel making units.
When compared with conventional treatment of steel in melting furnace, one achieves, besides
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 67
metallurgical advantages, a higher productivity of entire plant, lower direct cost per ton of treated
steel and better operational and environmental conditions.
The main features of the LRF process are:
Liquid steel is tapped from the EOF into the ladle. Bulk Ferro alloys and lime are added into the
ladle during tapping.
Transfer car with ladle is driven from EOF tapping location to the approach of EOT crane.
The ladle is then placed on the transfer car of LRF and then positioned below ladle furnace roof (
after necessary interlocks are satisfied)
Ladle furnace roof is lowered.
Steel temperature is measured and sampling done by means of manual lance through the LRF
door.
Arcing is started in lower taps.
Necessary quantities of calcined lime are added through FAFA system.
Trimming alloys are added as per grade and sample analysis requirement.
Sample is taken for analysis.
Arcing is shifted to higher taps and done as per final aimed temperature.
Wire feeding is done as per requirement.
Arcing is stopped, roof lifted and ladle transferred out from treatment position and lifted by EOT
crane to the VD station or Castor as desired.
The ladle furnaces now, have features for increased process flexibility as well as product range. The
furnace roof is provided with opening for three electrodes, alloy additions, injection devices, fume
extraction, sampling and temperature measurement.
3.5.7.5 Main Features
No. of Units : 2
Annual Liquid Metal Capacity : 5,28,710 TPA
Ladle Capacity : 35 t
Type of LRF : Moving Ladle Car self-propelled complete with
drive and with roof moving up & down
Transformer rating : 7 MVA
Primary Voltage : 33 KV
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 68
Secondary Voltage : 8-200 V in min six steps
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 69
3.5.8 Continuous Casting Machine
Continuous casting is the process to solidify molten steel into a semi-finished billet, bloom,
or slab for subsequent rolling. Prior to introduction of the continuous casting practice in
1950s, steel was poured into stationary molds to form ingots. But continuous casting has
substantially added to improved yield, quality, productivity and cost efficiency.
Steel from the EOF is tapped into a ladle and taken to the continuous casting machine. The
ladle is raised onto a turret that rotates the ladle into the casting position above the tundish.
Liquid steel flows out of the ladle into the tundish and then into water-cooled copper mold.
Solidification begins in the mold, and continues through the first zone and strand guide. In
this configuration, the strand is straightened, torch-cut and then discharged for intermediate
storage or hot charged for finished rolling. The melting /casting/ rolling processes are
linked while casting a shape that substantially conforms to the finished product. The
complete chain from liquid metal to finished rolling can be achieved within two hours.
End-use dictates quality, grade and shape of the cast product (billet, bloom, slab, beam
blank, and/or round).
To start a cast, the mold bottom is sealed with a dummy bar head attached to dummy
bar. The dummy bar is held in place hydraulically by Straightener Withdrawal units.
This head prevents liquid steel from flowing out of the mold. The steel poured into the
mold is partially solidified, producing a steel strand with a solid outer shell and a liquid
core. In this primary cooling area, once the steel shell has sufficient thickness, about 10– 20
mm, the straightener withdrawal units are started. The moving dummy bar starts to
withdraw the partially solidified strand out of the mold along with the dummy bar.
Liquid steel continues to pour into mold to replenish the withdrawn steel at an equal rate.
The withdrawal rate depends upon the cross-section, grade and quality of steel being
produced, and may vary widely depending upon section, quality and machine design
parameters. Casting times are typically matched with the EOF tap-to-tap time.
Upon exiting the mold, the strand enters a roller containment section and secondary cooling
chamber in which the solidifying strand is sprayed with water to promote solidification.
This area preserves cast shape integrity and product quality. Larger cross-sections require
extended roller containment. Once the strand is fully solidified and passed through the
straightener withdrawal units, the dummy bar is disconnected, removed and stored.
Following the Straightener, the strand is cut into individual pieces of required length and
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 70
discharged for further processing by rolling.
3.5.8.1 Main Features
No of Units : 2
Production Capacity : 5,18.135 T each
Days/ Year : 330 days
Grades of steel to be cast : Low and Medium Carbon steel grades
Heat Size : 35 t
Type of ladle ; Bottom pouring with slide gate system and porous plug
Billet/ bloom Quality : internationally acceptable for size surface quality, mechanical and
metallurgical properties.
Product size ; 130 X 130 mm & 110 X 110 mm
Billet length : 6 m
3.5.8.2 machine parameters
Type of Machine - 4 strand, curved mould, bow type
Machine Radius - 9/16m
Method of ladle placement - Rotating turret with independent lifting andlowering of the arms with facilities for Weighment
Strand cooling - Water/air mist
EMS - To be provided
Tundish - Of adequate size & capacity to facilitateSequence casting
Mould level control - To be provided with the mould
Billet cutting - To be provided along with auto operation
Method of discharge - Horizontal discharge roller table
Dummy bar - Flexible / rigid with replaceable heads fordifferent sizes
Casting speed - Variable for various grades
Mould oscillation - Short lever arm, variable frequency and variablestroke of oscillation.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 71
Tundish car - With lift lower and centering device
Withdrawal system - Hydraulically pressurized withdrawal machine withIndividual driven rolls for maintaining straightness of thecast strand
Drives - DC or VVVF Drives for withdrawal straightener,Mould oscillation etc.
3.5.9 Rebar Rolling Mill
3.5.9.1 Design Parameters
No of Units: - 2
Annual Capacity: - 5, 00,000 TPA each
Capacity: - 1515 TPD
Designed Product Mix:-
- TMT Bars : 5,00,000 TPA each in dia 6 mm and 40 mm
Steel grade: - Rebar Quality Mild Steel
Bar Bundles: - 2-4 T, 12 m long, tied at 5 places
3.5.10 Oxygen Plant
To meet the requirement of Oxygen one units of Oxygen plant of 100 TPD in Phase-1
and unit of Oxygen plant of 350 TPD in Phase-II has been considered. There is
practically no difference in cost between high purity oxygen (99.5 percent) plant vis-à-vis
medium purity oxygen (minimum 96 per cent) plant. However, the high purity oxygen
plant produces argon which is not available from medium purity plants. Oxygen (99.5 per
cent purity) will be required mainly for the blast furnace enrichment, lancing in the BOF
converters, ladle furnace, cutting operation in billet casters and scrap etc. and for other
general purpose usages.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 72
Figure 3.6 Process Flo Diagram
3.5.9 Plant Utilities & Other Facilities
It is same as previous ToR.
3.6 Raw material Requirement
Table 3.4 Raw material Requirement
Sl. No. Raw material Quantity in TPACoke oven
1 Hard Coal 3,78,0002 Soft Coal 1,62,000
Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven
Plant0Blast furnace
1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 72
Figure 3.6 Process Flo Diagram
3.5.9 Plant Utilities & Other Facilities
It is same as previous ToR.
3.6 Raw material Requirement
Table 3.4 Raw material Requirement
Sl. No. Raw material Quantity in TPACoke oven
1 Hard Coal 3,78,0002 Soft Coal 1,62,000
Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven
Plant0Blast furnace
1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 72
Figure 3.6 Process Flo Diagram
3.5.9 Plant Utilities & Other Facilities
It is same as previous ToR.
3.6 Raw material Requirement
Table 3.4 Raw material Requirement
Sl. No. Raw material Quantity in TPACoke oven
1 Hard Coal 3,78,0002 Soft Coal 1,62,000
Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven
Plant0Blast furnace
1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 73
Energy Optimization Furnace1 Scrap 2,35,0002 Flux 12,6883 LimeStone & Dolomite 1,00,453
3.7 Water & Power Requirement with its Source
3.7.1 Water Requirement
Water requirement for the project is as follows:
Table 3.5 Water RequirementSl.No.
Plant Unit Water Requirement in m3/HrFresh Water Soft Water DM Water Total in
m3
1 Sinter Plant 10 10 -- 202 BF Shop 95 100 -- 195
3
Pig Casting Machine(Considering 10%Utilization of PCM thewater requirement)
20 -- -- 20
4
EOF +LRF +VD(Transformer, Reactor &H.C. Cable Cooling)
64 60 26 150
5 Coke Oven Plant 70 -- -- 706 WHRB --7 CCM 50 -- -- 508 Rebar Mill 130 -- -- 1309 Oxygen Plant 20 -- -- 20
10Green belt & DustSuppression 20
-- -- 20
11 Miscellaneous Use 10 -- -- 10Total 489 170 26 685
Source of Water
The water requirement will be sourced from Tungabhadra Dam & Bore wells.Power RequirementThe total connected power of the plant is expected to be about 92 MW.
3.8 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their
Management/Disposal
Table. 3.5 Air Quality Environment & Management (Air Environment – Mitigation
Measures)
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 74
SL.
NO.
ITEMS DESCRIPTION POLLUTION CONTROL
1 Sinter plants
Dust Laden
Gases
From the Process Fume extraction & de-dusting plant
2 Blast Furnace (BF)
BF gas (1) From the Process BF gases having calorific value of 750
Kcal/m3 will be used in the plant after
GCP
3 Steel Melt Shop (SMS)
Flue gases From the EAF & LF Fume extraction & de-dusting plant-
Primary
From the top of SMS Shed Fume extraction & de-dusting plant-
Secondary
From the Ladles & CCM Fume extraction & de-dusting plant-
Secondary
From Raw material &
FAFA handling units
Fume extraction & de-dusting plant-
Secondary
4 Continuous Casting Machine
Flue gases
Containing SO2
From the Reheating
Furnaces
To be dispersed as per the CPCB formula
H=14xQ
Where H = Height of chimney, m
Q = Quantity of SO2 generated per hour in
kg.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 75
3.8.1 Waste Water Generation and Treatment
Table 3.6 Waste Water Generation Quantity and Management
SL.
NO.
ITEMS DESCRIPTION QUANTITY POLLUTION CONTROL
1 Blast Furnace (BF)
Sludge From Gas Cleaning
plant (GSP)
0.5 Kg/t of
HM
Solidified sludge from the
thickener to be charged back as
blend mix for sinter production
2 Steel Melt Shop (SMS)
Oil &
Grease
From the direct
Cooling Water at CCM
Scale Pit
0.04 Kg/t of
Billet
To be removed by oil skimmers
& stored in old drums
Backwash
Water
From the pressure filter
cleaning
0.05 Kg/t of
Billet
To be treated at Waste Water
Treatment Plant and discharged
or used for gardeningBlow down
water
From the Water
complex
0.1 Kg/t of
Billet
3 Rolling Mills
Oil &
Grease
From the direct
Cooling Water at RM
Scale Pit
Removed by oil skimmers &
stored in old drums
Blow down
water
From the Water
complex
Treated at Waste Water
Treatment Plant and discharged
or used for gardening
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 76
3.8.2 Solid Waste Generation and Utilization
Table3.7 Solid Waste Generation & Management
SL.
NO.
ITEMS DESCRIPTION QUANTITY POLLUTION CONTROL
1 SINTER & PELLET PLANTS
Sinter fines
(< 5mm)
After Screening from Blast
furnace
10% of Sinter Charged back as blend mix
for sinter production
Fine Dust Dust from Bag Filter/
Electro Static Precipitator
0.5 Kg/t of
Sinter
2 BLAST FURNACE (BF)
Slag From the Process 320 Kg/t of HM Disposed to Cement Plants
Flue Dust Dust from Primary dust
catcher
10 Kg/t of HM Charged back as blend mix
for sinter production
3 STEEL MELTING SHOP (SMS)
Slag From the Process 120kg/t of LS Charged back in Sinter
Plant & BF.
CCM Scales From the CCM 10 Kg/t of
Billets
Charged back to sinter
production
Fine Dust From the furnace & LF 13-21 Kg/t of
Billet
Charged back to furnace of
SMS
From the top of SMS Shed 0.5 Kg/t of
Billet
From the Ladles & CCM 0.25 Kg/t of
Billet
From Raw material & FAFA 0.5 Kg/t of
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 77
handling units Billet
4 ROLLING MILLS
Mill Scales From the Process 15 kg/t from
each mill
Charged back as blend mix
for sinter production
3.8.3 Noise Levels
The rotating equipment will be provided with necessary arrangements to keep the sound
level at 1.0 m distance at a level of 85 to 90 dB. This includes selection of packaged
equipment with acoustic enclosures, intake and outlet silencers, etc.
The start-up vent, safety valve outlets will be provided with silencers to reduce the noise level
to acceptable limits.
The Hogging Ejector will be provided with silencer. The turbine will be covered with
acoustic enclosure. The buildings where turbines, blowers and bare compressors are
installed will have sound proof walls separating the control rooms.
Measure like use of ear protecting plugs shall be enforced for people who have to
work occasionally very near the mill for checking / inspection during running of the
mill. This is generally required in the vicinity of blowers, Compressors and bar handling
area.
3.8.4 Green Belt Development
A greenbelt development plan will be prepared and implemented along with the project.
The main objective of the greenbelt is to provide a barrier between the plant and the
surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the
noise generated in the plant apart from improving the aesthetics of the plant site.
The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the
effects of emissions from the plant. The treated effluents from the plants will be utilized for
the greenbelt development.
The landscaping of the plant will be carried out. Roads for vehicular movement will be paved
and adequate mitigation measures will be provided to prevent fugitive emissions.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 78
CHAPTER-04SITE ANALYSIS
4.1 General
SMIORE propose to install the aforesaid unit At Danapur, Danayakankere & Hanumanhalli
Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka
4.2 Connectivity
The site is at 7.1 km West away from nearest town Hospet. National Highway [NH-13] is
550 m towards West and South Western Railway Hospet – Kottur broad gauge railway
line of South Western Railway passes close to the east side boundary of the existing Ferro
Alloy Plant.
The suitability of the project site has been assessed in the report. As the proposed
project shall be located in the existing well developed unit, there shall be minimal
cutting and filling activity. Easy access to raw material.
The following factors were considered while selecting the subject site:
Availability of adequate land free from extensive cultivation and forest for locating
the power plant with provision for future expansion.
Suitability of land from topography and geological aspects.
Location with respect to fuel sources and road/rail linkage.
Availability of adequate supply of water to meet condenser cooling water and other
service water requirements.
Facilities for ash disposal.
Ease of transportation of imported coal from the port
Facility for transportation of power plant equipment and construction materials to site.
Power Evacuation facilities.
Proximity to major load centres in the power system
Environmental aspects
4.2.1 Topography
The topography of the land is gently undulating and well suited for development of industrial
projects. Land for the proposed project is industrial land & Plant is not coming under the
dense forest category land. This area also does not form part of any National Park, Wild Life
Sanctuary and Natural/Biosphere reserve.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 79
4.2.2 Existing Land Use Pattern
The present land is gently undulating and well suited for development of industrial projects.
4.2 Climate Data
May month is usually the hottest with daily maximum of 38 ⁰C and December is the coldest
month with mean daily minimum of 17.2 ºC. The average annual rainfall of the area is 529
mm.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 80
CHAPTER – 05PLANNING BRIEF
5.1 Planning Concept
Technical Concept
The Sandur Manganese & Iron Ores Limited proposes to setup an Integrated Steel Facility for
the production of 1.00 MTPA Steel with finished product of 5.5 to 20 mm diameter wire
rods at Vyasanakere, Near Hospet in the State of Karnataka. The captive power
generation will be to utilize the waste heat from the Coke Ovens and waste gases of Blast
Furnace.
Human Resources
Human Resource is the most valuable asset in any industry. The accelerating pace of
technology advancement and fierce competition in the market has led to the increasing
importance of human resources. Continuous skill updating of the existing human resources
and generating new talents in consonance with the needs of the industry are vital for the
progress of the industry.
5.2 Land Use Planning
Total land required for the plant including existing & expansion is 320.79 Acre (129.81 Ha.).
Total land has already been acquired.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 81
CHAPTER – 06PROPOSED INFRASTRUCTURE
6.1 Industrial and Residential Area
The setting up of the 1.0 MTPA integrated steel plant comprising of Sinter Plant, Mini Blast
Furnace, Coke Oven Plant, Rebar Mill, WHRB & Oxygen Plant along with existing ferro
alloys plant requires 320.79 Acre (129.81 Ha.) of land. Coke plant will be within the existing
Plant premises. All other units shall be installed adjacent area to the existing plant.
6.2 Green BeltA greenbelt development plan will be prepared and implemented along with the project. Total
green belt area shall be of 33% of total area and will be developed in the plant.
Green belt Development plan
Green belt of 33 Acre will be developed in the plant premises as per CPCBguidelines.
10m wide greenbelt will be developed all around the plant.
The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind
firm, deep rooted. A three tire plantation is proposed comprising of an outer most belt of
taller trees which will act as barrier, middle core acting as air cleaner and the innermost core
which will act as barrier.
6.3 Others A garland drain around the plant is envisaged to collect surface run-off during rainy
season.
Drinking water facilities will be provided for employees as well as nearby villagers.
Existing road and rail network will be utilized for raw material and final products
transportation.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 82
CHAPTER – 07
REHABILITATION AND RESETTLEMENT (R & R) PLANNot Applicable as it an expansion project within the existing plant premises.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 83
CHAPTER – 08
PROJECT SCHEDULE & COST ESTIMATES
8.1 Project Schedule
In the cement industry, any one of the following three alternate modes of project execution is
adopted:
Turnkey
Semi Turnkey
Packaged procurement mode
In the turnkey mode, there is one implementing agency for the project having the total
responsibility. Hence, the project cost is the highest and at the same time, control on timely
execution is also high. The project cost is minimum in the last mode, also known as shopping
mode, where different items (major machinery or auxiliary; clubbed section wise or type
wise) of the project form the different packages, which are considered for procurement. Thus
control on timely execution is lowest. The semi turnkey mode falls in between the above two
modes, having 4 to 6 packages for procurement and construction & erection and is therefore
the most preferred mode.
Based on the consideration of cost and time, the package procurement mode will be followed,
by clubbing various activities to the extent possible.
Planning of Activities
Careful planning of all the activities is one of the pre-requisite for timely completion of the
project. Following activities will be given special attention
Pre Project Activities
Management Approvals.
Selection of location
Land acquisitions
Statutory Clearances
Financial Approvals and Tie ups.
Selection of Consultants
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 84
Conceptual Design
Preparation of main machinery tender
Evaluation of tenders
Project Activities (Implementation Stage)
Firm up basic design
Main Machinery Order placement
Detailed engineering of the project
Statutory approvals of Building Plans.
Preparation of Tender, Evaluation of tenders received and Order placement for
balance machinery
Completion of procurement activities on time
Release of civil drawing for civil construction
Civil construction
Supply of mechanical & electrical equipment
Inspection of major machinery at supplier’s works
Erection of all plant & machinery
Commissioning of the plant
Statutory Clearances
The proposed project will require various statutory approvals and clearances from various
authorities of The Government. Some of these will be required before start of the
construction activities, while others would be required during the course of execution of the
project and upon completion of the project before commencing operations. A list of Plan
sanction authorities is as given in Table 8.1 However other clearances, if any required shall
be identified in due course and necessary action will be taken to obtain the same.
Project Schedule
The commissioning of the plant is 24 months from ordering of main machinery. Following
activities have been considered.
The external agencies such as consultant, machinery suppliers, contractors of civil
construction and equipment will be selected carefully well in advance. An effective project
team shall be formulated with an experienced Project Manager as its leader.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 85
Strategies for Timely Execution of the Project
The following strategies would be adopted for smooth functioning as well as timely
execution of the project:
The task of implementing the project in time shall be achieved by ensuring a well
coordinated project implementation task force in- house and from external agencies.
A well chosen team of experienced personnel for project execution shall coordinate
the implementation of the project from in-house.
Experienced engineering consultants with proven track records shall be selected for
detailed engineering of the project.
Reputed and experienced contractors with adequate resources of finance, men,
material and tools and tackles, will be engaged for execution of the construction and
erection work.
Effective project monitoring including project planning schedule and monitoring shall
be employed in this project. Timely execution and resources will be monitored using
computer base project monitoring tools. In case of deviations in project progress, all
possible corrective actions such as crashing of network etc. will be carried out.
Effective monitoring and reporting procedure for review of progress and coordination among
various agencies shall be used. At least a monthly coordination meeting, if not earlier, shall
be held to closely monitor the project and take corrective action as required. The schedule
may vary depending on the project status.
8.2 Project Cost
An indicative estimated capital cost of the proposed expansion is Rs. 5300.00 Cr.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 86
CHAPTER – 09ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits
9.1.1 Improvements in the Physical Infrastructure
SMIORE has envisaged a lot of infrastructure developmental works in the periphery area.
Improving and building road network in the adjoining villages.
Strengthening School buildings with playgrounds.
Providing the Drinking Water Facilities.
9.1.2 Improvements in the Social Infrastructure
Social awareness programme will further improve by the local authority such as
sanitation and hygiene, HIV Prevention Program will be improved.
Through this project, adult education and female education will be provided to the
illiterate adults and backward females of the villages in the project surrounding
area. Sponsor education to Poor Students of the Proposed Area
The proposed project will set up training centre or tie up with Industrial Technical
Institutes to educate local youth as skilled labour.
Provide & conduct Free Eye & Health Check up Programmes.
9.1.3 Employment
The project is going to create substantial employment and income. Due to this project
activity, some person in the project area will be recruited as skilled, semi skilled and
unskilled workers by the company as per its policy. Therefore, substantial amount of
employment and income is likely to be generated for the local people. So, the project will
contribute in a positive manner towards direct employment in the project area. Some
employment potential benefits are given below:
9.1.4 Other Benefits
Improving and building road network in the adjoining villages.
Strengthening local school buildings with playgrounds.
M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka
Visiontek Consultancy services Pvt. LtdBhubaneswar Page 87
Improvement in social awareness programme such as sanitation and hygiene, HIV
Prevention Program.
Adult education and female education programmes will be provided to the illiterate
adults and backward females of the villages in the project surrounding area.
Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)
Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : visiontekin@gmail.com, visiontekin@yahoo.co.in, Visit us at : www.vcspl.org
Committed For Better Environment
top related