application for environmental clearance (ec) form 1 &...

of

Expansion of DRI Plant (300 TPD to 1700 TPD), SMS Plant (0.1 MTPA to

0.5 MTPA), Captive Power Plant (1x12 MW to 52 MW), Coal Washery

(100 TPH to 300 TPH), MBF (0.15 MTPA), Rolling Mill (0.35 MTPA),

Pellet Plant with Beneficiation (2600 TPD) in addition to pellet plant

(1800 TPD) & Ferro Alloys Plant (2x18 MVA)

FOR

M/s SHRI MAHAVIR FERRO ALLOYS PVT. LTD. At: Jiabahal, Kalunga Industrial Estate, District Sundergarh, Odisha.

NOV 2017

.

Application for Environmental Clearance (EC)

FORM 1 & PRE-FEASIBILITY REPORT

CEMCCEMC

CENTRE FOR ENVOTECH AND MANAGEMENT CONSULTANCY PVT. LTD. An ISO 9001-2015, OHSAS 18001:2007 & ISO 14001-2015 Certified Company, Empanelled with OCCL, ORSAC and SPCB of Govt. of Odisha

Accredited by NABET, QCI for EIA Studies as ‘A’ Category Consultant Organization. Empanelled with PCCF (Wildlife) & CWLW, Odisha Enlisted in CIDC (established by the Planning Commission Govt. of India), NABL MoEF&CC, Govt. of India,

Recognised Environment Laboratory under Environment (Protection) Act, 1986. Environmental Studies (EIA & EMP),Monitoring, Forest Diversion Planning, DPR, Wildlife Management Plan, Hazardous & Safety Studies,

RS& GIS, Baseline Survey, Hydrological & Geological Studies, Socio-economic Studies, DGPS & ETS Survey. Regd. Office: 1st Floor, N-5/305, IRC village, Nayapalli, Bhubaneswar-751015, Odisha, India, Mobile: 9861032826 E-mail- [email protected], [email protected], Website: www.cemc.in, Landline: 0674-2360344.

Laboratory At: Plot No. 800/1274, Johal, Pahal, Bhubaneswar-752101, E-mail: [email protected], Mobile: 9937631956, 8895177314

Contents

CHAPTER NO CHAPTER NAME PAGE NO CHAPTER-1 EXECUTIVE SUMMARY 1-6

1.1 Introduction 1 1.2 Project Site 1 1.3 Plant Layout 2 1.4 Brief Project Description 2 1.5 Raw Materials 2 1.6 Water Requirement & Source 3 1.7 Solid Waste Generation & Management 3 1.8 Green Belt Development 4 1.9 Amenities/Facilities 5

1.9.1 In-Plant Facilities 5 1.9.2 Employment Generation 5 1.9.3 Medical Facilities/Health Care Camps 5 1.10 Project Cost 6

CHAPTER-2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION 7-9

2.1 Identification of the project & project proponent 7 2.1.1 About the Project 7 2.2 Nature, size and magnitude of project 8 2.3 Need for the project 8 2.4 Project Objective and Its Importance to The

Country/ Region 8

2.5 Demand supply gap 9 2.6 Employment generation (Direct and Indirect) 9

CHAPTER-3 PROJECT DESCRIPTION 10-33

3.1 Type of project including interlinked and interdependent projects 10

3.2 Location and Accessibility 10 3.3 Details of alternate sites and selection of the site 12 3.4 Size or magnitude of operation 12 3.5 Process Description 12

3.5.1 Plant Layout 12 3.5.2 Process Description of DRI Plant 15 3.5.3 Process Description of SMS Plant 16 3.5.4 Process Description of Mini Blast Furnace 17 3.5.5 Process Description of Captive Power Plant (CPP) 19 3.5.6 Process Description of Coal Washery 19 3.5.7 Process Description of Pelletization Plant with

Beneficiation 23

3.5.8 Process Description of Ferro Alloys Plant 25 3.5.9 Process Description of Rolling Mill 26

3.6 Raw material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finished product

26

3.6.1 Source of Major Raw Material with mode of transport 26 3.7 Resource optimization/recycling and reuse envisaged

in the project 27

3.8 Availability of water its source, energy/power requirement and source 27

3.8.1 Source of Water 27 3.8.2 Summary of Plant Water Requirement 27 3.8.3 External water system 28 3.8.4 Plant water system 28 3.9 Energy 28 3.10 Environment Management 29

CHAPTER-4 SITE ANALYSIS 34-36

4.1 Connectivity of the site 34 4.2 Land form, land use and land ownership 34 4.3 Topography 35 4.4 Existing Land use Pattern 35 4.5 Existing Infrastructure 35 4.6 Climate Data 36

CHAPTER-5 PLANNING BRIEF 37-38

5.1 Planning concept 37 5.2 Manpower Projection 37 5.3 Land use 37

5.3.1 Green Belt Development 38 5.4 Amenities/facilities 38

CHAPTER-6 PROPOSED INFRASTRUCTURE 29-41

6.1 Industrial area (processing area) 39 6.2 Residential area (Non-processing area) 39 6.3 Green belt 39 6.4 Social infrastructure 39 6.5 Connectivity 39 6.6 Drinking water management 40 6.7 Sewerage system 40 6.8 Industrial waste management 40 6.9 Solid waste management 40 6.10 Power requirement & its source 41

CHAPTER-7 REHABILITATION & RESETTLEMENT (R & R) PLAN 42

CHAPTER-8 PROJECT SCHEDULE & COST ESTIMATES 43-46

8.1 Project Implementation 43 8.2 Project cost 46

CHAPTER-9 ANALYSIS OF PROPOSAL

(FINAL RECOMMENDATIONS) 47-48

9.1 Financial and social and Socio benefits 47 9.1.1 Improvements in the Physical Infrastructure 47 9.1.2 Improvements in the Social Infrastructure 47 9.1.3 Employment 47 9.2 Other Benefits 48

Pre-feasibility Report M/s Shri Mahavir Ferro Alloys Pvt. Ltd.

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1.1 INTRODUCTION

Shri Mahavir Ferro Alloys Pvt. Ltd. has an existing Mini Steel Plant (0.1 MTPA) consisting of a Pellet Plant (Inclusive of Beneficiation & Producer Gas Plant), DRI Plant, SMS Plant, Captive Power Plant & Coal Washery at Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundargarh, Odisha. They want to expand their capacity to 0.5 MTPA Steel Plant expanding all the units & adding a Mini Blast Furnace, Rolling Mill & also to SAF Furnace to produce Ferro Alloys for product diversion. The detail of existing units & proposed units and total capacity after expansion is shown in Table No. C1-1.

Table No. C1-1: Production capacity

Sl. No. Unit/Plant Existing

Capacity

Additional Capacity Proposed

Final Capacity after Expansion

1 DRI Plant 300 TPD (3x100 TPD)

1400 TPD (4x350 TPD) 1700 TPD

2 SMS Plant 0.1 MTPA 0.40 MTPA 0.50 MTPA 3 Captive Power

Plant 12 MW 40 MW

(AFBC - 12 MW, WHRB - 4x7 MW - 28 MW

52 MW

4 Mini Blast Furnace -- 0.15 MTPA 0.15 MTPA 5 Coal Washery 100 TPH 200 TPH 300 TPH 6 Pelletization Plant 1800 TPD -- 1800 TPD 7 Pelletization Plant

with Beneficiation --- 2600 TPD 2600 TPD

8 Rolling Mill -- 0.35 MTPA 0.35 MTPA 9 Ferro Alloys Plant -- 2 x 18 MVA 2 x 18 MVA ----

The existing project is coming under category ‘A’ project and requires Environmental Clearance from MoEF, Govt. of India as per EIA Notification 2006.

1.2 PROJECT SITE

The Proposed Expansion Plant is located in the Village Jiabahal, P.O. Kalunga, Dist- Sundargarh, Odisha. The area is situated in the survey of India Topo Sheet No. 73 B/11, 12, 15 & 16 and between latitude 220 18’ 19” to 220 19’ 00” North and Longitude 840 45’ 45” to 840 46’ 27” East. The site is accessible by all weather road from the district head quarter Sundargarh which is located at a distance of 80 km. The site is located in Kalunga Industrial Area nearer (4.0 KM) to SH-10 which is connecting Rourkela to Sambalpur. The nearest railway station at Kalunga which is about 2 km away from the site. Kalunga Railway station is on Howrah-Mumbai BG Railway line of South Eastern Railway. The nearest airport is at about 220 km from Rourkela at Ranchi, Jharkhand.


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1.3 PLANT LAYOUT

The project is developed over 110.373 Acres (In side). Pump House, Clarifier & Reservoir (Out Side) is 6.690 Acres & Out Side Land (Green Belt) is 22.910 Acres. So total land inside & outside Plant is 139.973 Acres. The layout plan for proposed expansion project has been prepared in such a way that space is properly and purposefully utilized, process flow is maintained and adequate circulation space is provided for operation and maintenance. The plant layout map, which shows the layout of DRI Plant, Power Plant, SMS Plant, Fly Ash Brick Plant, Coal Washery, MBF Unit, Pellet Plant, Rolling Mill, Ferro Alloys Plant Administrative Building, waste disposal area, raw material storage yard, rain water harvesting pond, RWTP and green belt etc.

1.4 BRIEF PROJECT DESCRIPTION

Shri Mahavir Ferro Alloys Pvt. Ltd. has an existing Mini Steel Plant (0.1 MTPA) consisting of a Pellet Plant (Inclusive of Beneficiation & Producer Gas Plant), DRI Plant, SMS Plant, Captive Power Plant & Coal Washery at Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundergarh, Odisha. They want to expand their capacity to 0.5 MTPA Steel Plant expanding all the units & adding a Mini Blast Furnace, Rolling Mill & also to SAF Furnace to produce Ferro Alloys for product diversion.

1.5 RAW MATERIALS

Table No. C1-2: Raw Material Requirement

Raw Materials Quantity DRI plant (1400 TPD)

Coal 630000 TPA Pellet 610000 TPA Dolomite 25200 TPA

SMS Plant (0.40 MTPA) Sponge Iron 410000 TPA Pig Iron 34800 TPA Ferro Alloys & Non Ferro Alloys 5500TPA MS Scrap 20200TPA

MBF (0.15 MTPA) Iron Ore Pellet 125000 TPA Coke 80000 TPA Sinter 125000TPA

Ferro Alloys Plant ( 2X18 MVA) Manganese Ore 71650 TPA Ferro Manganese Slag 39800 TPA Coke 7960 TPA Coal 23880 TPA Dolomite 3980 TPA

Rolling Mill (0.35 MTPA) Steel Billets 357000 TPA

Captive Power Plant (40 MW = AFBC-12 + WHRB-28 MW) Dolochar 60000 TPA Coal 30000 TPA


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Washery rejects 45000 TPA Pellet Plant (2600 TPD)

Iron Ore Fines 1120000TPA Bentonite 13200 TPA Dolomite/ Limestone 13200 TPA Coke 30000 TPA

1.6 WATER REQUIREMENT & SOURCE

Water requirement for the proposed expansion project is 380 m3/hr and Water requirement for existing project is 93 m3/hr, So total Water requirement for both existing & expansion project is 473 m3/hr. Water will be sourced from Sankha River.

Estimated make up water requirement to replenish the process and treatment losses for the facilities.

Table No. C1-3: Total Plant Raw Water Requirement

Sl. No. Plant Existing Expansion 1 DRI Plant 11 m3/hr 45 m3/hr 2 SMS Plant 12 m3/hr 48 m3/hr 3 Pellet Plant 6 m3/hr -- 4 Captive Power Plant 48 m3/hr 160 m3/hr 5 Coal Washery 15 m3/hr 30 m3/hr 6 Rolling Mill -- 35 m3/hr 7 Mini Blast Furnace -- 36 m3/hr 8 Ferro Alloys Plant -- 15 m3/hr 9 Pellet Plant with Beneficiation -- 10 m3/hr 10 Domestic 1 m3/hr 1 m3/hr

Total Water 93 m3/hr 380 m3/hr 1.7 SOLID WASTE GENERATION AND MANAGEMENT

The solid waste/tailings generated/to be generated from the process to be disposed off/reutilized as per the guide lines of CPCB and best practices adopted in the steel industries. The coal fines will be utilized in power plant and iron ore fines will be utilized in pellet plants. Dust collected from bag filters/APC devices will be disposed in char dumping area. Ash from PGP shall be used in Pellet plant. Part of fly ash generated from power plant will be utilized in fly ash brick making and shall be sold to tiles/cement manufacturers. Balance fly ash and bottom ash will be disposed of in form of ash in abandoned quarries as per relevant guidelines.

Table No. C1-4: Solid Waste Generation

Sl. No. Sources Qty. Ton/Day 1 Tailings 400 2 Char from DRI kilns. 200


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3 Dust from APC devices 50 4 Slag from induction furnaces/Arc

Furnaces/Ferro Alloys Plant 170

5 Ash from power plant 650 6 Slag from Blast Furnaces 2x40 7 Used resins from DM water plant 1450 ltr/3yrs 8 Solid Waste in form of garbage / food

waste from workers’ canteen. 15.20 kg/day

9 Used Oil 1.5 kl/Year Land Use:

The project is developed over 110.373 Acres (In side). Pump House, Clarifier & Reservoir (Out Side) is 6.690 Acres & Out Side Land (Green Belt) is 22.910 Acres. So total land inside & outside Plant is 139.973 Acres.

Table No. C1-5: Details of Land use break up

Sl. No Purpose Area (acres) 1. 3 x 100 TPD DRI Plant, Iron Ore Crusher (Existing) 4.50 2. 12 MW (Existing) & 12 MW (Proposed) Power Plant (

Dolochar, Coal & Washery Middling) 3.00

3. Steel Melting Shop 3 x 12 T Induction Furnace (Existing) 0.75 4. Fly Ash Brick Plant 0.50 5. Coal Washery- 100 TPH (Existing) & 200 TPH (Proposed) 2.50 6. 4 x 350 TPD DRI Plant (Proposed) 2.50 7. MBF Unit - 0.15 MTPA (Proposed) 2.00 8. Steel Melting Shop - 0.40 MTPA (Proposed) 1.00 9. 28 MW Power Plant (WHRB Based) (Proposed) 3.00 10. Pellet Plant - 1800 TPD (Existing),

Pellet & Beneficiation Plant - 2600 TPD (Proposed) 9.19

11. Producer Gas Plant (Existing) 0.81 12. Rolling Mill ( 0.35 MTPA) - Proposed 2.00 13. Ferro Alloys Plant - 2x18 MVA (Proposed) 3.00 14. Railway Siding (Existing) 7.00 15. Green Belt (Existing & Proposed) 37.60 16. Solid Waste Disposal 10.00 17. Raw Material Storage Yard

Coal Crusher & Storage Yard Administrative Building Finished Product Storage Water Harvesting & Settling Pond

21.023

Total Area 110.373

1.8 GREEN BELT DEVELOPMENT

Appropriate type of trees suitable for this region are planted in compliance of conditions of environmental clearance. With a view to attenuate air pollutants, to


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resist noise propagation from power generation units and uptake of treated effluent to some extent, the green belt all around the periphery of project sites and in vacant areas (34 % of the total acquired land) is being developed. Tree plantation has been undertaken in a large scale on land vacated after cessation of construction activities. Open spaces, where tree plantation is not possible are planted with flowering shrubs and grass which act as soil binders and also helpful in preventing erosion of topsoil.

1.9 AMENITIES/FACILITIES.

1.9.1 In-Plant Facilities

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and restrooms according to norms laid down in relevant factories act. The above facilities are adequately furnished and equipped.

1.9.2 Employment Generation

Establishment of small and medium scale engineering ancillaries, with cascading employment opportunities;

Increased revenue to the state by way of taxes and duties;

Improved green cover;

Better communication and transport facilities;

The proposed project has enhanced the prospects of employment. Recruitment for the unskilled workers for the plant is from the nearby villages. The basic amenities viz. roads, transportation, electricity, drinking water, proper sanitation, educational institutions, medical facilities, entertainment, etc. are developed as far as possible.

1.9.3 Medical Facilities/ Health care camps

Medicines are provided at the first aid centre present within the plant premises, which cater to the needs of adjoining population.

Periodic health camps like: Eye camp and Health camps for treatment of other diseases will be conducted by the company doctors.


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1.10 PROJECT COST:

The Capital Cost of the Expansion project is Rs 610 Crores.

The Project from concept stage to commissioning is being envisaged in three phases. Services of experienced consultants will be utilized for detailed planning, preparation of techno-economic feasibility report and other associated activities like discussions with financial institutions, phasing of capital expenditure etc. Considering the existing expertise of the company, the company expects to adhere to the schedule. However, the implementation primarily will depend upon the allotment of land by the State Government and statutory clearances including environmental clearances.

Table No. C1-6: Cost Breakup for Expansion Project

Sl. No Plant Specification Amount in Crores 1 DRI 4x350 TPD 120 2 SMS 0.4 MTPA 50 3 CPP 40 MW 180 4 Rolling Mill 0.35 MTPA 35 5 Coal Washery 200 TPH 35 6 MBF 0.15 MTPA 20 7 Ferro Alloys 2x18 MVA 40

8 Pellet with Benefication

2600 TPD 130

Total 610 Crores


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2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

Shri Mahavir Ferro Alloys Pvt. Ltd. is a private limited company incorporated under the companies Act 1956 on September 10, 1996 having its registered office at kalunga Industrial Estate, Kalunga, Rourkela, Dist- Sundargarh, Odisha. The company has established a Pellet Plant (1800 TPD), DRI Plant (3x100 TPD), SMS Plant (0.1 MTPA), Captive Power Plant (1x12 MW) & Coal Washery (100 TPH) now company has proposing for an Expansion of DRI Plant (300 TPD to 1700 TPD), SMS Plant (0.1 MTPA to 0.50 MTPA), Captive Power Plant (1x12 MW to 52 MW), Coal Washery (100 TPH to 300 TPH), MBF (0.15 MTPA), Rolling Mill (0.35 MTPA), Pellet plant with Beneficiation (2600 TPD) in addition to existing pellet plant (1800 TPD) & Ferro Alloys Plant (2x18 MVA) in the existing premises Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundargarh, Odisha.

Table No. C2-1: Contact Address

Address for correspondence

M/s Shri Mahavir Ferro Alloys Pvt. Ltd. Plot No. 283, Village: Jiabahal, IDC, Kalunga- 770031 Dist: Sundargarh, (Odisha)

Works (Plant Site Address)

M/s Shri Mahavir Ferro Alloys Pvt. Ltd. Plot No. 283, Village: Jiabahal, IDC, Kalunga- 770031 Dist: Sundargarh, (Odisha)

2.1.1 ABOUT THE PROJECT

Shri Mahavir Ferro Alloys Pvt. Ltd. has an existing Mini Steel Plant (0.1 MTPA) consisting of a Pellet Plant (Inclusive of Beneficiation & Producer Gas Plant), DRI Plant, SMS Plant, Captive Power Plant & Coal Washery at Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundergarh, Odisha. They want to expand their capacity to 0.5 MTPA Steel Plant expanding all the units & adding a Mini Blast Furnace, Rolling Mill & also to SAF Furnace to produce Ferro Alloys for product diversion.

The proposed production capacity of the company as envisaged is as under:

Table No. C2-2: Production capacity


Capacity




1400 TPD (4x350 TPD) 1700 TPD


Plant 12 MW 40 MW

(AFBC - 12 MW, WHRB - 4x7

52 MW


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MW - 28 MW 4 Mini Blast Furnace -- 0.15 MTPA 0.15 MTPA 5 Coal Washery 100 TPH 200 TPH 300 TPH 6 Pelletization Plant 1800 TPD -- 1800 TPD 7 Pellet Plant with

Beneficiation --- 2600 TPD 2600 TPD

8 Rolling Mill -- 0.35 MTPA 0.35 MTPA 9 Ferro Alloys Plant -- 2 x 18 MVA 2 x 18 MVA

Land:


2.2 NATURE, SIZE AND MAGNITUDE OF PROJECT:

Shri Mahavir Ferro Alloys Pvt. Ltd. has an existing Pellet Plant (1800 TPD), DRI Plant (3x100 TPD), SMS Plant (0.1 MTPA), Captive Power Plant (1x12 MW), Coal Washery (100 TPH) and is now proposing for an Expansion of DRI Plant (300 TPD to 1700 TPD), SMS Plant (0.1 MTPA to 0.50 MTPA), Captive Power Plant (1x12 MW to 52 MW), Coal Washery (100 TPH to 300 TPH), MBF (0.15 MTPA), Rolling Mill (0.35 MTPA), Pellet Plant with Beneficiation (2600 TPD) in addition to existing pellet plant (1800 TPD) & Ferro Alloys Plant (2x18 MVA) in its existing plant premises at Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundargarh, Odisha.

The Environmental Clearance for expanding our plant for 0.1 MTPA to 0.35 MTPA on 29th January, 2008 vide letter no. J-11011/606/2007-IA II (I), revalidated on 20th April, 2012 vide letter no. J-11011/606/2007-IA II (I).

2.3 NEED FOR THE PROJECT:

• Security of power supply through self-generation

• Reduced costs through high fuel efficiency, particularly when in CHP configuration

• Improved environmental performance resulting from fuel efficiency.

2.4 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/ REGION:

The Indian Steel Sector has grown to be the 5th largest steel producing country in the world. This has been achieved due to the thrust on infrastructure and housing sectors. Contributing to the development of India’s industrial and economic landscape for over 150 years, steel accounts for about 7 per cent of GDP and employs about 1.5 million people directly. With continued emphasis on building infrastructure and several green field projects under execution, the growth story is likely to gather momentum in the years to come. The steel industry in India has been moving from strength to strength and according to the Annual Report 2009-10 by the Ministry of Steel, India has emerged as the fifth


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largest producer of steel in the world and is likely to become the second largest producer of crude steel by 2015-16.

2.5 Demand and Supply Gap (Market Scenario)

Demand – Availability of iron and steel in the country is projected by Ministry of Steel annually.

Gaps in Availability are met mostly through imports. Interface with consumers by way of a Steel Consumer Council exists, which is

conducted on regular basis.

Interface helps in redressing availability problems, complaints related to quality.

Thus there is a strong requirement for these sort of industries.

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

The manpower requirement for the existing plant is 700 persons. In order to operate the proposed unit in full swing, the additional requirement of the man power will be approximately 500 for various activities like loading, unloading, handling, transportation, general cleaning, horticulture and other miscellaneous works inside the plant. So the total manpower requirement for the existing & proposed plant will be 1250. Three shifts working for 330 days is planned.

Training of O&M staff will be arranged through prevalent methods & practices which will include computerized plant operation, simulator, various audio visual cards, a well maintained library and requisite set up for training activity. These will be reinforced by:

In-plant training of the operators at the site itself prior to commissioning of the plant.

Continued training of O&M staff through experts & supplier’s staff as part of the in plant training programme.

Specialized training at various training institutes

Training during manufacture at supplier’s works and construction activities.

Table No. C2-3: Employment status

Sl. No. Particulars Total (Existing + Expansion)

1 Managerial 40 2 Supervisory 60 3 Skilled 200 4 Semi skilled 400 5 Unskilled 550

Total 1250


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3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS

Shri Mahavir Ferro Alloys Pvt. Ltd. has an existing Pellet Plant (1800 TPD), DRI Plant (3x100 TPD), SMS Plant (0.1 MTPA), Captive Power Plant (1x12 MW), & Coal Washery (100 TPH) at Jiabahal, Kalunga Industrial Estate, Kalunga, District Sundargarh, Odisha and is now proposing for an Expansion of DRI Plant ( 300 TPD to 1700 TPD), SMS Plant (0.1 MTPA to 0.50 MTPA), Captive Power Plant (1x12 MW to 52 MW), Coal Washery (100 TPH to 300 TPH), MBF (0.15 MTPA), Rolling Mill (0.35 MTPA), Pellet Plant with Beneficiation (2600 TPD) in addition to existing pellet plant (1800 TPD) & Ferro Alloys Plant (2x18 MVA) in the existing premises. The area comes in survey of India Topo Sheet No. 73 B/11, 12, 15 & 16 and between Latitude 190 20’ 03” North and Longitude 840 57’ 32” East.

3.2 LOCATION AND ACCESSIBILITY

The Proposed Expansion Plant is located in the village Jiabahal, P.O. Kalunga, Dist- Sundargarh, Odisha. The area is situated in the survey of India Topo Sheet No. 73 B/11, 12, 15 & 16 and between latitude 220 18’ 19” to 220 19’ 00” North and Longitude 840 45’ 45” to 840 46’ 27” East. The site is accessible by all weather road from the district head quarter Sundargarh which is located at a distance of 80 km. The site is located in Kalunga Industrial Area nearer (4.0 KM) to SH-10 which is connecting Rourkela to Sambalpur. The nearest railway station at Kalunga which is about 2 km away from the site. Kalunga Railway station is on Howrah-Mumbai BG Railway line of South Eastern Railway. The nearest airport is at about 220 km from Rourkela at Ranchi, Jharkhand.

Location details of the Project Site:

Village : Jiabahal District : Sundargarh State : Odisha Latitude : 220 18’ 19” to 220 19’ 00” North Longitude : 840 45’ 45” to 840 46’ 27” East Topo sheet No. : 73 B/11, 12, 15 & 16

a. Road Connectivity: The proposed plant is accessible by all weather road from the district head quarter Sundargarh which is located at a distance of 80 km. The site is located in Kalunga Industrial Area nearer (4.0 KM) to SH-10 which is connecting Rourkela to Sambalpur.

b. Rail Connectivity: The proposed site is close to the Mumbai-Howrah railway line. The company has a Railway siding inside in factory Premises. The nearest Railway station is at Kalunga which is 2.0 km from the site.

c. Airport: The nearest airport is at about 220 km from Rourkela at Ranchi, Jharkhand.


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Fig.No.C3-1: Vicinity map of the study area


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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE / SITE SUITABILITY:

This is a proposed expansion project within the existing plant premises. The project site conforms to the environmental setting guidelines as per MoEF and has enough existing infrastructure facilities to be selected for the expansion project. The site has advantages of availability of raw material and other infrastructural facilities like skilled labour, power, transportation, and water required for such type of industries. Hence, no alternative site has been considered.

3.4 SIZE OR MAGNITUDE OF OPERATION

M/s Shri Mahavir Ferro Alloys Pvt. Ltd. has expansion of Integrated Steel Plant i.e. DRI Plant, SMS Plant, CPP Plant, MBF, Coal Washery, Pelletization with Beneficiation, Rolling Mill & Ferro Alloys Plant. The size of the project is following.

Table No. C3-1: Size of the Plant


Capacity




1400 TPD (4x350 TPD) 1700 TPD


Plant 12 MW 40 MW

(AFBC - 12 MW, WHRB - 4x7 MW - 28 MW

52 MW

4 Mini Blast Furnace -- 0.15 MTPA 0.15 MTPA 5 Coal Washery 100 TPH 200 TPH 300 TPH 6 Pelletization Plant 1800 TPD -- 1800 TPD 7 Pellet Plant with

Beneficiation --- 2600 TPD 2600 TPD

8 Rolling Mill -- 0.35 MTPA 0.35 MTPA 9 Ferro Alloys Plant -- 2 x 18 MVA 2 x 18 MVA

3.5 PROCESS DESCRIPTION

3.5.1 Plant Layout

The layout has been developed keeping in view the need for unidirectional and streamlined movement of materials. A streamlined road network has been proposed to provide easy road access to different plant units.

The major parameters considered to develop the layout are as given below:

i) Adequate area for locating Mini Blast Furnace, Rolling Mill & Ferro Alloys Plant.

ii) Adequate area for storage and handling of different raw materials.

iii) Adequate area for various auxiliaries and ancillary facilities.

iv) Approach road, Power Sub-station and Water supply etc.

v) Dump area for storage of waste materials.


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vi) Adequate road and parking space ensuring safe and smooth movement of man and materials within the plant premises.

vii) Raw water Reservoir and Rain water harvesting

viii) Area for Green belt.

ix) Administrative building


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Fig No.C3-2: Plant Layout


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3.5.2 Process Description of DRI Plant:

Sponge iron is a direct reduced iron (DRI), which is produced from iron ore without phase change, i.e. without going into liquid stage as in the case of blast furnace. Sponge iron production requires small quantity of energy, as no melting process is involved. The DRI assumed nickname “Sponge Iron” due to its appearance of sponge under microscope. Sponge iron is a direct substitute for ferrous scrap for production of steel.

The ore/coal mix moves through the kiln, in counter-current to & the waste gas in the free board. After passing the preheating zone, iron ore reduction and carbon gasification, which provide the process with the necessary reducing gas, take place simultaneously.

The volatile components and the excess carbon monoxide emerging from the charge are burnt by the addition of air, introduced along the kiln in controlled columns, providing the process with the necessary heat.

In the preheating zone, part of the air can be injected directly into the material layer by special air injection nozzles. The remaining air for the preheating and reduction zone is introduced in the kiln freeboard by special air tubes.

The kiln discharge consisting of DRI, ash and char leaves the rotary kiln at the discharge end and is cooled in a rotary cooler. The discharge material is separated into DPI and char by screening and magnetic separation.

The waste gases leave the kiln at the feed end. For the elimination of soot, coal dust and combustible gas components they are subjected to after-combustion and are cleaned in an ESP after passing through the WHR Boiler.

The DRI unit consists of 4 Nos. Kilns having 350 TPD capacity each.

The reaction involves are as follows.

C+O2 CO2

CO2+C 2CO

Fe2O3 + 3CO 2Fe + 3CO2

Normally reduction takes place at temperatures around 1000°C and sponge iron produced porous and has the same shape as the original iron ore particle.

Off Gas System

Hot Waste gases leave the rotary kiln at about 800-8500C through kiln feed end, dust settling chamber and come to after burning chamber (ABC) where combustibles are burnt completely by supplying excess air. The gases at about 950-10000C will then be led to a waste heat recovery boiler to generate steam utilizing sensible heat of the waste DR off gas. The flue gas will then be cleaned in electrostatic precipitators (ESP) before letting them out into the atmosphere through stack.


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Process Flow Diagram:

Material Balance:

INPUT OUTPUT Coal 630000 TPA Sponge Iron 420000 TPA Pellet 610000 TPA Char/Dolochar 60000 TPA Dolomite/ 25200 TPA Dust Fines 50000 TPA LOI 735200 TPA Total 1265200 TPA Total 1265200 TPA

3.5.3 Process Description of SMS (Steel Melting Shop)

Steel Melting Shop of furnaces (Induction/Electric Arc). The primary application of the furnace is for remelting of steel scrap and melting Pig Iron and DRI. The charge mix may vary from 70%-80% of DRI to 20%-30% of scarp and Pig Iron. The heating/melting of feed material in achieved by creating a electric field (Induction) with the help of coils. In case of induction furnace by directly producing Electric Arc with the help of electrodes. Furnaces are continuously cooled externally with circulating water. The molten metal is then pured into a ladle of suitable capacity. The Ladle then pours this liquid metal to continuous machine to produce steel billets/blooms.


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Material Balance:

INPUT OUTPUT Sponge Iron 410000 TPA Steel Billets 4,00,000 TPA Pig Iron 34800 TPA Slag 41100 TPA Ferro Alloys & Non Ferro Alloys

5500 TPA Cut ends, rejects 11800 TPA

MS Scrap 20200 TPA Flue Dust 9800 TPA LOI 7800 TPA

Total 470500 TPA Total 470500 TPA 3.5.4 Process Description of Mini Blast Furnace (MBF):

Blast furnace is an age old equipment to produce Pig Iron. It is a refractory lined furnace with a hearth at the bottom and top holes just above the hearth to tap liquid Pig Iron ad Slag. It has arrangements to feed raw materials like Iron Ore, reducing agent coke and flux like limestone from top. The percentage of feed (raw material) mix into the BF varies from 150%-180% of Iron Ore/Sinters, 60%-70% of coke and 20%-30% of lime stone. Hot blast is given into the blast furnace through blowers. Being Heavy Molten metal is tapped from the bottom of the hearth and slag is tapped from the top. The molten Pig Iron is poured in the ladle and then either poured into a pig casting machine or into the EAF or to other equipments depending upon the finished product being manufactured.


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Flow Diagram:

Material Balance

INPUT OUTPUT Iron Ore Pellet 125000 TPA Hot metal 1,50,000 TPA Coke 80000 TPA Slag 40500 TPA Sinter 125000 TPA Sludge & Flue dust 55,500 TPA LOI 84000 TPA Total 330000 TPA Total 330000 TPA

FLOW CHART – BLAST FURNACE

Dolomite

Coke

Sinter

Iron Ore

Cooling Water

Make up Water Cap – 0.3

MTPA

Slag

Pig Iron


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3.5.5 Process Description of Captive Power Plant (CPP) Co-generation of power in Coal based Sponge Iron Plants is very common these days. The waste heat of a sponge iron kiln can be effectively utilized in steam generation which in-turn can generate power. In order to utilize the waste hot gases generated from DRI plant, WHRB (Waste Heat Recovery Boiler) based and in order to utilize the coal rejects, fines and DRI char generated from the sponge iron plant; AFBC (Atmospheric Fluidized Bed Combustion) type boiler is proposed, which will have total generation capacity of 52 MW electricity (Existing – 12 MW and Expansion- 40 MW). Hence, Captive Power Plant of both WHRB (4x7 MW = 28 MW) and AFBC (12 MW) based will be set up in expansion phase and with a total capacity of 52 MW. The ash disposal in the form of High Concentration Slurry Disposal has been contemplated for the power plant. In coal fired power station, the heat of combustion is turned into thermal energy and then to electrical energy.

The ROM coal will be used as fuel for the proposed 12 MW AFBC power plant. Crushed coal will be received from nearby coalfields. It will be unloaded into receiving hoppers and conveyed to boiler bunkers for feeding to boiler. The coal quality considered to design the power plant is given below:

Moisture 12% Ash 54% Volatile Matter 16% Fixed Carbon 18% Sulphur 0.5% GCV 2300 kcal/kg

Material Balance:

Input Quantity, TPA Output Quantity, TPA Dolochar 60000 Power 12 MW Coal 30000 Fly Ash 94500 Washery rejects

45000

3.5.6 Process Description of Coal Washery

The coal washery has been designed to wash the coal in heavy media circuit to produce clean coal with 28% ash and middling. The process consists of crushing of the ROM coal in a combination of rotary breaker and 2 stages roll crushers. The crushed coal is then washed in the heavy medic cyclone to produce clean coal and middling. The heavy media preparation / regeneration unit for maintaining the required density in the heavy media circuit is also included in the plant design. The effluent from various points in the circuit is collected and treated in the thickener. The thickened tailing is envisaged to be dewatered in a belt press while the clarified water is recycled back in the process circuit with make up water. The coal washery can be divided in the following sections:


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Primary Coal Preparation Circuit

A rotary breaker, which has a top size capacity of 800mm, is used to de- shell the ROM coal. This rotary breaker is provided with 250mm openings, which gives a positive control on the top size of feed to the plant. Following this, the coal size is reduced to 20 mm in 2 stage crushing. A primary screen is first used to remove the -20 mm material already present in the coal following which is fed to a roll crusher. The product from the roll crusher is then fed to a secondary screen separating -20 mm material. Oversize from the secondary screen feeds the secondary crusher, which operates in closed circuit with the secondary screen. 20mm from the screens is stored in a stockpile and feeders below the stockpile are used to feed to the washery building.

Desliming Module:

The ROM coal, crushed to -20mm size is drawn from the feed stockpile through conveyor. The reclaimed material is transferred through to discharge the material on the desliming screen. The feed shall be deslimed at 1 mm (alternatively 0.5 mm). Water shall be sprayed on the desliming screen to enhance the desliming by removing the attached fines on the bigger particles. The coal feed is treated in circuit of 200 TPH capacity. The screen overflow shall be collected in a fine coal sump and pumped to fine coat thickener for recovery of the coal fines.

The deslimed coal shall be collected in Heavy Media sump for further treatment in the H.M.Washing circuit.

H.M.Washing Module

The oversize of the desliming screen is collected in the Heavy Media lump where Heavy Media (finely ground magnetite) is mixed so as to maintain the desired pulp density based on the desired product quality. The coal-media slurry is then pumped to the Heavy Media Cyclones. The clean coal, being lighter shall report as the cyclone overflow. While the heavier fraction shall report to the cyclone underflow as rejects. The clean coal and the rejects shall be dewatered and rinsed with water on the separate D & ft screens.

The D & ft screens for clean coal are provided with 2 decks to separate the 5 mm. This enables in segregation of the clean coal into -20 to +5 mm product and -5mm product.

The products from b & ft screens still contains about 20-25% moisture, which is further dewatered in the vibrating screen ‘b centrifuges (1 no. on each size fraction of clean coal & 2 nos for rejects line). The final products from the centrifuges are then transferred to rejects stockpile and clean coal storage bins. The clean coal and rejects shall be reclaimed from the storage through the sector gate and transported to desired destination through loaders / trucks.

Fine Coal Module

The fine coal -1mm (alternatively 0.5mm) fraction from the desliming screen, rejects b & ft screen, clean coal b & ft screen and Centrifuges (clean coal and rejects) shall be collected in the fine coal sump. Then it is pumped to the fine coal


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thickener for thickening before further dewatering, as the solid concentration in the slurry is very low. The thickened slurry shall be reclaimed from the conical bottom of the thickener and pumped to a Belt press for further dewatering. The dry coal from the Belt Press shall be discharged on the fines conveyor. The clarified water from the thickener shall be collected in the thickener of sump and pumped back into the circuit for reuse in the process.

Media Preparation & Regeneration Module

The finely powdered magnetite feed (90% passing 45 microns), shall be stored in Magnetic Media feed bin. The media shall be reclaimed by weigh feeder via Rake & pinion gate and mixed with water in the feeding launders and added to the over-dense media sump as a make-up to maintaining the density.

The dilute media from the b & ft screens from the washing is collected in the dilute media sump. The dilute media contains finely ground magnetite and coal fine, which comes from rinsing the clean coal/rejects and a good quality of wash water. The dilute media is first pumped to a densifying cyclone. The thickened u/f from the cyclone is sent to the over dense media tank while the dilute overflow is sent to the magnetic separators for reclamation of magnetite. The magnetic fraction is collected in the over dense media sump while the non-magnetic fraction is used for rinsing in the D & R screens.

Density Control System

The objective of the control system for a heavy media cyclone is to maximize the clean coal yield subject to a specific ash constraint and to reduce product ash variation to a minimum. Full advantage of the dense media cyclone’s inherently sharp separation can be obtained only if some means is provided for maintaining the specific gravity of the medium at a point in the circuit the over-dense media (discharge line) feed to heavy media sump.

The application of a nuclear density gauge is to monitor the density of the over dense media tank. Any deviation from the desired specific gravity causes an error signal to be sent to the indicator / controller. If the medium specific gravity is too low, the controller sends a signal to the fresh magnetic feed, causing more medium to be directed to the over-dense medic sump. If the medium specific gravity increases, the controller either activates a water valve that, in turn, simply adds water to the over-dense media discharge line.


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3.5.7 Process Description of Pelletization Plant with Beneficiation

The iron ore fines (-10mm) procured from Mines will be grinded to 45 Micron size in Grinding Mills mixed with water for Pelletization. The fines grinded wet iron ore concentrate is mixed with flux and bentonite in definite proportion to induce better binding properties and mixed in a drum mixer. In case, the moisture content is high in the concentrate, the same will be dried in a dryer. The mixed material is then fed to balling discs for producing spherical balls (called the green pellets) of size ranging from 5 to 16 mm. The green pellets are then screened for the right size green balls and the undersize/ oversize green balls are recycled to the process. The right size balls are fed to a endless linear traveling grate machine which travel in a furnace. The green balls are dried and preheated to 1000-1100 Deg. Celsius by hot gases recycled from the cooler machine. The pre-heated balls are then transferred to a Rotary Drum furnace for heat hardening at 1350 Deg. Celsius to attain compressive strength for handling. The Rotary Drum furnace is fired from the discharge end using pulverized coal/ Producer gas / Pet Coke and Blast furnace gas. The gas from the Rotary Drum furnace is also used for Pellet pre-heating. The finished product is then cooled in an annular cooling machine to 150 Deg. Celsius before conveying to the storage yard. The cooled pellets are screened to get finished pellets of right granulometry. The undersize/ oversize pellets are stored separately for use in Blast Furnace.

Main Process Technique & Equipment:

The main sections of Pelletizing production line include : Iron Ore Grinding system, Iron ore concentrate store, bentonite store, blender mixer, Pelletizing, green ball screening & distributing system, Traveling Grate furnace system along with Rotary Drum furnace-annular cooler system, main I.D. fan and ESP system, Product storing & transportation system and etc.

Cooling pellet are discharged from discharge hopper of rotary cooler will be transported to product stock house through conveyer. It will be transported to BF stock house through belt conveyor.

Material Balance:

Input Output Item Quantity (TPA) Item Quantity (TPA) Iron Ore Fines 1120000 Pellet 780000 Bentonite 13200 Return Fines 225000 Lime Stone/ Dolomite 13200 LOI 171400 Coke (Dry) 30000 Return Fines (DRY) 68 Total 176400 Total 1176400


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3.5.8 Process Description of Ferro Alloys Plant

Two (2) furnaces each having a rating of 18 MVA will be installed to meet the annual production requirement of Ferro chrome.

Submerged Arc Furnace:

The technological parameters of the submerged are furnaces are as given in Table No. C3-2.

Table No. C3-2: Technological Parameters

Sl. No.

Parameter unit Value/Features

1. Ferro Manganese production T/yr 66,000 2. No. of furnace No. 2 3. Transformer rating MVA 18 (per furnace) 4. Power Factor 0.90 5. Consumption of power. per MT Units 7600 6. Furnace charge approx Manganese Ore % 75 LAM Coke % 12 BP Coal % 8 Other fluxes % 5 7. Method of charging the furnace Manganese

Ore/Coke/Coal - Belt Conveyor

8. Grades - High Carbon Ferro Chrome 9. Fume collection and cleaning - Bag filters with ID fan,

chimney, etc

Process:

Bulk Ferro Alloys like, Ferro-Manganese, Sillico-Manganese & Ferro-Sillicon are produced by Carbon-thermic process utilizing different raw materials & Electrical power as main raw material. Some fluxes like Quartzite, Magnesite and Dolomite are also used to correct the slag character.

Pre-Weighed and premixed raw materials are charged to a submerged Arc Furnace. In the furnace, electricity is passed through self-baking soderberg type electrodes. The charge mass, which offers resistance to the current flow changes the electrical energy to heat and increases the temperature of the raw materials.

At high temperature about 18000C the raw materials melt and liquid alloys and slag are formed.

Above formed liquid slag and alloys are tapped through a tap hole and collected in a refractory lined ladle.


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The volume of the refractory lined ladle is sufficient to accommodate of slag and metal, which is normally collected during a normal tapping. It may so happen due to process problem excess amount of slag metal may come out from the furnace. For this, before every tapping, a C.I. Mould is kept near the ladle, in which the excess amount of liquid product can be collected. The C.I. Mould has been provided with a spout, which allows the excess hot liquid product to be collected on a sand bed.

3.5.9 Process Description of Rolling Mill

The proposed project with annual capacity of 0.35 MTPA for rolling of MS / SS Alloy Steel / SS Bars / Wire Rods of different sizes from 5.5 mm onwards in private sector contributes to the development of the steel sector in this region. The rolling mill complex is dedicated to the latest block technology. On review of the market demand, there are only few units which have gone for the production of special, high, alloy and stainless steel. Further to this, the finished product shall have the following advantages;

Negative dimensional tolerances. Lower section below 5.5mm can be rolled. Secondary Scale loss in the range of 0.5-0.6 % Uniform mechanical properties of the bar Uniform dimensions along the length of the bar Yield of the order of 96.5% Reduction of wastage of finished product in handling

Material Balance for Rolling Mill

Input Quantity in TPA Output Quantity

in TPA

Steel Billets 357000 Rolled Products 350000

- - Burning Losses 3500

- - Mill Scale 3500

Total 357000 357000 3.6 Raw Material Required Along With Estimated Quantity, Likely

Source, Marketing Area Of Final Product/s, Mode of Transport of Raw Material And Finished Product.

3.6.1 Source of Major Raw Material with mode of transport

Table No. C3-3: Raw Material Requirement

Raw Materials Quantity DRI plant (1400 TPD)

Coal 630000 TPA Iron Ore 610000 TPA Dolomite/ 25200 TPA

SMS Plant (0.40 MTPA)


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Sponge Iron 410000 TPA Pig Iron 34800 TPA Ferro Alloys & Non Ferro Alloys 5500 TPA MS Scrap 20200 TPA

MBF (0.15 MTPA) Iron ore Pellet 125000 TPA Coke 80000 TPA Sinter 125000 TPA

Ferro Alloys Plant ( 2X18 MVA ) Manganese Ore 1650 TPA Non Manganese Ore 39800 TPA Coke 7960 TPA Coal 23880 TPA Dolomite 3980 TPA

Rolling Mill ( 0.35 MTPA) Steel Billets 357000 TPA

Captive Power Plant ( 40 MW = AFBC-12 MW + WHRB- 28 MW) Dolochar 60000 TPA Coal 30000 TPA Washery Rejects 45000

Pellet Plant ( 2600 TPD) Iron Ore Fines 1120000 TPA Bentonite 13200 TPA Dolomite / limestone 13200 TPA Coke 30000 TPA

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED

IN THE PROJECT

Waste generation in the CPP is in the form of fly ash and bottom ash which would be disposed in slurry form to ash disposal area. Slag form Ferro Alloys plant will be mitigated with disposal of Ash from Captive Power Plant. Hence, there will be resource optimization in the proposed project.

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND SOURCE

3.8.1 Source of water

The consumptive water required for the station will be drawn from Sankha River.

3.8.2 Summary of Plant Water Requirement

Water requirement for the proposed expansion project is 380 m3/hr and Water requirement for existing project is 93 m3/hr, So total Water requirement for both existing & expansion project is 473 m3/hr. Water will be sourced from Sankha River.

Estimated make up water requirement to replenish the process and treatment losses for the facilities.


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Table No. C3-4: Total Plant Raw Water Requirement

Sl. No. Plant Existing Expansion 1 DRI Plant 11 m3/hr 45 m3/hr 2 SMS Plant 12 m3/hr 48 m3/hr 3 Pellet Plant 6 m3/hr -- 4 Captive Power Plant 48 m3/hr 160 m3/hr 5 Coal Washery 15 m3/hr 30 m3/hr 6 Rolling Mill -- 35 m3/hr 7 Mini Blast Furnace -- 36 m3/hr 8 Ferro Alloys Plant -- 15 m3/hr 9 Pellet Plant with Beneficiation -- 10 m3/hr 10 Domestic 1 m3/hr 1 m3/hr

Total Water 93 m3/hr 380 m3/hr

3.8.3 External water system

The consumptive water required for the station has been drawn from the common intake pump house on the Sankha River.

3.8.4 Plant water system

As per the available data on river water quality, a cycle of concentration of 5 is considered in the estimation. As an alternative, Air Cooled Condenser (ACC) may be used for the water scare region. ACC may be of direct type or indirect type. For water cooled system, evaporative cooling is deployed but in case of air cooled system steam (for direct type) or DM water (for indirect type), primary coolant, would be cooled by convection and/ or radiation by passing cooled air by the fans. ACC is pitted with higher condenser pressure and thus loss of generation. Secondly, ACC is more cost intensive and the revenue cost is marginally higher. On overall basis, depending on ambient parameters cost of energy 4 to 5% higher. With loss of generation, marginally higher energy cost air cooled condenser is deployed in a ‘No Project Situation’ due to inadequate availability of water. For ACC as option, consumptive water requirement will be around 44 m3/ hr. With the water quality available, water treatment plant would comprise clariflocculation, sand bed filtration and demineralization plant.

3.9 ENERGY: Table No. C3-5: Total Power Requirement (Existing & Expansion)

Sl. No. Power Consuming Points Quantity of Power

in MW 1 Pelletizing Plant 5.0 3 Coal Washery 1.5 4 DRI Plant 4.0 5 Mini Blast Furnace 5.0 6 Ferro Alloys Plant 36.0 7 Steel Melting Shop 50


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8 Rolling Mill 8.0 9 Captive Power Plant 3.0

11 Administrative & Auxiliary 0.50 Total 113.0

Out of total power requirement of 113.0 MW, 52 MW power will be of captive generation and will be for in-house use and balance will be purchased from State Electricity Board.

3.10 Environment Management a. Air pollution control measures

Construction phase:

Construction phase will be for a short period and hence the impacts will also be for a short and temporary period. During construction activities, mainly emission of dust and gases from movement of vehicles and construction activity is expected. However, following measures will be taken to reduce / contain such emissions:

Water will be sprinkled on loose top soil to prevent re-suspension of dust into ambient air due to movement of vehicles etc.

Separate civil construction material storage yard will be created within the site and it will be enclosed.

Possibility of raising green belt along with construction activity will also be explored.

Transport vehicles and construction equipments / machineries will be properly maintained to reduce air emissions.

Vehicles and equipments will be periodically checked for pollutant emissions against stipulated norms.

Idle running of vehicles will be minimized during material loading / unloading operations.

All construction workers will be provided appropriate Pollution Protection Equipments like dust mask, ear plug, helmet, safety belt etc. and made to wear them during working hours.

Operation phase:

Air in and over the plant area and beyond its boundaries gets polluted with gases, fumes and dust particles emanating from the processes, chimneys, transfer points of conveying and handling equipment. The air pollutants in a steel plant are mainly dust and gases like sulphur dioxide, carbon monoxide, nitrogen oxide, etc.


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General Control Requirements during Transport of Material:

The Company will take precautions to minimize visible particulate matter (dust and muck) from being deposited upon public roadways as a direct result of these operations. Precautions include removal of particulate matter from equipment before movement to paved street or prompt removal of material from paved streets by construction equipment will be removed by sweeping in a prompt matter.

The company will ensure that vehicles with an open load carrying area used for moving potentially dust-producing material will have properly fitting side and tailboards. Materials having the potential to create dust will not be loaded to a level higher than the side and tail boards, and carried in vehicles fitted with cover lids or clean tarpaulin cover in good condition. The tarpaulin will be properly extended beyond side / tail board and secured properly.

Control Requirement at Dumping Sites

The company will ensure to place excavated materials only on the designated storage / dumping areas inside plant premises and will place material in a manner that will minimize dust production (Orientation of stock pipes with respect to predominant wind direction). Material will be stabilized by watering or other accepted dust suppression techniques. The heights from which materials are dropped will be kept minimum (practical height to limit fugitive dust generation).

The company will stockpile building materials at designated locations by creating suitable slopes. During dry weather and windy conditions acceptable dust control methods like wind breakers by making tall boundary wall (with tin / iron / asbestos sheet), covering stockpiles with plastic sheet or tarpaulin, making asphalt roads, regular sweeping and cleaning of work areas, water sprinkling, greenery development of boundary, etc will be used to prevent any dust from bowing away and pollute the surrounding environment. The company will provide water storage tanks, pumps, pressure gauge, pipeline network with water sprinklers at strategic points for dust suppression. Sufficient equipment spares water for dust suppression and trained personnel will be kept at the dumping site.

Spraying of water as required to suppress dust during handling of excavation soil or debris or demolition of any temporary structure will be looked after. Effective water sprays will be used during the delivery and handling of all raw sand and aggregate and other similar materials when dust is likely to be created and to dampen all stored materials during dry and windy weather. Interior areas within the sites where there is a regular movement of vehicles will have hard / stabilized surface that will be kept clear of loose surface material. If conveyors are used conveyor belts will be fitted with covers and transfer point and hopper discharge area will be enclosed to minimize dust emission. All conveyors carrying material that have the potential to create dust will be fitted with belt cleaner.

The company will restrict speed of all motorized vehicles to 15/km hr inside the work site and confine haulage and delivery vehicles to the designated roadways inside the site to minimize the fugitive dust generation.


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The measures to control the air pollution will ensure the ambient air quality standards as laid down by Central Pollution Control Board (CPCB) Notification, Nov, 2009 for industrial and mixed use areas as under:

Table No. C3-6: Ambient air quality standards

Sl. No.

Pollutant Concentration,* μg/m3 24 Hrs for industrial /rural area/residential/other area

1 Particulate matters (Size < 10 μm) 100 2 Particulate matters (Size < 2.5 μm) 60 3 Sulphur dioxide 80 4 Nitrogen dioxides 80 5 Carbon monoxide 04

The systems proposed for the air pollution control will provide acceptable environment condition in the working area and abate air pollution in the surrounding area of the integrated steel plant. The technological equipment and processes have been selected with the above objective. Depending upon the quality of emission from different sources, suitable air pollution control systems will be provided. The chimney heights will be as per CPCB norms to ensure Ground Level Concentration (GLC) of different pollutants within permissible limits.

Various dust collection equipment such as cyclone separators, fabric filters, ESP, etc. will be adopted to remove particulate matter from gas streams. The pollution itself will be collected through suction hoods, dust, etc. However, in order to meet the statutory GLC limits for SO2 and NOx, suitable chimney heights will be provided for proper dispersion.

Water Pollution Control Measures

Water Reservoir will be created inside the project area during the construction stage where rainwater and surface water runoff will be collected and stored.

Groundwater will be also used during the construction stage, for which permission from WRD will be obtained. The stored groundwater will be also used for various non potable requirements during the construction stage. Drainage network will be constructed to drain off all surface water from the work site into the reservoir. The drainage will be maintained removed and reinstated as required. Precautions will be taken for avoidance of damage by flooding and silt (by constructing sedimentation pits at strategic points to be identified later) The company will collect the wastewater arising from site offices, canteens and other washing facilities in a pit and reuse it for dust suppression. Oil separator / interceptor will be provided near vehicle parking site, workshop and canteen to prevent the release of oil and grease in to drainage system. The oil and grease separators will be cleaned on regular basis.

Sewage generated from the labour colony will be treated in Sewage Treatment Plants complete with sewerage network for collection of raw sewage. The treated sewage water will be reused for gardening and horticulture purpose.


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The measures envisaged for water pollution are expected to contain the water pollution within tolerance limits as specified in IS: 2490 (Part-1), IS: 3307, IS: 4764 and other related statutory norms. The pollutants present in the waste water will be reduced to acceptable levels by adoption of the following schemes in general.

Recirculating water in the process whereby discharge volume is considerably reduced.

Providing adequate treatment units removal of the suspended and colloidal matter.

Neutralization of acidic water by lime. Removal of oil and grease from the contaminated water by means of oil traps

and skimming devices. Treatment of fecal sewage in a sewage treatment plant and removal of sludge

after biological treatment.

Air and water pollution control facilities envisaged for different plant units.

Noise Pollution Control Measures

The company will make and bring into use reasonable efforts to minimize construction noise levels. Truck loading, unloading and hauling operations so as to minimize noise impact near surrounding villages will be properly scheduled.

Vehicular movement during night time will be avoided. Machinery that emits noise in one specific direction would where possible be oriented in a direction away from noise sensitive receptor. Silencers and mufflers on construction equipment, wherever required, will be properly fitted and maintained.

Solid Waste Management

The company will make inventory of all types of solid waste that are expected during the construction activity before standing the work. The transportation of construction spoil will be allowed only to designed dumpsites. Careful design, planning and good site management would minimize waste of materials such as concrete, mortars and cement grouts. Construction waste will be segregated as much as possible at site itself to increase the feasibility of recycling concrete and masonry as filling material and steel pieces as saleable scrap. Litter disposal and collection points will be established sound the construction work sites.

Domestic garbage will be generated during the construction and operating stage.

The garbage will be collected in containers and segregated at source. Biodegradable material (organic waste) will be used for composting. Recyclable material (Metal, Plastic, glass, paper, packaging material, etc) will be given to recycles.

The various waste materials arising out of the technological processes, would be reutilized to the extent possible. The solid wastes containing significant iron content (but not heavy metals, oil, lubricants, etc.) will be reused in the sinter plant. The blast furnace slag will be granulated and given for cement making. Coal ash will be utilized for cement making, brick making, low /waste land


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reclamation, etc. and the unutilized portion will be used to backfill nearby abandoned mines. Unutilized solid wastes will be stored in the dump yard. Soiled cotton / cloth wastes (generated during cleaning of machines and equipment) will be collected in bins burnt in the boilers of power plant. Electric wastes and used batteries will be collected and given to authorized recyclers. Domestic garbage will be collected from the township and plant in containers; biodegradable, inserts and non-biogradable materials in segregated manner. The biodegradable material will be composed and used as manure inside the premises. Recyclable materials like packaging materials, empty drums, bottles, glass, metals, paper, plastic, etc. will be given to recyclers. Non recyclable materials will be disposed in sanitary landfill sites as per the local laws and regulations.

Various Dust Extraction and Dust Suppression Systems

Various dust extraction and dust suppression systems envisaged are in indicated below:-

Table No. C3-7: Dust extraction system

Units Facilities Pellet Plant with

Beneficiation ESP, Bag Filter, Chimney

DRI Plant Bag Filter, ESP, Chimney Pig Iron Blast Furnace

The BF top gas will be cleaned in dust catcher and gas cleaning system.

Steel Melting Shop Suction Hood, Bag filter Rolling Mill Air Heating Recuperator, Chimney

Captive Power Plant

Dust Suppression System, Dust Collectors, ESP, Chimney

However, in order to meet the statutory ground level concentration limits for SO2 ,NOx and other gaseous pollutants, suitable stack heights will be provided for proper dispersion. All stack will be provided with port hole and working platform so that stack monitoring can be done as per norms of statutory authority.

The collected dust from bag filters and scrubbers will be transported to near by material handling system

b. Green Belt Development

Adequate green belt has already been developed in and around the existing plant premises. Locally available types of sufficient trees which are resistant to pollutants are and will be planted. Green belt is developed in 37.60 Acres of land, i.e. 34 % of the existing land area. Local species are used in green belt.


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CCHHAAPPTTEERR--44 SSIITTEE AANNAALLYYSSIISS

4.1 CONNECTIVITY

Road Connectivity: The proposed plant is accessible by all weather road from the district head quarter Sundargarh which is located at a distance of 80 km. The site is located in Kalunga Industrial Area nearer (4.0 KM) to SH-10 which is connecting Rourkela to Sambalpur.

Rail Connectivity: The proposed site is close to the Mumbai-Howrah railway line. The company has a Railway siding inside in factory promises. The nearest Railway station is at Kalunga which is 2.0 km from the site.

Airport: The nearest airport is at about 220 km from Rourkela at Ranchi, Jharkhand.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP


Table No. C4-1: Details of Land use break up

Sl. No Purpose Area (acres) 1. 3 x 100 TPD DRI Plant, Iron Ore Crusher (Existing) 4.50 2. 12 MW (Existing) & 12 MW (Proposed) Power Plant (

Dolochar Coal & Washery Middling 3.00

3. Steel Melting Shop 3 x 12 T Induction Furnace (Existing) 0.75 4. Fly Ash Brick Plant 0.50 5. Coal Washery- 100 TPH (Existing) & 200 TPH (Proposed) 2.50 6. 4 x 350 TPD DRI Plant (Proposed) 2.50 7. MBF Unit - 0.15 MTPA (Proposed) 2.00 8. Steel Melting Shop - 0.40 MTPA (Proposed) 1.00 9. 28 MW Power Plant ( WHRB Based) (Proposed) 3.00 10. Pellet Plant - 1800 TPD (Existing),

Pellet & Beneficiation Plant - 2600 TPD (Proposed) 9.19

11. Producer Gas Plant (Existing) 0.81 12. Rolling Mill ( 0.35 MTPA) - Proposed 2.00 13. Ferro Alloys Plant - 2x18 MVA (Proposed) 3.00 14. Railway Siding (Existing) 7.00 15. Green Belt (Existing & Proposed) 37.60 16. Solid Waste Disposal 10.00 17. Raw Material Storage Yard

Coal Crusher & Storage Yard Administrative Building Finished Product Storage Water Harvesting & Settling Pond

21.023

Total Area 110.373


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4.3 TOPOGRAPHY

The topography of the proposed land is generally flat and well suited for development of industrial projects.

4.4 Existing land use pattern, shortest distances from the periphery of the project to periphery of the forests, national park, wildlife sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ.

The project is developed over 110.373 Acres (In side). Pump House, Clarifier & Reservoir (Out Side) is 6.690 Acres & Out Side Land (Green Belt) is 22.910 Acres. So total land inside & outside Plant is 139.973 Acres. This area does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve.

Table No. C4-2: Environmental Setting

Sl. No.

Particulars Details

1 Location Village Jiabahal District Sundargarh State Odisha

2 Toposheet Number (10 Km radius) 73 B/11, 12, 15 & 16

3 Geographical Coordinates 220 18’ 19” to 220 19’ 00” North and 840 45’ 45” to 840 46’ 27” East

4 Vicinity Details A. Nearest Densely Populated Area Rourkela B. Nearest Highway SH-10 C. Nearest Railway Line Private Siding D. Nearest Airport Ranchi Airport 5 National Park, Reserve

forest/Protected forest/ Wildlife Sanctuary/ Biosphere reserve, Wild life corridor within 10 km radius study area)

There are no National Park, Wildlife Sanctuary, Biosphere reserve, Wild life corridor within 10 km radius study area.

6 Archeological/ Historical, Defense establishment within 10 Km radius study area.

No Archeological/ Historical, Defense establishment falls within 10 Km radius study area.

4.5 EXISTING INFRASTRUCTURE

Land



CEMC Pvt. Ltd. 36

Utilities

Power Requirement:

Sl. No.

Power Consuming Points Quantity of Power in MW

1 Pelletizing Plant 5.0 3 Coal Washery 1.5 4 DRI Plant 4.0 5 Mini Blast Furnace 5.0 6 Ferro Alloys Plant 36.0 7 Steel Melting Shop 50.0 8 Rolling Mill 8.0 9 Captive Power Plant 3.0 10 Administrative & Auxiliary 0.50 Total 113.0


Water: Total make up water requirement for the existing project is 93 m3/hr, total make up water requirement for Expansion project will be 380 m3/hr. The water will be sourced from Sankha River. The company has already given permission for 500 m3/hr from Irrigation Department.

Transport: The site is well connected with SH-10 which is passing at a distance of 4.0 km and all modes of transports are available.

4.6 CLIMATE DATA

The cold season from December to February is followed by hot season from March to May. The period from June to September marks the South West Monsoon and 70% of annual precipitation is received during this period. The normal rain fall of this district is 1444 mm. May is the hottest month. With the arrival of the monsoon by about the second week of June the day temperature decreases slightly while the night temperature continue as it was in the summer. Towards the end of September, after the withdrawal of south west monsoon, temperature decreases progressively. December is the coldest month. The relative humidity are high throughout the year specially in coastal areas. Winds are fairly strong particularly in coastal regions in summer and mansoon months.


CEMC Pvt. Ltd. 37

CCHHAAPPTTEERR--55 PPLLAANNNNIINNGG BBRRIIEEFF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES AND TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT AUTHORITY CLASSIFICATION

The Plant is located in the village Jiabahal Kalunga Industrial Area, Sundargarh district of Odisha. Plant provide many facilities is given below,

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and restrooms according to norms laid down in relevant factories act. The above facilities are adequately furnished and equipped.

5.2 MANPOWER PROJECTION

Establishment of small and medium scale engineering ancillaries, with cascading employment opportunities;

Increased revenue to the state by way of taxes and duties;

Improved green cover;

Better communication and transport facilities;

The proposed project has enhanced the prospects of employment. Recruitment for the unskilled workers for the plant is from the nearby villages. The basic amenities viz. roads, transportation, electricity, drinking water, proper sanitation, educational institutions, medical facilities, entertainment, etc. are developed as far as possible

5.3 LAND USE



CEMC Pvt. Ltd. 38

5.3.1 Green Belt Development

With a view to attenuate air pollutants, to resist noise propagation from power generation units and uptake of treated effluent to some extent, the green belt all around the periphery of project sites and in vacant areas (34 % of the total acquired land) is being developed. Tree plantation has been undertaken in a large scale on land vacated after cessation of construction activities.

5.4 AMENITIES/FACILITIES

Plant will source water from Sankha River. Canteen, transportation system, health center facilities etc. will be provided by plant for their employees. Medicines are provided at the first aid centre present within the plant premises, which cater to the needs of adjoining population. Periodic health camps like: Eye camp and Health camps for treatment of other diseases will be conducted by the company doctors.


CEMC Pvt. Ltd. 39

CCHHAAPPTTEERR--66 PPRROOPPOOSSEEDD IINNFFRRAASSTTRRUUCCTTUURREE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The project is developed over 110.373 Acres (In side). Pump House, Clarifier & Reservoir (Out Side) is 6.690 Acres & Out Side Land (Green Belt) is 22.910 Acres. So total land inside & outside Plant is 139.973 Acres. Company uses nearest road and railway siding for goods transportation and equipped with all other required facilities.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

The area around the site is developed with reasonably good communication facilities. Some area of plant is envisaged for staff canteen, toilet and bath room, vehicle stand etc.

6.3 GREEN BELT DEVELOPMENT

With a view to attenuate air pollutants, to resist noise propagation from power generation units and uptake of treated effluent to some extent, the green belt all around the periphery of project sites and in vacant areas (34 % of the total acquired land) is being developed.

6.4 SOCIAL INFRASTRUCTURE

SMFAPL will commence a lot of infrastructure developmental works in the periphery area. Some glimpses of the developmental activities are presented below:

Improving and building road network in the adjoining villages.

Strengthening School buildings with playgrounds.

Social awareness programme will further improve by the local authority such as sanitation and hygiene, HIV Prevention Program.

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.

The proposed project will set up training centre or tie up with Industrial Technical Institutes to educate local youth as skilled labour.

6.5 CONNECTIVITY

Road Connectivity: The proposed plant is accessible by all weather road from the district head quarter Sundargarh which is located at a distance of 80 km. The site is located in Kalunga Industrial Area nearer (4.0 KM) to SH-10 which is connecting Rourkela to Sambalpur.

Rail Connectivity: The proposed site is close to the Mumbai-Howrah railway line. The company has a Railway siding inside in factory Premises. The nearest Railway station is at Kalunga which is 2.0 km from the site.


CEMC Pvt. Ltd. 40

Airport: The nearest airport is at about 220 km from Rourkela at Ranchi, Jharkhand.

6.6 DRINKING WATER MANAGEMENT

Drinking water facilities will be provided for employees. A water treatment plant is envisaged for providing potable water to the employees. After ensuring the drinking water standards prescribed by CPCB water will be supplied for drinking purpose.

6.7 SEWERAGE SYSTEM

A garland drain around the plant is envisaged to collect surface run-off during rainy season.

6.8 INDUSTRIAL WASTE MANAGEMENT

The liquid wastes from CPP collected in the guard pond shall be treated and adequate retention time permitted. The treated waste water from the guard pond would be recycled to less priority areas for reuse. Attempt would be made to attain zero discharge of waste water from the plant during normal operation.

6.9 SOLID WASTE MANAGEMENT

The solid waste/tailings generated/to be generated from the process to be disposed off/reutilized as per the guide lines of CPCB and best practices adopted in the steel industries. The coal fines will be utilized in power plant and iron ore fines will be utilized in pellet plants. Dust collected from bag filters/APC devices will be disposed in char dumping area. Ash from PGP shall be used in Pellet plant. Part of fly ash generated from power plant will be utilized in fly ash brick making and shall be sold to tiles/cement manufacturers. Balance fly ash and bottom ash will be disposed of in form of ash in abandoned quarries as per relevant guidelines

Table No. C6-1: Solid Waste Generation

Sl. No. Sources Qty.Ton/Day 1 Tailings 400 2 Char from DRI kilns. 200 3 Dust from APC devices 50 4 Slag from induction furnaces/Arc

Furnaces/Ferro Alloys Plant 170

5 Ash from power plant 650 6 Slag from Blast Furnaces 2x40 7 Used resins from DM water plant 1450 ltr/3yrs 8 Solid Waste in form of garbage / food

waste from workers’ canteen. 15.20 kg/day

9 Used Oil 1.5 kl/Year


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6.10 POWER REQUIREMENT & SUPPLY/SOURCE

Table No. C6-2: Unit-wise power requirement

Sl. No.

Power Consuming Points Quantity of Power in MW

1 Pelletizing Plant 5.0 3 Coal Washery 1.5 4 DRI Plant 4.0 5 Mini Blast Furnace 5.0 6 Ferro Alloys Plant 36.0 7 Steel Melting Shop 50.0 8 Rolling Mill 8.0 9 Captive Power Plant 3.0 10 Administrative & Auxiliary 0.50 Total 113.0



CEMC Pvt. Ltd. 42

CCHHAAPPTTEERR--77 RREEHHAABBIILLIITTAATTIIOONN && RREESSEETTTTLLEEMMEENNTT ((RR && RR)) PPLLAANN

The project is developed over 110.373 Acres (In side). Pump House, Clarifier & Reservoir (Out Side) is 6.690 Acres & Out Side Land (Green Belt) is 22.910 Acres. So total land inside & outside Plant is 139.973 Acres. There is no existence of displaced habitants in the identified area as additional plant install within the existing land. Land is also devoid of any vegetation. Local people will be engaged for construction and operation activities.


CEMC Pvt. Ltd. 43

CCHHAAPPTTEERR--88 PPRROOJJEECCTT SSCCHHEEDDUULLEE && CCOOSSTT EESSTTIIMMAATTEESS

8.1 PROJECT IMPLEMENTATION

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

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. Clearances required for the proposed


CEMC Pvt. Ltd. 44

project shall be identified in due course and necessary action will be taken to obtain the same.

Project Schedule

The total project implementation schedule given in Table C8-1. The external agencies such as consultants, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance. An effective project team has been formulated with an experienced Project Manager as its leader.

The project schedule has been contemplated as below:

Table C8-1: Project Schedule

Sl. No. Task Time Taken CPP

1. Pre-project Activities & coming into force of contract

(-) 6 to 0 months

2. Technology supply & completion of Basic Engineering

0 to 2 months

3. Detailed Engineering 2 to 3months 4. Tendering, Procurement Action &

supply of Plant & Equipment & Electricals

3 to 5 months

5. Civil & Structural Work 4 to 18 months 6. Erection of Equipment 18 to 20 months 7. Trial run & Commissioning 20 to 21 months

DRI PLANT 1 Process know-how & Basic

Engineering

Within 5 years from zero date

2 Approval of Basic Engineering by SMFAPL

3 Detailed Engineering 4 Tendering, Procurement action,

Supply of Plant & Equipment 5 Civil & Structural Work 6 Erection of Equipment 7 Trial Run & Commissioning

SMS PLANT 1 Process know-how & Basic

Engineering




Supply of Plant & Equipment 5 Civil & Structural Work


CEMC Pvt. Ltd. 45

6 Erection of Equipment 7 Trial Run & Commissioning

MBF PLANT 1 Process know-how & Basic

Engineering





COAL WASHERY 1 Process know-how & Basic

Engineering





ROLLING MILL 1 Process know-how & Basic

Engineering





FERRO ALLOYS PLANT 1 Process know-how & Basic

Engineering




Supply of Plant & Equipment 5 Civil & Structural Work


CEMC Pvt. Ltd. 46

6 Erection of Equipment 7 Trial Run & Commissioning

8.2 PROJECT COST

The Capital Cost of the Expansion project is Rs 610 Crores.

The Project from concept stage to commissioning is being envisaged in three phases. Services of experienced consultants will be utilized for detailed planning, preparation of techno-economic feasibility report and other associated activities like discussions with financial institutions, phasing of capital expenditure etc. Considering the existing expertise of the company, the company expects to adhere to the schedule. However, the implementation primarily will depend upon the allotment of land by the State Government and statutory clearances including environmental clearances.

Table No. C8-2: Cost Breakup for Expansion Project

Sl. No Plant Specification Amount in Crores 1 DRI 4x350 TPD 120 2 SMS 0.4 MTPA 50 3 CPP 40 MW 180 4 Rolling Mill 0.35 MTPA 35 5 Coal Washery 200 TPH 35 6 MBF 0.15 MTPA 20 7 Ferro Alloys 2x18 MVA 40

8 Pellet with Benefication

2600 TPD 130

Total 610 Crores


CEMC Pvt. Ltd. 47

CCHHAAPPTTEERR--99 AANNAALLYYSSIISS OOFF PPRROOPPOOSSAALL ((FFIINNAALL EECCOOMMMMEENNDDAATTIIOONNSS))

9.1 Financial and social benefits

9.1.1 Improvements in the Physical Infrastructure

SMFAPL 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.

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 the education to Poor Students of the Proposed Area.

Provide & conduct the Free Eye & Health Check up Programmes.

9.1.3 Employment

The manpower requirement for the existing plant is 700 persons. In order to operate the proposed unit in full swing, the additional requirement of the man power will be approximately 500 for various activities like loading, unloading, handling, transportation, general cleaning, horticulture and other miscellaneous works inside the plant. So the total manpower requirement for the existing & proposed plant will be 1250. Three shifts working for 330 days is planned.

Training of O&M staff will be arranged through prevalent methods & practices which will include computerized plant operation, simulator, various audio visual cards, a well maintained library and requisite set up for training activity. These will be reinforced by:

In-plant training of the operators at the site itself prior to commissioning of the plant.

Continued training of O&M staff through experts & supplier’s staff as part of the in plant training programme.

Specialized training at various training institutes

Training during manufacture at supplier’s works and construction activities.


CEMC Pvt. Ltd. 48

Table No. C9-1: Employment status

Sl. No. Particulars Total (Existing + Expansion)

1 Managerial 40 2 Supervisory 60 3 Skilled 200 4 Semi skilled 400 5 Unskilled 550

Total 1250 9.2 OTHER BENEFITS

Development of the local area in terms of an enlarged market.

Besides above, indirect benefits have also occurred to the region by way of increase in industrial production.

application for environmental clearance (ec) form 1 &...

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