eia nmdc pellet plant

7/25/2019 EIA NMDC Pellet Plant

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Sponsor :

ENVIRONMENTAL IMPACT ASSFOR

THE PROPOSED EXPANSION OF NMDC INTEG

STEEL PLANT WITH ADDITION OF 2.0 MTPA PELLET AND CHOWKAWADA VILLAGE NEAR NAGARN

BASTAR DISTRICT, CHHATTISGAR

NMDC LimitedHyderabad

FINAL REPORT


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For and on behalf of VIMTA Labs Limited

Approved by : M. Janardhan

Signed :

Position : Head & Vice President (Env)

Date : 20thAugust, 2015

PREFACE

NMDC LimitedHyderabad

ENVIRONMENTAL IMPACT ASSESSFOR

THE PROPOSED EXPANSION OF NMDC INTEGRATED

STEEL PLANT WITH ADDITION OF 2.0 MTPA PELLET PLANT

AND CHOWKAWADA VILLAGE NEAR NAGARNAR, JAGBASTAR DISTRICT, CHHATTISGARH


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Environmental Impact Assessment for Proposed Expansion of N& Steel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PChowkawada Village near Nagarnar, Jagdalpur, Bastar District,

Table of Contents

Chapter Title

Table of Contents

List of Figures List of Tables

Executive Summary

1.0 Introduction

1.1 Purpose of the Report 1.2 Identification of Project and Project Proponent

1.3 Brief Description of Project 1.4 Scope of the Study

1.5 Methodology of the Study

2.0 Project Description

2.1 Introduction 2.2 Type of the Project

2.3 Need of the Project 2.4 Project Location and Layout 2.5 Project Requirement 2.6 Project Schedule for Approval and Implementati

2.7 Process Technology 2.8 Pellet Plant Facilities 2.9 Service Facilities

2.10 Electrics, Automation & Illumination 2.11 Fuel Oil Storage and Handling System 2.12 Sources of Pollutants

2.13 Control Measures

3.0 Baseline Environmental Status

3.1 Introduction 3.2 Geology and Hydrogeology 3.3 Land Use Studies


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Table of Contents (Contd.)

Chapter Title

4.3 Impacts and Mitigation Measures during Operati

5.0 Analysis of Alternatives for Technology and Site

5.1 Analysis of Alternative Sites 5.2 Analysis of Process Technology

6.0 Environmental Monitoring Program

6.1 General

6.2 Monitoring Schedule

6.3 Process Monitoring and Reporting Arrangements6.4 Implementation Schedule of Mitigation Measure6.5 Infrastructure for Environmental Protection

6.6 Cost Provision for Environmental Measures 6.7 Greenbelt Development

7.0 Additional Studies

7.1 Public Consultation 7.2 Risk Assessment 7.3 Approach to Study

7.4 Fuel Storage at the Plant 7.5 Hazard Identification 7.6 Hazard Assessment and Evaluation 7.7 Disaster Management Plan 7.8 Emergencies 7.9 Emergency Organization

7.10 Industrial Safety and Fire Fighting 7.11 Off-Site Emergency Preparedness Plan 7.12 Occupational Health and Safety 7.13 R & R Policy

8.0 Project Benefits


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Table of Contents (Contd.)

Chapter Title

10.0 Summary and Conclusions

10.1 Introduction

10.2 Nature of the Project 10.3 Baseline Environment 10.4 Summary of Anticipated Environmental Impacts

and Mitigation Measures 10.5 Risk Assessment and Disaster Management Plan 10.6 Budget Requirement for Environment Protection 10.7 CSR activities

10.8 Conclusions

11.0 Disclosure of Consultants

11.1 Introduction 11.2 Vimta Lab Limited Environment Consultant

List of Annexures

Annexure-I TOR Letter and its Compliance Annexure-II EC Letter and Certified Compliance Report Annexure-III Six Months Compliance Report Annexure-IV CTE Letter and Recent Monitoring Report Annexure-V Applicable Environnent Standards Annexure-VI Methodology for Sampling and Analysis Annexure-VII Land Procurement Letter Annexure-VIII Water Allocation Letter

Annexure-IX Hydrogeology Report Annexure-X Land Use Details Annexure-XI SODAR Study Annexure-XII Ambient Air Quality Levels Annexure-XIII Demographic Details Annexure-XIV Emission Calculation Annexure-XV R&R Policy


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List of Figures

Figure Title

1.1 Index Map

1.2 Study Area Map 1.3 Google Image 1.4 Photographs showing the Existing Plant Site 1.5 Photographs showing the Proposed Pellet Plant Site 2.1 Layout of the Proposed Pellet Plant 2.2 Water Balance Diagram 2.3 Mass Balance Flow Sheet of the Proposed Pellet Plant 2.4 Energy Balance Flow Sheet of the Proposed Pellet Plant2.5 Equipment Flow Sheet of the Proposed Pellet Plant

3.2.1 Drainage Map of the Study Area 3.2.2 Geology of the Study Area 3.3.1 Satellite Imagery of the Study Area 3.3.2 Land Use Pattern Based on Satellite Data 3.3.3 Digital Elevation Model 3.4.1 Seasonal Windrose of Pre Monsoon & Monsoon IMD J3.4.2 Seasonal Windrose of Post Monsoon & Winter IMD Ja3.4.3 Annual Windrose IMD Jagdalpur 3.4.4 Site Specific Windrose

3.4.5 Average Mixing Height 3.5.1 Ambient Air Quality Monitoring Locations 3.6.1 Water Sampling Locations 3.7.1 Noise Monitoring Locations 3.8.1 Soil Sampling Locations 3.9.1 Ecological Sampling Locations 4.1 Short Term 24 hourly Incremental GLCs of PM 4.2 Short Term 24 hourly Incremental GLCs of SO24.3 Short Term 24 hourly Incremental GLCs of NOx 4.4 Cumulative Short Term 24 hourly Incremental GLCs of 4.5 Cumulative Short Term 24 hourly Incremental GLCs of 4.6 Cumulative Short Term 24 hourly Incremental GLCs of 4.7 Isopleths showing Incremental Concentrations for CO 4.8 Isopleths showing Incremental Concentrations for NOx 4.9 Schematic Diagram of Proposed MBR based STP


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List of Tables

Tables Title

1.1 Environmental Setting of Expansion Project 1.2 Environmental Attributes and Frequency of Monitoring

2.1 Classification of LandBreakup

2.2 Land Use Breakup 2.3 Raw Material Requirement 2.4 Details of Raw Material Transportation

2.5 Breakup of Recirculation Water and Process Consumpti2.6 Water Balance Details 2.7 Man Power Requirement 2.8 Chemical Analysis of Raw Materials 2.9 Material Balance 2.10 Hourly Energy Balance 2.11 Quality of Pellets 3.2.1 Regional Stratigraphic Succession 3.3.1 Land Use pattern in the Study Area 3.3.2 Land Use/Land Cover Classification System

3.3.3 Land Use Break Up of the Study Area 3.4.1 Sensitivity of Meteorology Monitoring Equipment 3.4.2 Climatological Data Generated at IMD Jagdalpur

3.4.3 Summary of Wind Pattern IMDJagdalpur

3.4.4 Summary of the Meteorological Data Generated at Site3.4.5 Summary of Wind Pattern at the Study Area 3.5.1 Details of Ambient Air Quality Monitoring Locations 3.5.2 Summary of Ambient Air Quality Results

3.5.3 Summary of Chemical Characterization of RSPM 3.6.1 Details of Water Sampling Locations 3.6.2 Surface Water Quality 3.6.3 Ground Water Quality

3.7.1 Details of Noise Monitoring Locations 3.7.2 Noise Levels in the Study Area 3.8.1 Details of Soil Sampling Locations 3.8.2 Soil Analysis Results

3.8.3 Standard Soil Classification 3.9.1 Flora in the Core Area

3 9 2 l h ff


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List of Tables (contd..)

Tables Title

3.11.1 Traffic Density

3.11.2 Composition of Existing Traffic Volume

4.1 Model Setup 4.2 Details of Stack Emission from the Proposed Pellet Plan4.3 Predicted Short Term Modeling Results (24 hourly)

4.4 Resultant Ground Level Concentration (24 hourly) 4.5 Cumulative Stack Emissions from the Existing plant and

Proposed Pellet Plant

4.6 Cumulative Predicted 24-Hourly Short Term IncrementConcentrations

4.7 Cumulative Resultant Ground Level Concentrations 4.8 Proposed Facilities for Control of Air Pollution

4.9 Control Measures on the Roads 4.10 Emission Norms for Air Pollution Control Measures 4.11 Input to the Model

4.12 Predicted Peak Hourly Air Pollution due to Additional Tr4.13 Wastewater Treatment 4.14 Noise Levels from the Proposed Expansion Plant 4.15 Solid Waste Generation and Disposal

4.16 Hazardous Waste Generation and Its Disposal 5.1 Comparison between Drum and Disc Pelletiser 5.2 Comparison of Travelling Grate and Grate Kiln Process 5.3 Status of Major Pellet Plant Installed in India 6.1 Environmental Monitoring during Project Construction S6.2 Environmental Monitoring during Operational Stage 6.3 Implementation Schedule

6.4 Environment Monitoring and Frequency 6.5 Cost Provision for Environmental Measures 6.6 List of Species Showing High Air Pollution Tolerance Ind6.7 Year Wise Greenbelt Development

7.1 Category Wise Schedule of Storage Tanks 7.2 Hazardous Materials stored, Transported and Handled 7.3 Properties of Fuels used at the NMDC Pellet Plant 7.4 Applicability of GOI Rules to Fuel/Chemical Storage


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Environmental Impact Assessment for Proposed Expansion of NMDSteel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PlChowkawada Village near Nagarnar, Jagdalpur, Bastar District, Ch

1.0 PROJECT DESCRIPTION

1.1 Introduction

M/s. NMDC Limited,intends to set up 2.0 MTPA Pellet Planttheir upcoming 3.0 MTPA Integrated Iron and Steel Plant a

District, Jagdalpur, Chhattisgarh.

Now a day in Iron and Steel industry, pelletization is the call othe inherent nature of the pellets; the productivity of steel pthus reducing the cost of steel making per ton. Further pelutilizing the unused iron rich slimes which after beneficiationpellet feed concentrate suitable for pellet making. Due to which are lying as waste till date will also get used for steproposed expansion is the right direction for effective utilislimes. The proposed plant will also have positive impact development of local people. Total project cost is estimated tcrores and EMP cost is about 15.32 crores.

The proposed project can be classified as 3(a) type activity unas per EIA notification dated 14thSeptember 2006.

As per New Environment Impact Assessment Notification dat

2006 and as per TOR conditions issued by MoEF&CC, the puexisting 3.0 MTPA NMDC Integrated Steel Plant was conducte2009. Hence, exemption of public consultation for this proposanotification 2006 was requested to MoEF&CC. As per the requhad exempted the proposed project for installation of pellehearing under Clause 7 (ii) of EIA Notification 2006.

1.2 Environmental Setting

The study area map of 10 km radius around the proposed expin Figure-1. The environmental setting of the proposed expfollows:

The proposed pellet plant falls at the intersection of Latitto 1905'17.0 N and Longitude 8211'8.67 E to 8211'l ti f b t 545 t 550 b l l (


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Nearest railway station from the plant is Amaguda at abodirection; and

Proposed expansion site does not fall in any critically polluCPCB/MoEF&CC circular dated January 2010.


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2.0 PROCESS DESCRIPTION

The proposed pellet plant processes are as follow:

Raw materials receipt, storage and proportioning

Iron ore concentrate {() 325 mesh, 80 % minimum} shall

pellet plant in the form of slurry at 68% solids concentratslurry will be received in slurry storage tank of pellet subsequently pumped to the filtration unit for dewatering uptusing pressure filters. The filter cake is then stored in two (2) each having an effective volume of 600 m3. Individual covereenvisaged for unloading limestone/Dolomite, coke breeLimestone, coke breeze and bentonite will be unloadedumper/truck inside the covered storage building. Adequate

been provided for loading the materials to underground underground hoppers, 1 no. belt conveyor will be there for onof materials to additive crushing building.

Coarse additive grinding

The additives, as received, in pellet plant will not be fine enoformation; therefore, the particle size of these materials shall

to (

200 mesh, 80 %) by suitable grinding in this unit. Additivthree separate bins of 160m3effective volume. Coke breeze sstorage bin to one vertical roller mill by means of belt whopper. Limestone & bentonite shall be fed from the respecanother vertical roller mill by means of belt weigh feeders & fsharing basis for grinding. Ground material from this unit respective ground material storage bins in balling unit by pneu

Mixing of filter cake and ground additives

Filter cake and the ground additive materials from the respectbe fed to a high intensity mixer, at a preset ratio. Bulk of wathe mixer for thorough mixing. The mixed material will be balling unit by a series of belt conveyors.

ll


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312 m2 area (3.0 m wide and 118 m long) through a recwhich feeds the green pellets uniformly across a wide belt cothe green pellets onto a double deck roller screen to separateand undersize (9mm) green pellets for recirculation/ dumpingfraction of green pellets will be fed to indurating machine. Gindurating machine will pass through several thermal zones f

and heat hardening. Pellets discharged from the induratintransported to the pellet screening unit for separation of heafinished product. The finished pellets will be stored in finished the help of trippers and reclaimed by scrapper reclaimers, whe

2.1 Infrastructural Facilities and Raw Material Requirement

Land Requirement

About 74.19 Ha (183.32 acres) of acre of land is in possessionand Chowkawada village. About 33% of the area will be reseThe area includes road side plantation, plantation near infrastr

Raw Material Requirement

The Raw materials requirement for 2.0 MTPA pellet plant are g

Iron ore Concentrate (Filter cake) - 20.06 LTPALimestone/Dolomite - 0.40 LTPACoke Breeze - 0.36 LTPABentonite - 0.14 LTPA

Water Requirement

The water requirement for the proposed pellet plant is mostlyand equipment with a small part of the requirement being

needs and drinking & other needs such as dust suppressioconserve upon the fresh water requirement the major water cpellet plant has been envisaged to be met from the slurry filtrecirculation/treatment facilities/circuits will be adopted tocooling water needs.

The clarified filtrate water received directly from slurry filt


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Power requirement

The estimated power requirement of the proposed plant as fol

o Maximum Demand : 20.58 (MVA)o Annual energy consumption : 96.98 (106kWH)

The most feasible option for meeting the power requirementplant of NMDC may be taken from the source of 33kV switchMRS located at NISP, Nagarnar, which is 3 km away from ththe power supply for slurry pumping station (PS3) at Nagaavailable from proposed HT switchboard of Pellet plant at 6.6rating of DG set shall be envisaged to take care emergency loof normal power supply.

3.0 BASELINE ENVIRONMENTAL STATUS

The study area generally represents mostly flat and vacant landpredominantly from southwest. The nearest IMD station is at Jaof about 15 km from the project site.

The baseline environment quality has been monitored during p(summer) 2015. With regard to the air quality in the study area

of particulate matter (PM10 and PM2.5), sulphur dioxide (Snitrogen (NOx) and other pollutants levels are within the stipula16th November, 2009 Notification. The contributors to the air are predominantly rural, residential activities, domestic coal unpaved open surfaces in the region. There are no major operastudy area except NMDC steel plant.

The water quality in the area covering surface and ground wregion is in compliance with the stipulated standards of IS:1

water quality does not reflect any major industrial contaminatioThe soil in the project site is predominantly clayey and thesufficient quantity as compared to soil classification given bAgricultural Research, New Delhi. The soil quality does not visible contamination. However, the surfaces in the region appetraffic and windblown dust.


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wildlife are observed or recorded by locals and field records of foonly Kanger reserve forest area.

The following mitigation measures will be taken for protection oarea:

o

Educate the local people to develop awareness to protecto Formulate wildlife protection committees in nearby vi

poaching and hunting;o

Protect and regulate the herbivorous animals in the forearea;

o Wild life patrolling committee would be formed to monmovement; and

o Develop thick green belt around the plant site with fruiwill attract the avi-fauna in the study area and increase

of the area.

Aquatic Ecology

Basillariophycean, Chlorophyceaen, Myxophyceaen, Rotifers apredominant in the studied water bodies. Plankton diversity Indand zooplankton varies from 2.50 to 3.06 and 1.64 to 1.8biological parameters and diversity index reveals that the stud

oligotrophic to slightly mesotrophic in nature.

Thus, the monitoring of environmental attributes like ambient acharacteristics, noise levels, terrestrial and aquatic ecology etpollution concentrations are within the permissible limits. Baenvironmental data of the area, the proposed project is environit has sufficient buffer assimilative capacity.

4.0 IMPACT ASSESSMENT AND MITIGATION MEASURES

The summary of anticipated adverse environmental impacts dproject during operation and mitigation measures are given be

Air Environment

Th i ll i l d i h d


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supports needed for construction will be ensured to shorteperiod vis--vis to reduce pollution;

The construction sites will be adequately camouflaged from opollution can be confined to the construction site only;

Construction materials will be stored in covered go down or prevent the windblown fugitive emissions;

Stringent construction material handling / overhauling pfollowed;Truck carrying soil, sand, stone dust, stone will be duly coveand fugitive emissions;Adequate dust suppression measures such as regular wvulnerable areas of construction sites will be undertaken to c

during material handling and hauling activities in dry seasons;The construction material delivering vehicles will be coveredspills;Low emission construction equipment, vehicles and generator It will be ensured that all construction equipment and veworking condition, properly tuned and maintained to keep permissible limits and engines turned off when not in use to reVehicles and machineries would be regularly maintained

confirm to standards of central pollution control board (CPCB)Monitoring of air quality at regular intervals will be conductedphase; andConstruction workers will be provided with masks to protect dust.

The following mitigation measures will be employed during reduce the pollution level to acceptable limits:

o

Dry fog type DS system for material handling junction o Dedusting system in lime & dolo plant;o Stack monitoring to ensure proper functioning of differeo Air monitoring in the work-zone to ensure proper fun

emission control facilities;o

Adequate plantation in and around different units;V hi l d hi i ld b l l i i


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Integrated Steel Plant Project, NMDC, Nagarnar for furtherrequirement.

Water pollution may be caused due to discharge of polluted wand by contaminated leachate from land disposal / dumpingPellet Plant, industrial water is generally used for purposes like

o Directly in process;o Material conditioning and transportation i.e. for slurri

scale removal, rinsing, etc;o Air pollution control, i.e., for wet scrubbing of air polluto Heat transfer, i.e., water used for protecting the eq

refractory and shell of equipment; ando Water pollution from the industry mainly comprises ino

in suspension or in solution, like oil, grease, etc.

The measures envisaged in the existing process for water poto contain the water pollution within tolerance limit as specifierelated statutory norms. The following measures will beoperation phase to reduce the pollution level to acceptable lim

o Recirculating water in the process whereby the dibrought to minimum;

o

Clarifier and sludge pond for removal of suspended solio Neutralization of acidic water by lime;o Removal of oil and grease from the contaminated wa

traps and skimming devices;o Effluent quality monitoring at inlet & outlet of differen

plants to ensure proper functioning of different effluento Use of treated waste water in different shops, dust

plantation development as far as practicable.

Solid and Hazardous Waste Management

Pellet plant generates solid wastes, maximum of which are nowaste materials will be reused / re-utilized in the plant process

Used Oil/cotton wastes are the hazardous waste produced i j hi h ill b di d ff i d


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Highly noise intensive construction activities will be restricteGreenbelt will be developed from construction stage. Further,high noise areas will be provided with necessary protective deear-muffs etc.

Biological Environment & Greenbelt Development

During construction vegetation will be disturbed. However, pretaken to disturb only to the minimum extent possible. Greenbephase wise during construction to improve the aesthetic valuescreen out the fugitive dust generated during construction.

The removal of vegetation from the soil and loosening of tcauses soil erosion. However, such impacts will be confined towill be minimized through paving and water sprinkling. T

existing matured trees in the site. However, greenbelt surrounding the plant facilities in the open areas. The expreserved to the extent possible.

The tree species selected for green belt include the native spplanted in several rows with adequate width around the pmaintained as per CPCB guidelines. The inter-spaces will be pbushes and hedges. Greenbelt is thus a set of rows of trees plthat they form an effective barrier between the plant and tthat community noise impact and air pollution will be reduced

Socio - Economics

The proposal implementation will generate employment both dto development of ancillary industries. During the constructionis going to create substantial employment and income. A larglikely to trickle down to the local people. Besides this, man

study area will get employment on permanent basis for actuplant in the form of skilled or semiskilled or unskilled labouamount of employment and income are expected to be genpeople. Hence, it can be ascertained that the project is goingemployment and income effects. The estimated manpower operational stage of the pellet plant is 150.


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5.0 RISK ASSESSMENT AND DISASTER MANAGEMENT PLAN

A detailed risk assessment and consequence analysis has beeplant operations in the proposed expansion. A suitable disastehas been recommended. A qualified and experienced safappointed. The responsibilities of the safety officers include

hazardous conditions and unsafe acts of workers and advice oconduct safety audit, organize training programs and provideadvice on various issues related to occupational safety andresponsible to ensure compliance of works safety rules/statuto

All the potential occupational hazardous work places will be mThe health of employees will be monitored once in a year foany ailment due to exposure to noise, respirable dust and haThe audiometry and lung function tests will be included

program.

6.0 PROJECT BENEFITS

The growth of the industry significantly contributes to econation as it generates employment both directly and also dueancillary industries. Peripheral development takes placeinfrastructure facilities and due to more influx of money throuimportance of the area increases and overall the infrastrucconditions will improve.

NMDC is coming up with educational complex comprisinsecondary school with boys & girls hostel, ITI College, Polytequarters, Community hall and shops for meeting the requiremNMDC Iron and Steel Plant & Pellet plant and local populatioimplementing CSR works in the areas of education, health, civic utilities in nearby areas for meeting the social infrastruct

7.0 ENVIRONMENT MONITORING PROGRAMME

The environment monitoring for the proposed pellet plant shall be conducted as follows:

Ai li


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8.0 CONCLUSION

The proposed expansion project has certain level of adverse ienvironment. However, with the judicious implementationpollution control and environment management measures,impacts anticipated due to construction and operation of the p

will be mitigated. Further, development of this project beneficial impact/effects in terms of bridging the raw materplants and supply gap and providing employment opportucreated during the course of its setting up and as well as duphase of the project.

Thus, in view of considerable benefits from the project with environmental impacts, the proposed expansion projeadvantageous to the region as well as to the nation.


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Environmental Impact Assessment for Proposed Expansion of N& Steel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PChowkawada Village near Nagarnar, Jagdalpur, Bastar District, C

1.0 INTRODUCTION

M/s. NMDC Limited, intends to set up 2.0 MTPA pellet plantheir upcoming 3.0 MTPA integrated iron and steel plant aJagdalpur tehsil, Bastar District, Chhattisgarh.

This chapter describes the purpose of the present Env

Assessment (EIA) report, identification of the project and projdescription, nature, size, location of the project and importaregion. The chapter also includes the details of regulatory scper Terms of Reference (ToR) issued by the Ministry of EnvirClimate Change (MoEF & CC), Government of India (GoI), New

1.1 Purpose of the Report

As per the Environmental Impact Assessment (EIA) Not

September 2006, the proposed expansion project falls undproject type 3(a) and requires Environmental Clearance (EC) MoEF&CC before the commencement of construction activity.

In line with new EIA Notification 2006, proposed expaconsidered by the reconstituted Expert Appraisal Committee (meeting held during 19th-20th December 2013, for preundertaking detailed EIA/EMP study and TOR was issued vide11011/300/2013-IA-II (I) dated 5th January 2014. However

intents to shift the location of pellet plant from Mandpal vilChowkawada village, where the land is already in possessioapplication for TOR has been submitted on 6thMay 2014 anthe Expert Appraisal Committee meeting held on 18 th-19thSecommittee decided that since there is only change of the localand is already under possession, the same TOR granted earlirevised TOR.

This EIA report has been prepared, covering all the TOR condMoEF&CC vide letter no. F. No. J-11011/300/2013-IA-II(I) d2014. A copy of TOR letter along with its compliance to enclosed as Annexure-I. The report cover the primary dataMarch-2015 to 31stMay-2015 representing pre monsoon seaso

The EC letter for the existing 3 0 MTPA NMDC Integrated Iron


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notification 2006 was requested to MoEF&CC. As per the reqhad exempted the proposed project for installation of pellehearing under Clause 7 (ii) of EIA Notification 2006.

1.2 Identification of Project and Project Proponent

1.2.1 Identification of the Project

NMDC intends to install a 2.0 MTPA Pellet Plant adjacent tointegrated steel plant (NISP) at Nagarnar, Bastar Districutilizing the ore concentrate from Bailadila iron ore miDantewada District, Chhattisgarh.

The proposed pellet plant at NMDC, Nagarnar is intendedFurnace (BF) grade iron ore pellets for use in blast furnace in i

Beneficiated iron ore concentrate shall be obtained frbeneficiation plants of NMDC at Bacheli in the form of slurry th

1.2.2 Identification of the Project Proponent

NMDC is a Government of India enterprise, IncorporatGovernment of India fully owned public enterprise. NMadministrative control of the Ministry of Steel, Governmeinception involved in the exploration of wide range of mineral

copper, rock phosphate, lime stone, dolomite, gypsum, bediamond, tin, tungsten, graphite, beach sands etc.

NMDC is India's single largest iron ore producer, presently million tonnes of iron ore from 3 fully mechanized mines viz14/11C, Bailadila Deposit-5, 10/11A (Chhattisgarh State) andMines (Karnataka State). NMDC is presently producing about iron ore from its Bailadila sector mines and 10 million tonnsector mines.

NMDC has made valuable and substantial contribution to thethe mineral sector during the last five decades and has been of schedule-A Public Sector Company. In recognition to the status and consistent excellent performance, the Company hby the Department of Public Enterprises as "NAVRATNA" Pub


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The Bailadila sector is served by KK railway line of East Coastcater to a maximum of 25 MTPA and will not be in a position tproduce from the Bailadila sector in the present state. In thesreduce dependence on railways, NMDC intends to devetransportation system as an alternate mode of transport fofines in slurry form subsequent to their conversion to iron ore to making pellet feed concentrate.

Pelletization plant has to be set up to convert the pellet fepellets. NMDC intends to set up 2 MTPA pellet plant at Nproduce pellets for use as raw material in iron mak ing in blasupcoming steel plant to the maximum extent possible therebythe raw material requirement of the steel plant.

Now a day in Iron and Steel industry, pelletization is the call othe inherent nature of the pellets; the productivity of steel p

thus reducing the cost of steel making per ton. Further pelutilizing the unused iron rich slimes which after beneficiationpellet feed concentrate suitable for pellet making. Due to which are lying as waste till date will also get used for steproposed expansion is the right direction for effective utilislimes.

1.2.4 Cost of the Project

The cost estimated for the proposed 2 MTPA Pellet Plant incluauxiliary services etc., is about Rs. 818 Crores.

1.3 Brief Description of the Project

1.3.1 Nature of the Project

The nature of the Project is a pyro metallurgical industry invoore Pellets utilizing iron ore concentrate received through Slurore concentrate shall be obtained from the Beneficiation planup by NMDC. The process of pelletisation essentially involves t

Filtration of iron ore concentrate to produce filter cake whof particle size of 40 microns;This filter cake along with additives are fed to Disc pell


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The index map of the project area, study area map of proposesite (10 km radius), google image and photographs of the exexpansion project site are given in Figure-1.1 toFigure-1.5.

1.3.3 Environmental Setting of the Proposed Expansion Project

The environmental setting of the proposed expansion proj

Table-1.1. TABLE-1.1ENVIRONMENTAL SETTING OF EXPANSION PROJECT (

Sr. No. Particulars Details

1 Project area Kasturi & ChowkawadaJagdalpur, Bastar Distr

2 Project site coordinates CornerPoint

Latit

A 1905'9B 1905'1

C 1905'6

D 1904'5

E 1904'54

F 1905'1

3 Elevation above MSL 545 m to 550 m

4 Climatic conditions (Based onIMD Jagdalpur-15 km, W)

Annual mean max temAnnual mean min tempAnnual total rainfall: 1Predominant wind dire

5 Nearest highway NH - 43 (adjacent, S)

6 Nearest railway station Amaguda railway statio

7 Nearest airport Raipur Airport (300 kmJagdalpur Air strip, non

8 Nearby villages Kasturi village (0.2 kmChowkawada village (0Nagarnar village (1.6 k

9 Nearest town Jagdalpur Town (15 km

10 Reserve forest/ protected forest Kanger RF (2.5 km, S)Kakadapasar RF (5.3 kUlnav RF (8.7 km, NW)Malcherma RF (9.5 km

11 Notified Historical/Archaeological/ Tourist Places

Nil

12 Ecological Sensitive areas Nil


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1.4 Scope of the Study

Based on the prescribed TOR, the Environmental Impact Asprepared covering study area (10 km radius) around the pproject area. The scope of study broadly includes:

To conduct literature review and to collect data relevant to

To undertake environmental monitoring so as to estaenvironmental status of the study area;

To identify the ambient air quality levels in the project area

To predict incremental levels of pollutants in the studproposed project activities;

To evaluate the predicted impacts on the various environ

the study area by using scientifically developed anenvironmental impact assessment methodologies;

To prepare an Environment Management Plan (EMP) outfor improving the environmental quality and scope for fuenvironmentally sustainable development; and

To identify critical environmental attributes required to be

The literature review includes identification of relevant ar

publications, collection of data from various government sources.

1.5 Methodology of the Study

M/s. Vimta Labs Limited, Hyderabadhad conducted a recand sampling locations were identified on the basis of:

Predominant wind directions in the study area as

Meteorological Department (IMD), Jagdalpur;

Existing topography, location of surface water bodies likerivers;

Location of villages/towns/sensitive areas;


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Environmental Impact Assessment for Proposed Expansion of NMDC Integrated Iron & Steel Plant (Pellet Plant at Kasturi and Chowkawada Village near Nagarnar, Jagdalpur, Bastar District, Chhattisgarh

VIMTA Labs Limited, Hyderabad

TABLE-1.2

ENVIRONMENTAL ATTRIBUTES AND FREQUENCY OF MONITORSr.No.

EnvironmentalComponent

SamplingLocations

SamplingParameters

TotalSampling

Period

SamplingFrequency

Detection Limit

1 Surfacemeteorology

One centrallocation

Temperature, windspeed, winddirection

3 months Hourly WS: +/-0.02 m/secWD: +/- 3 degreesTemp: +/- 0.2 oC

Rainfall 3 months Daily Rainfall: 0.2 mm

Relative humidity,cloud cover

3 months Hourly RH: +/- 3%

2 Ambient AirQuality

8 locations As per NAAQS2009

Two days perweek for 13weeks

24 hourly PM10

: 5 g/m3

PM2.5: 2 g/m3

SO2: 4 g/m3

NOx: 9 g/m3

CO: 12.5 g/m3O3 : 2 g/m

3

3 Water Quality 16 locations

(8-surfacewater8-groundwater)

As per IS:10500 Grab sampling Once in studyperiod

EC:+/-0.1 us/cmTSS/TDS: 0.5 mg/lO&G:0.1mg/lDO: 0.5 mg/lBOD:2 mg/lCOD: 0.5 mg/lCa, Mg, Na, K: 0.1mg/l Alkalinity, PO4,

SO4, Cl, NO3: 0.1 mg/lColiform: 1 MPN

Heavy metals (As,Hg, Pb, Cd, Cr-6,Total Cr, Cu, Zn,Se, Fe)

Grab sampling Once in studyperiod

0.001 mg/l


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Environmental Impact Assessment for Proposed Expansion of NMDC Integrated Iron & Steel Plant (Pellet Plant at Kasturi and Chowkawada Village near Nagarnar, Jagdalpur, Bastar District, Chhattisgarh

VIMTA Labs Limited, Hyderabad

Sr.No.

EnvironmentalComponent

SamplingLocations

SamplingParameters

TotalSampling

Period

SamplingFrequency

Detection Limit

4 Noise 8 locations Leq Hourlyreadings for24 hours

Once in studyperiod

SPL: 0.1 dB(A)

5 Soil 8 locations Soil profile,chemicalconstituents,suitability foragricultural growth

Compositesample up to1.0 m depth

Once duringstudy period

EC: 0.1 s/cmN, P, K: 0.1 mg/kg

6 TerrestrialEcology

Total studyarea

Flora and fauna Fieldobservations

Once in studyperiod

-

7 Demography andSocio-economicaspects

Total studyarea

Demographicprofile

- - -

8 Land Use Total studyarea

Trend of land usechange fordifferent categories

- - -

9 Geology Total studyarea

Geological history - - -

10 Hydrogeology(Surface andground)

Total studyarea

Drainage pattern,nature of streams,aquifercharacteristics,recharge anddischarge areas

- - -

11 Traffic Study 2 locations

(Importanttrafficjunctions)

Traffic density

survey will becarried out atsuitable locations

24 hours Once during

study period

-


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Environmental Impact Assessment for Proposed Expansion of NM& Steel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PChowkawada Village near Nagarnar, Jagdalpur, Bastar District, Ch

2.0 PROJECT DESCRIPTION

2.1 Introduction

This chapter presents the major resources required for p

project, project schedule, process description, technological

configuration, raw material requirement and handling and leffects due to the proposed project and proposed mitigation m

2.2 Type of Project

The present project involves setting up of pellet plant of cap

falls under Category A of project type 3(a)as per the new E14thSeptember 2006.

2.3 Need for the Project

As the demand for steel in India is projected to grow in the this in turn would call for increased demand for iron ore. NMD

meet the expected increase in demand by enhancing produthe existing iron ore mines and by opening up new mines anMTPA integrated iron and steel plant.

2.3.1 Pellet Plant - Indian Scenario

India figured in the worldpelletizing map in the year 19

installation of Chowgule's Pellet Plant at Pale, Goa. The planoriented unit with 110 m2travelling grate supplied by Lurgi.

Subsequently, pellet plants were installed by TISCO, MPL, KIO

JSW. There are also many upcoming pellet plants proposed toit can be seen that pelletisation of iron ore fines is iimportance and new pellet plants of various sizes are execution stage. With scarcity of lump ore growing day by

soaring high, pellet seems to be the only feasible solution, demand supply gap. Further, the new blast furnaces enprivate entrepreneurs are mostly of high capacity where prhigh consistency is required This also underlines the necess


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2.4

Project Location and Layout

The proposed site for pellet plant is located near Kasturi & ChoBastar district of Chhattisgarh and is about 16 km in North

Jagdalpur town and the project site is well connected to NH-4layout is shown in Figure 2.1.

2.4.1 Size and magnitude of the Project

About 183 acres of land is in possession of NMDC at KastVillage. The capacity of the Pellet Plant is to produce 2 MTPA expected to operate in continuous mode to the maximum ext

to operate 7200 hours per annum.

2.5 Project Requirements

NMDC intends to set up 2.0 MTPA Pellet Plant as a backwardupcoming Integrated Iron and Steel Plant at Nagarnar, BastarChhattisgarh. Beneficiated iron ore concentrate shall be

proposed beneficiation plant of NMDC at Bacheli in the formpipeline. The finished iron ore pellets is envisaged for chargito blast furnace of NISP (NMDC Iron & Steel Plant), Nagadomestic sale.

2.5.1 Land Requirement

About 74.19 Ha (183.32 acres) of acre of land is in possessionand Chowkawada village. The breakup of the land classificatio2.1. The land possession document is enclosed as Annexure-

TABLE-2.1CLASSIFICATION OF LAND - BREAKUP

Sr. No. Village Private Land (ha) Government L

1 Kasturi 58.89 2.95

2 Chowkawada 12.35 0.00Total 71.24 2.95

Source: NMDC, Project Report

About 33% of the area will be reserved for green belt. The areplantation, plantation near infrastructure, etc. Land use b


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2.5.2 Raw Material Requirement

The Raw materials requirement for 2.0 MTPA Pellet Plant is sh

TABLE-2.3RAW MATERIAL REQUIREMENT

Sr.No

Material AnnualRequirement

(LTPA)Cons

1 Iron ore Concentrate (Filter cake) 20.06

2 Limestone/Dolomite 0.40

3 Coke Breeze 0.36

4 Bentonite 0.14

TOTAL 20.96


2.5.2.1 Size of Raw materials

The Raw Material Handling System (RHMS) have been plafollowing assumption.

Beneficiated iron ore concentrate : (-) 325 mesh

Lime Stone/Dolomite : (-) 40 mmCoke Breeze : (-) 40 mm

Bentonite : (-) 50 mm

2.5.2.2 Source of raw materials

Iron ore concentrate

Requirement of iron ore concentrate in slurry form shall be iron ore beneficiation plant, NMDC at Bailadila. The slurry sfrom beneficiation plant to the Pellet plant at Nagarnar throug

Limestone

BF grade limestone (CaO: 46 48%) from Chitapur Potna

areas of Jagdalpur Tehsil in Bastar district of Chattisgaenvisaged to meet the requirement. Alternately, limeSatnaMaihar region of Madhya Pradesh have been identified


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Unloading, Storage and Transportation of Raw material to Pell

The transportation of limestone, coke breeze and bentonite wdumper/truck to the plant premises. Individual covered storagenvisaged for unloading limestone, coke breeze and bentoni

breeze and bentonite will be unloaded by self tripled dump

covered storage building. Adequate payloader has also been

the materials to underground hopper. 1 no. underground hopp

storage building will be provided. Below the underground hconveyor will be provided for onward transportation of mcrushing building to make desired sizes with the help of cradditive crushing building, 1 no. roll crusher & 1 no. vibra

envisaged. From additive crushing building, the ground addititransported to ground storage bins in pellet plant.

2.5.2.2 Mode of Transport

The iron ore slurry will be transported through dedicated sNMDC, Bacheli to proposed pellet plant at Nagarnar (approx.

truck is required for the iron ore transportation. However,materials like Bentonite, Limestone, Coke breeze, etc., willroadways and the details are given in Table-2.4.

TABLE-2.4(A)DETAILS OF RAW MATERIAL TRANSPORTA

Sr.No.

Material Annualrequirement

(T)

MaterialBulk DensityConsidered(T/Cum)

Annual TConsiderinCapacity TDumper) (

1 Bentonite 14,000 1.0 934

2 Limestone 40,000 1.5 1818

3 Coke breeze 36,000 0.5 4500

TABLE-2.4(B)DETAILS OF RAW MATERIAL TRANSPORTA

Sr Material Annual requirement Annual Traffic


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2.5.3.1 Source of Power Supply

The most feasible option for meeting the power requirementplant of NMDC may be taken from the source of 33kV switcMRS located at NISP, Nagarnar, which is 3 km away from th

the power supply for slurry pumping station (PS3) at Naga

available from proposed HT switchboard of Pellet plant at 6.6rating of DG set shall be envisaged to take care emergency lo

of normal power supply.

2.5.4 Water Requirement

The water requirement for the proposed pellet plant is mostlyand equipment with a small part of the requirement beingneeds and drinking & other needs such as dust suppressioconserve upon the fresh water requirement the major water c

pellet plant has been envisaged to be met from the slurry filtrecirculation/treatment facilities/circuits will be adopted tocooling water needs.

The clarified filtrate water received directly from slurry filttreated stored and supplied to various units of pellet plamakeup water and drinking water will be received from m

water system of 3 MTPA Integrated Steel Plant Project, Nfurther distribution as per requirement. The water allocation lesteel plant is enclosed as Annexure-VIII. The unitwise breawater and process consumption is given in Table-2.5. The wa

given inTable-2.6 and the water balance diagram is shown in

TABLE-2.5BREAK

UP OF RECIRCULATION WATER AND PROCESS

Sr. No. Unit Circulatingwater

(m3/h)

ProcessConsumpti

(m3/h)

1 Indurating machine crosslintel and other coolingsystem

600 -


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TABLE-2.6

WATER BALANCE DETAILS

Sr. No. Total Water Balance

A Reclaimed Water from slurry filtrate

1 Process needs for pellet plant

2 Dust suppression requirement B Fresh industrial makeup water & DW System

1 Fresh industrial makeup water requirement including coo

circuit losses, miscellaneous, etc.

2 DW requirement Source: NMDC, Project Report

RECLAIMED WATER

FROM FILTERING

THE SLURRY

(130 CU.M PER HOUR)

MAKE UP WATER FROM

NMDC's UPCOMING

INTEGRATED STEEL

PLANT

(65 CU.M PER HOUR)

PROCESS NEEDS

(80 CU.M PER HO

ACVS

(70 CU.M PER HO

MAKE UP WATER

REQUIREMENT

INCLUDING PRO

LOSSES

(40 CU.M PER HO

DRINKING WAT

(5 CU.M PER HO

80

50

20

40

5


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The following water circuits have been planned in the pellet pl

Indirect Circulation Water (ICW) For cooling of varindustrial water. The return hot water is cooled through coDirect spray water to mixer Used up in process; and

Make-up water system To feed make-up water to variou

2.5.4.1 Water System

Indirect cooling system

To cater to the cooling water requirements of lintels, etc.

machine, industrial water recirculation system consisting ovalves, piping, etc., shall be provided. Water lost in threplenished by fresh water from the existing make-up water n

Process water and auxiliaries cooling system

To cater to the process water requirements and cooling water

auxiliaries of the proposed pellet plant, a separate industrial wconsisting of pumps, piping and valves etc. will be providefrom the pellet plant itself i.e. the filtrate of filtering unit wplant. A separate group of pumpsets along with associate

provided for process water in mixer & balling disc.

Reclaimed water system

Water reclaimed from filtration unit shall be treated and the sback to circulating water pumphouse. A part of (approx.130m3/h) shall be used in mixer & balling disc and m

system.

Makeup water system

Makeup water will be pumped to different consumers, sumpipeline network complete with valves, fittings and appurtenawater pumps will be housed in a proposed common pump

circulation water system


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Firefighting System

To cater to the needs of water based firefighting system,

house associated fire water piping network shall be planned whydrants and internal hydrants at regular intervals.

The firefighting water network will be provided with adequahydrants and in-shop landing valves to combat fire hazards into the needs of water based firefighting system, a fire water

be planned with provision of yard hydrants and internal

intervals. The proposed network shall be connected with the the battery limits with an isolation gate valve.

The following specification of work shall be considered:

i) Category at hazardordinary (as par TAC)

ii) Yard hydrants at 45 m intervals

iii) Internal hydrants at 30 m intervals

iv) Minimum pressure at remotest hydrant 3.5 kg/cm2

Accessories:

Hoses : two nos. of 15 m long RRL as per IS : 636 PartI withand female coupling for yard hydrant and 15 m long RRhydrant.

Hose box : 1 no. of hose box each landing valve to keep 15 mnozzle and spanner.

The piping network will be provided complete with pipelinesfittings and appurtenances.

Interplant pipelines

Industrial water for makeup water supply, firefighting purpos

usage will be met through the proposed pipeline to be laid

water system to these units. Fire water system of the pla

pressurized pipe network. Adequate number of yard hydranthydrants will be provided on firefighting water network cover


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proposed manpower also includes preventive maintenanc

requirements which are given in Table-2.7.

TABLE-2.7MAN POWER REQUIREMENT

Sr. No Category N1 Chief executive /GM

2 Sr. Executive/Jt GM/DGM

3 ExecutiveI

4 ExecutiveII

5 Non-executive

Total


2.6 Project schedule for Approval and Implementation

The pellet plant will be commissioned in a period of 30 montreceipt of all approvals from statutory authorities.

In order to adhere to the project schedule, it will have tsimultaneous work progress is achieved in many fronmobilization of constructional resources. Selection of constragencies, mobilization of requisite resources of men, materia

machinery as well as construction and erection expertise on mtrends, will be essential to complete the project on time. It wto ensure timely availability of site infrastructure like constrwater, electric power, site amenities for the workers, sewefacilities, etc. during the execution period at site.

2.7 Process Technology

The main process stages for production of pellets from rafollows:

Raw material preparation;Formation of green balls; andInduration of green balls.


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concentrate ( 325#, 80%) from the proposed iron ore ben

Bacheli in the form of slurry through slurry pipelines inside the

Dewatering of iron ore slurry shall be carried out to obtain disc filters, ceramic filters and pressure filters are generally

However, for this project pressure filters have been adopt

efficiency even with high Alumina content as is prevalent in In

Coarse additive grinding

The additives, as received, in pellet plant will not be fine enoformation; therefore, the particle size of these materials shall

to (200 mesh, 80 %) by suitable grinding in this unit, coarslimestone, bentonite and coke breeze are ground to requiredroller mill on time sharing basis. Roller mill is complete wit

cyclone, bag filter, hot gas generator, circulation fan, surge hvessel. Magnetic separator is provided before each roller mfrom roller mill is carried to respective ground material storagby pneumatic conveying.

Binder and Additives

Bentonite is the most common binder used for iron ore pellet

been considered for this project. Selection of flux materialsenvisaged as the fluxing material which shall be availa

PotnarBaranji, Deorapal areas of Jagdalpur Tehsil in

Chhattisgarh state.

Formation of Green Balls

The ground iron ore fines/ concentrates along with additivconverted to green pellets after thorough mixing. The degree

materials, critical amount of water, amount of binder in theimportant for production of green pellets with adequate comprsize. The strength of green pellets results predominantly fcaused by wetting with water and mechanical consolidation,action. The critical amount of water varies from 8 to 13% d

nature of feed material


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and a good lifting effect for the pellet feed, a moist ore bed

thickness is layered on the bottom and is controlled by scrapper designs have been developed such as stationaryrotating spirals. Attempts have been made to utilise a maximarea for green ball formation and 90% of bottom area utilis

formation have been achieved after extensive research and

during ball formation a classification occurs up to the disdesired size, the quantity of necessary pellet feed correspond

pellets discharged. If nevertheless, small amount of undersmostly occurs during transportation, these are separated brecycled. The size of the ball in a disc pelletiser is easily conthe moisture content of raw feed, angle of inclination of disc,

disc, etc.

Induration of Green Balls

The green pellets of desired size are subjected to thermal trepreheating, firing and cooling; during which the pellets attainto withstand handling, transportation and charging into furnac

porosity, reducibility and reduction strength, etc. The major ideveloped for thermal treatment of green pellets are as follow

Shaft furnace;

Graterotary hearth

shaft furnace;Annular furnace;

Circular indurating furnace;

Travelling grate; andGratekiln cooler.

However, majority of the pellet plants worldwide use either

grate kiln cooler process. In this project, travelling grate pfor induration of green balls.

Travelling Grate Process

The Travelling grate machine used for induration of green pewellknown sintering machine of Dwight Lloyd design. The

three main parts:


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The system serves to circulate the necessary drying, heating

gases through the moving pellet bed. Important process eqwith which the process gases are moved through the chargetreatment is achieved during one passage of pallets on the Thus no transfer of green pellets from preheating to firing is

case of Grate Kiln. To protect the grate bars from thermal sho

layers of indurated pellets are used. A number of procesdesigned the travelling grate process. However, most of the T

commercial plants are either designed by M/s Lurgi or M/s ACo. and the share of Lurgi designed plants are more.

The advantages of travelling grate induration process are

from different types of iron ore fines, uniform quality of pelleof different types of fuels of relatively low specific heat consof large pellet quantities in one machine, etc. As a result, th

the most popular processes for production of pellets. As the sophisticated system of gas recirculation within the indiviprecision control and high degree of automation have also most economic operation of the travelling grate machines. In

operating pellet plants are equipped with travelling grate proce

2.7.1 Operating Regime, Material Balance and Quality of Raw Materia

Operating Regime

The proposed pellet plant will be operating on the basis of th

300 days in a year after taking into consideration the shutdowplanned maintenance and unscheduled breakdowns. The capiplant are envisaged as 15 days in a year.

Quality of Input Raw material

The quality of input raw materials used for pellet production iTable-2.8.

TABLE-2.8

CHEMICAL ANALYSIS OF RAW MATERIA


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the process flow sheet along with mass balance and the e

sheet are shown in Figure-2.3 andFigure-2.4.

TABLE-2.9MATERIAL BALANCE (NET AND DRY)

Input

Material TPH TPA % Material TP

Iron oreconcentrate

278.61 2006000 67.75 Pellets 200

Bentonite 1.94 14000 0.47 Side &Hearthlayer

590

Coke breeze 5.00 36000 1.2 Losses 361

Limestone/Dolomite 5.56 40000 1.35

Side & Hearth layer 82.00 590420 20.00

Water 36.90 265690 9.00Total 410.02 2952110 100 Total 295


TABLE-2.10HOURLY ENERGY BALANCE

ENERGY INPUT

Material Hourly

Consumption

Calorific value

Kcal/Kg

Consumption

Factor

Specif

(m.Kc

Coke 5263.16 5923 85.71% 267,1

Fuel oil 5397.94 10000 100.00% 539,7

Total 806,98

ENERGY OUTPUT

Material Hourly Output Specific heatKcal/Kg

K

Temp Diff (dt)K

Specif(m.

Kc

Product pellet 3,07,787.01 0.15 65 30,00

Exhaust from stack 19,34,764.54 0.3 145 570,2

Water & LOI 40749.13 0.3 55 206,7

Total Output 806,98


Quality of Pellets


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2.8 Pellet Plant Facilities

BF grade pellets will be produced in the proposed 2.0 MTPpellet plant proper based on straight grate technology following major technological units:

Covered ground storage unit for coarse additives (limestobreeze and bentonite);

Coarse additive storage bins & grinding;Slurry storage tank;Filtering, ground material storage, mixing & balling;Induration unit including process gas flow;

Pellet screening;Emergency filter cake & finished pellet stock piles; andBelt conveyors, junction houses & interconnecting gallerie

Apart from the above major units, all auxiliary facilities likewater supply system, compressed air, fuel, ventilation & airdedusting, repair shop, nonfactory buildings, electrics

automation and telecommunication facilities etc. have alsAdequate hoisting facilities have been provided in all themaintenance and operation.

2.8.1 Covered Ground Storage Unit for Coarse Additives

The additives (limestone, bentonite and coke breeze) will band unloaded manually in the covered shed and stocked by aseparate stock piles one each for limestone, coke breeze ground storage capacity of different materials is given below.

Material Total Qty (TPA)(net & dry)

No. of D(

Limestone/Dolomite (040 mm) 40,000

Coke breeze (040 mm) 36,000

Bentonite (050mm) 14,000


2.8.2 Additive


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Sr. No Material Eff. Volume of bin,m3 Stor

1 Coke breeze 160

2 Limestone/Dolomite 160

3 Bentonite 160


Coke breeze shall be fed from the storage bin to one vertical of belt weigh feeder & feed hopper. Limestone/Dolomite & be

from the respective storage bins to another vertical roller mweigh feeders & feed hopper on time sharing basis for grindbe complete with mill feed hopper, cyclone, bag filter,

circulation fan, surge hopper and transport vessel. Magneticprovided before each roller mill. Ground material from this unrespective ground material storage bins in balling unit by pneu

2.8.4 Slurry Storage Tanks

Iron ore concentrate (-325 mesh, 80%) will be received, in t

68% solids concentration by weight, in the slurry storage complex through slurry pipeline from iron ore beneficiatioNMDC. One slurry storage steel tank has been envisaged for sto take care of any contingency during shutdowns. The tank

and 15m height and shall be provided with agitators. This wilminimum one day.

A slurry pump house shall be constructed near the slurry storaslurry pumps of adequate capacity. Slurry is pumped from sand fed to individual pressure filters in the filtration unit.

2.8.5 Filtering, Ground Material Storage, Mixing & Balling

Slurry will be pumped to individual pressure filters by sepa

Dewatering of iron ore slurry shall be carried out in three f1std. by) located in this building. The slurry distributor shalslurry to these filter presses.Pressure filters are recessed plate membrane filters in whichorizontally. Individual filter plates have either singlesided

doublesided filtration area depending on the filter model.


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controlled by the filters programmable logic controller that als

equipment such as pumps and conveyors.

The filtrate water from filters shall be collected and after clrecycled to pellet plant for further use. Filter cake discharged

shall be collected by a common belt conveyor and transporte

bins of approximate volume 2x600m3

through reversible coThe capacity of each filter cake bin being approximately 1300

In case of emergency, facility of diversion arrangement for filfrom filter presses, stacking on the ground, reclaiming and tconveyor for onward transportation to filter cake bins shall als

Ground limestone, coke breeze and bentonite from additive gtransported pneumatically to this unit and stored in three

material storage bins of volume 160m3. One ESP dust bin of a50m3 shall also be envisaged in this unit. ESP dust shatransported to this bin from ESPs.

Belt weigh feeders shall be mounted at outlet of filter cake binfeeder at outlet of ground material bins & ESP dust bin. Materthese bins shall be transported to one High intensity mixer bmixing. Belt weigh scales shall be installed on conveyors b

mixer. The HI mixer (approximately 350 tph capacity) shthorough mixing of ground materials.

The mixed material from the mixer shall be transported conveyors to respective mixed material bins over four ballingby) in balling area. Over and under size green balls rejects fro(at the feed end of indurating machine) will be recirculated to

fresh mix feed through mix material bins and balling discs.

The mixed material shall be distributed to four (4) mixed mappropriate storage capacity of 40m3 each (capacity ~80 t

above the corresponding balling discs. All the bins shall be lohorizontal conveyor equipped with pneumatically operated plothe mixed materials into the mixed material bins. Any spilthese ploughs will be discharged at the head end of the con

E i t l I t A t f P d E i f NM


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The inclination and the rpm of the discs shall be variable. O

(approx. 45 to 50 deg) is determined during startup depend

material properties, desired green ball diameter and feed rateto regulate the disc rpm from 5 to 12 during operation.

The belt conveyor below each balling discs transfer the green

green balls collecting conveyor which in turn feeds green balconveyor. The reciprocating conveyor feeds the material to w

ensure smooth handling of the green balls. A belt weigh scalebelt for weighing the total amount of green balls dischargediscs, which is one of the parameters for the indurating machi

2.8.6 Induration

For distributing the green balls from the balling unit smoothly

indurating machine, a reciprocating conveyor will be installgreen balls uniformly onto a 3.0 m wide belt conveyor. Thconveyor, in turn, discharges the green balls onto a doubleconsisting of an upper and a lower deck of stainless steel ro

each deck being driven through a chain by a variable speedriven rollers.

Oversize and undersize green pellets will be recycled by belt

the mixed material stream between the mixer and the discs. balls, in the size range of 9 mm to 16 mm will be fed to the for heat hardening. Green balls (green pellets) will be indura

grate having reaction area of 312 m2 (approximately 3.0 mlong). The travelling grate indurating machine consists of apallet cars moving on tracks. The height of the green ballsimportant factor in determining the productivity of the machi

bed height of the indurating machine is envisaged to be 42process prerequisites for obtaining a uniform product qualit

height which is ensured by automatic control of the grate spethe green pellets feed rate by a series of ultrasonic level senso

A grate bar cleaning device is located near the lowering sttrack of the travelling grate. The pallets and the grate bars shwell proven design for the induration process enabling long

Environmental Impact Assessment for Proposed Expansion of NM


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minimum time delay and thus protects the pallet cars an

overheating.

The three feed components are charged onto the pallet caorder.

First, hearth layer is fed onto the indurating machine followfeeding of side layers (both sides) and green balls onto the

already been loaded with hearth layer earlier.

Green pellets are then subjected to the following different ththe process of induration on travelling grate machine:

Up draught drying Zone (UDDZ);Downdraught drying Zone (DDDZ);

Preheating Zone;Firing (Induration) & After firing Zone;First cooling zone; andSecond cooling zone.

After drying of green pellets in the up draught and downdr

the dried pellets will be preheated to a progressively highinitiate oxidation and sulphur burning with fuel (coal) present

The dried pellets will then be fired at approx. 1300recrystallization and slag bonding which will impart adequa

pellets. The firing in carried out in this indurating zone wherefuel oil burner will be installed in the hood, and the temperature position and temperature will be adjusted byposition and airfuel oil ratio. The temperature of pellet varies

An unfired short section designated as after firing allowscompletely penetrate into the bottom of the bed thereby

quenching of pellets and consequent deterioration of pellet pro

Cooling of indurated pellets shall be accomplished by up drau

supplied by a cooling air fan, through the pellet bed. The coolthe indurating machine at 100C or less.



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For the purpose of recovery of heat, the travelling grate will

refractorylined hood above the machine all along the length.

in different zones to seal this indurating hood against the movheat loss. The hood will be provided with watercooled side an

The following is a brief account of the process gas flow:

The cooling air, supplied by the cooling air fan, picks up indurated pellet bed in the first and second cooling zonesrecycled to the process as a heat carrier.

2.8.8 Recirculation from Cooling Zone II to Updraught Drying Zon

Hot air from the second cooling zone (UCZ II) will be blow

drying fan and forced through a duct into the wind boxes of

zone of the grate.

In order to stabilize the temperature of this hot air for optdrying, ambient air may be sucked in ahead of the updraugh

a bleeding. The air will be forced through the green pellets bcleaned in an ESP, collected by the hood exhaust fan and atmosphere through the common waste gas stack.

Excess air not required for up

draught drying and causing exthe wind boxes of the Updraught drying zone is bypassed duct.

2.8.9 Recirculation from Preheating/ Firing zone to Down Draught D

The hot process gas from the firing and partly from the after fthe drying gases in the down draught drying zone of the traare sucked through the pellet bed in the firing zone by the wi

fan and then forced via gas duct into the hood above the dowIn order to protect the wind box recuperation fan from overh

ambient air, equipped with control dampers are provided at the fan.

The hot air passing through the down draught drying zone wil



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The air will be heated in the chamber according to a

controlled by the operator. The arrangement and sizing of thuniform hot gas temperature over the width of the pellet bedare divided into several control zones, an optimum temperaachieved, thus permitting an optimum heat treatment o

temperatures in the individual zones of the preheating and

with thermocouples for automatic control of gas flow to the ind

2.8.11 Pellet Screening

The fired pellets discharged from the bin (load cell mountindurating machine shall be conveyed to Pellet screening unit

be made in Pellet screening unit with two nos. two way chutscreen with required amount to hearth layer route (ii) sepquantity of pellet for feeding to hearth layer route prior to fe

on the feedback of weigh scale mounted on hearth layer conve

The screen shall have three aperture, () 5mm, 12.5mm andout


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p p p& Steel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PChowkawada Village near Nagarnar, Jagdalpur, Bastar District, Ch



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& Steel Plant (3.0 MTPA) with addition of 2.0 MTPA Pellet PChowkawada Village near Nagarnar, Jagdalpur, Bastar District, Ch

2.9 Service Facilities

2.9.1 Civil works

The Civil design and construction work shall be carried out as

standards. The following concrete grades will be adopted for R

M25 RCC works for all foundations/substructures, supe

of all buildings, equipment foundations etc.

M20 For drains, minor structure, like pits, etc.

For all RCC work, reinforcement bars has generally been consstrength deformed bars conforming to IS: 17861985.

2.9.2 Steel Structures

The design of steel structures shall be as per IS: 800 1984 plates shall be as per IS: 2062 latest (Gr. A or B).

Fabrication of all structural steel works shall be in accordance

Fabricated structures shall confirm to tolerance as specified in

The method of construction, selection of construction ma

erection and painting of structures shall also conform Standards.

2.9.3 Fuel oil facilities

Low sulphur heavy stock (LSHS)/Furnace oil fuel has been e

the proposed pellet plant. However, light diesel oil (LDO) shfor start-up and flame stabilization of the indurating furnace LSHS oil pipelines during shut down / maintenance and fresh c

The estimated LSHS requirement will be around 43,5consumption shall be 145KL (approx.).

To meet the storage requirement, two storage tanks of 460Kone LDO storage tank of 50KL capacity along with handlin

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3 x 12 Nm3/min (2W+1S) Screw Compressors. Discharg

compressor is 9 kg/cm2(g); 3 x 12 Nm3/min (2W+1S) Refrigerant Type Air Drying Unit 2 x 14.5 Nm3/min (1W+1S) Reciprocating Compressors.

of each compressor is 13 kg/cm2(g); and

2 x 14.5 Nm3/min (1W+1S) Refrigerant Type Air Drying U

The steam requirement (tracing of LSHS storage tanks & pipto be met through steam pipeline drawn from NISP, Nagarnar

to supply steam at 5.5 kg/cm2 with an outlet temperature of be provided.

2.9.5 Water supply facilities

The water requirement for the proposed pellet plant will be m

plant and equipment with a small part of the requirement beinneeds and drinking & other needs such as dust suppression etTo conserve the fresh water requirement the major water c

pellet plant has been envisaged to be met from the slurry filtrecirculation circuits have been adopted to meet the various co

The clarified filtrate water received directly from slurry f

required treatment will be stored and supplied to various uFresh industrial makeup water and drinking water is envisa

from makeup & drinking water system of 3 MTPA Integrated

NMDC, Nagarnar for further distribution as per requirement.

2.9.6 Process gas & Plant dedusting

The measures to control the air pollution will ensure the standards as laid down by Ministry of Environment & Forests (November 2009.

Various dust collection equipment such as cyclone separafabric bag filters, electro static precipitator (ESP), etc. will beparticulate matter from gas streams. The dust laden air w

different dust generating points by means of suction hoods, dcleaned in the ESP to let out clean air to atmosphere throug

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2.9.7 Ventilation and airconditioning

Buildings & shops will generally be provided with natural venventilation will be provided for premises where adequate cannot be provided.

Water cooled package air conditioner will be provided for Room & Automation Rooms. Window air conditioners / Split a

be envisaged in office and incharge rooms.

2.9.8 Residential Area

The area is well connected with Jagdalpur, where NMDC will employees. No additional township is envisaged.

2.9.10 Green Belt

About 33% of the area will be reserved for green belt. The areplantation, plantation near infrastructure, etc.

2.9.11 Social Infrastructure

NMDC is coming up with educational complex comprisinsecondary school with boys & girls hostel, ITI College, Polytequarters, Community hall and shops for meeting the requiremNMDC Iron and Steel Plant & Pellet plant and local populatio

implementing CSR works in the areas of education, health, civic utilities in nearby areas for meeting the social infrastruct

2.9.12 Connectivity (Traffic & Transportation Road/Rail/Metro/Water w

The proposed site for 2.0 MTPA pellet plant is located near

Bastar district of Chhattisgarh. The site is at about 16 km in from Jagadalpur town. The proposed pellet plant site is locaside of the proposed 3 MTPA Integrated Steel Plant, Nagarnar railway station is located at about 3 km from the proposdirection. The location map of the site is shown in the drawin

Nagarnar Manganpur Ambaguda Dhanpunji villages are

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supply shall be brought to the 6.6kV/415V transformers and H

plant area through cables. The Secondary Power shall be s6.6kV to 415V and shall be fed to the PCCs through 6.6/0.415kV. Distribution Transformer for onward distributionfeeders, lighting distribution boards (MLDBs) and Power

(PDBs). All LT load shall be catered at 415V.

2.10.1 SCADA/Automation

The automation of operations and monitoring of pellet planthrough HMI system by using SCADA from the central controIt shall be possible to operate any motor in Remote mode fro

through SCADA. To monitor the status of various drive moprovided in the control room at Pellet plant (Nagarnar).

2.10.2 Illumination

All Electrical premise (Indoor/Outdoor) in the Pellet plant willlighting transformers, lighting distribution boards, feeder lighting circuits. It is proposed to carry out illumination of a

like Pellet Plant, Electrical premises (Indoor/Outdoor) using fittings (CFL/LED).

2.10.3 Earthing System

System as well as equipment earthing are envisaged to be in aCode of Practice for Earthing IS 3043 1993 and IEEE80.

with the relevant clauses of Indian Electricity rules.

2.10.4 Telecommunication System

Automatic Telephone Communication system

One electronic private automatic digital telephone (EPBAX) and expandable to higher capacity shall be provided to cater t

2.11 Fuel Oil Storage and Handling System

2 11 1 General

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2.11.2 Proposed Facilities

For storage of fuel oil, it has been envisaged to providecylindrical vertical mild steel tanks each of capacity 460 kldesigned as per IS: 8031976. Each tank will be provided

accessories and fittings, i.e., steam heated floor coil heat

thermal insulation of storage tanks and piping network. Theater will be adequately designed to meet the temperature r

at desired conditions. For storage of LDO, it has envisaged toLDO storage tank.

2.11.3 Unloading of oil from road tanker to storage tanks

2 nos. unloading pumps (1 Working+1 Standby) shall be instaLSHS/furnace oil from road tankers to storage tanks. The ca

pump shall be 20 m3

/hr. Similarly, for unloading of LDO frstorage tank, 2 nos. (1 Working + 1 Standby) pumps, each oshall be installed.

2.11.4 Fuel oil Supply to the consuming units

2 nos. delivery pumps (1 Working +1 Standby) each of 8.5 be required for supply of LSHS/furnace from central storagstorage tanks of the pellet plant.

The entire LSHS/fuel oil delivery system including pumps, pip

be electrically / steam heat traced & lagged with mineraaluminium cladding.

Duplex filters at suction side of each unloading pumps & del

storage tanks will be provided.

Adequate provision will be made in the design of piping systeoverhead and supported on shop columns.

2.12 Sources of Pollutants

2 12 1 Air pollution

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( )Chowkawada Village near Nagarnar, Jagdalpur, Bastar District, Ch

Directly in process;

Material conditioning and transportation i.e. for slurring, qremoval, rinsing, etc;Air pollution control, i.e., for wet scrubbing of air pollutantsHeat transfer, i.e., water used for protecting the equ

refractory and shell of equipment; andWater pollution from the industry mainly comprises inorgasuspension or in solution, like oil, grease, etc.

2.12.3 Noise pollution

The noise generation sources from the proposed plant inc

compressed air station, ID fans, material handling systems, Dused during emergency conditions, etc. The noise levels generange of 75 - 90 dBA at 1m from source.

2.13 Control Measures

2.13.1 Air pollution

There may be some increase in levels of SO2, NOx, PM10, PMair. However suitable air pollution control systems like ESP/type dust extraction systems will be provided to control tpermissible limits. The chimney heights will be provided as

ensure ground level concentration (GLC) of SO2and NOXwithiESP dust shall be recirculated in the process to the maximum

2.13.2 Water pollution

The measures envisaged in the existing process for water po

to contain the wa

eia nmdc pellet plant

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