pellet plant -...

Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan

PROJECT REPORT

PELLET PLANTat

village : Pur, Dist: Bhilwara(RAJASTHAN)

Jindal Saw Limited,12, Bhikaji Cama Place

New Delhi-110066

NOVEMBER 2014


Table of Contents

Chapter Title Page

1.0 Executive Summary 3

2.0 Introduction of the Project 13

3.0 Project Description 18

4.0 Site Analysis 33

5.0 Planning Brief 37

6.0 Proposed Infrastructure 39

7.0 Rehabilitation and Resettlement (R & R) Plan 43

8.0 Project Schedule & Cost Estimates 44

9.0 Analysis of Proposal 45


1.0 EXECUTIVE SUMMARY

M/s JINDAL SAW LIMITED (JSL) has installed and operating 1.2 MTPA pellet plant at

village Pur, District Bhilwara (Rajasthan) using captive iron ore concentrate.

Rajasthan State Pollution Control Board given Consent to establish by order no 2012 –

2013 /MUID/881 (File no (MUID) / Bhilwara (Bhilwara) /2(1)/2010-2011/3687-3689)

and consent to operate by order no 2013 – 2014 /MUID/1172 (File no (MUID) /

Bhilwara (Bhilwara) /2(1)/2010-2011/384-386 .Rajasthan State Pollution Control Board

vide letter no F.14/Tech Bhilwara (11) RSPCB/MUID/3707 dated 7th October 2014 has

directed to apply for TOR & EC as per directive of MOEF.

Environmental clearance for 7 MTPA iron ore mining and 2.5 MTPA iron ore

concentrate using Beneficiation Plant had been obtained from Ministry of Environment

and Forests, Government of India.

Pellet plant, purpose, location, capacity and use of finish productsJindal saw is having mining reserves of low grade magnetite ores with Fe content varying

from 28-38 %.The ore is being made usable for iron making process by beneficiation

(grinding-magnetic separation) process. The concentrate fraction size after beneficiation is

100-350 mesh. These super fine materials can be utilized for iron making by pelletizing

process.

After assessing the potential of Pelletizing of iron ore in India, Jindal Saw Ltd. (JSL)

installed pellet plant of 1.2 MTPA near village- Pur, District- Bhilwara in the State of

Rajasthan.

The pellet plant is utilizing available iron ore concentrate to produce pellets. The pellet

plant is installed at a location adjoining to existing mining lease area of JSL’s Dhedwas

Iron Ore, Copper and Associated Minerals Mine. The unit size and production capacity

of pellet plant is as below:-

Name of Unit Size & Production Capacity, Product

1 Pellet Plant 1.2 MTPA Pellet

2 Supporting Utilities RMH Yard, Nitrogen Plant, PCI, Laboratory, FuelComplex


The finished product detail of the pellet plant is as below:-

Product Capacity Use of finished product

Pellets (MT/Annum) 1.2 MTPA Captive use and sale to

Market

Land Requirement and Land type of project area:

The Pellet plant is located adjoining to the Dhedwas Iron ore and associated minerals

mine of JSL at village Pur, District Bhilwara, Rajasthan. No forest land is involved in

the project site. The transportation infrastructure is already available and maintained

in the existing mining lease area. NH 79 is at a distance of 2 km from project site in

East direction. Nearest railway station (Bhilwara) is at a distance of 10.0 km from

project site towards East direction.

Jindal Saw Limited already purchased 88.76 acres of industrial land. Out of

88.76 acres, 40.76 acres land has been covered by pellet plant and other facilities.

Land allotment papers are attached as Annexure #2.

Water Requirement –Quantity and source for industrial and domestic use

The water required for the pellet plant is supplied from treated sewage in the

Company’s STP at Kewara, near Bhilwara Town. The total domestic water demand is

25 KLD. The domestic water is supplying from tube well. Actual water consumption of

pellet plant is given in below table:

Sr. No. Month Pellet Plant Water Consumptions (KL/Month)1 Apr-13 02 May-13 2991(Trials)3 Jun-13 4196 (Regular Production)4 Jul-13 39015 Aug-13 47376 Sep-13 51157 Oct-13 48608 Nov-13 49929 Dec-13 4768

10 Jan-14 574111 Feb-14 345012 Mar-14 2267

Total FY 13-14 47018


1 Apr-14 28312 May-14 51853 Jun-14 60254 Jul-14 54705 Aug-14 55536 Sep-14 56027 Oct-14 6609

Power Requirement

Power for the pellet plant is available from RVVNL, Rajasthan, by existing transmission

line from GSS grid to the site.

Actual data of power consumption:-

Sr.No. Month Power Consumption

1000 Unit/Month1 Apr-132 May-133 Jun-134 Jul-13 16955 Aug-13 21426 Sep-13 22177 Oct-13 25328 Nov-13 25899 Dec-13 2428

10 Jan-14 280211 Feb-14 268112 Mar-14 3233

Total FY 13-14 223191 Apr-14 28032 May-14 25853 Jun-14 29114 Jul-14 28135 Aug-14 28616 Sep-14 30597 Oct-14 3139

Total 6 months 20172

Manpower requirement at construction and operation phases

Construction Manpower - NA

Current operational manpower of pellet plant is given below:-


Type of employment Skilled Un-Skilled Total

Direct 149 27 176Indirect 20 86 106Total 169 113 282

Employment has been generated for local people in surrounding villages and only

highly skilled manpower is sourced from outside area.

Type and Quantity of solid and liquid waste generated and its management

Actual generation of solid waste is given as below

Sr.No.

Month ESP dust(Ton)

Broken Pellets &Fines(Ton) Use

1 Apr-13

Reuse in the preparation ofpellet by dispatching toproportioning room(100 %recycle)

2 May-133 Jun-13 89 6194 Jul-13 145 19195 Aug-13 158 11506 Sep-13 170 5967 Oct-13 227 11098 Nov-13 239 11879 Dec-13 229 316

10 Jan-14 284 63011 Feb-14 258 189912 Mar-14 339 2284

Total FY 13-14 2137 1171013 Apr-14 266 357014 May-14 236 708515 Jun-14 274 262816 Jul-14 280 187717 Aug-14 248 197718 Sep-14 295 136619 Oct-14 314 826

Total FY 14-15 1915 19329

Other types of wastes generated from the project are shown below:Actual data of other waste generation is as below


S.N MONTHUSED OIL

GENERATED(Liter)

IN-HOUSE REUSE/ CONSUMPTION

(Liter)

BALANCEAVAILABLE

(Liter)

DISCARDEDCONTAINERS

/BARRELSDETAILS(Nos)

IN HOUSEREUSE

BARRELS(Nos)

1 Apr-13 NIL NIL NIL NIL NIL2 May-13 NIL NIL NIL 5 53 Jun-13 NIL NIL NIL 5 54 Jul-14 NIL NIL NIL 10 95 Aug-13 NIL NIL NIL 1 26 Sep-13 1500 500 1000 3 27 Oct-13 800 300 500 2 28 Nov-13 140 28 112 1 29 Dec-13 140 28 112 1 2

10 Jan-14 140 28 112 1 211 Feb-14 140 28 112 1 212 Mar-14 140 28 112 1 2TOTAL FY 13-14 3000 940 2060 31 351 Apr-14 425 25 400 2 12 May-14 44 30 14

12

3 Jun-14 44 22 22 24 Jul-14 44 25 19 15 Aug-14 296 30 266 2 16 Sep-14 44 25 19 1 1TOTAL FY 14-15 897 157 740 6 8

DATA FOR HYDRAULIC OIL 68 IN PELLET PLANT

S.NO MONTH USED OIL GENERATED(Liter)

IN-HOUSEREUSE/CONSUMPTION

(Liter)

BALANCEAVAILABLE

(Liter)1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 50 NIL 506 Sep-13 75 25 507 Oct-13 64 20 448 Nov-13 33 15 189 Dec-13 33 15 18

10 Jan-14 33 15 1811 Feb-14 33 15 1812 Mar-14 33 15 18

TOTAL FY 13-14 354 120 234


1 Apr-14 5 Nill 5

2 May-14 Nill Nill

3 Jun-14 6 Nill 6

4 Jul-14 5 Nill 5

5 Aug-14 5 Nill 5

6 Sep-14 8 Nill 8

TOTAL FY 14-15 29 0 29

DATA FOR GREESE CG -10 IN PELLET PLANT

S.N MONTH USED GREESE GENERATED(Kg)


(Kg)

BALANCEAVAILABLE

(Kg)1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 220 90 1306 Sep-13 220 90 1307 Oct-13 168 90 788 Nov-13 168 90 789 Dec-13 168 90 78

10 Jan-14 168 90 7811 Feb-14 168 90 7812 Mar-14 168 90 78TOTAL FY 13-14 1448 720 7281 Apr-14 350 Nill 3502 May-14 350 Nill 3503 Jun-14 350 Nill 3504 Jul-14 350 Nill 3505 Aug-14 350 Nill 3506 Sep-14 350 Nill 350TOTAL FY 14-15 2100 0 2100

DATA FOR GREASE HT IN PELLET PLANT


S.NO MONTH USED GREESE GENERATEDIN MONTH(Kg)


(Kg)

BALANCEAVILABLE

(Kg)

1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 155 60 956 Sep-13 155 60 957 Oct-13 89 60 298 Nov-13 89 60 299 Dec-13 89 60 29

10 Jan-14 89 60 2911 Feb-14 89 60 2912 Mar-14 89 60 29TOTAL FY 13-14 844 480 3641 Apr-14 313 Nill 3132 May-14 313 Nill 3133 Jun-14 313 Nill 3134 Jul-14 313 Nill 3135 Aug-14 313 Nill 3136 Sep-14 313 Nill 313TOTAL FY 14-15 1878 0 1878

Green belt development program

JSL planted 1500 saplings in project site area. The green belt development progress is

continuing. Around 13.0 acre land has been allocated for green belt development .It is

proposed to plant more than 600 trees per Acre of land area. The schedule of plantation

as given in below Table will be followed.

Year Area (Acre)Present

No. of trees to bePlanted

2014 2.4 1500

2015 2.65 1600

2016 2.65 1600

2017 2.65 1600

2018 2.65 1600

Total 13.0 7900

The name of trees planted / being planted are as below


Sl. No. Common Name Scientific Name

1. Neem Azadirachta indica2. Dhanbaher/ Amaltas Cassia Fistula3. Kumat Acacia Senegal4. Jand Prosopis Spicigera5. Khaira Acacia Catechu6. Karir Capparis deciduas7. Jungle jalebi Inga dulcis8. Imli Tamarindus Indica9. Ber Zizyphus jujube10. Babul Acacia Arabica11. Peepal Ficus Religiosa12. Vilayati babul Prosopis juliflora13. Khejri Prosopis cineraria14. Bargad Ficus benghalensis15. Gulmohar16. Amaltas17. Ashok

Rehabilitation and Resettlement Plan

The pellet plant is within existing industrial land owned by JSL. No human settlement

exists on the identified land. No agriculture activity is done on the identified land. The

land does not belong to private ownership. Hence no Rehabilitation and Resettlement

is required.

Project schedule and cost of Project

Pellet plant is already is in operation from June, 2013The Pellet plant projected cost is as below:

The total project cost of the pellet plant is Rs. 322.63 crores. The summarized project cost isgiven below:

Particulars Rs. (in crores)


Land and Site development 0.59

Building 20.88

Plant and Machinery 246.26

Preliminary and Pre-operative expenses 54.90

TOTAL 322.63

Financial and Social Benefits

The low grade iron ore deposit of Pur-Banera Belt of Rajasthan has remained

unexploited so far even though it was explored by Geological Survey of India, way

back in the year 1969-70. Jindal Saw Ltd with their innovative ideas and international

exposures have thought of upgrading iron ore from 35% Fe to 65% Fe by way of

magnetic separation and other separation methods as the Ore is mostly magnetite

along with magnetite quartzite. The Concentrate is palletized in pellet plant and sold to

the DRI producers and steel plants for production of sponge iron and steel. Jindal saw

ltd is in process of establishing integrated steel plant for long product production.

The opening of the mine and beneficiating the ore has provided employment to some

1000 persons, besides paying royalty to State Govt. to the tune of Approximately Rs.

25.00 crore per year. It will increase to about Rs. 50.00 crore per year as the production

increases. Pellet plant helped the nearby areas to get quality pellets locally instead of

getting from Orissa, Karnatika etc. Apart from this the pellet plant provided employment

to additional 282 persons and in-direct employment to 300 persons in transport,

upkeep & maintenance, ancillary units. The pellet plant is generat ing

Approximately Rs 100 crore per year indirect tax revenue.

Actual royalty and tax data are shown as below (in INR):


Month Royalty Excise duty Service Tax CST Entry Tax WCT Total

2011-12 1,288,766 1,288,766

2012-13 33,294,580 8,221,424 12,345,164 53,861,168

2013-14 246,323,213 745,953,797 73,204,538 128,086,477 7,227,570 15,648,073 1,216,443,6682014-15 -

Apr-14 29,405,092 108,712,418 6,054,604 19,229,693 509,426 27,519 163,938,752

May-14 26,565,796 90,679,959 7,576,260 16,127,423 411,933 882,734 142,244,105

Jun-14 28,611,410 108,372,150 8,453,265 19,443,900 220,369 466,912 165,568,007

Jul-14 27,310,605 98,973,295 9,504,262 17,859,796 1,022,982 396,125 155,067,065

Aug-14 29,509,812 92,082,383 6,613,863 16,741,730 995,229 769,929 146,712,946

Total 422,309,275 1,244,774,002 111,406,792 217,489,019 18,608,934 30,536,456 2,045,124,478


2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of project and project proponent

2.1.1 Project proponent

M/s Jindal Saw Limited is a company incorporated in the year 1985 under the

Companies Act, 1956 and is pioneer in manufacturing and supplying of large diameter

pipes, seamless tubes and pipes, ductile iron and cast iron pipes.

Jindal SAW Ltd. is a part of the O.P. Jindal Group, Country's one of the topmost

industry houses and the foremost indigenous steel producers and exporters. It is the

first company in India to manufacture Submerged Arc Welded (SAW) Pipes using the

internationally acclaimed U-O-E technology.

Jindal SAW Ltd. is in a commanding position in Indian market, being the undisputed

leader with a turnover in excess of Rs. 7500 Crore.

With integrated facilities at multiple locations and an ever expanding market

opportunity, Jindal SAW Ltd. has diversified from a single product company to a multi-

product company, manufacturing large diameter submerged arc welded pipes and

spiral welded pipes for the energy transportation sector; carbon-alloy and stainless

steel seamless pipes and tubes manufactured by conical piercing process used for

industrial applications; and Ductile iron (DI) pipes for water and sewage/wastewater

transportation. Besides these, the company also provides various value added products

like pipe coatings, bends and connector castings to its clients.

JSL has been granted a mining lease for Iron Ore, Copper and Associated Minerals

over an area of 1556.7817 Ha near Dhedwas Village, Bhilwara District Rajasthan for 30

years starting from 8th December’10.

Jindal Saw Limited is currently operating a 2.5 MTPA capacity Iron Ore Beneficiation

Plant and 1.2 MTPA Pellet Plant at Bhilwara (Rajasthan).The pellet plant is using the

iron ore concentrate produced from its own Beneficiation Plant located at the same site.


2.1.2 Identification of project

PROJECT AT A GLANCE

Project proponent M/s JINDAL SAW LTD, Bhilwara, Rajasthan

Company Name M/s JINDAL SAW LTD

Type of project 1.2 MTPA pellet plant

Category of Project Category A , Sector 8 , Schedule 3a – Pellet plant

S.No in the schedule as perEIA notification, 2006

Schedule 3,Pellet Plant

Total area 40.76 Acre

Location Bhilwara district ,Rajasthan at Captive mine head

Village Pur

Khasra numbers 6711, 9697/6711

District Bhilwara

State Rajasthan

Latitude 250 18’ 56.32” to 250 19’ 13.70” N

Longitude 740 32’ 16.07” to 740 32’ 29.93” E

Near by Features

Highways-NH-79-Approx.2.2 km- East Railways-Bhilwara Railway Station-Approx 10 km-East

Airport- Dabok Airport-Approx 150 km-South West

Village /Town-Pur Village-Approx.2.0 km-South

Distance to nearest Protectedarea

No protected area within 10 km radius

2.2 Brief Description of Nature of the project

The plant is purported to make iron ore balls of 8 to 16 mm size from the concentrated

iron ore power by adding about 0.94% bentonite with some water and heating. These

balls are first dried by hot air and then preheated up to 1100 °C and after preheating

are fed to rotary kiln for indurations. In indurations at about 1200°C the bentonite gets


fused, making the bonding of iron ore grains and the balls become firm and compact

attaining compressive strength of about N2500 per pellet. These hot balls are

discharged from rotary kiln to annular cooler for cooling. From there the hot air is

recovered and sent back to Rotary kiln, preheating chambers and drying chambers.

Pellet plant consisting of Raw material system,6 nos ball and disc, coal pulverized

system, travelling grate, rotary kiln, annular cooler,stacker,ESP,120 meter height stack

etc.

Detail plant description with process details is given in point no 3.5.

2.3 Need of the Project and its importance to the country and or region

Need of the Project

The Company has two mining leases (area 1556.78 ha and 451.00 ha) in Bhilwara

District covering a part of the area earlier prospected by Geological Survey of India. The

exploration report of GSI reveals that the Ore body consists of magnetite, the average

content of Fe to be 35 %. The Company has installed to beneficiation process for the ore.

Considering the iron ore to be of poor grade (on an average 35% Fe) and base metals of

poor grade as well as low tonnage, it was never been considered viable to be

economically exploited.

Jindal Saw Ltd. with their innovative ideas and international exposure has proposed to

upgrade the iron ore, from 35% Fe to about 65% Fe by way of magnetic separation and

other beneficiation methods as the ore is mostly magnetite along with magnetite quartzite

and as per prospects of GSI the reserves are adequate to last for 30 years.

It has been studied that if the BMQ is ground to – 100 mesh size there is total liberation

of magnetite and quartzite. Based on the exploration done so far, sufficient reserves of

iron ore have been established and its beneficiation tests have confirmed the reserves to

be viable.

The mined iron is first ground and processed in 3 stages to -200 mesh. The processed -

200 mesh magnetite concentrate is used for manufacturing of pellets in 1.2 million tons

per annum capacity pellet plant near village - Pur, District-Bhilwara, Rajasthan.


2.3.1 Importance of the Project to the Country

Considering the recent trend in production and consumption of steel globally and in

India, the National Steel Policy, 2005 had projected 110 MTPA steel making capacity in

India by 2019-2020 at 7.3% growth rate. It was noted subsequently in year 2006-07

that domestic production grew at 10.9% and domestic consumption by 11%.

Emboldened by buoyancy of the Indian economy, the Ministry of Steel, Govt. of India,

has revised the goal and projected a capacity of 180 MTPA by 2019-20. This creates

huge opportunity for investment in steel industry with high returns. This pellet plant

proved that low grade iron can be used for pellet production and it will certainly

contribute to the growth of steel industry.

2.3.2. Importance of the Project to the Region

The iron ore deposit of the region was explored by GSI in the year 1969-70. It remained

unexploited due to its poor grade. The opening of the mine and beneficiating the ore

has provided employment to some 1000 persons, besides paying royalty to State Govt.

to the tune of approximately Rs. 25.00 (FY 13-14) crore per year. It will increase to

about Rs. 50.00 crore per year as the production increases. Pellet plant is helping local

industry to get quality pellets locally instead of getting from Orissa, Karnataka etc. Apart

from this the pellet plant has provided employement to 282 persons and in-direct

employment to 300 persons in transport, upkeep & maintenance, ancillary units. The

pellet plant is generat ing Rs 100 (97 crore in FY 13-14) crore per year indirect tax

revenue. This pe l le t p l a n t i s t he first pellet plant in the state of Rajasthan and it

will also supply the quality pellets to our upcoming steel plant and DRI plant.

Actual Data of Royalty and Taxes Paid

Month Royalty Excise duty Service Tax CST Entry Tax WCT Total

2011-12 1,288,766 1,288,7662012-13 33,294,580 8,221,424 12,345,164 53,861,1682013-14 246,323,213 745,953,797 73,204,538 128,086,477 7,227,570 15,648,073 1,216,443,6682014-15 -Apr-14 29,405,092 108,712,418 6,054,604 19,229,693 509,426 27,519 163,938,752May-14 26,565,796 90,679,959 7,576,260 16,127,423 411,933 882,734 142,244,105Jun-14 28,611,410 108,372,150 8,453,265 19,443,900 220,369 466,912 165,568,007Jul-14 27,310,605 98,973,295 9,504,262 17,859,796 1,022,982 396,125 155,067,065

Aug-14 29,509,812 92,082,383 6,613,863 16,741,730 995,229 769,929 146,712,946

Total 422,309,275 1,244,774,002 111,406,792 217,489,019 18,608,934 30,536,456 2,045,124,478


2.4 Demand – Supply gap

Jindal Saw is the only company who installed pellet plant in Rajasthan. This pellet

plant filled vacuum of quality pellets in Rajasthan and nearby areas.

2.5 Import vs Indigenous Production

Pellet plant is meeting the Indigenous demand of quality pellets and reduced the import

requirement of pellets.

2.6 Export Possibility

Presently we are supplying pellets to domestic market and will explore the possibilities ofexport in near future.

2.7 Domestic/ export markets

Presently we are supplying these pellets mainly to Gujarat, Maharashtra etc .In future

major quantity of these pellets will be consumed in our upcoming steel and DRI plant.

2.8 Employment generation (Direct and Indirect) due to the project

The total man power presently employed in the pellet plant is 282 persons as detailedbelow:-

Type of employment Skilled Un-Skilled Total

Direct 149 27 176Indirect 20 86 106Total 169 113 282


3.0 PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects, if any

Pellet plant is interlinked with mining and beneficiation plant for which EC has already

been obtained & commercial production already going on.

3.2 Location with coordinates

Location (Google map showing general location, specific location, and project boundary

and project site layout) is shown in below Google map. The location of site with type

of land and boundary coordinates is as below:

Feature Description

Site Village: Pur, District: Bhilwara, Rajasthan

Type of land/ land

use

Existing Industrial land

Latitude and longitude of plant site

Latitude Longitude

250 18’ 56.32” to 250 19’ 13.70” N 740 32’ 16.07” to 740 32’ 29.93” E


Location Map and Images of Pellet Plant Site

Pellet plant Layout is attached as Annexure #1


3.3 Details of alternate sites considered and the basis of selecting the proposedsite, particularly the environmental considerations gone into should behighlighted

The Pellet plant site is adjoining company’s existing beneficiation plant where iron ore

concentrate is being produced, which is the main raw material for the pellet plant. Jindal

Saw is already in possession of 88.76 Acre (143.14 Bhiga) industrial land from which

40.76Acre land has been used by this pellet plant and other facilities (Beneficiation

plant).No alternate site was considered as developed infrastructures was already

available there.

3.4 Size or Magnitude of Operation

The company has installed 1.2 MTPA pellet plant unit and supporting utilities.

Actual Production details are shown in below table:

Sr. No. Month Month wise Pellet Production(Tons)

1 Apr-13 02 May-13 03 Jun-13 301014 Jul-13 411695 Aug-13 433526 Sep-13 489567 Oct-13 685288 Nov-13 822309 Dec-13 75862

10 Jan-14 10140011 Feb-14 9537012 Mar-14 121020

Total FY 13-14 7079881 Apr-14 1040602 May-14 901503 Jun-14 1059104 Jul-14 1030205 Aug-14 910506 Sep-14 1146307 Oct-14 112200

Total FY 14-15 721020


3.5 Project Description with Process Details:

Process Flow and Layout of Pellet plant


Pellet Plant Process Details

Mixing & BallingIron Ore Concentrate containing + 65% Fe, is received from Dhedwas Mine

Beneficiation Plant of the Company is mixed with Bentonite and Water and transferred

to Φ 6.0m balling disc rotating with adjustable angle, frequency and speed for higher

degree of balling. Some 0.5% to 1.5% water is added by regulating valve during the

process of balling to achieve the optimal moisture of the mixed material for balling.

Drying and Pre HeatingThe green ball produced by the balling disc is sent to the green ball distribution system

in Traveling Grate room by belt conveyor. The undersize (-8 mm) and oversize

(+16mm) balls is separated and sent back to the balling room via return system. The

green balls of 8 to 16mm size range, called qualified balls, are passed on to the grate

bed of Travelling grate. The thickness of the material (balls) bed on the grate will be

kept 185mm. The green balls will pass through 4 zones of the grate viz. drying zone-I

and II, preheating zones I and II.

The temperature of these zones is 300°C, 500°C, 700°C and 1100°C respectively.

The green ball is dried and preheated on the Travelling grate of 4.0 X 42m size for

about 23.3 minutes. After preheating, the green balls attain enough strength, they are

discharged into Kiln through discharging plate and large chutes.

Induration in Rotary KilnThe preheated balls discharged into the Rotary Kiln of Φ 5m X 35m size and 4.25%

slope and is indurated for about 35 minutes while rolling, mainly due to heat radiation

of the flame produced by burning of pulverized coal. The induration temperature of

1200º to 1250ºC is attained in the Rotary Kiln. The Kiln is Φ 5m X 35m, inclined at

4.25%, operating at about 1 R.P.M. The speed of the Kiln is adjusted according to

variation of the raw material to determine retention time and consequently the quality

of the pellet. The indurated pellet is discharged to the receiving hopper of the annular

cooler through Chute and fixed screen in the Kiln head hood.


Annular Cooler

The Annular Cooler receives the red-hot-pellet with temperature upto 1230ºC

discharged from the Kiln, its particle size being 8-16mm. The pellets are distributed on

the pallet bed in the annular cooler, up to 760mm thickness. The annular cooler is

provided with 3 air blowers. The pellets are cooled in 3 stages, from 1230º C to 900ºC,

from 900º to 550ºC and from 450 ºC to 90-105 ºC. The discharged hot air from annular

cooler is used for drying, pre-heating and indurating sections, thus most of the heat

generated during pellet cooling is effectively utilized in the pellet production process.

The pellet discharged from annular discharge hopper after cooling is stacked in the

finished Pellet Storage yard.

Main workshopMain process workshops of this project include: proportioning room, mixing room, balling

room, feed distribution system, grate-kiln, rotary kiln and annular cooler system, product

system, and main induced draught system. The main facilities in this project include: general

layout and transportation within the plant limit, power supply and distribution facilities, water

supply and drainage facilities, gas flow facilities, ventilation and dedusting facilities.

Auxiliary facilities of this project include: laboratory, repair facilities and spare parts

warehouse.

Proportioning roomQualified iron ore concentrate fine is transferred into 5 numbers of iron ore concentrate

bunkers in the proportioning room. Bentonite is carried to 2 numbers of Bentonite bins

in proportioning room for proportioning by pneumatic conveying pipeline. The collected

dust by the multi-cyclone and ESP of main induced draught system is sent to one dust

bin in proportioning room for proportioning through pneumatic pipeline. Pressure type

bag de-duster is adopted at bin top. Load cell is set up in each ore bin to measure ore

level and control material charging system, the setting value of proportion is controlled

and adjusted by PLC (Programmable Logic Controllers). Steel structure is adopted for

ore bins. Wear-resisting lining plate is fixed inside the concentrated Iron ore bin.

Vibrator is set up inside the concentrated Iron ore bins and bentonite bins to prevent

from material clogging.


Mixing roomThe mixing room is equipped with one continuous type heavy duty mixer. Mixed material is

conveyed to the balling room by belt conveyer. Moisture detector is provided on belt

conveyer to detect the moisture of the mixed material to control the water addition on the

mixer.

Balling roomMixed material is conveyed to the upper part of the balling room by belt conveyor and

discharged respectively to 6 mixed material bins by plough tripper on the belt conveyer. Six

sets of Φ 6m balling discs are provided under bins. Stock level display is provided in mixed

material bin of balling room to control the discharging position of the belt conveyer. Roller

belt weighing system is provided under bin. Rotating speed of the disc feeder is controlled

by interlocking with constant weighing feeder to feed the mixed material constantly to the

balling disc. The rotating speed and inclination of the balling disc can be adjusted to ensure

the pellet quality. Adequate water is added during the process of balling to achieve the

optimal moisture of the mixed material for balling. Regulating valve is adopted for water

addition. Water addition is regulated on time manually according to the moisture of the

mixed material. Green ball produced by the balling disc is sent to the green ball distribution

system in Travelling grate room by material collecting belt and 0-1 belt conveyer.

Green ball distributing systemDistribution system is consisted of swing belt conveyor, big ball roller screen, wide belt

conveyor and roller distributor. Green ball from balling room is sent to the distribution

system by belt conveyer. Swing belt conveyor discharges green ball to the big ball roller

screen. During its swinging, unqualified green ball bigger than 16mm will be separated

and sent back to balling room via return system; green balls smaller than 16mm are

distributed on the wide belt conveyor. The wide belt conveyor is VWF type, through

which green ball is sent to the roller distributor. Roller distributor screens out residual

unqualified small ball less than 8mm and distribute qualified ball of 8~ 16mm to the

grate bed of the Travelling grate. Unqualified green balls are returned to balling room by

belt conveyer.


Induration systemInduration system consists of three main machines, i.e. travelling grate, rotary kiln and

annular cooler. Green balls are dried and preheated on the Travelling grate, hardened

and indurated in the rotary kiln and cooled in the annular cooler.

Travelling grateTravelling grate is 4.0x42m. Distributing thickness is 185mm. Traveling Grate has 4

zones, up-draught drying zone I of 9m, down-draught drying zone II of 9m, preheating

zone I of 9m and preheating zone II of 15m. Process features of each zone of the grate

are as follows:-

Up-draught drying zone IThe decrepitating temperature of green ball is relatively low. In the up-draught drying zone

I, recovered off-gas from heat resisting fan at the lower part of the preheating zone II mixed

with hot gas from annular cooler zone III (1500) to reduce the fume temperature to below

2500 to 3500 will be blown. The up draught from the bottom of bed make green ball fully

dewatered and dried, so that the green ball can resist temperature above 3500C in the

drying zone II without decrepitation.

Off-gas from wind box of up-draught drying zone I is exhausted to the atmosphere by the

main induced fan through ESP after dedusting and meeting the environmental requirement.

Up-draught drying zone is 9m long and equipped with 4 wind boxes.

Down-draught drying zone II350-4000 C recovered off-gas from heat resisting fan at the lower part of the preheating

zone II is downdraught from top of the bed layer to further dewater and dry the green ball,

so that the ball can resist temperature above 7000C in preheating zone I without

decrepitation. Off-gas from wind box of down-draught drying zone II is also exhausted to the

air by the main induced fan through ESP after de-dusting and meeting the environmental

requirement. Down-draught drying zone is 9m long and equipped with 4 wind boxes.

Preheating zone IIn preheating zone I, hot air flow of above 6000C come through bed layer to further dewater

and dry the green ball to ensure that the pellet can resist the high temperature of above

1050-11000C in the preheating zone II.

The main heat source of preheating zone I come from hot off-gas from zone II of annular


cooler, and mixed with some hot air flow of 11000C from preheating zone II. This hot air flow

is introduced in preheating zone I at 7000C through preheating zone I and II partition hole

between hood. Hot off-gas of preheating zone I through header at the both sides of the

wind box together with hot off-gas from down-draught drying zone will be exhausted to the

air through ESP, main induced fan and stack, and then discharged after meeting the

environmental requirement. Preheating zone I is 15m long, 5 wind boxes.

Preheating zone IIAt the pre-heating zone II, the heat source is mainly the hot flue from 950° to 1050° C from

the tail of the rotary Kiln. Temperatures of hot air flow is further heat the pellet and impart

complete/ partial consolidation function to ensure that the pellet has attained required

strength to bear the impact force when falling from grate to the kiln and not get broken

during the rotating in the kiln.

Preheating zone II is 15m long with 7 wind boxes. Relief stack and relief valve is provided

on the top of hood of preheating zone II for furnace preheating and emergency

operation.

Green balls are dried and preheated on the Travelling grate. After preheating, green

ball has enough strength and are discharged into kiln through discharging plate and

large chute. Leakage of discharging plate shall not be more than 3%.

Dry revert systemSpillage from dust hopper of the Travelling grate and discharging end of rotary kiln is

returned to kiln through 1# dust bin and special bucket elevator for pellet. Dry return

from dust leg of grate wind box is collected to the return conveyer by dust belt conveyer

and sent to the balling system together with mixed material.

One electrical single beam overhead crane is shared by distribution system and

Travelling grate building for maintenance. An electrical hoist is installed on the head of

Travelling grate for maintenance of driving unit of the Travelling grate.

Rotary kilnSpecification of the rotary kiln is Φ 5m X 35m, inclination is 4.25%, operating rpm is

about 1, two points supported. Compound lining of high alumina brick and high strength

insulating pouring composite lining are adopted, which has a good property of anti-heat

shock, anti-impacting and anti-wearing as well as insulating to extend operating life and

reduce out surface temperature of the kiln. After preheating on the Travelling grate, pellets


are discharged to kiln tail end through discharging plate and chute. Kiln head is equipped

with specially designed double adjusting moving burner (Pulverized coal injecting gun), and

the shape and length of the flame can be controlled and adjusted by movement of the

burner and the adjustment of primary wind volume. Pellet in the kiln is indurated while

rolling; mainly due to the heat radiation ~ achieve uniform strength. Indurating temperature

is 12000 ~ 1250°C. Temperature of hot air flow in the kiln depends on the quantum of the

coal injected. Speed of the kiln can be adjusted according to variation of the raw material to

determine the retention time and consequently the quality of the pellet.

Kiln head hood and tail hood adopts new type sealing device and is equipped with structural

cooling fan.

A combination of infrared radiation thermometer-bicolor pyrometer-fixed thermocouple is

adopted for detection to adjust and control the Indurating of the pellet in the kiln.

Indurated pellets are discharged to the receiving hopper of the annular cooler through chute

and fixed screen in the kiln head hood.

Annular cooler(1) Effective area of the annular cooler is 69m2, intermediate diameter is Ф12.5m, width

of the pallet is 2.2m. Normal operation output is 151.5t/h. Cooling time is 44.4 min, bed

layer thickness is 760mm. The annular cooler is composed of rotary part, wind box,

driving unit, frame and upper hood. 3 blast cooling fans and 1 structural cooling fan are

provided. Annular cooler receives red hot pellet with temperature up to 12300C

discharged from the rotary kiln, its particle size is 8~16mm. The kiln may discharge

large lump once in a while due to the high temperature operation. The lumps are sorted

out by the fixed screen in the kiln head hood and discharged by the lump discharge

chute. Pellets are distributed on the pallet in the annular cooler by distributing device,

and distributing thickness is 760 mm which is maintained by AC variable frequency

speed control of the annular cooler according to discharging amount of the kiln.

(2) There are total 9 wind boxes, with one blower for 3 wind boxes. The annular cooler

fume hood is divided into three parts: in 1st cooling section, the 900-1100'C hot air

stream directly returns to rotary kiln through kiln head hood above receiving bucket and

parallel duct, which is applied to increase the kiln inside temperature and be used as

the secondary combustion air for pulverized coal firing ; in 2nd cooling section, the

5500C hot air stream goes through hot blast pipe to Travelling grate I section fume

hood, which is used for pellet drying and preheating; in 3rd cooling section, the 1200C


waste gas is discharged mostly to the up-draught drying zone I and some directly to

the stack of annular cooler with the density of less than 100mg/m3. The annular cooler

blower is use wind gate to regulate cooling wind volume automatically and control

return hot air temperature. Through the process, most of the hot air generated during

pellet cooling can be effectively utilized in the three-dimensional pellet production

process.

(3) Under annular cooler discharging bucket, one surge bin will be provided.

The electro-hydraulic feed gate can control uniform discharging. The pellet ore

temperature goes down under 1200C in annular cooler, discharged to belt conveyer

through discharging bucket and then stored in product storage yard. Under annular

cooler, 18 duct buckets are supplied with one electric double-layer dust discharging

valve for each bucket. A hand operated car is used to collect bulk material, which is

sent to belt conveyer and transported out with product ore. The belt conveyer is

equipped with an electronic belt scale for measuring the finished pellets.

Main induced draught systemThe waste fume is collected from the wind boxes of travelling grate preheating section-I,

draught drying section I & II, dedusted by electro static precipitator to reach the

standard, and induced by main induced fan to be discharged by chimney. In future we

will install a de sulphurising unit to further treat the sulpher in waste gases after ESP is

need arises. The Electro-Static Precipitator is 170m2 with four electric fields. The fume

flow rate is 0.98m/s. The precipitator is provided with temperature, pressure and flow

rate measuring devices with dust content measuring holes arranged at incoming &

outgoing duct. The collected dust is pneumatically transported from duct channel,

through duct and to dust bin in proportioning room.

The designed wind flow for main wind induced fan is 60x104 m3/h, with negative pressure of

5.5 kPa. The dust content discharged from electric precipitator, main induced fan and

chimney is ≤50mg/m3. The inner diameter for chimney outlet is < Φ3.2m; the flow rate

is designed as 19.50m/s; the chimney height is 100m. The inner lining of chimney is

wear-resisting anti-corrosive type.


PCI systemRaw coal is constantly fed to the middle speed grinding mill through sealed electrical belt

weighing feeder for grinding. Ground coal fine (-200 mesh > 85%) is carried by hot fume

through rising pipe directly to the coal fine collector in which air and solid is separated. Coal

fine is sent to the coal fine bin through deposit hopper and discharging valve. Tail gas is

filtered by bag and discharged into atmosphere with discharging density <50mg/m3. An

exhaust fan is installed at the end of pulverizing system as the power source for the

whole system. A silencer is installed at the exit of the exhaust fan to reduce the

noise of the system to <85 db (A).

Raw coal needs hot fume for drying during the grinding. Hot fume is generated by the

furnace and come into the grinding mill through pipeline. Adjusting valve and flow meter is

provided in the pipeline to control fume flow.

Root’s fans (one in operation, one standby) are adopted to transfer coal fine to the kiln

head. Pressurized air generated by Root's fan is mixed with coal fine after the flexible

air lock device and send the coal fine to the kiln head coal burner. Two Root's fans and

two sets of ring balance weighing devices, through switching of valves in the

connecting pipeline realized alternating standby of the coal transfer and coal feeding

equipment to ensure the continuous supply of coal fine to the kiln head.

Finished product system

The pellet discharged from annular discharge hopper after cooling is carried

into 2# transfer station via belt conveyer, and is sent to heavy discharging

wagon via belt conveyer to discharge at finished yard and stored in the open

air or is sent into auto discharging bins.

Material balanceThe raw material for the pellet plant is concentrated magnetite of the percentage of about

65% Fe. The same is added with bentonite powder as per below material balance table:-


Material Balance

Input Output

Material Ton/Annum Proportion% Material Ton/Annum Proportion

%Iron

concentrate 1204635 95.9%Final

Pellets 1200000 95.5%

Bentonite 10842 0.9%PelletFines 24490 1.9%

Lime 1205 0.1% Dust 3614 0.3%

Dust 3614 0.3%BurntLoss 28330 2.3%

Coal 36139 2.9%Total 1256434 Total 1256434

3.6 Raw Material required along with estimated quantity, likely source,marketing area of final products, mode of transport of raw materials and finishedproducts:

Actual production and corresponding Raw material consumption is shown in below

table

Sr.No. Month Production

(Tons)

Concentrate (Filter

cake)(Tons)

Concentrate(Purchase)

(Tons)

MillScale

(Tons)

Bentonite(Tons)

Coal(Tons)

1 Apr-13 02 May-13 0 03 Jun-13 30101 31593 0 0 331 8244 Jul-13 41169 43226 0 0 552 13465 Aug-13 43352 44554 0 2244 633 14606 Sep-13 48956 45828 0 3577 580 15747 Oct-13 68528 57968 4345 4609 819 21028 Nov-13 82230 67294 12015 3638 1032 22149 Dec-13 75862 64178 11281 297 1140 2120

10 Jan-14 101400 90846 11122 0 1536 262911 Feb-14 95370 87984 10523 0 1499 238812 Mar-14 121020 109845 11077 0 2009 3134

Total(FY13-14) 707988 643316 60363 14365 10131 197911 Apr-14

104,060 85471 13480 169 1685 2662


2 May-1490,150 70538 14964 5866 1037 2364

3 Jun-14105,910 91181 11631 4265 1143 2745

4 Jul-14103,020 83113 15004 5210 1111 2803

5 Aug-1491,050 78557 11179 2302 1187 2482

6 Sep-14114,630 99096 11716 2655 925 2950

7 Oct-14112,200 88956 19586 3800 839 3143

Total (FY14-15)up to Oct’14 721020 596912 97561 24267 7927 19149

The Captive Iron ore concentrate is transporting to pellet plant by conveyor and

bought out material like purchased iron, Bentonite, coal and lime is transporting to

plant by road. All conveyors are covered with dust suppression system at transfer

points.

Details of finished product, market area and mode of transport

S.No.Name OfFinishedProduct

Market Area Mode oftransport

1 PelletsSales within Rajasthan, MP,Gujrat, UP, Haryana ,Maharashtra, Export

By Road/Rail/sea

3.7 Resource optimization / recycling and reuse envisaged in the project

100% dust collected from ESP is reused in the process.

3.8 Availability of water, its source, Energy / Power requirement andsource

Availability and source of water

Jindal Saw has already established Bhilwara city Sewage Water Treatment plant

(STP) and treated water is being supplied by pipelines to its Mining & pellet plant.


Availability and source of electricity

Power has being sourced through the existing 220 KV substations.

3.9 Quantity of wastes to be generated (Liquid and solid) and scheme for theirManagement/disposal

100% dust collected from ESP is reused in the process. No wastewater is generated fromthe process.

Type and Quantity of actual liquid and other waste generated and its management

No wastewater is generated from the process.

Other types of wastes generated from the pellet plant are as follows:

Waste generated Quantity Disposal planUsed / Spent oil 10.0 KL/annum 3.0 KL Re-used and balance sent to

registered recyclerUsed / Spent Greese 10 Ton/annum 2.0 Ton Re-used and balance sent to

registered recyclerEmpty /ContaminatedDrums

300Nos /Annum Re-Using for storing of used oil and surplusdrums sold to registered recycler.

Cotton waste / Oilsoaked cloths

0.8 MT/ Year sending to registered recycler

Burnt / UsedRefractory

100 MT/Annum

Sale to refractory manufacturer for Re-cycle, / Landfill

E-Waste - sending to registered recycler

3.10 Schematic representations of the feasibility drawing which gives informationof EIA purpose

The pellet plant does not generate any solid wastes or liquid wastes from the

process. So there is no disposal issue. Dust collected from air pollution control

equipment are 100% reused in pellet making process. Air pollution is controlled

using ESP and Bag Filters.


4.0 SITE ANALYSIS

4.1 Connectivity

The connectivity of the project site with the major road/ railways/ ports and human

settlement is as given in table

Description Distance

TransportationRoad : ~ NH79 –approx 2.2 KM (East)Rail : ~ Bhilwara railway station approx 10 km(East).

NearestTown/City

Bhilwara town-approx 7 km north east

NearestVillage

Pur-approx 2 km south

4.2 Land form, land use and land ownership

The Pellet plant is located adjoining to the Dhedwas Iron ore and associated minerals

mine of Jindal Saw Limited at village Pur, District Bhilwara, Rajasthan. No forest

land is involved in the proposed project site.

The total industrial land covered by pellet plant and other utilities (Beneficiation plant) is

40.76 Acre Jindal Saw Limited has already purchased 88.76 acres of industrial land

from Government of Rajasthan. The land ownership documents are attached as

Annexure II

4.3 Topography

The project region shows undulating topography, elevation of the study area was in the

range of 399-547 m. above mean sea level. The nearest habitation to the project site is

the Pur village, which is located at a distance of two kilometers towards South. Nearest

Railway Station from p e l l e t plant site is in Bhilwara at 10 km (East). NH-79 is at

02 km (East) and SH-12 is 2.3 km South from Project site. The Kothari River is flowing

from West to East through the North (7.7 km from the project location. There are ponds,

and irrigation Canals present within study area.


4.4 Existing land use pattern

The land for the pellet plant is a part of notified industrial land allotted by Government of

Rajasthan. The land allotment letter from Government of Rajasthan is attached as

Annexure -II.

4.5 Existing Infrastructure

The company is operating currently Iron ore beneficiation & pellet plant at the site.

Following infrastructure facilities are available at site

- Roads

- Water Reservoir

- 220 KV Electric sub station

- Drainage

- Communication system

- Emergency staff hostel

- Laboratory

- Stores

- Weighbridges

- Offices, canteen, IT Infrastructure.

- OHS (Occupational Health Center)

4.6 Soil classification

The pellet plant area soil texture was found to be loam characteristics which were

determined by correlating the results of soil samples. The soil is in Brown to Blackish

Brown colour. The Gravel (<0.2 mm) was in the range of 3.2 % by weight to 46.8 % by

weight. The pH of the soil samples was in the range of 6.64 to 9.80, which show that the

soil nature in between the neutral and alkaline. The Moisture Content in the soil

ranged from 5.18% to 10.4%. The Organic Matter and Organic Carbon in the soil

varied from 0.67% to 1.43% and 0.39% to 0.83%, respectively. The Available

Phosphorous, Potassium and Total Kjeldahl Nitrogen (TKN) varied from 14.9 mg/100gm

to 30.4 mg/100gm, 0.47 to 1.56 mg/100gm and 0.14 % by mass to 0.3 % by

mass, respectively.

The Calcium, Magnesium and Sodium in the samples ranged from 8.34 mg/100gm to


16.0 mg/100gm, 3.9 mg/100gm to 6.89 mg/100gm, 0.68 mg/100g to 1.48 mg/100g,

respectively. The Sodium Absorption Ratio (SAR) in the soil varied from 0.71 to 1.47,

which signifies that the soil is non-saline in nature.

4.7 Climate data from secondary sources

There are four prominent seasons in the pellet plant area, Summer, South

West Monsoon, Post Monsoon and Winter. The summer season is from March to

June and is followed by South West Monsoon season, which lasts till the mid

September. The period from mid September to November constitutes the post

monsoon season. The winter season is from December to February. The historical

met data (30 years average) from IMD Bhilwara is given below

Month Temperature(deg C) dailyMax Min

RelativeHumidity, %Max Min

Rainfall(mm)

Windspeedkmph

Predominantwinddirection(from)

January 24.0 7.4 60 30 4.2 4.0 NE, N

February 27.2 10.4 51 23 4.1 4.8 NE, N

March 32.5 15.4 38 17 5.7 5.5 SW, NE

April 37.9 21.7 29 18 1.6 6.5 SW, W

May 40.8 25.9 34 17 5.4 9.1 SW, W

June 38.6 26.2 57 35 58.5 11.2 SW, W

July 33.6 24.8 77 61 207.4 10.0 SW, W

August 31.4 23.6 83 71 231.9 7.8 SW, W

September 32.9 22.2 75 54 112.8 6.1 SW, W

October 34.0 18.3 54 32 9.5 4.4 SW, W

November 30.0 13.2 54 33 12.5 3.4 NE, N

December 25.5 8.9 61 34 4.4 3.6 NE, N


4.8 Social infrastructure available

The basic amenities and facilities within the study area, as per Census of India, 2001 are given

in below Table shows the basic amenities and facilities at different location in the study area.

Pur, Samodi, Dhedwas, Lakhshmipura, Malikhera, Dariba , Salampuira

Basic Amenities and Facilities in the Study Area

Sl.No. Habitation

Basic Amenities and Facilities(As Per Census of India, 2001)

1. Dhedwas School: Primary School = 1,Drinking Water Facility: Tank Water, Tube WellElectricity: Available

2. Dariba School: Primary School = 2, Middle School = 1, Secondary School = 1Medical Facilities: Not AvailablePost Office = 0, Telephone Connection = 0Drinking Water Facility: Tap water, Wells, Hand PumpElectricity: Available

3. Samodi School: Primary School = 1Medical Facilities: Family Welfare Centre = 1Post Office = 1Telephone Connection = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available

4. Pansal School: Primary School = 2, Middle School = 1, Secondary School = 0Medical Facilities: Health Centre = 1Post Office = 1Telephone Connection = 10Drinking Water Facility: Tap water, Wells, Hand Pump, Tube WellElectricity: Available

5. Lakshmipura

School: Primary School = 1, Drinking Water Facility: Tube WellElectricity: Available

6. Salampura School: Primary School = 1Medical Facilities: Family Welfare Centre = 1Post Office = 1Telephone Connection = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available

7. MaliKhera#

School: Primary School = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available

8. PurVillage#

School: Secondary and Senior Secondary School = 10 -12Medical Facilities: Govt. Dispensary = 1, Vet nary Hospital =1, AyurvedicHospital = 1Drinking Water Facility: Wells, Hand Pump, Tap Water, Tube WellElectricity: Available


5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities, transportation etc) Town andcountry planning/ Development authority classification.

The proposed project is brown field project and the state government has allotted it as

industrial land after conversion of waste land. Also the industrial area and the related

facilities are already developed hence no planning is envisaged.

Also, due to the presence of industries including The Rajasthan State Industrial

Development& Investment Corporation- RIICO (located about 4.5 km in the North East

direction from the project site), which are located near to the proposed project site, has led

to conducive infrastructural facilities like paved roadway and electrical substation, for

establishing an Industry.

5.2 Population projection

There is no significant increase in the population of surrounding area as the workers

for the pellet plant operation come from the local residents in the surrounding

villages. No major influx of people in the area due to pellet plant. Only highly skilled

manpower is taken from outside which is not available in the nearby area.

5.3 Land use planning (break up along with green belt etc

The detailed land use planning and the area break up is as given in the table

TOTAL AREA 164946 (40.76 Acre)

PELLET PLANT AREA 18920(4.67 Acre)

ROADS AND DRAINS 22864 (5.65 Acre)

OPEN AREA/STORAGE YARD 68712 (16.98 Acre)

GREEN BELT 54450 (13.45 Acre)

GREEN BELT 33%


5.4 Assessment of infrastructure demand (Physical & social)

As the pellet plant is within the existing industrial premises the basic infrastructure like

water, Electricity and road are available at the plant site.

5.5 Amenities/Facilities

Following facilities are available in the existing industrial premises:-

Canteen

Bachelors Hostel

Sanitation Medical

Safety department with all safety training facilities

Fire Tender & Fire fighting services

Conveyance for staff and workers

Rest rooms for workers


6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (Processing area)

Jindal Saw Limited purchased 88.76 Acres of Industrial land out of which 40.76 Acres

of land is used for the Pellet plant and other facility.

6.2 Residential area (Non processing area)

No labour colony is envisaged for this pellet plant. Pellet plant site is very near to the

Pur village and Bhilwara city so Residential colony is not required.

6.3 Green belt

JSL planted 1500 saplings in project site area. The green belt development progress is

continuing. Around 13 Acre of land has been allocated for green belt development. It is

proposed to plant more than 600 trees per Acre of land area. The schedule of plantation

as given in below Table will be followed.

Green Belt Development Implementation Schedule

Year Area (Acre) Present No. of trees to be Planted

2014 2.4 1500

2015 2.65 1600

2016 2.65 1600

2017 2.65 1600

2018 2.65 1600

Total 13.0 7900

The list of plant species, which is proposed to be used for the green beltdevelopment is given in below.


Sl. No. Common Name Scientific Name

1. Neem Azadirachta indica2. Dhanbaher/ Amaltas Cassia Fistula3. Kumat Acacia Senegal4. Jand Prosopis Spicigera5. Khaira Acacia Catechu6. Karir Capparis deciduas7. Jungle jalebi Inga dulcis8. Imli Tamarindus Indica9. Ber Zizyphus jujube10. Babul Acacia Arabica11. Peepal Ficus Religiosa12. Vilayati babul Prosopis juliflora13. Khejri Prosopis cineraria14. Bargad Ficus benghalensis15. Gulmohar16. Amaltas17. Ashok

The pit size for the plantation of saplings is about 1 m × 1 m × 1 m. These pits are

filled with soil and manure up to 2/3rd

of its depth, about 5 to 10 days in advance

before plantation. After fifth year, efforts will be taken to replace the dead plants, whichhave been planted during the five years.

6.4 Social infrastructure

The company is bound for the upliftment of social infrastructure in the surrounding area.

Dedicated fund shall be contributed for the development of hospitals, schools and

drinking facilities in the surrounding area.

6.5 Connectivity (Traffic and transportation road/rail/metro/ water ways etc)

The major road/ rail in the area are as given below


Transportation

Road : - Highway NH-79 , 2 km (east)Highway SH-12 , 2.3 km (south)

Rail : ~ 10 Km (Bhilwara)Nearest Town/City ~ 7 Km (Bhilwara)

Nearest Village Pur (~ 2.0 Km)

6.6 Drinking water Management (Source & Supply of water)

Water required for drinking purpose is about 25 m3/day (25 KLD) and presently it is supplied from tube well.

6.7 Sewerage system

Domestic waste water generated from office toilets is directly discharged through soak pit / septic tank.

6.8 Industrial waste management

No industrial waste is produced from the pellet plant.

6.9 Solid Waste/by product Management

Type and Quantity of actual solid waste generated and its management

Sr. No. Month ESP Dust(Ton)

Broken Pellets &Fines (ton) Use

1 Apr-13

Reuse in thepreparation of pelletby dispatching toproportioningroom(100 %Recycle)

2 May-133 Jun-13 89 6194 Jul-13 145 19195 Aug-13 158 11506 Sep-13 170 5967 Oct-13 227 11098 Nov-13 239 11879 Dec-13 229 316

10 Jan-14 284 63011 Feb-14 258 189912 Mar-14 339 2284Total FY 13-14 2137 11710

13 Apr-14 266 357014 May-14 236 708515 Jun-14 274 2628


16 Jul-14 280 187717 Aug-14 248 197718 Sep-14 295 136619 Oct-14 314 826Total FY 14-15 1915 19329

6.10 Power requirement & supply/source

Total power requirement of pellet plant is fulfilled from the existing 220 KV feeder.


7.0 REHABILITATION AND RESETTLEMENT PLAN

7.1 Policy to be adopted (Central/ state) in respect of the project affected persons including homeoustees, land oustees and landless laborers

Not applicable, because no human settlement or agriculture land is involved in the identified project land. The

Pellet plant is within the existing industrial premises.


8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion

The pellet plant was commissioned in June 2013.

8.2 Estimated project cost along with analysis in terms of economic viability of the project

The details cost bifurcation of pellet plant is as below:

Particulars Rs. (in crores)

Land and Site development 0.59

Building 20.88

Plant and Machinery including environmental monitoring andcontrol equipments

246.26

Preliminary and Pre-operative expenses 54.90

TOTAL 322.63


9.0 ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

Based on the future demand of pellets in the market over the next 5 years, the proximity of the present pellet

plant to iron ore mines is an advantage with respect to price logistics. The financial viability also shows a good

rate of return from the pellet plant. Other financial and social benefits that could be obtained from this

pellet plant are described below:

The plant is generating considerable growth of transport sector in the region.

Providing direct & indirect employment opportunities and development of peripheral /supporting

services and amenities.

Supporting infrastructure development like road, power supply, reality sector.

No environmental significant impacts are envisaged.

Best applicable mitigative measures have been proposed for management of anticipated

environmental impacts.

Community development activities are initiated under CSR programs.

The pellet plant is providing the significant revenue to the exchequer in the form of excise and taxes

etc.

The pellet plant is created opportunity for industrial development in the state.

Jindal Saw Limited has a focus on the all-round development of the communities in and around the plant

and in Bhilwara city and is actively promoting social & welfare activities of the surrounding society. In

past 2 years it has spent Over Rs 5.8 Crore for various social & welfare activities of the nearby society. Over

and above company resources has also been deployed for improving society & welfare programs. Apart

from providing suitable employment for local populations, the key focus of Jindal Saw social & welfare

activities are

- Improving hygiene & sanitary conditions, Drinking water

- Green Belts development & Society parks

- Medical facilities & health awareness

- Education promotion & support- Support for natural calamities & emergencies

- Religious & Cultural activities support, Fodder for animals

Jindal Saw Ltd. has taken an initiative for maintenance of community parks. Presently, more than 80 parks are

being maintained by Jindal Saw Ltd. In addition to that to maintain hygiene and healthy environment in and

around the city, Jindal Saw has also taken a task for community drainage maintenance.


Jindal Saw ltd works meticulously for the development of schools in villages around the plant. Contribution

has been made towards construction of boundary wall to Government High School in Dhulkhera village,

sponsorship cost for celebrating republic day in Sophia Senior Secondary School, Bhilwara.

Jindal Saw ltd has also undertaken focused initiative for social & religious development, sports & cultural

activities, disaster relief and women welfare in & around villages. Contribution has been made to Vishwa

Hindu Parishad towards the sponsorship for the Tailoring Training Centre for Ladies. Contribution has also

been made to Shree Anand Krishna Gaushala Sewa Samity, Suras village, for providing Fodder to Cattles and

to Sidhudhuni Hathipada Ashram, Pur village, as Sponsorship towards the procurement of Cement Bags for

the construction of temple. Jindal Saw has also contributed in sponsorship towards marriages in the villages,

drinking water facilities and higher education.

Jindal saw ltd. has taken up a cause of health care with considerable commitment and focus. Jindal saw

organized a number of voluntary activities within the area of community health. Regular blood donation

drives are organized at plant site, witnessing enthusiastic participation by Jindalites. Occupational Health

Surveillance Camp was also organized for general health check up and disseminating information on

health care.

Apart from these, a multipurpose Fire Tender is available with trained staff round the clock for attending any

type of fire emergency call in and around the plant site.

Jindal Saw Ltd. constantly strives to move beyond regulatory standards and do more. Jindal Saw is now

building on community development to create a sustainable framework that allows Jindal plant to amplify the

positive impact they have.

In future these social & welfare activities will be continued and few new initiatives like Girl Education, Skill

development & industrial training and Sports promotion etc will be added. In order to access need of nearby

population a systematic “Need Assessment Studies” will be undertaken with help of reputed institutes

and local Government bodies.

CORPORATE SOCIAL RESPONSIBILITY

Along with being a successful Business entity JINDAL SAW LTD. has an active sense of social

responsibility. As a Leading transnational, The Company is committed to be a good corporate citizen wherever

the company is engaged in business activities and interests. The company’s Corporate SocialResponsibility Programme voluntarily integrates Social and Environmental concerns into their operations.


As a responsible corporate entity JINDAL SAW LTD. shoulders many responsibilities.

To work in tandem with the environment without upsetting the ever-fragile eco-system is our philosophy.

Strict environment management systems for air, water, and waste treatment in and around the plants ensure

stringent procedures and international compliances. The organization attempts to give its workforce a quality

life, hazard free working environment, and drive them to a higher standard of living by providing them access

to amenities like housing, transportation, medical facilities, schools, and other civic infrastructure. As part of

community service, JINDAL SAW LTD. has adopted many villages surrounding the plants. Active

volunteers from the organization undertake regularly literacy drives; organize free health camps, mobile eye-

care units and are continuously striving to make these villages independent and progressive.

For JINDAL SAW LTD. high-quality products and services are inseparably bound with our obligation to

society and environment. “Indeed adding value to all our businesses”.

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