project execution byenvironmentclearance.nic.in/writereaddata/... · report for product mix...

Rashmi Cement Limited Amendment of Environment Clearance File No-J-11011/604/2008.I A II(I) dated 12.02.2009 for product mix inclusion of Ferro Chrome due to unprecedented recessionary condition at village – Jitusole, P.O – Garhsalboni, P.S – Jhargram, District: Paschim Medinipur, W.B.

PROJECT REPORTS

FOR

AMENDMENT IN EC (PRODUCT MIX) INCLUSION OF FERRO CHROME IN

COMBINATION OF FERRO ALLOY

AT

VILLAGE-JITUSOLE, P.O – GARHSALBONI, P.S – JHARGRAM

DISTRICT – WEST MEDINIPUR, WEST BENGAL

Ref: EC File No-J-11011/604/2008.I A II (I)

Expansion of Sponge Iron Plant (3, 00,000 MTPA to 6, 00,000 MTPA), Ferro Alloy

(72000 MTPA)

Project Execution By

RASHMI CEMENT LIMITED

PREMLATA BUILDING, 6thFLOOR 39, SHAKESPEARE SARANI, KOLKATA – 700 017

WEST BENGAL Ph No.–033 – 22894255/56


CONTENTS

Page No.

Chapter -1 -Executive Summary

1.0- Introduction 01

Chapter -2 –Brief Description


2.1- Present Project 07

2.2- Market Demand 08

2.3- Need for the Project 11

2.4- Demand Supply Gap 11

2.5- Process Concept 16

Chapter -3 – Detail of Plant Operation


3.2- Production Process for Sponge Iron & WHRB based CPP 26

3.3- Production Process for Ferro Alloy Plant 28

Chapter -4 – Existing Pollution Control Facility

4.1- Detail 34

Chapter -5 – Environment Management Plan of RCL

5.1- Air Pollution Management 38

5.2- Noise Pollution Management 40

5.3- Solid Waste Management 41

5.4- Water Pollution Management 41

5.5- Occupational Health Management Plan 42

5.6- Green Belt Development Plan 44

5.7- Rain Water Development Plan 45

5.8- Monitoring Scheme 45


Page No.

Chapter -6– Comparative Statement (Ferro Alloy & Ferro Chrome)


Chapter -7–Conclusion

7.1- Detail 48

Annexure-I- Plant layout

Annexure-II- Existing Green Belt Pictures of RCL

Annexure-III- Rain Water Harvesting Pictures

Annexure-IV- Consent to Operate & Establish Certificate from WBPCB

Annexure- V- Environment Clearance Certificate

Annexure-IV- Analysis Report of RCL.


Report for product mix (inclusion of Ferro Chrome) in combination of Ferro Alloy by using 6 x9 MVA SEAF Page 1

1. Executive Summary

M/s Rashmi Cement Limited presently comprises of two units - Rashmi Cement Limited

(Steel & Power Division) and Rashmi Cement Limited (Cement Division), in Eastern

India leading Sponge Iron, Cement producer. The plants are situated at JANGAL MAHAL

AREA and its registered Office at Raghunathpur, Jhargram, West Medinipur, West Bengal

and corporate office is at Premlata Building, 6th Floor, 39-Shakespeare Sarani, Kolkata –

700 017 in West Bengal.

Project detail:

Expansion of Sponge Iron Plant (3, 00,000 MTPA to 6, 00,000 MTPA), Ferro Alloy (72000

MTPA) at Village- Jitusole, P.O-Garhsalboni, P.S- Jhargram, District- Paschim Mednipur,

West Bengal

Environment Clearance detail:

RCL has already obtained EC on 12.02.2009 vide File No--J-11011/604/2008.I A II (I) & on

4th Meeting of Expert Appraisal Committee of Industrial-I Sector Project held on 25th-26th

February 2016 in the MoEF, New Delhi got extension of the validity of environment

clearance for another 3 years i.e. up to 11th-Feburary 2019

Pollution Clearance (‘CONSENT’ to Establish & Operate) detail:

We have obtained Consent to Establish from West Bengal Pollution control Board for 5

x100 TPD DRI vide NOC No-57706 vide memo No-65-2N-46/2007(E) 28.04.2008 and

further for 4 x 100 TPD + 2 x 350 TPD DRI and 6 x 9 MVA Ferro Alloy vide NOC-61742 vide

memo No- 231-2N—46/2007 (E)-PART-I dated 20.04.2009 & Consent to Operate FOR



Sponge Iron Plant with WHRB vide CFO No- 45925 dated 24.09.2009 for 10 x 100 TPD DRI

& CO-58671 dated 18.04.2011 for 18 MW WHRB based CPP; CO-74148 dated -07.08.2015

for 1 X 350 TPD with 10 MW WHRB.

Consent to Operate is issued by West Bengal Pollution control Board for 2 x 9 MVA Ferro

Alloy Plant vides CO-16841; dated 13.02.2012 & CO-16855 dated 28.01.2013.

The validity of Consent to Operate for the complete plant issued vide Memo No 650-

128/WBP (HRO)-K/ 2003(Pt-I); dated 02.11.2015 & Memo No-5443-hl—CO-5/10/0399

dated 27.06.2016 is valid up-to December 2016.

Pollution Control System detail:



We have a full-fledge Pollution Control System installed at our Plant in order to meet the

emission level less than 100 mg/Nm3 as per approval.

2 x 9 MVA SAEF are provided with fume extraction system and pollution control system

consisting of spark Arrester, Gas collar, internal ducting, and butter fly valves, dust

conveyor, ID Fan etc. The SEAF are provided with stack of height 30 meters from ground

level. Stack emission are monitored at regular interval. Copy of Analysis report enclosed as

Annexure-VI.

Present Proposal:

Due to sever and difficult market condition in domestic as well as international market and

in order to make our project viable and operational, the management is planning to

produce High Carbon Ferro Chrome subject to your approval . The proposed proposal is

amendment in EC awarded (product mix) by inclusion of Ferro Chrome (additional

product) in combination of Ferro Alloy by using 6 x 9 MVA Submerged Electric Arc

Furnace



2. Brief Description

2.0 Introduction

M/s Rashmi Cement Limited presently comprises of two units - Rashmi Cement

Limited (Steel & Power Division) and Rashmi Cement Limited (Cement Division), in

Eastern India leading Sponge Iron, Cement producer. The plants are situated at JANGAL

MAHAL AREA and its registered Office at Raghunathpur, Jhargram, West Medinipur,

West Bengal and corporate office is at Premlata Building, 6th Floor, 39-Shakespeare

Sarani, Kolkata – 700 017 in West Bengal.

Rashmi Group founded in 1966 really got impetus from its real promoter, a true

visionary, Sri. Sajjan Kumar Patwari. Rashmi Group of companies is a fast growing

Group in the field of manufacturing steel and cement. The company has developed core

competence in minerals, steel and cement with 40 years of experience. The Group’s

turnover is around Rs.2100.0 Crores and net worth is Rs.2139.0 Crores. Rashmi Group

awarded ‘Ultra Mega Project’ status by Govt. of West Bengal. The Group is also engaged

in import/export of Mineral & Mineral based products. The growth of the group during

last few years has been phenomenal and fast catching the attention of bankers,

professionals and industry as a whole.

RCL has already obtained EC on 12.02.2009 for Expansion of Sponge Iron Plant (3, 00,000

MTPA to 6, 00,000 MTPA), Ferro Alloy (72000 MTPA) at Village- Jitusole, P.O-

Garhsalboni, P.S- Jhargram, District- Paschim Mednipur, West Bengal vide File No--J-



11011/604/2008.I A II (I) & on 4th Meeting of Expert Appraisal Committee of Industrial-I

Sector Project held on 25th-26th February 2016 in the MoEF, New Delhi got extension of

the validity of environment clearance for another 3 years i.e. up to 11th-Feburary 2019.

Copy of EC Enclosed as Annexure-IV. The project Cost is Rs 220 Crores and land area

requirement 120 Acres. The detail about EC obtained is as mentioned in Table-2.1

Table-2.1

M/s Rashmi Cement Limited at present operating DRI Plant (10 x 100 TPD + 1 x 350 TPD)

and producing 0.39MTPA Sponge Iron with 28 MW WHRB based Captive Power Plant

along with 2 x 9 MVA SEAF for production of 0.24MTPA Ferro Alloy (FeMn, FeSi, SiMn) at

village - Jitusole, P.O. Garhsalboni, P.S-Jhargram, District Paschim Mednipur in West

Bengal after obtaining necessary Consent (Operate & Establish) from West Bengal

Pollution Control Board.

Current Status of the implementation of the project mentioned in Table-2.2



Table-2.2

Rashmi Group is going to set up another 1.0 million TPA Steel Plant and 200 MW power

plant at Jamuria, Dist.-Burdwan in West Bengal by the name of Rashmi Cement Limited,

for this MOEF, Delhi has already issued the Environmental Clearance (File No. J -

11011/112/2010-IA II (I)) dated 26th August 2014.

Due to the unprecedented recessionary condition the prices of Ferro Alloys namely Silico

Manganese, Ferro Manganese and Ferro Silicon have come down to record low level, and

it’s not viable to operate. Now most of the plants in India are closed and some are at the

verge of closure. We have made a study and also contacted our overseas buyers who are

willing to take High Carbon Ferro Chrome from us on regular basis and on long term

lease. With this arrangement the management has decided inclusion of Ferro Chrome

(additional product) in combination of Ferro Alloy by using 6 x 9 MVA Submerged

Electric Arc Furnace for which EC already being awarded at the existing premises at



Village- Jitusole J.L. No- 702 & 703, Jitusole Junglekhas J.L. No-731 & Baghmundi J.L. No-

928, P.O- Garhsalboni, P.S.-Jhargram, Dist. Paschmi Mednipur in West Bengal.

2.1 Present Project

Due to sever and difficult market condition in domestic as well as international market and

in order to make our project viable and operational, the management is planning to

produce High Carbon Ferro Chrome subject to your approval . The proposed proposal

(product mix) inclusion of Ferro Chrome (additional product) in combination of Ferro

Alloy by using 6 x 9 MVA Submerged Electric Arc Furnace for which EC already being

awarded vide File No- J-11011/604/2008.I A II (I) dated 12.02.2009 at the existing

premises at Village- Jitusole J.L. No- 702 & 703, Jitusole Junglekhas J.L. No-731 &

Baghmundi J.L. No-928, P.O- Garhsalboni, P.S.-Jhargram, Dist. Paschmi Mednipur in West

Bengal for following reason:

Easy availability of raw material

Close to high growth of Steel Billets markets for secondary steel making process in

small scale foundries

10-15% less gas emission in case of Ferro Chrome production.

Using the Eco-friendly clean Technology

Economies of scale will result in lower operating cost

Offers freight advantage vis-à-vis competitors

The markets in the East & North-East are potential territories for non structural steel

products & offer great opportunity to infrastructures market, which is well accepted in

other parts of the country.



2.2 Market Demand

India’s steel production capacity is going to increase manifold in the coming years. The per

capita consumption of steel is only 49 kg in our country compared to world average of 182

kg. In addition various steps have been taken to increase domestic steel consumption. India

is the 5th largest crude steel producer in the world and is expected to become the second

largest by 2015-16.

India continues to maintain its lead position as the world's largest producer of direct

reduced iron (DRI) or sponge iron during January-December 2010. 222 MoUs have been

signed with various States for planned capacity of around 276 million tonne. In order to

have product flexibility keeping in view the demand supply scenario and contribution the

company will use the same facility fully or partially to manufacture Ferro Alloys like High

Carbon Ferro Chrome, Ferro Manganese and Silico Manganese, etc.

Demand: Global production of Stainless steel, which consumes about 95% of chrome ore,

increased from 24.3 MMT in 2005 to 28.4 MMT in 2006, due to which the demand for

ferrochrome during this period grew from 7.0 MMT to 7.5 MMT. Due to the global recession

stainless steel production further declined to 24.6 MMT by 2008 resulting in a lower

consumption of ferrochrome to 6.8 MMT in 2008. Demand for ferrochrome during 2005-09

grew at a CAGR (Compound Annual Growth Rate) of 3.4%. But stainless steel has shown

recovery in 2009 with increase in production quantities quarter-to-quarter and has

improved the global demand scenario.



Supply: Global installed capacity of ferrochrome stood at about 9.8 MMTPA during 2009,

with an average utilization of 60% during the same period at 5.8 MMT. It is to be noted that

despite sustained levels of stainless steel production in 2009, the overall ferrochrome

production was lower due to the import restrictions in China during last quarter of 2009.

Compared to growing imports by China, on the other hand, coincidentally South Africa - the

largest producer of ferrochrome, has been facing power supply shortage in the recent

years, resulting in stagnant production capabilities. Hence it is compelled to export un-

beneficiated chrome ore resulting in a geographical shift in global demand and supply

scenario of ferrochrome. The global chrome ore reserves are about 11 billion tonnes

against which about 24.4 million tonnes have been extracted. Globally South Africa,

Zimbabwe and Kazakhstan account for more than 95% of ore reserves and hence those

countries became the highest producers of ferrochrome globally. Also India’s increase in

export duty of chrome ore has led to focus on indigenous ferrochrome production, which

shall boost the requirement in capacity enhancement in India.

Demand-Supply Gap: Looking at the scenario in the year 2009, it is noted that there was a

supply deficit as the demand was 6.7 MMT against the supply of 5.8 MMT. This shortfall

was made up through normalizing the inventory levels which had increased, due to stock

pileups in 2007 and 2008. Hence there is a demand-supply mismatch which needs to be

addressed in the global market.

Domestic Scenario- HC Ferro Chrome: Domestic demand for ferrochrome stood at about

0.54 MMT during 2009-10. Domestic demand for ferrochrome witnessed a CAGR of about



5.14 % during 2005-10. According to IFAPA Ferrochrome contributes 40% to total Ferro

Alloys demand.

Supply: Although the licensed capacity of chromium alloys plants is 1.30 MMTPA, the

active operational plants account for 1.06 MMTPA of installed capacity as of 2009-10.

Considering this capacity, the capacity utilization was around 75% during 2009-10.

Production stood at 0.79 MMTPA out of which 0.50 MMT was exported during 2009-10.

The net domestic supply considering imports was around 0.4 MMTPA.

Ferrochrome trade: India’s exports of ferrochrome have shown an increasing trend over

the recent years and the quantities are quite large in comparison to the imports.

Conclusion:

Global Demand of Ferrochrome was estimated at 6.7 MMT during 2009.

Global installed capacity of Ferrochrome stood at about 9.8 MMTPA during 2009

with a capacity utilization of 60%.

Global scenario indicates clearance of earlier piled up inventories due to which the

supply (6.74 MMT) was more than the production (5.83 MMT) in 2009. At this

juncture, with revival in Stainless Steel Industry, new additions may be envisaged

globally.

The global industry dynamics pose a gradual shift in production bases, with power

shortages in South Africa and imposition of higher export duties in few other

countries. Domestic demand for Ferrochrome stood at about 0.54 MMT during

2009-10.



Installed capacity of chromium alloys during 2009-10 was 1.06 MMTPA. Industry

witnessed an average capacity utilization of 75% during 2009-10.

Exports play a major role in India’s ferrochrome industry with 0.5 MMT against the

0.79 MMT productions going towards export.

2.3 Need For the Project and Its Importance to the Country and/or Region.

& 2.4 Demand- Supply Gap

Performance of the HC Ferrochrome is directly linked with the performance of its major

end user - Stainless Steel industry. A brief overview of the market for stainless steel has

been presented in this section.

Global Stainless Steel Industry: Against growing competition from alternative materials

like aluminium and plastics, stainless steel remains the only choice where corrosion

resistance properties are required. As production of stainless steel is dependent on

ferrochrome the need for ferrochrome has grown in tandem with the demand for stainless

steel. The signs of recovery in global economy, and the drop in the current inventory levels,

will optimistically improve the utilization levels of stainless steel and consequently

ferrochrome producers and also led to augmentation of capacities. This industry is cyclical

in nature and has indicated peaks and troughs over a period of every 3-4 years. It is

expected that as compared to the stainless steel production levels in 2008 and 2009,

stainless steel production shall grow at a CAGR of 7% during 2010-18.



Alloy Steel: Both, domestic demand and production of alloy steel have improved owing to

rapid industrialization and development of high technology industries. Some of the major

demand drivers for stainless steels are –

Upcoming projects in chemicals, petrochemicals and oil and gas.

Boom in infrastructure sector including housing.

Increased per capita income leading to higher demand for steel in household sector.

Taking a conservative approach, it anticipates a growth rate of 8% during 2010-18 for

Alloys Steel.

Global HC Ferro Chrome Demand: Based on the projected performance of end-user

segment, the HC Ferrochrome growth rate has been computed. A conservative approach

has been taken for estimating the demand of Ferrochrome. Table No.2.3 represents the

projected growth rate of Ferro chrome during 2010-18.

TABLE-2.3



Supply: As per the secondary sources, a capacity addition of 0.8 MMT is envisaged in HC

Ferrochrome segment. Based on the discussions carried out in the earlier sections, it is

apparent that Ferrochrome production is significantly driven by the production of its key

end-users.

Projected Demand-Supply: The detailed demand – supply gap in the Global HC Ferro

Chrome market during 2010-20 is indicated in the Table No. 2.4.

TABLE-2.4

From the above table the following have been concluded.

The demand for Ferrochrome is projected to grow at a CAGR of 7% during 2010-20

and is likely to reach 16.8 MMT by 2020.

Supply indicated above is arrived at a production capacity of 10.84 million by 2013

and an average utilization of 80%.

Timely capacity additions likely to take charge of the improving demand.



Regulatory constraints for Ore exports and power infrastructure constraints in

some global regions will lead to better export opportunities for India which shall led

to capacity enhancements.

Domestic Demand: Based on performance of end-user sectors, the growth rate of HC

Ferro Chrome has been tabulated. The Table No. 2.5 represents the projected growth rate

of Ferro Chrome for the period 2010-18.

TABLE-2.5

From the Table No. 03, the followings have been noted down;

Demand for HC Ferro Chrome in India is significantly driven by demand in stainless

steel industry.

HC Ferrochrome market is projected to grow at a CAGR of 7% during 2010-18

As mentioned earlier, South African Ferrochrome industry is facing power supply

shortfall and has envisaged power capacity enhancements, but this would take

about 3-4 years. Also as India’s ore exports will be restricted, more ore would be

available for domestic production of on ferroalloys.



Projected Demand- Supply Gap: The detailed demand-supply gap in the domestic HC

Ferro Chrome market during 2010-21 is indicated in the in the Table No. 2.6.

TABLE-2.6

.

From the above table the followings have been concluded;

The demand supply gap during the first three years is considered at 75% utilization

levels. This scenario is expected to change in the subsequent years due to increased

demand for stainless steel in domestic as well as export markets.

The demand of HC Ferro Chrome likely to reach 1.14 MMT by 2021.

The gap is likely to increase from 0.19 MMT in 2010-11 to 0.95 MMT by 2020-21.

Timely capacity additions likely to take charge of the improving demand capacity

enhancements and will facilitate export opportunity for Ferro chrome producers.



Conclusions:

Global HC Ferro Chrome demand is projected to grow at a CAGR of 7.00% during

2010-20.

The global demand of HC Ferro Chrome likely to reach 16.8 MMT by 2020.

Domestic HC Ferro Chrome demand is projected to grow at a CAGR of 7% during

2010-21.

Capacity additions of about 0.1 MMT are on the anvil. The domestic demand of HC

Ferrochrome is likely to reach 1.14 MMT by 2021.

Since the demand-supply gap likely to emerge only from 2013-14 onwards, the

proponent has to keenly focus on export market for sale of major portion of HC

Ferrochrome production prior to this period.

This proposal inclusion of Ferro Chrome (additional product) in combination of Ferro Alloy

by using 6 x 9 MVA Submerged Electric Arc Furnace for which EC already being awarded at

the existing premises by the name of RASHMI CEMENT LIMITED at Village- Jitusole J.L. No-

702 & 703, Jitusole Junglekhas J.L. No-731 & Baghmundi J.L. No-928, P.O- Garhsalboni, P.S.-

Jhargram, Dist. Paschmi Mednipur in West Bengal shall be partially fulfilling the supply

demand gap.

2.5 PROCESS CONCEPT & TECHNOLOGY

Ferro Alloys- Alternatives Processes Ferro Alloys with different base elements can be

manufactured by adopting alternate technologies, which vary primarily with respect to

type of furnace used. The generally used furnace types for different ferroalloys are:



Submerged electric arc furnace (SAF)

Exothermic (metallo-thermic) reaction furnace and

Electrolytic cell

As per industry best practices, it is noted that SAF is the most suitable route for production

of High Carbon Ferrochrome (HCFC) and Rashmi Cement Limited have adopted this

technology and have got EC for 6 x 9 MVA SAF for 0.72 MTPA Ferro Alloy production , as it

is relatively more economical as compared to the other processes.

Submerged Electric Arc Furnace

Smelting in an electric arc furnace is accomplished by conversion of electrical energy to

heat. An alternate current applied to the electrodes causes’ current to flow through the

charge between the tips of the electrodes. This provides a reaction zone at temperatures up

to 2000ºC. The tip of each electrode changes polarity continuously as the alternating

current flows between the tips. To maintain a uniform electric load, electrode depth is

continuously varied atomically by mechanical or hydraulic means. The lower part of the

SAF is composed of a cylindrical steel shell with a flat bottom or hearth. The interior of the

shell is lined with two or more layers of carbon black. The furnace shell is water cooled to

protect it from process heat. A water-cooled cover and fume collection hood are mounted

over the furnace shell. Normally, three carbon electrodes arranged in a triangular

formation, extend through the cover and into the furnace shell opening. Prebaked or self-

baking (Soderberg) electrodes ranging from 76 to over 100 centimetres (30 to over 40

inches) in diameter are typically used. Raw materials are sometimes charged to the furnace



through feed chutes from above the furnace. The surface of the furnace charge, which

contains both molten material and unconverted charge during operation, is typically

maintained near the top of the furnace shell. The lower ends of the electrodes are

maintained at about 1 to 2 meters (3 to 7 feet) below the charge surface. The schematic

picture of Submerged Arc Furnace is given below in Diagram No. 01.

FERRO CHROME PRODUCTION PROCESS:

The chemistry behind the process is:

Cr2O3 + Fe2O3 + C = FeCr + CO2

(Chrome Ore + Carbon Reductants = Ferro Chrome + Carbon Dioxide Gas)

Charging: The reactants consist of metallic (chrome) ore and a carbon-source reducing

agent, usually in the form of coke, low-volatility coal or wood chips. Limestone may also be

added as a flux material. Raw materials are crushed, sized, and some cases, dried, and then



conveyed to a mix house for weighing and blending. Conveyors, buckets, skip hoists, or cars

transport the processed material to hoppers above the furnace. The mix is then gravity-fed

through a feed chute either continuously or intermittently, as needed.

Smelting: Three-phase electric current arcs are formed from electrode to electrode

through the charge material. Power is applied continuously. The carbonaceous and reduces

them to base metals. The reactions produce large quantities of carbon monoxide (CO),

which passes upward through the furnace charge. In the further reaction, this carbon

monoxide gets converted into carbon dioxide (CO2). Feed materials may be charged

continuously or intermittently.

Tapping / Pouring: The molten metal and slag are released through a tapping process.

One or more tap holes extending through the furnace shell at the hearth level. Tap holes are

opened with pellet shot from a gun, by drilling or by oxygen lancing. The molten metal and

slag flow from the tap hole into a carbon-lined trough, then into a carbon-lined runner

which directs the metal and slag into a ladle, ingot moulds, or chills (chills are low, flat, iron

or steel pans that provide rapid cooling of the molten metal). Tapping is generally an

intermittent process based on production rate of the furnace and may vary between 1-5

hour intervals. Tapping typically lasts 10 to 15 minutes. In some cases, tapping is done

continuously. After tapping is completed the furnace is resealed by inserting a carbon paste

plug into tap hole. Chemistry adjustments may be necessary after furnace smelting to

achieve a specified product. During tapping, slag is skimmed from the surface of the molten

metal and the metal is transferred to the ladles for pouring into moulds. The slag can be



disposed of in landfills, or used as a raw material in a furnace to produce a chemically

related some ferroalloy product. Tapping and post tapping operations can be carried out

using a mechanized system, which supports following processes:

Tap hole installation at proper locations and with refractory lining around tap holes.

This helps in ease in repair of tap hole and more suitable tapping platform.

Drilling to tap hole prior to oxygen lancing using a Drilling machine.

Closing of the tap hole using a Mud gun.

Receptacles of floating slag on hot metal prior to casting.

Casting of alloy in safe, economical and environmentally acceptable manner

achieving compact structure or metal. This can be achieved by using variable speed

casting machine and water showers for metal solidification.

Product car tub.

Crushing, sizing and handling of finished product.



After cooling and solidifying, the large ferroalloy castings may be broken with drop weights

or hammers. The broken ferroalloy pieces are then crushed, screened (sized) and stored in

bins until dispatch. In some instances, the alloys are stored in lump form in inventories

prior to sizing for dispatch.

Table 2.7-Materials Balanced For the Product Mix for which amendment in EC is being applied

Name of the Input Materials

Quantity input in (TPA)

Name of the output Materials

Quantity output in (TPA)

Chromium Ore (@2.2 t/t)

1,58,400 Ferro Chrome 72000

Coke (@0.65 t/t) 46,800 Slag 24,800

Coal (@0.25 t/t) 18,000 Dust 2500

Dolomite (@0.03 t/t)

2,160 LOI 1,44,060

Quartzite (@0.25 t/t)

18,000

Total 2,43,360 2,43,360



Table-2.8 Raw Materials Requirement Detail

Sr. No. Raw material Requirement, TPA *

Source Mode of transport (from

source to

plant)

1. Chrome Ore 1,58,400 Orissa, Jharkhand etc. Rail / Road

2. Quartzite 18,000 From Belpahar Orissa / /

Bilaspur, Raipur CG

Rail / Road

3. Dolomite 2,160 From Belpahar Orissa / / Bilaspur, Raipur CG

Road /Rail

4. Coal/Coke** 18,000/ 46,800

Purchased from BCCL, Dhanbad Alternate source: Imported

Rail/ Road/Ship

FERRO ALLOY PRODUCTION PROCESS:

The chemistry behind the process is:

MnO2 + SiO2 + Fe2O3 + C = Fe Si Mn + CO2

(Mn Ore + Quartz+ Carbon Reductants = Ferro Silico Manganese + Co2 Gas)

Ferromanganese or ferrosilicon is used to make various grades of

stainless steel. The process comprises continuous smelting of manganese

ore, coke and coal and quartz in smelting electric furnace (Submerged Arc

Furnace - SAF) 72000 TPA ferroalloys will/are be produced from the 6 x 9

MVA furnace. During smelting operations, solid charge like ore, coal and

quartz are transformed into liquid form as metal and slag. The raw materials

are taken in required proportion, conveyed to the top of SAF and charged

into the furnace through charging bins and tubes. The temperature of the

furnace is maintained at 1250 deg C. After sufficient liquid metal and slag



are formed, liquid metal and slag are tapped from separate doors. The

liquid metal is allowed to cool in the cast iron mould. The solid metal is

manually sized to desired size as per specifications of the customer and

dispatched through trucks after weighing and bagging. The slag is allowed

to cool and then used for road making, etc.

Table 2.9-Materials Balanced For the Project for which EC is being obtained

Name of the Input Materials

Quantity input in (TPA)

Name of the output Materials

Quantity output in (TPA)

Manganese Ore (@2.6 t/t)

1,87,200 Ferro Silico Ferro Manganese Silico Manganese

72000

Coke (@0.65 t/t) 46,800 Slag 27,600

Coal (@0.25 t/t) 18,000 Dust 2550

Dolomite (@0.03 t/t)

2,160 LOI 1,70,010

Quartzite (@0.25 t/t)

18,000

Total 2,72,160 2,72,160

Table-2.10 Raw Materials Requirement Detail

Sr. No. Raw material Requirement,

TPA *

Source Mode of

transport (from source to

plant)

1. Manganese Ore

1,87,200 Captive mines in Balaghat, MP

Rail / Road

2. Quartzite 18,000 From Belpahar Orissa / / Bilaspur, Raipur CG

Rail / Road

3. Dolomite 2,160 From Belpahar Orissa / / Bilaspur, Raipur CG

Road /Rail

4. Coal/Coke** 18,000/ 46,800

Purchased from BCCL, Dhanbad Alternate source: Imported

Rail/ Road/Ship

The Power consumption for Ferro Alloy & Ferro Chrome is 4000 KWH/MT.



The process flow of existing ferroalloy plant is given below



3. Detail of Plant Operation

3.1 Introduction:

RCL has already obtained EC on 12.02.2009 for Expansion of Sponge Iron Plant (3, 00,000

MTPA to 6, 00,000 MTPA), Ferro Alloy (72000 MTPA) at Village- Jitusole, P.O-

Garhsalboni, P.S- Jhargram, District- Paschim Mednipur, West Bengal vide File No--J-

11011/604/2008.I A II (I) & on 4th Meeting of Expert Appraisal Committee of Industrial-I

Sector Project held on 25th-26th February 2016 in the MoEF, New Delhi got extension of

the validity of environment clearance for another 3 years i.e. up to 11th-Feburary

2019.The project Cost is Rs 220 Crores and land area requirement 120 Acres. The detail

about EC obtained is as mentioned in Table-1

Table-3.1


and producing 0.39MTPA Sponge Iron with 28 MW WHRB based Captive Power Plant along

with 2 x 9 MVA SEAF for production of 0.24MTPA Ferro Alloy (FeMn, FeSi, SiMn) at village -



Jitusole, P.O. Garhsalboni, P.S-Jhargram, District Paschim Mednipur in West Bengal after

obtaining necessary Consent (Operate & Establish) from West Bengal Pollution Control

Board. The consent Detail are enclosed as Annexure-III.

Current Status of the implementation of the project mentioned in Table-2

Table-3.2

3.2 Production Process For Sponge Iron Plant & WHRB based CPP

Direct-reduced iron (DRI), also called sponge iron is produced from

direct reduction of iron ore (in the form of lumps, pellets or fines) by a reducing gas

produced from natural gas or coal. ‘Reduced iron’ derives its name from the chemical

change that iron ore undergoes when it is heated in a furnace at high temperatures in the

presence of hydrocarbon-rich gasses. Direct reduction refers to processes which reduce

iron oxides to metallic iron below the melting point of iron. The product of such solid

state processes are called direct reduced iron.

https://en.wikipedia.org/wiki/Reduction_(chemistry)

https://en.wikipedia.org/wiki/Iron_ore

https://en.wikipedia.org/wiki/Natural_gas




and producing 0.39MTPA Sponge Iron by using Popuri Technology with 28 MW WHRB. The

process flow diagram is given below

Waste gases generated from rotary kiln contain carbon monoxide and other volatile

matter which after combusted releases significant heat. This heat contains

significant calorific value (GCV of mixed fuel - about 2300 kcal/Nm3). This heat will be

used to produce steam through Waste Heat Recovery Boilers. The high pressure steam

will be used to run turbines and generate 28 MW electricity. Capacity of WHRB

attached with 10 DRI of 100 TPD based WHRB (10 Nos.) are 10

TPH, 108 ata and 520oC and with one no 350 TPD DRI is 39 TPH.



3.3 Production Process For Ferro Alloy Plant

High Carbon Ferro Manganese: Is made in the three phase open or closed top furnace of a

power of 7.500-16.500 kva at a linear voltage of 120-130 V with current of 33-38 KA with

electrodes 900-1150 mm in diameter operating at a voltage o 120-130 V. The Hearth and

walls of the furnace are lined Carbon bricks and with fire clay bricks.

The charge of making high-carbon Ferro-Manganese may be composed of Manganese Ore

coke breeze and dolomite.

Physio-Chemical Condition of the process; High carbon Ferro-manganese is smelted by a

continuous process with the electrodes submerged deep into the charge.

The reducing condition in the furnace ensures that phosphorus to be reduced almost fully.

The acid slag cannot absorb phosphorus, which is removed with furnace gases and 75-80

percent passes to the alloy.

A great part of electric energy is lost in the slag, which raise the temperature of the slag

above that of the metal. The mass of the manganese ore in the batch is establish at 500-700

and the amount coke breeze and dolomite are taken accordingly to a charging table which

specifies. The composition of the manganese ore and the moister content ore, dolomite and

coke breeze.

Mixed charge is delivered to the furnace bays along nine charging chutes. Three chutes

serve to deliver the charge to spaces between the electrodes. Charging is done periodically



to alloy the previous charge settle t the top, to move down, with normal run of the furnace,

yellow flame shoots evenly all over the surface of the furnace top.

The following measures are essential to maintain the top in normal condition:

a) The charge should always have the specified composition;

b) The charge should be given evenly to each phase electrode;

c) Consumption of electrical energy should strictly correspond to the number of units

charged. Without letting the top over heat.

d) Charge cones should be pierced periodically.

Disturbance in the furnace run may be caused by various factors. Most often they are linked

with an inappropriate consumption of the slag and with a deficiency or excess of reducer in

the charge. Each type of disturbance has quite typical external features: deep or shallow

position of the electrodes, an increase or decrease in slag viscosity an increase or decrease

in the content of the carbon or silicon, overheating or chilling of the top evolution of white

smoke at the electrodes, ejects of coke breeze, intense slag formation of slag at the

electrodes etc.

Electrodes are slipped every shift or sometimes twice a day. The metal and slag are tapped

simultaneously three times a shift. During tapping the tap hole often poked with iron bar so

as to let out the metal and slag completely from the furnace. The tap hole packed with clay

as soon as metal and slag drain out.

The following process takes place when making high carbon Ferro-manganese:



a) Pre-heating of the materials

b) Drying and removal of volatiles and moisture from the charge and hearing of the

charge by the heat of burning gases which leave the furnace and after-burn at the

top.

c) Reduction of oxides.

d) Melting of the elements reduced with formation of molten Ferro-manganese;

e) Formation and melting slag;

f) Reduction of silicon from slag;

Melt procedure: As has been mentioned earlier, melt for high carbon Ferro-manganese is

carried out with the furnace top being closed. For a furnace of 8200 KW and 60 V, the

electrode depth is 900-1200 mm. In a melt for high carbon Ferro-manganese, slag is

formed in the hearth that is why there is single large pool of metal the electrodes, instead

of individual “pools” as in case the process for silicon alloys.

Hygroscopic moisture of the charge material is removed in 10-15 minutes upon charging,

while the volatile matters are run off in the temperature range of between 200-1000 deg.C.

The iron content in the manganese ore is reduced to a high extent in the process. Ferric

Oxide are reduced with carbon monoxide and hydrogen at 500-600 deg.C. temperature

and after that with solid carbon in the deeper zones of the bath.

The reduction of the manganese from pyrolusite occurs step wise: MnO2----Mn3O4----

MnO----Mn3C. With reducing atmosphere in the furnace, the dissociation of manganese



oxide can takes place at low temperature. Carbon monoxide and hydrogen can also reduce

Mn3O to MnO at low temperature.

High carbon Ferro manganese can be smelted with addition of fluxes or by flux less

process. In the latter cases, a valuable by product of the process is high manganese low

phosphorus lag which is used in smelting silico manganese and manganese metal.

HIGH CARBON SILICO MANGANESE: Is made in three phase open or closed top furnace of

a power of 5000-12000 Kva with electrodes 900-1150 mm in diameter, operating at a

voltage 90-160 V. The hearth of furnace is lined with carbon and fire clay bricks.

The charge of high carbon silico manganese is composed of manganese ore, quartz.

Dolomite and coke breeze.

Manganese ore is blended to equalize its particle size and composition. The size of lump is

usually not more than 80 mm. The amount of lumpy ore in the mixture should not be less

50 percent. A constant composition and uniform quality of manganese ore and quart

determine normal run of the furnace. The reducer may be graded coke breeze in lumps 10-

25 mm in size; it should contain not more than 0.5 percent sand 0.04 percent P.

Physio-Chemical Conditions of the process: The following processes take place when

making high carbon Silico manganese.

a) Removal of volatiles and moisture from the charge and hearing of charge by the heat

of burning gases which leave the furnace and burn at the top;

b) Reducing of iron and ores with simultaneous formation of metal carbides;



c) Melting of the elements reduced with the formation of molten metal;

d) Formation and melting of slag;

e) Reduction of Manganese and silicon from the slag.

Ferro Alloy Manufacturing Process

The Plant Layout of the Ferro Alloy Unit Enclosed As Annexure-I.

The Latitude is 22˚2′30″N & longitude is 87˚20′30″E and the elevation from main sea level

288 Ft of the plant.

The Google View of the plant is given as:



Existing Plant Pictures



4 Existing Pollution Control Facility

4.1 Detail

Air Pollution Control Measures for Existing Running Unit of RCL

Ferro Alloy Section

BAG HOUSE FOR SUB-MERGED ARC FURNACE

For this application, we are proposing to you a compartment type bag house having @ 8 to

10 compartments with filter bags per furnace or as per the vendors design, GERSPL will

prepare the detailed tender document for this pollution control system.

The flue gases from furnace are sucked through an interconnecting ductwork by induced

draft fan & exhaust to the chimney.



The gases first enter to heat Exchange at @ 250 to 300o C, where it is cooled down to 120

Deg. It also removes/extinguish the sparks if any. Cooled flue gases go to next equipment

i.e. Bag House & collected dust is discharged from bottom hopper through a Rotary Airlock

valve. Two Screw Conveyors are provided below all the bag house compartments with

Rotary Airlocks. The Dust from all compartments will be discharged in screw conveyor

through Rotary Airlock and can be collected in trolley.

Bag house is provided with inlet & outlet manifold duct for proper distribution of the gas.

The gas passes through the filter bags depositing the dust on the outside of the filter bags.

The dust is allowed to build up until it forms a dust cake. The filtration takes place with the

help of dust cake and filter media ensuring removal of fine particulates. The clean gas

exists through outlet manifold to exhaust fan and then to atmosphere through chimney.

The cleaning of filter bags will be OFF LINE, i.e. the compartment under the cleaning cycle

is an isolated using outlet pneumatic damper. Thus at any time one compartment is under

cleaning and the rest are in operation.

Pilot operated diaphragm valves controlled by solid-state sequential timers perform this

operation. A Master in turn operates the timers controller. The cleaning sequence is ON

DEMAND. If the pressure drop across the compartment exceeds a preset limit, it

automatically isolates the compartment by closing outlet pneumatic damper, triggers the

cleaning cycle and brings down the pressure drop. When pressure drop reaches lower set

point, the cleaning cycle stops. This method of ON DEMAND cleaning ensures optimum

cleaning and results into higher bag life and high filtration efficiencies.



The bag house has to be with inlet manual dampers and outlet pneumatic dampers for

isolation purpose. If any compartment is down for outline check up, maintenance or for

any other reason, the bag house can be still operated with other compartments.

The duct to inlet of the bag house will be fitted with RTD probes to detect and monitor the

temperature of flue gases. If the measured temperature at any point exceeds a set point

(i.e. beyond operating limit of the filter bag fabric), there is likely hood of damage to the

filter fabric. To avoid this situation, by pass pneumatic dampers must be provided with this

system. When higher temperature is sensed. It will immediately bypass the system by

automatically closing the damper in the inlet duct to heat Exchanger. Simultaneously it will

open the damper in the bypass duct, thereby bypassing the gases to the atmosphere.

BAG HOUSE FOR TAPPING OPERATION FUMES:

The fume exhaust hood with duct must provided around the furnace circumference to

capture the fumes generated during tapping operation. All the compartments will be in

operation at any time. The cleaning will be OFF LINE & will take place after tapping

operation is over. The cleaning cycle will be ON-DEMAND based on the pressure drop

across the Bag House. Each compartment is provided with manual inlet & automatic outlet

dampers for isolation purpose during maintenance/trouble shooting if any. Emission level

at the outlet of Bag house for furnace fumes & Tapping fumes must be less than 50

mg/Nm3.



Specification for Air Pollution Control Devices

It is pertinent to mention here that our existing 9 MVA Submerged Arc Furnace stack

connecting high efficiency Bag Filter (Air Pollution control Device) is quite capable to

handle the another 9 MVA Submerged Arc Furnace pollution load because our existing Bag

Filter designed 2.5 times higher from the single 9 MVA SEAF for managed the pollution

load. So, we will be used same Bag Filter for both 9MVA Sub Merged Electrical Arc Furness

and using same stack.

High efficiency Bag Filter System for cleaning the gas emission from 9MVA Submerged

Electrical Arc Furnace of low hood type, manufacturing bulk Ferro alloys like high carbon

Ferro Manganese/high carbon Ferro – silicon etc.

Stack Emission Details of the Existing Plant

Particle Size Distribution at the bottom of the Bag Filter

(** Above Percentage are taken by weight)



5 Environment Management Plant of RCL

Environment Management Plan (EMP) is the key to ensure a safe and clean

environment. A plan may have taken proper pollution control measures. A plan may

have taken proper pollution control measures but without a management plan to

assure its proper function, the desired results may not be obtained.

5.1 Air Pollution Management

Control of Point Emission:

i. EMP FOR DRI SECTION

Clean gases having less than 100 mg/Nm3 of dust content are exhausted

through a stack of height 60-35 m height.

Whenever Air pollution control systems fail, production in that unit will be stopped till

the problem in the air pollution control system is rectified.

ii. EMP FOR FERRO ALLOY SECTION Clean gases having less than 100 mg/Nm3 of dust content are exhausted

through a stack of height 35 m height.

Fugitive Emission Control:

All pollution control systems are connected to energy meters and the records are

maintained for run hours, failure time and efficiency.

Clean technologies/measures are implemented in the following way.

Flue gases are used for drying the Green pellet.

De-dusting is provided for product handling area.



Fugitive emissions are suppressed by using dust suppression system

Every possible effort is made to conserve the raw materials, energy and water

consumption to match with the international standards.

Good housekeeping practices are maintained

Raw Materials Handling Plant :

All vibrating screens are already covered to preventing the leakages of Dust

Dust suppression system is adopted to control the fugitive dust emanated during

extra quantity of raw materials unloading operations.

Raw Materials Storage system :

All discharge and feed points wherever the possibility of dust generation is there,

are provided with dust suppression system.

All material transfer points are connected with dust suppression water nozzles to

avoid the pollution

Feed system :

The raw material in the form of balls are fed into the Traveling grate through a

distribution screen, which seals the false air entry into the Traveling Grate and gas

leakage from the grate. The chutes are sealed with a double pendulum flap.

Travelling Grate :

Sealed system to avoid false air entry as well as exit. So that the desired quality can

be produced. So, there will not be any chance for pollution in this area

Rotary Kiln / Drum :



The transfer point between traveling grate to Roasting Unit is completely sealed to

avoid the false air entry and gas leakages.

Product Handling :

All conveyors are covered with G. I. Sheets, to control the dust emission.

All bins are totally packed and covered. So that there is no chance for dust

leakage.

Telescopic chutes are provided below the hopper to discharge the product

directly into the truck for dispatch to avoid the pollution.

All the above material handling systems are connected with de-dusting system

All discharge points and feed points wherever the possibility of dust generation

is there, a de-dusting suction point are provided to collect the dust.

The collected dust are taken by pneumatic conveying system and stored in a

dust storage bin.

5.2 Noise Pollution Management Plan

Noise is minimized through regular maintenance of equipment / machines. Low noise

generating equipment is being used for the plant. Proper vibration dampening

arrangement is being provided to minimize the noise generation. It is ensured that the

noise level at plant boundary compiles with the standards of 75 dB (A) during day time and

70 dB (A) during night time. The layout of the plant and greenbelt is designed

appropriately to achieve the standard. In other case enclosure or sheds is constructed.



Ear plugs / ear muffs are provided to personal working near high noise areas to ensure that

no plant personnel are over exposed. Sound absorbing material is provided in rooms where

both the noise source and plant personal is present so that the reflecting sound is absorbed

5.3 Solid Waste Management Plan

Solid Waste Utilization Detail of the Running Units

5.4 Water Pollution Management Plan

The equipment and machines that requires cooling water are grate machine, rotary kiln,

circular cooler, lubricating system of ball mill and air compressor. Circulating type system

is being used for the plant, which reduces the raw water requirement. The cooling water is

passed through cooling towers. Only make-up water (chlorinated with bleaching powder)

is added. Cooling tower blow down water is very less, which is taken to tank for storage.

This water will is reused for making green pellets (in the additive mixing section) and for



fire fighting. The entire wastewater from the plant is reused and there is no discharge of

wastewater outside the plant premises under normal circumstances.

5.5 Occupational Health Management Plan

Exposure problems to noise, dust, heat and gases are the main occupational hazards

identified in this project. Silicosis, Bronchitis and Noise induced hearing loss are the

occupational health hazards identified from the plant. Workers involved in raw material

handling activity, dust and ash handling are exposed to high dust levels. Workers working

near/ close to the furnaces are exposed to heat stress. Over a long period of time such

exposure is likely to result in respiratory problems and occupational health problems.

Engineering measures will be implemented to reduce the dust generation at the originating

point by installing appropriate control devices and / or regular water sprinkling.

Regular monitoring of work environment for humidity, heat, illumination, metal fumes,

gases, dust, etc is carried out and shall be done in near future also. Plant personnel working

in dust prone areas are encouraged to wear personnel protective equipment like air filters

over their nose.

Job rotation schemes are being practiced for over-exposed persons, including heat stress.

Proper illuminations are maintained at each and every nook and corner of the work places.

Regular advice is given to the workers through special campaigns and illustrations related

to safe work practices so that they do not develop any muscular strain or fatigue during

their work schedules.



It is ensured that workers are not exposed above the threshold noise levels through

suitable administrative controls. PPE like earplugs and muffs are provided and

administrative pressure applied for using them. Auditory examination by qualified doctors

upon the first employment and thereafter periodic examination are conducted which

include determination of auditory threshold for pure tones.

Medical check-up of all the employees are done during pre-employment. The healths of

workers are regularly monitored under an occupational surveillance programme. Under

this programme, all the employees are subject to detailed medical examination at the time

of employment. The medical examination covers the following tests.

General Physical Examination and Blood Pressure X-Ray Chest and ECG Sputum Examination Routine Blood and Urine Examination Lung Function Test Eye Test Audiometric Test

The medical histories of all the employees are maintained in a standard format. Thereafter

the employees are subjected to medical examinations on annual basis. The following tests

results will upgrade the data base of medical history of the employees. The recommended

medical examinations are shown in following Table.

Recommended Medical Examination for Employees

Sr. No. Disease Tests to be conducted

1. Heart Disease ECG, blood for lipid profile, stress test, 2D-Echo and other tests are required

2. Lung Diseases Total Count (WBC Count), Differential Count, Sputum examination, X-ray Chest, Alveolar macrophage

3. Respiratory Disorders Differential Count, ESR, X-ray chest, Lung Function Tests (Spirometry) and Sputum examination



4. Diabetes Random blood sugar, urine sugar, if positive, BSL-Fasting / pp, Diabetic profile

5. Hypertension Blood Pressure reading, if required Renal profile, ECG and stress test

6. Abdomen Pain Routine Urine for Albumin, Sugar bile salts, Liver function test

7. Ear, Nose, Throat Routine Eye Test, Fundus examination, retinopathy test, colour blindness, nose infections, auditory threshold for pure tones.

Plant personnel working in dust prone areas are encouraged to wear personnel protective

equipment like air filters over their nose. Job rotation schemes are practiced for over-

exposed persons. It is ensured that workers are not exposed above the threshold limits

prescribed above through suitable administrative controls. PPE like earplugs and muffs is

provided and administrative pressure applied to the workers to using them despite

uncomforted. Workers exposed to mechanical accident-prone areas are given personal

protective equipment (PPE). The non-respiratory PPE includes tight rubber goggles, safety

helmets, welders hand shields and welding helmets, plastic face shields, ear plugs, ear

muffs, rubber aprons, rubber gloves, shoes with non-skid soles, gum boots, safety shoe with

toe protection. All safety and health codes prescribed by the Bureau of Indian Standards

are implemented. Safety data sheets of the hazardous chemicals are displayed at specific

locations. The data is in English, Hindi and Bengali language / script.

5.6 Greenbelt Development Plan

RCL has developed the Green Belt near by the plant. The copy of the same is enclosed as

Annexure-II. While selecting trees species following things are considered: The tree

species to be selected for the plantation are pollutant tolerant, fast growing, and wind firm,

deep rooted. A three tier plantation is proposed comprising of an outer most belt of taller



trees which will act as barrier, middle core acting as air cleaner and the innermost core

which may be termed as absorptive layer consisting of trees which are known to be

particularly tolerant to pollutants.

5.7 Rain Water Harvesting Plan

RCL has already developed rainwater harvesting reservoir. The coy of the same is enclosed

as Annexure-III. The capacity is 1, 00,000 KL. Surface runoff from the plant area collected

in the water reservoir located inside the plant. This stored water is used inside the plant.

The groundwater depth at the site is minimum 5 m during post-monsoon season.

The entire land of the plant area has to be leveled in such a way that Rain Water flows

down to the RCC constructed Rain Water storage pond. Water will enter into the storage

pond through filter bed. Filter bed will be made with different size of gravels and core sand.

The filtrate water will be stored in the pond. The same water will be rinsed for industrial as

well as domestic purposes through water pump and motor. The residue of the filter bed

will be removed manually from time to time. The storm water drainage channel passing

through the site will also be connected to the said pond for conservation of the rain water,

which shall be used for various purposes inside the plant.

5.8 Monitoring Scheme

We are having continuous monitoring system and also the monitoring of the stacks are

being done frequently by WBPCB on quarterly or half yearly basis. Third party monitoring

for ambient, fugitive, noise & water is being done once in a year by MoEF/ WBPCB

approved laboratory.



6 Comparative Statement

(Ferro Alloy & Ferro Chrome Comparison)

Comparative Statement Showing Ferro Alloy & Ferro Chrome

Operation comparison

Sr.

No

Description Ferro Alloy (FeMn, FeSi,

SiMn)

Ferro Chrome (FeCr)

1 Capacity of

Furnace

9 MVA 9 MVA

2 Quantity/ No. of

Furnace

06 06

3 Production

Quantity

72000 TPA (As per EC) 72000 TPA

4 Power

Consumption

4000 KWH/MT 4000 KWH/MT

5 Equipment &

Production

Process

Submerged Electric Arc

Furnace

Submerged Electric Arc

Furnace

6 Raw Material

Details

Sr.

No

Detail Quantity

(TPA)

Sr.

No

Detail Quantity

(TPA)

A Manganese

Ore

1,87,200 A Chromium

Ore

1,58,400

B Quartzite 18,000 B Quartzite 18,000

C Dolomite 2,160 C Dolomite 2,160

D Coal 18,000 D Coal 18,000

E Coke 46,800 E Coke 46,800

7 Slag Production For 1 MT Ferro Alloy 1 MT For 1 MT FeCr 800Kg Slag



Slag Produced Produced

8 Recovery Manganese (%) recovery from

input in Metallic Form-80 %

Chromium (%) recovery from

input in Metallic Form-88 %

9 Pollution Control

System

Sr.

No

Sources APC

Device

Detail

Capacity Sr.

No

Sources APC

Device

Detail

Capacity

i Air

Pollution

(Stack &

Fugitive)

Bag

Filter

i Air

Pollution

(Stack &

Fugitive)

Bag

Filter

ii Water

Pollution

NIL ii Water

Pollution

NIL

iii Noise

Pollution

NIL iii Noise

Pollution

NIL

10 Permissible

Emission Limit

Less than 100 mg/Nm3 as per

CFO Condition

As per Environmental Norms

11 Tapping

Arrangement

Gravity Separation of Slag &

Metal

Gravity Separation of Slag &

Metal

12 Hazardous

Characteristic of

Slag

Non Hazardous Non Hazardous

13 Slag Slags are stored and are used

in land filling, and road

construction.

Slags shall be stored/ dumped

at dump yard or as per

Environmental Norms &

disposed accordingly.



7 Conclusion

Presently our Company has reduced the production and incurring huge losses on account

of break or interruption in operation of its Plant, resulting forcefully reduction in the

manpower to compensate the production loss, resulting decrease in revenue generation of

the Govt. We are under tremendous pressure from the local authorities to run the Plant at

full capacity, but we are finding ourselves helpless due to the present economic conditions.

In order to have viability and also provide jobs to nearby people, we wish to produce High

Carbon Ferro Chrome and request that kindly include this product High Carbon Ferro

Chrome in the Environment Clearance Approval with a condition that production of High

Carbon Ferro Chrome should not increase the level of gas emission in comparison to the

production of Silico Manganese. We are ready to abide by such stipulation.

Further the Company will also abide by the norms stipulated by the Pollution Control

Department for inclusion of High carbon Ferro Chrome in our Consent to Operate approval.



Annexure-I

(PLANT LAYOUT)


Report for product mix (inclusion of Ferro Chrome) in combination of Ferro Alloy by using 6 x9 MVA SEAF

Annexure-II

(GREEN BELT PICTURES)



Annexure-III

(RAIN WATER HARVESTING FACILITY PICTURES)



Annexure-IV

(CONSAENT TO ESTABLISH & OPERATE

CERTIFICATE FROM W.B.P.C.B )



CONSENT TO ESTABLISH



CONSENT TO OPERATE

DRI-10 X100 TPD + 18 MW WHRB + 2 x 9 MVA Ferro Alloy Plant (Valid CFO Till Dec-2016)



DRI-1 X350 TPD + 10 MW WHRB (Valid CFO Till Dec-2016)



DETAIL OF First CFO ISSUED FOR 2 x 9 MVA Ferro Alloy Plant

CFO for 1st No- 1 x 9 MVA SEAF Ferro Alloy Plant

.



CFO for 2nd NO-1 x 9 MVA SEAF Ferro Alloy Plant



.

Annexure-V

(Environment Clearance Certificate)

File No- J-11011/604/2008.I A II (I)



Annexure-VI

(ENV. ANALYSIS REPORT NABL ACCREDITED LAB)

&

(STACK ANALYSIS FROM W.B.P.C.B APPROVED

LAB)



ENV. ANALYSIS REPORT NABL ACCREDITED LAB

Ambient Air:



Fugitive Air:



Effluent Analysis:



Drinking Water Analysis:



Noise Level Monitoring Report:



Leachate Study Report:



(STACK ANALYSIS-W.B.P.C.B APPROVED LAB)

DRI units:-



Ferro Alloy (SEAF) units:-

project execution byenvironmentclearance.nic.in/writereaddata/... · report for product mix...

Documents