m/s. bhushan steel limited

PRE-FEASIBILITY REPORT

On

PROPOSED 21 MTPA IRON ORE BENEFICIATION PLANT AT – KU-MUNDI & 4 Nos. OF SATELLITE GRINDING STATIONS AT-GANDHAMARDAN,JALPAPOSHI,BALAJORI,TEHRAI IN KEONJHAR& SUNDARGARH DISTRICT WITH SLURRY & WATER PIPELINESCONNECTING THE UNITS WITH INTEGRATED STEEL PLANT ATMERAMANDALI,DHENKANAL DISTRICT OF ODISHA

OF

M/s. BHUSHAN STEEL LIMITED

Prepared by:- SEPTEMBER-2014

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

M/s Bhushan Steel Limited Form-1 Report on Proposed 21 MTPA Iron Ore Beneficiation Plant at-Kumundi & 4 Nos. of Satellite Grinding Stations at Gandhamardan, Jalpaposhi,Balajhori, Tehrai in Keonjhar&Sundergarh district of Odisha with water &Slurry Pipelines Connecting the units with Integrated Steel Plant at Meramandali,Dhenkanal district of Odisha.

Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 1

SR.NO CONTENT PAGE NO.

1

EXECUTIVE SUMMARY 1.1.0 Introduction 3

1.2.0 Project Description 6

1.3.0 Site Analysis 8

1.4.0 Land Use Planning 9

1.5.0 Proposed Infrastructure 10

1.6.0 Rehabilitation & Resettlements (R & R) Plan 10

1.7.0 Project Schedule & Cost Estimates 11

1.8.0 Analysis of Proposal 11

2

PROJECT BACKGROUND

2.1.0 Identification of Project & Project Proponent 13

2.2.0 Market Scenario, Demand – Supply Cap 14 2.3.0 Import Vs Indigenous Production 19 2.4.0 Export Possibility & Domestic/Export Markets 19 2.5.0 Employment Generation(Direct & Indirect)Due to the Project 20

3

PROJECT DESCRIPTION

3.1.0 Location 22 3.2.0 Site Selection 31 3.3.0 Magnitude of Operation 33 3.4.0 Raw Material 33 3.5.0 Process Detail 35 3.6.0 Tailing Disposal 50

3.7.0 Iron Ore Slurry Pipeline System 54

3.8.0 Plant and Machinery Source 57 3.9.0 Process Water Balance 57

3.10.0 Power Requirement 58 3.11.0 Quantity of Waste To Be Generated 59 3.12.0 Noise Levels 61 3.13.0 Green belt Development 62 3.14.0 Schematic Representation of EIA/ EMP 63

4

SITE ANALYSIS

4.1.0 Land Form, Use and Ownership 64

4.2.0 Justification For Locating Slurry Pipeline Project in Forest Area 66

4.3.0 Existing Infrastructure 73

5 PROJECT PLANNING



5.1.0 Planning Concept 74

5.2.0 Population Projection 74

5.3.0 Land Use Planning 74

5.4.0 Assessment of Infrastructure Demand 76

5.5.0 Design Philosophy 76

5.6.0 Amenities/ Facilities 79

6

PROPOSED INFRASTRUCTURE

6.1.0 Industrial Area (Processing area) 81

6.2.0 Residential Area (Non-Processing Area) 81

6.3.0 Socio-Economic Benefits & Social Infrastructure 81

6.4.0 Connectivity 82

6.5.0 Drinking Water Management 82

6.6.0 Sewerage System 82

7 REBAHILITATION & RESETTLEMENT (R & R) PLAN

7.1.0 Policy To Be Adopted For R & R Plan 83

8 PROJECT SCHEDULE

8.1.0 Schedule Details 84

9

ANALYSIS OF PROPOSAL

9.1.0 Financial and Social Benefits 87 9.2.0 Employment 88 9.3.0 Other Benefits 88

Enclosures: Project Location Map & Slurry Pipeline route Eco-Sensitive Map of Odisha Showing Ariel Distance from the Proposed Iron Ore Slurry Pipeline-Keonjhar to Dhenkanal



CHAPTER - I

EXECUTIVE SUMMARY

1.1.0 INTRODUCTION

Bhushan Steel Limited (BSL) is one of the leading steel manufacturers of India. Annual turnover of company is more than Rs. 11,800 Crores. The company has three manufacturing units at three locations in India. The three manufacturing units are Sahibabad in NCR, Khopoli in Maharashtra and Meramandali in Odisha.

The Integrated steel plant at Meramandali has operating capacity of 3.1 MTPA and soon it will be achieving 5.6 MTPA capacity status. The company has planned to expand the capacity to 9.0 MTPA, with the commissioning of Phase – II in future.

To cater the need of Iron Ore requirements in future for 9 MTPA Integrated Steel plant, BSL is planning to set up a 21.0 MTPA (throughput Dry basis) Centralized Iron Ore Beneficiation plant (BP) at Kumundi in Keonjhar District to produce 12.0 MTPA Iron ore concentrate (Dry Basis) along with Iron Ore Slurry & Water Pipeline System. The BP will be fed with washed iron ore slurry, from 4 Nos. Satellite grinding stations (SGS), i.e, Jalpaposi, Koira Sector-A (Tehrai), Koira Sector- B (Balajori) and OMC Gandhamardan. In these SGS washing and wet grinding techniques will be deployed and iron ore will be ground to 300 microns and below size. Adaptation of slurry pipeline transportation will almost eliminate fugitive dust emission. Further beneficiation of iron ore will be done at Kumundi and tailings generated along with the slime slurry from SGS will be disposed off at Urumunda. The Iron ore concentrate produced will be transported to Meramandali Steel plant by slurry pipeline for feeding pellet/sinter plants.

The planned SGSs capacities are given below.

Description Capacity (Dry basis)

SGS – Jalpaposhi - 9.0 MTPA

SGS – Koira Sector A(Tehrai) - 6.0 MTPA

SGS-Koira Sector B(Balajori) - 3.0 MTPA

SGS – Gandhamardan (Taljagar) - 3.0 MTPA



Project Configuration and Salient Features of Project Units

In India, at present, the selective mining of high grade iron ore & washing of lumpy ore are being practiced to cater the needs of iron and steel industries. Simultaneously, low grade fines, slimes and tailings are generated from these sources. It is essential to utilize low grade fines generated to maximize the resource conservation. To challenge this problem, advance processes of beneficiation and agglomeration of fines are to be adopted. In beneficiation of hematite ore, characteristics of ore with respect to mineralogical, physical and chemical properties are to be understood. For beneficiation of low grade ores or fines, the clay content plays a vital role to develop the process flow sheet. It is essential to remove the clay associated fine particles at the beginning of the process by utilizing the attrition technique. For this purpose, either attrition scrubber or screw scrubber may be used, depending on the particle size of feed materials otherwise the clay minerals increase the pulp viscosity, because of its swelling properties. As a result, the performance of beneficiation equipment drastically decreases, and it also gives adverse effect on the control over the fluid dynamics of the pulp in the process. Ultimately the desired grade and recovery is not achieved as per design parameters. In general, the objective of the iron ore beneficiation is to meet the raw material requirement of BF, DRI, Sinter and Pellet grades by adopting the suitable process flow sheet based on the characteristics of ore.

Iron ore available in Barbil region contains good amount of goethite and clay minerals along with hematite depending on input Fe content of ore. In general, If Fe content is more than 60%, it contains within 10% of goethite. Within 55-60% Fe, goethite content in ore varies from 10-30%. Similarly



within 50-55% Fe, goethite content in ore varies from 30-50%. Once goethite increases, kaolinite content in the ore also increases. Based on the characteristics ores examined earlier, the process flowsheet was developed by reputed mineral research institute, I.M.M.T. Bhubaneswar.

1.1.1 Identification Of Project And Project Proponent

BSL intends to set up 21.0 MTPA (throughput) BP with Iron Ore Slurry & water Pipeline System to produce iron ore concentrate of 12.0 MTPA (dry basis) at Kumundi, District- Keonjhar in the state of Odisha.

1.1.2 Employment Generation

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

opportunities;

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

Improved green cover;

Better communication and transport facilities;

The proposed project shall enhance the prospects of employment. Recruitment of unskilled workers for the proposed plant will be from the nearby areas. The basic amenities viz. roads, transportation, electricity, drinking water, proper sanitation, educational institutions, medical facilities, entertainment, etc. will be developed as far as possible.

It is estimated, that the total requirement of permanent manpower during operation of project, will be 450 including Sr. Executives, Managers, Administrators, Engineers, Supervisors and Skilled Technicians.

The Unskilled labours will be recruited from the local area and surroundings during the construction period, and approximately 6, 45,000 man-day’s work force will be engaged. In addition to direct employment, Project will generate number of indirect job opportunities for locals on regional basis.

1.2.0 PROJECT DESCRIPTION

1.2.1 Site Selection

The proposed sites have following facilities:

Proximity to the sources of iron ore fines,

Availability of common Infrastructure facilities / utilities (water / power, land

etc.),

It is not located on the mineralized zones.



1.2.2 Technology Selection

Technology selection involves an analysis of past achievements, present status and future prospects of technology under consideration keeping in view the following criteria.

Availability of project plant capacity/module.

Suiting to selected product mix & raw materials

Availability of input such as power & potable water.

Considerations of capital & maintenance cost.

Delivery schedule

Operational flexibility

Environment

Plant is designed to beneficiate low grade iron ore fines to produce iron ore concentrate through BP. Iron ore concentrate will be utilized as pellet/sinter feed. The concentrated ore will be transported to BSL’s plant at Meramandali in slurry form through pipelines, where it will be dewatered and used in Pellet/Sinter Plants.

1.2.3 Project Profile

Iron Ore Slurry Pipeline & Return water Pipeline Pipeline Route Distance x No.of turns Length Units Kumundi - OMC Gandhamardan =6 x 3 18 Km Kumundi – Koira Sector A-Tehrai =46 x 3 138 Km Koira Sector A – Koira Sector B-Balajori =10 x 3 30 Km Jalpapasi – Kumundi =27 x 3 81 Km Kumundi- Urumunda =4 x 3 12 Km Kumundi-Meramandali =106 x 2 212 Km Total Pipeline length

491 Km (approx.)

Note: The Right of User (RoU) width in non-forest area is 20 mtrs while in forest area, the RoU width

is restricted to 7.25 mtrs only. The width of conveyor belt corridor is 10 mtrs (Gandhamardhan site).

1.2.4 Water and Power Requirement

The water requirement of BP is estimated to be 2400 m3/hr and shall be sourced from River Mahanadi through the Main BSL Plant at Meramandali. Water requirement for potable purpose is estimated to be 612 m3/day, which will be drawn from underground.

After dewatering the iron ore concentrate slurry in the filtration plant at Meramandali, filtrate water (1685 m3/hr) along with required quantity of makeup water (715 m3/hr) will be pumped to Kumundi. Water from Kumundi will be distributed to all 4 Nos. SGS. There will be no waste water generation based on principle of zero discharge. (Refer clause 3.9.0 of Chapter-3)



105 MW power will be required for the proposed project, which will be sourced from nearby substations for different unit locations.

1.2.5 Waste Generation and Management

Waste water generated from SGS & BP Process Unit Waste water

qty (m3/hr) Source Waste water

characteristics Waste water management

Satellite Grinding Stations –Gandhamardan, Jalpaposhi, Balajori, Tehrai & Beneficiation Plant

No waste water generation.

- TSS Complete recirculation

Domestic 20.4 Domestic use from plant

TSS, BOD, Oil & Grease

Will be treated in STP and reused for greenbelt

Solid Waste Generation and Management is given below the table.

Units Solid Wastes Qty In TPA (Dry) Disposal practice BP Tailings 9,000,000 Will be disposed in paste form to tailing

disposal area of 195 Acres, at Urumunda & Kumundi

Domestic Solid Wastes

Units Solid Wastes Qty In TPA Disposal practice STP STP Sludge 30 Will be used as manure for

landscaping Canteen and staff colony

Garbage and food waste

60 Organic and inorganic portion of waste will be separated, organic waste will be vermi-composted and used for greenbelt development. Inorganic portion will be given to scrap dealers.

1.3.0 SITE ANALYSIS

The project envisages setting up a centralized BP at village Kumundi with 4 Nos. SGS and tailing

disposal at village Urumunda. The Iron ore will be transported from SGS to BP and beneficiated iron

ore concentrate will be pumped in slurry form to Main BSL Plant at meramandali.

1.3.1 Connectivity

The BP site at Kumundi is at about 15 km away from the nearest city and district headquarters,

Keonjhar. The national highway (NH-215) runs at a distance of 15 KM from the proposed plant.



Details of Connectivity of Sites:

Site National Highway State Highway SGS-Gandhamardan NH 49 6.2 Km 1Km SGS-Jalpaposhi NH 215 40 km 3 km SGS-Balajori NH 215 4.5 Km - SGS-Tehrai NH 215 3.3 Km - BP-Kumundi NH 49 10.0 Km 5 Km TDA-Urumunda NH 215 14.0 Km - Site Nearest Rly Stn Airport SGS-Gandhamardan Keonjhar Bhubaneswar SGS-Jalpaposhi Nayagarh Bhubaneswar SGS-Balajori Barbil Bhubaneswar SGS-Tehrai Barbil Bhubaneswar BP-Kumundi Keonjhar Bhubaneswar TDA-Urumunda Keonjhargarh Bhubaneswar Site Nearest Town Dist HQ SGS-Gandhamardan Suakati Keonjhar SGS-Jalpaposhi Barbil Keonjhar SGS-Balajori Koida Sundergarh SGS-Tehrai Koida Sundergarh BP-Kumundi Bansapal Keonjhar TDA-Urumunda Keonjhar Keonjhar

1.3.2 Topography and Existing Land use Pattern

The terrain along the proposed route of the slurry and water pipelines, is nearly flat for 35 km, hilly 20 km and remaining length is undulating in nature. The Proposed pipeline route passes through forest area for a length of about 30.687 Ha. The proposed pipeline route does not pass through Wild Life Sanctuary, National Park, Historical places, place of tourist importance or its buffer zone.

1.3.3 Climate Data

The climate of Keonjhar district is characterized by an oppressively hot summer, with high humidity. During summer, the mean maximum temperature is 42.7 0C. The temperature in the month of December/January is lowest i.e. 6.9 0C. Lowest temp recorded is 2.2 0C. The average annual rainfall is 1269.1 mm.

In Dhenkanal district, the mean maximum temperature is about 44.4 0C during summer and during winter season lowest temperature is about 9.2 0C. The average annual rainfall is 1287.0 mm.

The district of Sundargarh has extreme climatic conditions. In summer temperature lies above 45 °C for most of the time. The months of April, May and June are oppressively hot. The region receives abundant rainfall in monsoon months. The winter starts in November and continues up to January. Winter can be exceedingly cold, as low as 7-8 °C. The average annual rainfall is 1422.4mm.



1.4.0 LAND USE PLANNING

Total land requirement for the proposed SGSs & BP is about 202.342 Ha/500 Acres, which is already identified and is in the process of acquisition. The break-up of land area is given as under :-

Plant Facilities/Sites Land available in Hectares(Ha) in Acres(Ac)

Iron ore beneficiation Plant (Central) – Kumundi 62.726 155

SGS-Gandhamardan 19.020 47

SGS –Jalpaposhi 29.542 73

SGS-Balajori 20.234 50

SGS-Tehrai 20.234 50

Tailing Disposal Area-Urumunda 50.586 125

Total 202.342 500

Note: A total of 219.25Ha/541.8 Acres of land will be used in laying slurry & water pipelines under the purview of Petroleum and Mineral pipeline Act 1962. After laying of pipeline, land will be restored to its original condition and will be handed over to respective owners and authorities.

1.5.0 PROPOSED INFRASTRUCTURE

1.5.1 Industrial Area

The land requirement to set up the main plant facilities, raw material storage, tailing pond, raw water storage reservoir, auxiliary facilities, viz. administrative building, technical building, workshop, QC lab, switch yard, greenbelt (33%), etc. require 202.342Ha/500 Acres of land in total.

1.5.2 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total green belt area shall be of 33% of the total area (i.e.66.77Ha/165 Ac). The main objective of the greenbelt is to provide a curtain between the plant and the surrounding areas. In addition, compensatory afforestation will be carried out separately for the land used in laying slurry & water pipelines. The forest diversion proposal of 30.687 Ha of forest land has already been submitted to Forest Authorities, Govt. of Odisha and is under active consideration.

Others

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

season.



Additional Drinking water facilities will be provided for employees as well as locals.

A residential colony will be constructed for the operational staff & workers.

1.6.0 REHABILITATION AND RESETTLEMENTS (R & R) PLAN

Total land requirement for the proposed unit, excluding slurry & water pipelines is about

202.342Ha/500 Acres. A total of 219.25Ha/541.8 Acres of land will be used in laying slurry & water

pipelines, which will be returned to land owners after completion of job. So the proposed project of 4

Nos. SGS, BP and tailing disposal will come up in 202.342Ha/500 acres of land in the final phase of

Operation. Total land has already been identified and is in process of acquisition. There is no existence

of displaced habitants in the identified land. Hence, R & R not planned for the project.

1.7.0 PROJECT SCHEDULE AND COST ESTIMATES

1.7.1 Project Schedule

The total project implementation schedule is 36 months from zero date of land acquisition. The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance.

1.7.2 Project Cost

An indicative estimated capital cost of the proposed Plant is Rs. 2300 Crores, including the pre-operative expenses, contingency and interest during construction.

A broad break-up of the indicative estimate of the Project capital cost is provided below:

TENTATIVE COST OF PROJECT

Sl No Details Amount in

(crores) Rs.

1 Land (202.342Ha/500 acres) 160

2

Plant & Machinery 650 for BP Kumundi 160 for SGS Koira (Balajori & Tehrai 80 for SGS Gandhamardan 190 for SGS Jalapaosi

1080

3 Pipeline 562 for Pipe Cost 398 for ROU& laying

960

4 Utilities , Power, Water etc 100

Total 2300



1.8.0 ANALYSIS OF PROPOSAL

The proposal envisages utilization of low grade iron ore in order to conserve reserves of high grade iron ore. This in itself is a resource conservation strategy. The entire process is aimed towards minimizing use of road/ rail transportation and reducing air pollution significantly.

Slurry pipelines are preferred, as they do not cause noise, dust pollution, negative visual impacts etc. It results in lower greenhouse gas emissions than conventional modes of transport.

The economic incentive in selecting a slurry pipeline as a mode of transportation is a proven technique.

Some of the main factors which affect the economics of slurry transport system are tonnage and

transportation distance, existing infrastructure, characteristics of ore and terrain conditions. Moreover,

the pipeline concept will substantially reduce the cost of iron ore transportation from SGSs to

Meramandali Steel plant. No effluent is let out from the pipeline system. Water used in the entire

process will be recycled in close-circuit with zero discharge.

The project will have a positive impact on the regional and National economy, consolidating employment in the Indian mineral processing industry and its allied subsidies. Value addition to low grade Iron Ore fines by converting it to Iron Ore pellets is a great achievement for the steel industry. The socio-economic benefits of the proposed project are as follows:

Increase in employment opportunities.

Reduction in emigration of locals for employment.

Increase in literacy rate.

Increase in per capita income.

Increase in quality of standard of living.

Improvement in quality of basic amenities and education.

Overall positive impact on the socio economic environment is anticipated.

---------



CHAPTER – 02

INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

BSL is one of the leading steel manufacturers of India. Annual turnover of company is more than 11,800 Crores. The company has three manufacturing units, product details as follows:

a) Sahibabad (NCR, Delhi):

Products – Cold rolled coils/ sheets, Corrogated plain/ galvanized sheets, color coated coils/

sheets , precision tubes, galume coils/sheets.

b) Khopoli (Maharashtra):

Products – Cold rolled coils/ sheets, Corrugated plain/ galvanized sheets, Color coated coils/

sheets, cold rolled annealed, precision tubes, galume coils/sheets., ERW pipes, High tensile steel

strapping.

c) Meramandali (Odisha):

Products – DRI, Pig Iron, Billets, Hot rolled coils/Cold rolled coils, Galvanized sheets/coil,

Color coated sheets/coils, tubes & pipes.

The Integrated steel plant at Meramandali has operating capacity of 3.1 MTPA and soon it will be achieving 5.6 MTPA operating capacity status. The company has planned to expand the operating capacity to 9.0 MTPA, with the commissioning of Phase – II in future.

To cater the need of Iron Ore requirements for 9 MTPA Integrated Steel in future, BSL is planning to set up a 21.0 MTPA (throughput dry) BP in Kumundi, Keonjhar District to produce 12.0 MTPA Iron ore concentrate (Dry Basis) along with Iron Ore Slurry & Water Pipeline System.

2.1.1 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND REGION

Visualizing the demand of iron and steel in the country and to promote maximum value addition within the state, the state government of Odisha has signed number of MoUs for establishment of steel plants. The present reserves of high grade iron ore within the state suitable for manufacture of Iron and steel is limited and will be consumed within coming 20-25 years. Therefore, there is an urgent need for utilization of iron ore fines lying in all the iron ore mines located in Barbil-Joda sector of Keonjhar district, Bonai sector of Sundargarh district, etc. The country has abundant reserves of iron ore fines and dumps which can be beneficiated and used for the production of sponge iron & steel making.

Steel finds wide applications in our day to day life. Various key industries like construction, transport, communication, agriculture and energy cannot sustain without steel. The manufacturing process from



iron ore to finished product involves production of a large number of intermediate products. All the intermediate products have a domestic as well as a global market.

To fulfill the increased requirement of raw material for 9.0 MTPA integrated steel plant, BSL is planning to set up the 21.0 MTPA (throughput) BP at Kumundi to produce iron ore concentrate of 12.0 MTPA ,which will be used for the production of pellet and Sinter. Pellet and Sinter will further be utilized to produce sponge iron & pig iron which will be used in making steel.

Further, transporting minerals in slurry form through pipelines has a perceived advantage. Slurry/water pipeline is also a proven conveying system for transportation of minerals/water.

Lower cost of transportation

Lower transit losses

Lower energy intensiveness

Safety and Reliability -minimum disruptions

Environment friendliness

Multi-product handling

Stationary carrier

Augmentation at low cost

Minimal use of land

Decongestion of surface transport systems

2.2.0 MARKET SCENARIO, DEMAND – SUPPLY GAP

Iron Ore Reserve: India occupies sixth position in the world’s Iron ore reserves and is one of the major Iron-ore producer and exporter. India’s Iron ore reserve is around 25,249 million tons apart from Banded Hematite-Quartzite (BHQ) and Banded Hematite Jasper (BHJ) with large reserves of Iron ore containing average grade around 58% Fe (normally Iron ores with Fe content around 62-65% or higher are desirable to achieve better productivity either in blast furnace or direct reduction).

Production Target: India has set itself a target of achieving production capacity of 230 Mn. Ton of Steel by 2020 and the required quantity of Iron ore is projected at around 400 Mn. Ton. Over the next few years, demand for Indian Iron ore is expected to rise by more than 200 Mn. Tons per year to meet the internal and export demand. Two major shifts in Iron ore supply for the Indian Iron and Steel industry have occurred:

Export to foreign market owing to liberalization in the economy.

Adaptation of beneficiation and pelletization practices to utilize low-grade ores fines.



Futuristic Role of Beneficiation & Pellets: For economic and industrial growth, a number of Steel plants have been planned in the states of Odisha, Jharkhand, Chhattisgarh, Karnataka and Maharashtra. As the quality of available raw materials declines, the impact of Iron making processes on pollution control and energy required will worsen in days to come. Most of the ROM (run of the mine) Iron ore contains lot of impurities that needs beneficiation prior to use. Therefore research on utilization of low grade Iron ore to produce quality raw material would play a key role in future, which is a fact acknowledged by Iron and Steel industry. Such a situation warrants for the widespread usage of beneficiation techniques. Moreover, as mentioned earlier the huge quantities of fines generated in the process of mining & sizing of iron ore needs to be effectively utilized, wherein the agglomeration techniques (such as sintering & pelletizing) comes in to the picture.

Pellets Demand (BF Grade)

Use of pellets is restricted in the Indian Blast Furnaces mainly due to high cost of pellets compared to lump ore and sinter. Availability of pellet is also limited in the country as the existing pellet plants are either captive for internal use like Essar-Hazira & Jindal Vijaynagar or the pellets are exported from the plants like KIOCL & Mandovi Pellets Ltd due to high demand in the international market. In the recent past, Indian steel producers with major blast furnaces felt the necessity of using pellets in blast furnaces to utilize the iron ore ultra fines generated during mechanized mining.

All India production of Sponge Iron during April 2008- January 2009 is reported as 15.94 MT with share of 4.03 MT from gas based units and balance 11.91 MT from coal based units. Capacity utilization in gas based DRI Units, on all-India basis during 2008-09 works out to about 55%. Therefore, considering the total of all India gas based DRI capacity and anticipated capacity utilization, all India demand for pellets in gas based DRI is estimated at 8.4 Mt in 2011-12 onwards.

The total number of working coal based sponge iron units in the country are about 300 with a total capacity of 24 MTPA (incl. some upcoming expansions).

Presently, calibrated lump ore (CLO) is being used by DRI units. A few units are also using iron ore pellets to a limited extent. With sharp increase in CLO price and marked difference in price of ultra fines and CLO, the use of pellets in coal based DRI units is inevitable in the future years. While the total installed capacity of coal based sponge iron units is about 24 MTPA, the effective capacity utilization has been roughly 70%. In the near future, the pellets replacement quantity (even at 15% replacement) would be in the range of 4.5 - 5 Mn. Since, an average of 1.7 – 1.8 ton of ore (incl. handling loss etc.) is consumed per ton of sponge iron produced

Export Market for Iron Ore Pellets

In the export market, the present and future DRI/HBI producers in Southeast Asia, Middle East and



North African regions etc. are the potential destinations, as there would be natural markets for iron ore pellets. Supplies from Bahrain, Brazil and Sweden are meeting the present Middle East/North African DR pellet requirements. With transportation costs being a competitive factor, Indian pellet producer’s proximity to Southeast Asia, Middle East and North Africa have given them a definite advantage over the suppliers from Brazil, North America and Sweden.

The pellet deficiency in the target market is being currently met from South America (CVRD, Samarco) and Europe. In view of potential market in South East Asian region and exports of iron ore pellets by India in the past, a provision of 40% of total anticipated domestic demand of pellets is kept for export.

As discussed above, Pellet is considered to be a superior feed stock for any primary Iron Making Process. While Smelting Reduction Processes and Gas Based Direct Reduction Process is currently utilizing palletized ore, Blast Furnace based process still prefers to use sinter as it is produced in-house. However sinter plants are not very environment friendly, as such it is predicted that slowly Blast Furnaces will start using a part of its burden as pellet. With increasing trends of pellet usage in Blast Furnaces, there shall be great demand for pellets as is evident from the demand from steel in next few years.

Steel Demand Forecast for India

Sector structure/Market size: The steel industry in India has been moving from strength to strength and according to the Annual Report 2009-10 by the Ministry of Steel, India has emerged as the fourth largest producer of steel in the world and is likely to become the second largest producer of crude steel by 2015-16. According to Ministry of Steel, Govt. of India, the prospects for Indian Steel industry has been envisaged as under:

The Indian steel industry have entered into a new development stage from 2005-06, riding high on the resurgent economy and rising demand for steel. Rapid rise in production has resulted in India becoming the 4th largest producer of steel.

It has been estimated by certain major investment houses, such as Credit Suisse that, India’s steel consumption will continue to grow at nearly 16% rate annually, till 2012, fuelled by demand for construction projects worth US$ 1 trillion. The scope for raising the total consumption of steel is huge, given that per capita steel consumption is only 40 kg – compared to 150 kg across the world and 250 kg in China.

The National Steel Policy has envisaged steel production to reach 110 million tonnes by 2019-20. However, based on the assessment of the current ongoing projects, both in greenfield and brownfield, Ministry of Steel has projected that the steel capacity in the county is likely to be 124.06 million tonnes by 2011-12. Further, based on the status of MOUs signed by the private



producers with the various State Governments, it is expected that India’s steel capacity would be nearly 293 million tonne by 2020 http://steel.nic.in/overview.htm [May be referred for further details]

Production: India’s Position in World’s Crude Steel Production:

In Million Metric Tons 2009 2010

Country Rank Tonnage Rank Tonnage Share (%) China 1 573.6 1 626.7 44.3 Japan 2 87.5 2 109.6 7.8 United States 5 58.2 3 80.5 5.7 India 3 63.5 4 68.3 4.8 Russia 4 60.0 5 66.9 4.7 South Korea 6 48.6 6 58.4 4.1 Germany 7 32.7 7 43.8 3.1 Ukraine 8 29.9 8 33.4 2.4 Brazil 9 26.5 9 32.9 2.3 Turkey 10 25.3 10 29.1 2.1 Others 224.9

263.9 18.7

World Total 1230.7 1413.5 100

www.worldsteel.org; World Steel Association’s Report, 2011.

According to the Ministry of Steel, 222 memorandum of understanding (MoUs) have been signed with various states for planned capacity of around 276 MT. Major investment plans are in Odisha, Jharkhand, Chattisgarh, West Bengal, Karnataka, Gujarat and Maharashtra. According to the Annual Report 2009-10 by the Ministry of Steel, domestic crude steel production grew at a compounded annual growth rate of 8.6 per cent during 2004-05 and 2008-09.

Consumption

India's steel consumption rose 8% in the year ended March 2010, over the same period a year ago on account of improved demand from sectors like automobile, infrastructure and housing. The country’s steel consumption increased to 60.6 MT in the year 2010 from 35.3 MT in year 2004, thereby an increase by 71.67% and the Per Capita Consumption has gone up from 32.90 KG (in year 2004) to 51.70 Kg (in year 2010), as per the World Steel Association’s Report, 2011.

Finished Steel Consumption- India & World

Year World (in Million

tonnes)

India (in Million

tonnes)

Per Capita Cons – World

(in Kgs)

Per Capita Cons – India (in

Kgs) 2004 976.70 35.30 164.30 32.90

2005 1,044.70 39.90 173.90 36.60



2006 1,141.90 45.60 188.00 41.20

2007 1,223.70 51.50 199.40 45.80

2008 1,205.90 51.40 194.40 45.10

2009 1,134.20 55.30 181.00 47.80

2010 1,283.60 60.60 202.70 51.70

% Increase- 2004 to 2010 31.42 71.67 23.37 57.14

www.worldsteel.org; World Steel Association’s Report, 2011.

2.3.0 IMPORT VS. INDIGENOUS PRODUCTION

Due to availability of high-grade iron ore in the country, iron ore lumps were the main iron bearing material for blast furnace. However, the sintering technology was adopted gradually keeping in view the utilization of huge quantity of fines generated during the production of calibrated iron ore lumps. Today, Indian blast furnaces are using sinter as major iron bearing material, thus making sinter plant as the integral part of integrated steel plant.

In the coming years, other major blast furnaces in the country are likely to use pellets as feed materials partially replacing iron ore lumps and sinters. Considering the existing blast furnaces as well as under planning stage up to 2011-12 in the country, estimated production of hot metal will be about 50 MT. The cost of pellets has been in the order of 115.51 US cents per % Fe (Brazil to Europe); 120.06 US cents (Canada to Europe) while pellets from Sweden to Europe are available at a cost of 128.0 US cents per 1% Fe.

2.4.0 EXPORT POSSIBILITY AND DOMESTIC/EXPORT MARKET

Market Condition The Government, in order to discourage the export of iron ore fines having “Fe” content of 62% or more has imposed export duty of Rs.300/- M.T and for less than Fe 62% the export duty is Rs.50/- M.T. Despite imposition of the export duty the export of iron ore fines has increased and is all expected to grow in coming years, until the technology for making pellets from iron ore fines is available in India with manufacturing facilities. Until that time, there is no apprehension for a complete ban of iron ore fines from India.

The current economic policy announced by the Government of India and the financial package announced by Ministry of Finance for corporate sector, has been extending friendly approach towards this sector and has created enormous investment opportunities both from domestic as well as foreign investors. This will naturally create a support in the demand for raising, exporting and transporting of iron ores.



Global Market

Further, emergence of China, as a major producer of steel in the world has opened up newer market potential for Iron Ore from India in addition to countries like Japan, South Korea, Pakistan, Iran and the like.

Competition in exports is mainly from CVRD (Brazil),LKAB(Sweden),GIIC(Bahrain) and Savage river(Australia).In view of the present situation, Indian pellet industry will have competitive advantages viz.

Proximity to china and other Asian Markets

Customer needs to maintain less inventory

Lower freight costs

Domestic/Export Markets

Years Demand Total Availability Gaps (-)/Surpluses(+)

Domestic Exports Domestic With Exports

2006-07 13200 5280 18480 18000 (+)4800 (-)480 2011-12 26500 10600 37100 20800 (-)5700 (-)16300

The products of BSL are marketed all over India and have dominant position in the auto ancillary segment. Marketing of the products post capacity expansion will not have much problem.

2.5.0 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT Establishment of small and medium scale engineering ancillaries, with cascading employment

opportunities;

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

Improved green cover;

Better communication and transport facilities;

The proposed project shall enhance the prospects of employment. Recruitment of the unskilled workers for the proposed plant will be from the nearby areas. The basic amenities viz. residential colony, roads, transportation, electricity, drinking water, proper sanitation, educational institutions, medical facilities, entertainment, etc. will be developed as far as possible. The Unskilled labors will be recruited from the local area and surroundings during the construction period and approximately 6,45,000 man-days work force engaged. In addition to direct employment proposed project will generate number of indirect job opportunities on local and regional basis. Employment will be generated during implementation of the project. There will be 450 persons on regular role including Sr. Executives, Managers, Administrators, Engineers, Supervisors and Skilled Technicians.



Employment status

Sl. No Category No. of Employees

01. Sr. Management 25

02. Middle and Jr. Management 50

03. Services 35

04. Skilled & Semi-Skilled 160

05. Unskilled 180

Total 450



CHAPTER – 3

PROJECT DESCRIPTION

3.1.0 LOCATION

The geographical location of proposed 4 Nos. Satellite grinding stations and Beneficiation Unit is

shown below:



Location Map



Topo Map (KUMUNDI)



Topo Map (GANDHAMARDAN)



Topo Map (JALPAPOSHI)



Topo Map (BALAJORI)



Topo Map (TEHRAI)



Topo Map (URUMUNDA)



PHOTOGRAPHS OF SITE

Kumundi, Keonjhar, Odisha

Jalpaposhi, Keonjhar, Odisha Balajori, Sundergarh, Odisha



Meramandali, Dhenkanal, Odisha

Gandhmardan , Keonjhar, Odisha

Tehrai, Sundergarh, Odisha Balajori, Sundergarh, Odisha

Tehrai , Sundergarh, Odisha



3.2.0 SITE SELECTION

The selection of project site/location has been carried out based on the following considerations.

Proximity to the sources of iron ore fines.

Availability of Infrastructure like power/ water.

Land for proposed project neither involves any displacement of habitation nor any diversion of

forest/ vegetation,

Availability of land, with common approach road well connected. Access to high growth

domestic steel markets and future industrial and infrastructure development has been planned.

3.2.1 Route Selection for Slurry & Water Pipelines

The selection of iron ore slurry and water pipeline route has been based on the following considerations.

Pipeline route shall be as short as possible.

Avoid more numbers of Turning points (TPs) and avoid acute angles at Turning point.

Avoid water logged and swampy area, ravines, meandering rivers, marshy area, unstable ground,

hard rock, rocky outcrops areas etc.

Avoid environmentally sensitive area.

Avoid mining/quarrying areas, built-up areas, towns, cities, industrial areas etc.

Route will be accessible from road.

Avoid more numbers of crossings i.e. Railways, Roads, Rivers, Canals etc. Following points

should be considered while making these crossings.

Avoid coal and other iron ore ML block.

Identify rivers / crossings coming under CRZ.

NH & rail crossing will be at right angle and away from existing structures.

Procure the maps of all the cities / Major towns along the pipeline route and study all notified

development Plans (City, Industrial, Capital, etc) from the respective authorities and superimpose

them on SOI Maps prior to selection of the pipeline route. The pipeline route shall be selected,

avoiding development areas. If it is unavoidable, then it must confirm to the norms laid down by

the concerned level of development authority.

Route selected such, that the laid pipeline slope is not more than 15% in hilly areas.

Avoid parallel alignment of the pipeline with overhead power lines and railway lines. Minimize

interference with other pipelines cables etc.



3.3.0 MAGNITUDE OF OPERATION

Production Capacity

SI. No. Plant Facilities Location/ District Capacity (Dry)

1. SGS

Taljagar, Near Gandhamardan (OMC )/Keonjhar 3.0 MTPA

Jalpaposhi/ Keonjhar 9.0 MTPA Koira Sec B-Balajori/Sundergarh 3.0 MTPA Koira Sec A-Tehrai/Sundergarh 6.0 MTPA

Total 21.0 2. BP Kumundi/Keonjhar 12.0 MTPA (Concentrate)

3.4.0 RAW MATERIAL

The analysis of Iron Ore fines is as follows.

Fe % --------- 55 %(Av.) SiO2%--------- 7% Al2O3---------- 6.5% LOI------------- 6% P--------------- 0.06% S--------------- 0.02%. Moisture------ -6% Maximum Size: Below 10mm material.

MATERIAL BALANCE



3.5.0 PROCESS DETAIL

3.5.1 PROCESS DETAILS IN SGS-JALPAPOSI (9.0MTPA Dry)

Plant capacity: This unit will be designed to process 9.0 MTPA iron ore fines (throughput).

Total Stream Feed Size -10 mm; Throughput 1260 TPH Working Days 300 Days, Working Hours 24 Hours/ Day, i.e. 7200 Hours Throughput 7200 Hrs x 1260 TPH= 9,072,000

TPA~9.0 MTPA Output 8.0 MTPA (Iron Ore Slurry)

1.0 MTPA (Slime)

Raw Material

Iron ore shall be unloaded from railway siding and collected from surrounding mines by road. Iron ore fines having about average 55% Fe content is abundantly available in the Koira- Joda-Barbil Iron Ore sector.

Process:

In this SGS, ore undergoes two processes. One is washing and the other is grinding .The ore is de-slimed to remove the clay minerals by screw scrubber and the screw scrubber overflow is to be further de-slimed by hydro-cyclone. The hydro-cyclone overflow will be sent to the slime thickener. Underflow of slime thickener will be fed to slime slurry storage tank & from there pumped to the tailings pump box of the BP. The underflow of de-slime hydro cyclone will be fed to iron ore slurry storage tank. The screw scrubber underflow will be classified by vibrating screen at 1 mm size. The +1mm Size will be treated in Washing Unit whose underflow will be taken as product. . The washed overflow and +10 mm size will be ground in ball mill to below 1 mm size. Then -1 mm size will be classified in 0.3 mm screen and +0.3mm size will be ground by ball mill & mill discharge to be pumped to 0.3 mm screen to improve grinding efficiency. i. The underflow of 0.3 mm vibrating screen will be fed to iron ore slurry storage tank. Below 0.3 mm material along with de -sliming cyclone underflow will be transported by pipeline to BP



PROCESS FLOW SHEET



LAYOUT MAP OF SGS-GANDHAMARDAN



3.5.2 PROCESS DETAILS IN SGS - TEHRAI (6.0 MTPA Dry)

Plant capacity: This unit will process 6.0 MTPA iron ore fines.

Total Stream Feed Size -10 mm; Throughput 840 TPH Working Days 300 Days, Working Hours 24 Hours/ Day, i.e. 7200 Hours Throughput 7200 Hrs x 840 TPH= 604,800 TPA ~6.0

MTPA Output 8.0 MTPA (Iron Ore Slurry including 2.6

MTPA from Balajori) 1.0 MTPA (Slime including 0.4 MTPA from Balajori)

Raw Material:

6.0 MTPA Iron ore fines shall be transported to SGS from mines through road.

Process:

In Tehrai SGS, the ore will be de slimed by screw scrubber and the screw scrubber overflow is to be further de-slimed by hydro-cyclone. The hydro-cyclone overflow will be sent to the slime thickener and underflow of slime thickener will be fed to slime slurry storage tank & from there pumped to the tailings pump box of the BP through pipeline. The underflow of hydro-cyclone will be fed to iron ore slurry storage tank. The screw scrubber underflow will be classified by vibrating screen at 1 mm size. The +1 mm size along with +10 mm size will be ground in ball mill to below 1 mm size. Then -1 mm size will be classified in 0.3 mm screen and +0.3mm size will be ground by ball mill in closed circuit to improve grinding efficiency. The underflow of 0.3 mm vibrating screen will be fed to Iron ore slurry tank along with de sliming cyclone underflow. From this tank below 0.3 mm size slurry will be transported by pipeline to BP.



LAYOUT MAP OF SGS- TEHRAI



3.5.3 PROCESS DETAILS IN SGS - BALAJORI (3.0 MTPA Dry)

Plant capacity: This unit will process 3.0 MTPA iron ore fines.

Total Stream Feed Size -10 mm; Throughput 420 TPH Working Days 300 Days, Working Hours 24 Hours/ Day, i.e. 7200 Hours Throughput 7200 Hrs x 420 TPH= 3,024,000 TPA ~3.0MTPA Output 2.6 MTPA (Iron Ore Slurry)

0.4 MTPA (Slime)

Raw Material:

3.0 MTPA Iron ore fines shall be transported to SGS from mines through road.

Process:

The process is similar to the process proposed at Tehrai SGS.



LAYOUT MAP OF SGS- BALAJORI



3.5.4 PROCESS DETAILS IN SGS- GANDHAMARDAN (3.0MTPA Dry)

Plant capacity: This unit will be designed to process 3.0MTPA iron ore fines.

Total Stream Feed Size -10 mm; Throughput 420 TPH Working Days 300 Days, Working Hours 24 Hours/ Day, i.e. 7200 Hours Throughput 7200 Hrs x 420 TPH= 3,024,000 TPA ~3.0MTPA Output 2.6 MTPA (Iron Ore Slurry)

0.4 MTPA (Slime)

Raw Material:

3.0 MTPA Iron ore fines shall be transported to SGS from mines (OMC Mines at Gandhamardan) through conveyor/Road.

Process:

The process is similar to the process proposed at Tehrai SGS.



LAYOUT MAP OF SGS- GANDHAMARDAN



3.5.5 BP - KUMUNDI (21.0 MTPA Dry)

Plant capacity: BP will be designed to produce 12.0 MTPA iron ore concentrate(Dry Basis).

Feed Size : -0.3 MM

Feed Fe(T) : Average 55%

Product Fe(T) : 63%

Throughput : 21.0 MTPA

Output : 12.0 MTPA (Beneficiated Ore)

9.0 MTPA (Tailings)

Raw Material & Supply/Source

A total of 21.0 MTPA Iron ore and slime slurry from all 4 Nos. SGSs will be transported to BP which will be processed to produce 12.0 MTPA iron ore concentrate. Beneficiated iron ore will be transported through slurry pipeline to Meramandali steel plant where it will be used as pellet & sinter feed.

Handling & Storage of Iron Ore

Iron ore slurry from SGSs will be transported through pipelines in slurry form and stored in slurry storage tanks. From storage tanks iron ore slurry will be pumped to BP for beneficiation.

Process Description:

In BP, the Iron ore slurry will be received in Iron ore slurry receiving tank. Then it will be classified by hydro-cyclone at around 75 micron. The overflow of hydro-cyclone will be sent to intermediate thickener I. The underflow will be fed to rougher spirals and rougher concentrate will be again fed to cleaner spirals if required for further up-gradation of iron values. The spiral concentrate which is one of the product, will be fed to the regrinding circuit to produce pellet feed.

The spiral tailings will be dewatered by dewatering cyclone. The overflow of dewatering cyclone will be sent to the intermediate thickener I. The underflow of dewatering cyclone will be fed to coarse magnetic separator. The coarse magnetic separator concentrate will be sent to regrinding ball mill for making pellet feed. The non-magnetic fraction (magnetic separator tailings) will be dewatered by dewatering cyclone before feeding to secondary ball mill circuit. The overflow of dewatering cyclone will be sent to the intermediate thickener I. The underflow of dewatering thickener will be ground in secondary ball mill circuit to grind below 100 microns. The overflow of hydrocyclone in this circuit will be sent to intermediate thickener I. The underflow of intermediate thickener I will be sent to fine magnetic circuit.



In the fine magnetic circuit, there are two stages namely rougher magnetic separator and cleaner magnetic separator. Based on the characteristics of ore, it requires 9000-11000 Gauss of magnetic intensity in rougher circuit to discharge desired level of tailings. The rougher magnetic separator tailings will be sent to the tailings thickener. Then the magnetic concentrate is further cleaned in cleaner magnetic separator if required. Otherwise rougher magnetic separator concentrate is one of the final products. The rougher magnetic concentrate/cleaner magnetic concentrate is sent to concentrate thickener.

If cleaner magnetic separator is in operation in the circuit, then the cleaner magnetic separator tailings is sent to intermediate thickener-II to make required pulp density for flotation circuit.

In flotation circuit, the material is received from underflow of intermediate thickener-II. Then it will be conditioned with required reagents at 40% solid concentration. It is conventional flotation to float the iron phase minerals. Oleic acid is used as collector. Sodium silicate is used as dispersing agent. Acacia is used as slime depressant. Sodium hydroxide is used as pH regulator. In the first conditioner, the slurry is treated with reagents. In second conditioner, the required pulp density is maintained by adding additional water. Two stages flotation circuit i.e. roughing and cleaning are designed using column flotation process. The cleaner concentrate will be fed directly to the slurry tank. The tailings of both flotation columns will be sent to the tailings thickener.

The rougher spiral concentrate/cleaner spiral concentrate along with coarse magnetic separator concentrate will be ground in regrinding mill circuit to produce pellet feed materials. The ground product from overflow of hydro cyclone from this circuit will be sent to concentrate thickener for settling of particles.

The total circuit of the process of Kumundi plant is shown below. The underflow of concentrate thickener will be pumped to the concentrate slurry tank. From slurry tank the slurry will be pumped to Meramandali Steel plant for further processing.



PROCESS FLOW SHEET –BP-KUMUNDI



LAYOUT MAP OF BP - KUMUNDI



3.6.0 Tailings Disposal The solid waste generated in form of tailings from BP is the primary source of solid waste which needs

appropriate storage, disposal and handling system. An area of 78.913Ha/195 Acres has been proposed

for tailing disposal. A tailing disposal area of 50.586Ha/125 Acres is located at Urumunda, Tehsil-

Bansapal, Dist.-Keonjhar. At Kumundi emergency tailing pond of 70 Acres planned. The layout map is

enclosed. The tailings generated at BP will be treated in tailing thickeners and will be disposed in paste

form at Urmunda. The initial Plant operating capacity of the project for the 1st year & 2nd year will be

60% & 75% respectively & from the 3rd year onwards it will be 90%. An area of 78.913Ha/195 Ac has

been apportioned as solid waste disposal area. Leaving aside 7.891Ha/19.5 Acres for garland drains,

26.04Ha/64.35 Acres for green belt, a total of about 44.98Ha/111.15 Acres shall be utilized for

dumping of tailings. There will be a provision for tailing disposal at Kumundi & Urumunda site for five

years. The tailing pond details have been calculated as below:

Tailing Disposal Details

Particulars Values

Area of Tailing Dump 449808.5 m2

Height of Tailing Dump 12.0 m (Approx. in two

compartments)

Total Tailing Generation in 5 yrs 36,450,000 T

Density of Tailing Material 3.5 Tones/ m3

Total volume of Tailing Generation in 5 yrs 10,414,286 m3

Life of Tailing Pond 5 years

Typical Analysis of Tailings

1) Fe---------- 40 % 2) SiO2--------12 % 3) Al2O3-------11 % 4) LOI---------- 9%. 5) Size----------Below 150 Microns.

3.6.1 Disposal/Reuse:

The Project envisages use of paste thickener, the carry over moisture with the slurry is expected to be substantially low (about 15%) in the long run. The specific gravity will increase and lesser disposal area will be required. Since it is paste, first it is proposed to store inside BP area. In the tailing disposal area at Urmunda, there will be two areas at Urmunda for retaining the tailings which will be disposed and reclaimed alternatively thereby maintaining the tailing dump height to a safe limit.



Tailings are proposed to be used for manufacture of eco-friendly building materials and land-fills in abandoned mine sites for rehabilitation of natural vegetation for eco-restoration. Considerable work on utilization of tailings as an alternative raw material has been done with respect to development of cost effective construction material like bricks for various applications and decorative tiles to conserve use of top natural agricultural soil which is the main ingredient for making construction material. Many alternative bio-fertilizers are being developed to be mixed with the tailings for land and eco-restoration viz., growth of particular plant species suitable to the soil.

The proposed project is a long term project. No closure plan has been assessed for post operational phase. However, all the solid waste disposal area will be progressively reclaimed with proper plantation.



LAYOUT MAP OF TDA – URUMUNDA



3.7.0 IRON ORE SLURRY PIPELINE SYSTEM

Transportation of Iron Ore in slurry form is not a new technology. Government of India has already enacted act called “Petroleum Pipelines & Mineral Act” (P&MP) which came into existence in the year 1962 and subsequently it was amended in the year 1977 to include mineral transportation in the slurry form.

Under the provisions of the P&MP Act, pipeline will be laid underground at a depth of minimum 1.50 meter throughout the alignment including crossings for rail, road and river. After laying the pipeline affected area will be restored to its original condition and returned to the respective owners for prompt resumption of agriculture and other surface land uses as before.

Iron Ore Slurry pipelines have an aesthetic advantage, in addition to commercial gains, over other modes of solids transportation. All facilities are buried underground and out of sight with only a few widely separated surface structures. Iron Ore Slurry pipelines are environmentally preferred, as they do not cause any noise, dust pollution or negative visual impacts. More efficient use of energy results in lower greenhouse gas emissions than conventional mode of transport.

The preliminary reconnaissance survey to determine the shortest possible / feasible route has been carried out, as per specific requirement of the Project. The routes have been identified based on the feasibility to lay the pipeline without disturbing existing structure as far as possible. After physical inspection of the various alternatives along with merits & de-merits, physical and geo-graphical site conditions, the final route has been selected for laying the iron ore slurry & water pipelines.

The water requirement for BP at Kumundi, SGS-Jalpaposhi, SGS-Gandhamardan, SGS-Koira Sec A-Tehrai, & SGS-Koira Sec B-Balajori area are planned to be fulfilled by laying water supply pipeline from BSL Plant at Meramandali to respective stations, to ensure optimal use of water.

3.7.1 PIPELINE ROUTE CORRIDOR DESCRIPTION

1) Proposed Pipeline route from Jalpaposi to Kumundi

The route of the pipeline corridor generally traverses in the southern direction from Proposed SGS at Jalpaposhi and terminates at Proposed BP at Kumundi. The total length of the pipeline is 27.373Kms. The pipeline corridor will have 3 pipelines (1 Iron Ore Slurry + 1 Slime + 1 Return water pipeline) up to chainage 16.50Kms near Talraiguda. At this junction the proposed pipeline from BSL, Koira will converge in Jalpaposi corridor, so there will be 6 pipelines (2 Iron Ore Slurry + 2 Slime + 2 Return water pipelines) from Chainage 16.50Kms to 27.373Kms. The pipeline corridor will traverse through Barbil, Jhumpura and Banspal Tehsil of Keonjhar District.



The pipeline corridor crosses 1 railway line, 13 roads, 4 carttracks, 1 river and 16 nalas/drains. The major water bodies enroute pipeline corridor are Baitarni River (58 mtr wide), & Bamni nala (51 mtr wide). The major railway crossing is Keonjhar-Joda BG railway having a width of 50 mtr.

2) Proposed Pipeline route from Tehrai- Balajori to Kumundi

The sequence of pipeline route is Tehai Birdihi, Khajurdihi, Rakma, Mundasahi, Kadokala, Kadodihi,

Talraiguda and then Kumundi. Total distance from Talraiguda to Kumundi is approx. 46 Kms. The

ground elevation of Talraiguda is 520 m (MSL) and Tehrai is 620 m (MSL). The highest elevation

enroute is 860 m (MSL). The slope varies from 2 – 12%. The proposed pipeline route crosses 24.426

Kms through private land and balance along with road corridor. Enroute it crosses one State highway, 7

MDR/ ODR, 10 village roads, 2 rivers and 7 nallas. The pipe line route passes through rocky strata for a

stretch of about 8.5 Kms. Rock is expected to encounter upto 3 m depth at various locations where

controlled blasting may be required for laying underground pipe Line. The pipeline route from Tehrai to

Balajori is plain. It crosses one SH, 4 Village roads and 4 Nallas. It comes under Koida Tahasil of

Sundergarh District. The proposed pipe line does not pass through wild life and national park and kept

away from all historical places.

3) Proposed Pipeline route from Gandhamardan Mines to Kumundi

The route of the pipeline corridor generally traverses in the Western direction from Proposed SGS at

Gandhamardan mines up to a length of 4.70Kms. Thereafter, it traverses in the southern direction

terminating at Proposed BP at Kumundi. The total length of the pipeline corridor is 5.526 Kms. The

pipeline corridor up to 4.70 Kms chainage will have 3 pipelines (1 Iron Ore Slurry + 1 Slime + 1 Return

water pipeline). At this junction the proposed pipeline will converge with the pipeline corridor from

Jalpaposhi and so there will be 9 pipelines (3 Iron Ore Slurry + 3 Slime + 3 Return water pipelines)

from Chainage 4.70Kms to 5.526Kms.

The pipeline corridor crosses 2 roads and 3 nalas/drains. The pipeline corridor passes through Banspal

Tahasil of Keonjhar District. Out of 4 villages 2 villages are having common RoU for Gandhamardan

and Jalpaposhi lines. The length of Conveyor belt from OMC, Gandhardan to SGS-Gandhamardan

is1.063Kms.

4) Proposed Pipeline route from Kumundi to Meramandali

The route of the pipeline corridor generally traverses in the Southern direction from BP at Kumundi. The total length of pipeline corridor is 104.599Kms, out of which 55.203Kmsis in Keonjhar district and 49.396 Kms is in Dhenkanal district. The pipeline corridor will have two pipelines (1 Iron ore slurry + 1 Return water line).



The pipeline route will cross three Reserved Forests, namely:

Samakoi R.F. – In RoU

Bandhanajhari R.F. – 167.76 m

Anatapur R.F. – 1155.08 m

The pipeline corridor passes through forest land for a stretch of 23.383Kms and non-forest land for a

stretch of 31.820Kms in Keonjhar District.

The pipeline corridor passes through forest land for a stretch of 10.086 Kms and non-forest land for a

stretch of 39.310Kms in Dhenkanal District.

The pipeline corridor crosses 3 railway lines, 3 National highways, 2 rivers, 10 canals/minors, 52 roads,

38carttracks, 52nalas/drains, 5 pipelines and 2 OFC cables enroute.

The major rivers enroute pipeline corridor are Samakoi River (69 mtr wide), & Brahmani river (688 mtr wide). The major canal crossings are Rengali Left bank canal (92 mtr wide), Rengali right bank canal (69 mtr wide & 63 mtr wide at 2 locations).

The major National highway crossings are NH-6, NH-200 & NH-55.The major railway crossing is Meramandali-Talcher road BG railway having a width of 56 mtr.

The pipeline corridor passes through Banspal & Telkoi Tahasils of Keonjhar District and Kankadahad, Parajang & Odapada Tahasils of Dhenkanal District.

3.8.0 PLANT AND MACHINERY SOURCE

All plant and machinery will be sourced from globally reputed and proven suppliers having vast experience of supply of various equipments required for the steel Industry. All equipment will incorporate the latest state of the art design and technology, eco friendly and will conform to global standards of workmanship.

Taking into account, reliability of equipment and matching capacities between the different sections of the plant, the type of equipment/ installation system and the departmental capacities have been estimated.

3.8.1 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT

a) Fire Protection Facilities: In order to combat any occurrence of fire in plant premises the following tire protection facilities have been envisaged for the various units of the plant.

b) Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances.



The distribution and election of extinguishers will be done in accordance with the requirement of IS: 2130-92.

c) Hydrant System: Internal hydrants will be provided at suitable locations and at different levels inside the major plant units. Yard hydrants will be provided normally along the road and in the close vicinity of the units to meet the additional requirement of water for existing fire.

d) Automatic Fire Detection System: Unattended and vulnerable electrical premises like electrical control rooms, cable tunnels, MCC. Transformer rooms, switch gear rooms, etc. will be provided with automatic fire detection and alarm systems.

3.9.0 PROCESS WATER BALANCE

SL.No. Unit Locations Water into Kumundi (M3/hr)

Water out of Kumundi ( M3/hr)

Make up water (M3/hr)

Water loss/retention(

M3/hr) 1 Jalpaposi 948 1055 - 107 2 Koira Sec A.Tehrai 948 1055 - 107 3 Gandhamardan 323 359 36

4 Kumundi Evaporation Loss - - - 414

Water In ( M3/hr)

Water Out ( M3/hr)

5. Urmunda 2128 1292 - 836 6. Meramandali 900 2400** 1685 185*

Total 1685 * Loss in the form of moisture in Iron ore concentrate after filtration at Meramandali. ** Filtrate water recycled from Meramandali-Kumundi = 715 m3/hr + 1685 m3/hr make up water from Mahanadi through BSL plant at Meramandali.

WATER BALANCE

3.10.0 Power Requirement



The total Power requirement for the Project is estimated at 105 MW, which will be available from NESCO, nearby substation.

Total Power Requirement

Sl.No Unit Location Supply/Source Power Requirement in MW

1 Jalpaposhi Substation at Brahmanidihi, Nayagarh

30

2 Gandhamardan Substation at Gopinathpur, GRIDCO

12.5

3 Kumundi

Substation at Gopinathpur, GRIDCO

27

4 Tehrai Substation at Koira 23 5 Balajori Substation at Koira 12.5

Total 105

3.11.0 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT/DISPOSAL

Solid Waste Generation and Management

Units Solid Wastes Qty In TPA (Dry)

Disposal practice

BP Tailings 9,000,000 Will be disposed in paste form in tailing disposal area of 195 Acres at Urumunda & Kumundi.

Domestic Solid Wastes

Units Solid Wastes Qty In TPA Disposal practice STP STP Sludge 30 Will be used as manure for

landscaping Canteen and staff colony Garbage and food

waste 60 Organic and inorganic portion of

waste will be separated, organic waste will be vermi-composted and used for greenbelt development. Inorganic portion will be given to scrap dealer.

Hazardous Wastes

Hazardous Wastes Quantity Hazardous Wastes Management Used Lubricants 4.2 KL/Annum Collected used lubricants will be stored in close drums

and will be disposed to authorized re-processors. Used Oil Filters 80-90 Nos/Annum The used oil-filters are considered a hazardous waste.

The same will be disposed in Hazardous Wastes Landfill.

Oily sludge 2.0 TPA Disposed as per hazardous waste management and handling Rules, 1989 and amendment thereof.



Source of air pollution and control measures

Section Source of Pollution Pollutants Air pollution control Measures

SGS Units

Raw Material Stock Yard Dust Water Sprinkling

Raw material Handling (Normally transfer for bunker)

Fugitive dust emission

Dry fog system will be provided at feeding and transfer points.

Note – No dry raw material will be handled at BP.

Water Environment

The discharge of waste water from the different plant units is given in following table and figure:

Waste water generated from plants below.

Waste Water Generation and Reuse

Process Unit Waste water qty (m3/hr)

Source Waste water characteristics

Waste water management

SGS at Jalpaposhi, Balajori, Tehrai, Gandhmardan & BP at kumundi

No waste water generation.

- TSS Complete recirculation

Domestic 20.4 Domestic use from plant

TSS, BOD, Oil & Grease

Will be treated in STP and reused for greenbelt

Mitigation Measures

Waste Water Treatment and Water Recovery from the Process

The concept at BSL is to follow Zero Discharge Concept for the Process. With the above concept, thickeners are to be installed in all the SGSs as well as in the BP at Kumundi. Thickeners are to be installed to thicken Iron Ore slurry & slimes at all four SGS. At Kumundi, the thickeners are to be installed before magnetic separator as well as before column flotation conditioners as intermediate thickeners. The Spiral Concentrate will be ground in regrind ball mills with closed circuit with cyclones. The overflow from cyclone will be fed to concentrate thickeners. The tailings generated at Kumundi will be treated in tailing thickeners and will be disposed in paste form in tailing disposal area of 78.913Ha/195 Acres at Urumunda & Kumundi.

Thickeners in each SGS.

1) Iron Ore Slurry thickeners-2 Nos 2) Slime Thickeners -2 Nos.

Thickeners in Kumundi.



1) Concentrate Thickeners-2 Nos 2) Tailing Thickener-3 Nos. 3) Intermediate Thickeners-3 Nos.

In addition to the above Water recovery thickeners, BSL is planning to use the Concept of installing Paste Thickeners at Urmunda to recover about 60% of water from tailing thickener underflow of Kumundi. It will be first time in India, that a paste thickener for disposing Iron Ore Tailings will be installed. With the combination of Normal and Paste Thickeners, more than 70 % of water from the tailings proposed to be recovered. The Paste dumped inside doesn’t flow on its own. Hence, no tailing dam is required.. The water recovered from tailings to the extent of 1292 m3/hr by using paste thickeners.

At Meramandali Steel plant, the concentrate slurry will be filtered in pressure filters. The filtrate from the pressure filters to be fed into thickener at Meramandali filtration area. Overflow water will be taken to Water reservoir located. This reservoir will cater to overall water requirement at Kumundi.

BSL envisages adopting zero discharge system for this project.

3.12.0 Noise Levels The major source of noise will be the grinding units and DG sets (used only during power breakdown).

The noise control will be done in four ways, namely by selecting low noise prone equipment which

would have led level below 75 dB (A) at 1 meter distance:

By selecting low noise generating equipment, which would have noise level within permissible

limits. This is taken care at the equipment design stage.

By isolating the noise unit from the working personnel’s continuous exposure by providing

acoustic aids for plant personnel.

By administrative & safety measures, providing noise level monitoring, remedial measures,

providing noise safety appliances.

The noise impact on the surrounding environment during the construction phase will be within

acceptable limits. The operation of high noise generating equipment shall be restricted during

the night time.

Various measures proposed to reduce noise pollution include reduction of noise at source,

provision of acoustic lagging for the equipment and suction side silencers, selection of low

noise equipment and isolation of noisy equipment. The plant personnel in noisy area will be

provided with high noise reduction aid such as ear muffler & also the duration of exposure of

the personnel will be limited as per the norms. Thick green belt development is planned for the

attenuation of noise pollution and to maintain ambient noise quality within the statutory limit.



3.13.0 Green Belt Development

A greenbelt development plan will be prepared and implemented along with the project. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the noise generated in the plant apart from improving the aesthetics of the plant site.

The Greenbelt area of 33% of plant area of each location i.e., 66.77Ha/165 Acres will be used so as to mitigate the effects of emissions from the plant. The treated effluents from the plants will be utilized for the greenbelt development. The area of green belts at individual sites will be as follows-

Unit location

Total Greenbelt area in Hectares in Acres

SGS-Jalpaposhi 9.750 24.09

SGS-Balajori 6.677 16.50 SGS-Tehrai 6.677 16.50 SGS_Gandhamardan 6.273 15.51 BP-Kumundi 20.700 51.15 TDS-Urumunda 16.693 41.25 Total 66.77 165.0

Compensatory afforestation will be carried out to replace the forests affected on the route of slurry pipelines. The landscaping of the plant will be carried out. Roads for vehicular movement will be paved and adequate mitigation measures will be provided to prevent fugitive emissions.

3.14.0 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE.



CHAPTER -04

SITE ANALYSIS

4.1.0 LAND FORM, USE AND OWNERSHIP

Total land requirement for the proposed plant, is about 202.342Ha/500 Acres. A total of 219.25Ha/541.8 Acres of land will be used in laying of slurry & water pipelines which will be returned to land owners after the completion of job. So the proposed project of SGS and BP will come up in 202.342Ha/500 acres of land in the final phase of Operation. Total land has already been identified and acquisition is in process.

4.1.1 TOPOGRAPHY

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

4.1.2 EXISTING LAND USE PATTERN

Currently proposed it is undeveloped/non-irrigated agricultural land (Kissam- Sarad, Patita, taila, Pahada ,mala, goda & Gochar, etc). The sites for the Plants are not coming under the dense forest category land. This area does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve. The locations are also not susceptible to flooding. The district lies in Seismic Zone II and there is low earthquake probability. Landslides/ erosion are not likely to happen.



Details of Land Involved for Laying of Pipelines in hectares:

Sl. No. Purpose of utilization

Forest land in ha.

R.F. V.F. DLC Revenue

Forest with kisam

Total

1 Pipeline corridor from Jalpaposhi to Meramandali.

a Total - Keonjhar 0.122 5.492 2.508 12.786 20.908

b Total -Dhenkanal 0.837 1.135 0.000 5.336 7.308

Total - (Keonjhar + Dhenkanal) 0.959 6.627 2.508 18.122 28.216

2 Pipeline corridor from Gandhamardan to Kumundi(Keonjhar)

0.000 0.000 0.000 1.008 1.008

3 Conveyor Belt Corridor from OMC, Gandhamardan to SGS, Gandhamardan

0.000 0.610 0.000 0.453 1.063

Total 0.95 Ha (2.35 Acres)

7.23 Ha (17.85 Acres)

2.50 Ha (6.17 Acres)

19.58 Ha (48.36 Acres)

30.687 Ha (74.80 Acres)

Statement Showing Details Of District Wise Forest Area Involved

Sl.No District

1 Keonjhar 0.122 6.102 2.508 14.247 22.979

2 Dhenkanal 0.837 1.135 0.000 5.336 7.308

Total 0.959 7.237 2.508 19.583 30.687 Note: The Right of User (RoU) width in non-forest area is 20 mtrs, while in forest area, the RoU width is restricted to 7.25 mtrs only. The width of conveyor belt corridor is 10 mtrs.



4.2.0 Justification for Locating Slurry Pipeline in Forest Area

Considering stringent guidelines of Forest (Conservation) Act, 1980 and Forest (Conservation) Rules, 2003 the proposal has been prepared. While aligning and routing the pipeline, utmost care has been taken to avoid involvement of any type of forest. Accordingly, three different alternate routes were studied in-depth to ensure least involvement of forest.

All endeavors and sincere efforts were made to avoid forest land but due to location disadvantages, terrain and geographical conditions total avoidance of forest area is not possible. Considering geography and demography, further studies were carried out and final pipeline route has been selected which involves minimum forest land.

Due care is taken to avoid existing / proposed National Parks / Wildlife sanctuaries in the study area of BP / slime dam i.e., within 10 km. radius of the project.

The pipeline concept of the project will overall minimize road transportation which reflects minimisation of fugitive dust emission.



SGS-GANDHAMARDAN



SGS- BALAJORI



SGS- TEHRAI



SGS-JALPAPOSI



BP-KUMUNDI



TAILING DISPOSAL AREA - URUMUNDA



4.3.0 EXISTING INFRASTRUCTURE

Transport

The transportation to the SGSs from nearby mines will be by trucks. The SGSs can be approached from the nearest National/State highways. The company will also utilize the railway siding at Jalpaposhi as required. To overcome the inherent restrictions of surface transportation, ore, slimes and water will be transported in slurry form from the SGSs to BP at Kumundi and from there the concentrated ore will be pumped to Meramandali plant of BSL.

Communication

Communication facilities such as telephone, tale fax and internet are available in nearby area and once the project implementation starts the company will take steps to install additional facilities as required.

Habitation

Nearest habitation is in town Banspal, Keonjhar. The area is sparsely populated. All basis amenities such as school, hospital, market, places of worship etc. are available in 10 Km area.

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CHAPTER – 05

PROJECT PLANNING

5.1.0 PLANNING CONCEPT

BSL intends to set up 21.0 MTPA (throughput) BP along with Iron Ore Slurry & Water Pipeline System to produce 12.0 MTPA iron ore concentrate at Kumundi, in Keonjhar district of Odisha.

For integrated steel plant at Meramandali, BSL has proposed slurry & water pipelines passing from 4 Nos. SGS to BP at Kumundi and terminates at BSL Meramandali plant.

The present project is based on the concept of beneficiation of low grade iron ore fines and transport the product concentrate through slurry pipeline to Meramandali Steel plant, which will be utilized further to produce pellets/ sinter.

5.2.0 POPULATION PROJECTION

With the set up of proposed project, infrastructure and social development will simultaneously take place. Project will contribute for raising the population of the locality as it creates job opportunities and economic upliftment of the area. Plant activities will also boost the ancillary industries, business and market establishments. The whole set will invite both skilled and unskilled workers from within and outside. This will result in increase in population density due to industrial setup.

The company will be providing employment 6, 45,000 man-days during construction phase and during the operation period of the proposed project. Apart from this 450 persons are directly benefited by this project during the operation phase. The local people will be engaged in various industrial activities.

5.3.0 LAND USE PLANNING

Currently it is undeveloped/non-irrigated agricultural land.

Land use planning (breakup along with green belt etc)

SGS-Koira-A-Tehrai Site

Sl. No. Description Area in Hectares Acres

1. Main Plant Built-up 2.630 6.50 2. Raw material storage & handling area 4.250 10.50 3. Utilities area 2.023 5.00 4. Thickener & slurry storage area 2.226 5.50 5. Water storage & water pump houses area 2.428 6.00 6. Greenbelt (33%) 6.677 16.50 Total 20.234 50.0



SGS-Koira-B-Balajori Site



SGS-Gandhamardan Site



SGS-Jalpaposi Site


1. Main Plant Built-up 2.796 6.91 2. Raw material storage & handling area 6.273 15.50 3. Utilities area 2.630 6.50 4. Thickener & slurry storage area 3.237 8.00 5. Water storage & water pump houses area 4.856 12.00 6. Greenbelt (33%) 9.750 24.09 Total 29.542 73

BP-Kumundi site


1. Main Plant Built up(BP , admin build, control room & others)

2.428 6.0

2. Water Storage area 4.856 12.0 3. Utilities area1(Electrical, DG set) 0.607 1.50 4. Utilities area 2(Repair shop & store) 0.404 1.00 5. Thickener & Slurry storage area 4.047 10.0 6. Tailing disposal area 28.328 70.0 7. Emergency dump pond area 0.708 1.75 8. Road, residential facility & others 0.648 1.60 9. Greenbelt (33%) 20.700 51.15 10. Total 62.726 155



TDS-Urmunda site


1. Tailing Disposal area 33.893 83.75 2. Greenbelt 16.693 41.25 Total 50.586 125

Total area required is 78.914Ha/195 Acres (inclusive of 28.328Ha/70 Acres area at Kumundi for tailing disposal).

5.4.0 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

The existing infrastructure facility is adequate in the proposed project site. The social infrastructure like school, college, temples and play ground already exist in this area. However the above all infrastructure facilities need further development. Apart from these the following facilities should be maintained.

a) Administrative Building, Service Building b) Construction offices and stores c) Time and security offices d) First Aid and fire fighting station e) Canteen and welfare centre f) Toilets and change rooms g) Car parks and cycle/ scooter stands h) Training centre

5.5.0 Design Philosophy

5.5.1 System Design for high Unit availability

The high availability of the Unit and associated auxiliaries objectives will be achieved by adopting the following principles;

Use of equipment and systems of design performance and high availability which has been fully

established by a considerable record of successful operation for similar service conditions in coal

fired utility stations.

Use of only proven design concepts and conservative designs.

Strict implementation of quality assurance norms during design, manufacture as well as

installation and commissioning stage.

Strict compliance with the project company approved pre-commissioning and commissioning

procedures as well as standard checklists forming a part of commissioning documents for the

project.



5.5.2 Sizing of critical equipment- margins & redundancy/standby Adequate margins will be provided, while sizing all important auxiliaries and sub-systems to ensure

operation of the Unit at full rated capacity under the worst conditions taking into consideration normal

wear & tear.

5.5.3 Design for efficient operation

Centralized maintenance system will be followed. All repairs of capital nature, heavy maintenance jobs,

refractory maintenance and plant civil maintenance will be done by engaging specialized external

agencies.

Implementation of computer systems including local area network (LAN) with standard user friendly

software’s in the field of financial management, personnel management, materials management, order

scheduling, sales and marketing management, management information systems (MIS), production

planning and control, maintenance and spares planning, etc. has been considered to increase work

efficiency and to reduce manpower requirement.

5.5.4 Operation Performance Management System (OPMS)

The operation of the plant will be optimised by implementation of OPMS. This system will clearly

define the responsibilities of all key O&M personnel including the shift-in-charge. This will also cover

the system of daily reporting to the project company Corporate Office and monthly O&M review

meetings.

5.5.5 Operation & Maintenance Philosophy

It is presumed that most of the key positions in operation and maintenance of the proposed plant at

different categories will be manned by the qualified persons having experience in the similar field.

However, depending on the type of equipment/facilities along with the degree of automation

contemplated, the operation and maintenance personnel of the plant so recruited will require specific

need based training which is proposed to be carried out on site by the respective equipment supplier

during equipment erection, start up and commissioning of different plant units.

5.5.6 Maintenance Management System

The maintenance of the plant will be carried out as per the maintenance management system to be

developed by the project. This system should aim at maximizing the availability of the generating units

while ensuring minimum maintenance cost and safety of plant & personnel. The system should cover

organizational structures, preventive maintenance schedules, detailed work specifications covering all

maintenance jobs, permit-to-work system, long term maintenance planning, safety aspects etc.



5.5.7 Spare Parts Management System

The primary objective of the system will be to ensure timely availability of proper spare parts without

excessive build-up of non-moving inventory. The system will cover the following aspects:

Proper codification/identification & retrieval of all spares & consumables

Proper storage & protection

Spare parts indenting and procurement policy

Judicious fixing of inventory levels and spare part ordering based on experience of similar Units

or other benchmarks.

Development of indigenous sources/in-house capability for imported spare parts.

Development of more than one source wherever applicable.

5.5.8 Special Tools & Tackles

All equipment supply contracts will include the provision of supply of special tools & tackles, wherever required, for installation, commissioning, and maintenance of the plant & equipment. These will be handed over to the O&M department at the appropriate time after commissioning of the Unit.

5.5.9 O&M Training

An experienced O&M staff will be placed at an early stage to introduce the best system and operational management and practices. Depending on the type of equipment/facilities along with the degree of automation contemplated, the operation and maintenance personnel of the plant so recruited will require specific need based training which is proposed to be carried out on site by the respective equipment supplier during equipment erection, start up and commissioning of different plant units.

5.6.0 AMENITIES/FACILITIES.

5.6.1 In-Plant Facilities The following facilities shall be provided in this station:

a) Administrative Building, Service Building

b) Construction offices and stores

c) Time and security offices

d) First Aid and fire fighting station

e) Canteen and welfare centre

f) Toilets and change rooms

g) Car parks and cycle/ scooter stands

h) Training centre

i) Residential facility



According to norms, laid down in relevant Factories Act, office space, canteen, toilets and restrooms have been planned. The above facilities shall also be adequately furnished and equipped.

5.6.2 Employment Generation:

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

opportunities;

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

• Improved green cover;

• Better communication and transport facilities;

The proposed project shall enhance the prospects of employment. Recruitment for the unskilled workers for the proposed plant will be from the nearby areas. The basic amenities viz. roads, transportation, electricity, drinking water, proper sanitation, educational institutions, medical facilities, entertainment, etc. will be developed as far as possible.

5.6.3 Medical Facilities/ Health care camps

Medicines will be provided at proposed first aid centre in the plant premises, which will cater to

the needs of adjoining population.

Periodic health camps like: Eye camp; and Health checkup camps for treatment of other diseases

will be conducted by the company through government doctors and their staff.

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CHAPTER – 06

PROPOSED INFRASTRUCTURE

6.1.0 INDUSTRIAL AREA (PROCESSING AREA)

The setting up of the Main Plant Facilities, Raw Material Storage, Tailing Pond, Raw Water Storage Reservoir, Auxiliary facilities, viz. Administrative Building, Technical Building, Workshop, QC Lab, Switch Yard, greenbelt (33%, )etc. will require 202.342Ha/500 Acres land in the 4 Nos. SGSs and BP. Company uses nearest road for goods transportation and equipped with all other required facilities.

6.2.0 RESIDENTIAL AREA (NON PROCESSING AREA)

Around 450Nos. people will be engaged in the plant and town is very close to the project site. The area around the site is under development with reasonably good communication facilities. Other social infrastructure like housing, schooling and medical facilities has been developed and in some area it is underdeveloped. However, in BP at Kumundi, residential facilities will be provided to workers & employees

6.3.0 SOCIO-ECONOMIC BENEFITS & SOCIAL INFRASTRUCTURE

BSL will commence a lot of infrastructure developmental works in the periphery area. The project will have a positive impact on the regional and National economy, consolidating employment in the Indian mineral processing industry and its allied subsidies. Value addition to low grade Iron Ore fines by converting it to Iron Ore pellets is a great achievement for the steel industry. It also helps society and surrounding to prosper in many ways.

Increase in employment opportunities.

Reduction in migration of locals for employment.

Increase in literacy rate.

Growth in service employment.

Increase in consumer prices of indigenous produce and services, land prices,

house rent and labour prices.

Increase in per capita income.

Improvement in transport, communication, health and educational services.

Increase in employment due to increased business, trade commerce and

service order.

Overall no negative impact on the socio economic environment is anticipated.



6.4.0 CONNECTIVITY

Proposed project site for the BP is well connected to NH-215 and also connected to the Keonjhar Railway station. However the existing road network will be strengthened and new road network will be built in the adjoining areas if required.

6.5.0 DRINKING WATER MANAGEMENT

Drinking water facilities will be provided for employees. A fresh water tank will be constructed for this drinking purpose. Drinking water requirement for the staff and workers at respective sites will be 612 m3/day. The water will be sourced from underground at the respective sites.

A water treatment plant is envisaged for providing potable water to all employees.

6.6.0 SEWERAGE SYSTEM

A garland drain around the plant is envisaged to collect surface run-off during rainy season. Separate Internal drainage system will be constructed to collect domestic and industrial effluent. A common basin will be constructed for the treatment of effluents in the plant. The sewage from the various plant buildings will be taken to a common STP through trenches. The treated water from the STP will be used for greenbelt and dust suppression. As the sewage is taken in trenches the soil will not get contaminated. Sludge from STP will be used as manure for greenbelt development.

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CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1.0 POLICY TO BE ADOPTED FOR R & R PLAN

The proposed project will come up on about 202.342Ha/500 acres of land. An additional 219.25Ha/541.8 Acres of land will be used for laying of slurry & water pipelines, which will be returned to land owners after completion of the job in fully restored condition.

In 202.342Ha/500 Acres of land, which will be utilized by BSL, there will be no displacement of locals. Therefore, R & R plan is not envisaged.

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CHAPTER – 08

PROJECT SCHEDULE 8.1.0 SCHEDULE DETAILS

In this industry, any one of the following three alternate modes of project execution is adopted:

Turnkey

Semi Turnkey

Packaged procurement mode

8.1.1 Planning Of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the project.

Following activities will be given special attention.

8.1.2 Pre Project Activities

Management Approvals.

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups.

Selection of Consultants

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

8.1.3 Project Activities (Implementation Stage)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of Tender, Evaluation of tenders received and Order placement for balance

machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works



Erection of all plant & machinery

Commissioning of the plant

8.1.4 Statutory Clearances

The proposed project will require various statutory approvals and clearances from various authorities of the Government. The statutory clearances required for the proposed project, have been identified and necessary actions initiated, to obtain these approvals.

8.1.5 Project Schedule

The total project implementation schedule is 36 months from zero date. Land acquisition will be completed before commencement of construction. The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance. An effective project team has been formulated with an experienced Project Manager as its leader.

8.1.6 Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely execution of the project:

The task of implementing the project in time shall be achieved by ensuring a well coordinated

project implementation task force in-house and from external agencies

A well chosen team of experienced personnel for project execution shall coordinate the

implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected for detailed

engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men, material and

tools and tackles, will be engaged for execution of the construction and erection work.

Effective project monitoring including project planning schedule and monitoring shall be

employed in this project. Timely execution and resources will be monitored using computer

based project monitoring tools. In case of deviations in project progress, all possible corrective

actions such as crashing of network etc. will be carried out.

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CHAPTER – 09

ANALYSIS OF PROPOSAL 9.1.0 FINANCIAL AND SOCIAL BENEFITS

BSL is setting up the project in the mineral rich district of Keonjhar. It will be a major thrust on value addition in line with government objectives by utilizing the huge amounts of low grade Iron Ore fines lying in the Mining belt of Koira/Keonjhar/Joda –Barbil of Odisha. In view of the increasing demand for Iron ore pellets, both indigenous and export, the project will be financially profitable and viable. It will also help in conservation of high grade ores for the future and mitigate the pithead environmental pollution.

Besides there will be immense social benefits, to the backward region with this project.

9.1.1 Improvements in the Physical Infrastructure

BSL has envisaged a lot of infrastructure developmental works in the peripheral area.

Improving and building road network in the adjoining areas.

Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure Increase in employment opportunities. Reduction in migration of locals for employment. Increase in literacy rate. Growth in service employment. Increase in consumer prices of indigenous produce and services, land prices, House rent and labor wages. Increase in per capita income. Improvement in transport, communication, health and educational services. Increase in employment due to increased business, trade commerce and service order. Overall no negative impact on the socio economic environment is anticipated.

9.2.0 Employment

Employment opportunity will be generated during implementation of the project. There will be permanent employment of 450Nos. persons including Sr. Executives, Managers, Administrators, Engineers, Supervisors and Skilled Technicians.

The Unskilled labours will be recruited from the local area and surroundings during the construction period and there will be approximately 6, 45,000 man days work force will be engaged.



In addition to direct employment, proposed project shall generate number of indirect job opportunities on local and regional basis.

9.3.0 OTHER BENEFITS

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

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

industrial production.

Thus, the proposed project will lead to improvement in social and economic conditions of people living in and around the project sites.

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Visiontek Consultancy Services Pvt. Ltd(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : [email protected], [email protected], Visit us at : www.vcspl.org

Committed For Better Environment

m/s. bhushan steel limited

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