pre feasibility report (amendment in tor)...

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

PRE FEASIBILITY REPORT

(AMENDMENT IN TOR)

Of

By

SHRI BAJRANG POWER & ISPAT LIMITED



1.0 EXECUTIVE SUMMARY

1.1 Name of the Project Proponent: : Shri Bajrang Power and Ispat Ltd.

1.2 Location : Village – Borjhara, Urla - Guma Road, Urla Industrial Area, Raipur (C.G.) - 493 221

1.3 Office (Regd.) : Village – Borjhara, Urla - Guma Road, Urla Industrial Area, Raipur (C.G.) - 493 221

1.4

Existing Production

capacity and configuration

Expansion proposal (capacity after expansion and

configuration)

TOR granted

TOR Amendment Requested

Remark

Sponge Iron - 2,10,000 TPA 2 x 350 TPD x 300 days

Sponge Iron – 2,64,000 TPA 2 x 400 TPD x 330 days


No Change Sponge iron process optimization with same 2 kilns by use of good quality coal

Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler 60 TPH Fuel : Rice Husk & Dolo Char

WHRB – 18 MW CPP – 8 MW AFBC Boiler 60 TPH Fuel : Rice Husk & Dolo Char


No change Change in fuel Mix for CPP. To include coal/ coal fines as fuel in addition to Rice Husk& Dolochar

SMS – 1, 29,600 TPA 6 x 8T Induction Furnace

SMS – 2, 11, 200 TPA

SMS – 2, 11, 200 TPA

Change in Configuration Existing 6 X 8 T furnace will be changed to 3 X 15 T capacity furnaces to get the present production of 129600 TPA New 2x15 T furnaces will be installed as per the TOR obtained for additional production of 81,600 tons

Ferro Alloys – 14.400 TPA 2 x 4 MVA (SAF) (Combined EC of Ferro & Biomass)

Ferro Alloys – 19,800 TPA 1 x 5 MVA + 1 x 6 MVA (SAF)


Existing furnaces 4 MVA – 2 Nos. will be replaced by higher capacity transformer 1X5 MVA 1X6 MVA



Rolling Mill – 0.15 MTPA

Rolling Mill - 0.21 MTPA


Optimization of production capacity of Rolling Mill by curtailing Idle running hours.

Coal Washery- 1.2 MTPA



No change in capacity

Pellet plant (0.6 MTPA) CTE granted by CECB, but plant yet not installed Pellet plant with coal Gasifier will be installed now

Proposed - Pellet Plant (0.6 MTPA)


New Pellet Plant will be installed with coal gasifier of 9000 Nm3/hr

1.5 Total Project Area : Present Land utility: 21 Ha Additional Land utility for expansion : 6.8 Hectare Total land after expansion : 27.8 Ha

1.6 No. of Working Days : 330 Days

1.7 Cost of Project : Proposed expansion : Rs. 120 crores

1.8 Man Power Utilization : Present Manpower – 750 Additional manpower – 100

2.0 INTRODUCTION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

GOEL GROUP is one of the leading business houses in Chhattisgarh. The Group having diversified business activities, but mainly engaged in manufacturing of Steel and generation of power and has interest in manufacturing of Sponge Iron, Iron Ore Beneficiation, Pellets, Induction/ Arc Furnace with Continuous Casting Machine for production of Steel Billets and Blooms, Hot Re-Rerolled Steel products, Ferro Alloys, Fly Ash Bricks and Captive Power Plant together with their backward and forward integration. The Group is totally integrated to produce finished steel under one roof and selling all products under the Brand Name “GOEL” which is well-established and well-known for its quality products in the steel sector. There are six different Goel Groups of Companies out of which „Shri Bajrang Power & Ispat Ltd.‟ (Borjhara Division) is one of them. This company under backward integration, the company has established mega project with the investment of Rs. 230 Crores. Presently the company has established the existing production capacity of 2x350 TPD Sponge Iron Plants with 26 MW Captive Power Plant, 6 x 8 MT Induction Furnace with Continuous Casting machine, 2 x 4 MVA Ferro Alloys plant and 1.2 MTPA Coal Washery and 0.15 MTPA Rolling Mill at village Borjhara, in Urla Industrial complex, Raipur. The company proposed to add the following production/ generation capacity and change in configuration with existing EC: (Table 1A as per the TOR & Table 1B TOR Amendment Requested)



Table 1A as per the TOR:

PRODUCTION/ GENERATION CAPACITY EXPANSION AND CHANGE IN CONFIGURATION

Existing Installed Capacity and Total Capacity after expansion

Existing Production capacity and configuration

Total capacity after expansion and configuration

Remark



Sponge iron process optimization with same 2 kilns by use of good quality coal



No change in capacity Change in fuel Mix for CPP. To include coal as fuel in addition to Rice Husk& Dolochar


SMS – 2, 11, 200 TPA

Two more induction furnace of 15 T each along with continuous casting machine and LRF to be installed for additional production 81,600 TPA.




Rolling Mill – 0.15 MTPA Rolling Mill - 0.21 MTPA Optimization of production capacity of Rolling Mill by curtailing Idle running hours.

Pellet plant (0.6 MTPA) CTE granted by CECB, but plant yet not installed


New unit – Applying for EC

Table 1B TOR AMENDMENT REQUESTED

PRODUCTION/ GENERATION CAPACITY EXPANSION AND CHANGE IN CONFIGURATION

Existing Production

capacity and configuration


configuration)

TOR granted


Remark








No change in capacity Change in fuel Mix for CPP. To include coal/ coal fines as fuel in addition to Rice Husk& Dolochar


SMS – 2, 11, 200 TPA

SMS – 2, 11, 200 TPA

Existing 6 X 8 T furnace will be changed to 3 X 15



T capacity furnaces to get the present production of 129600 TPA Two more induction furnace of 15 T each along with continuous casting machine and LRF to will be installed for additional production 81,600 TPA.





Rolling Mill – 0.15 MTPA Rolling Mill - 0.21 MTPA



Coal Washery- 1.2 MTPA Coal Washery- 1.2 MTPA






New Pellet Plant will be installed with coal gasifier of 9000 Nm

3/hr

2.2 Brief Description and Nature of the Project:

The project already has sponge iron manufacturing through Iron Ore, Coal and Dolomite. Steel Melting Shop with configuration of 6 x 8T of Induction Furnace. Ferro Alloys with existing capacity of 14,400 TPA (2 x 4 MVA SAF) along with Captive Power plant having capacity of 26 MW capacity in which 18 MW power generated through WHRB and rest of 08 MW generated through bio mass. Similarly the company has also taken combined environmental clearance for Coal washery and rolling mill having capacity of 1.2 MTPA and 0.15 MTPA respectively within the same plant premises. Now, the said proposal for expansion of production capacity with change in configuration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to 2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MW captive power plant since availability of Rice Husk is not consistent as per our requirements hence coal/coal fines will also be used in addition to Rice Husk & Dolochar.The expansion of Submerged Arc Furnace involves the enhancement of capacity and modernization. The existing SAF production capacity is 14,400 TPA (2 No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase in production capacity of 19,800 TPA (1 No. x 5 MVA +1 No. x 6 MVA Transformer).

Existing Steel Melting Shop (SMS) production capacity of 1, 29,600 TPA will be enhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which will have additional production capacity of 81,600 TPA. Now, the existing 6x8 t furnaces will be replaced with 3x15t furnaces. Rolling mill capacity will be enhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due to curtailment of Idle



Running Hours since it is to run in synchronization with SMS as we have adopted direct rolling technology. A new Pellet plant (0.6 MTPA) is proposed.

2.3 Need for the project and its importance to the country and/or region:

Steel is one of the most important products of the modern world and is of strategic importance for any industrial nation. Historically, all nations during their industrialization phase have been supported by a strong steel industry of their own. From construction, industrial machinery to consumer products, steel finds a wide variety of applications. It is also an industry with diverse technologies based on the nature and extent of use of raw materials.

Honorable Prime Minister Shri Narendra Modi has envisaged the growth of steel sector to attain a production capacity of 300 Million Tonnes by 2020, hence in order to achieve this capacity, it is essential to create the facilities based on local resources to produce steel.

The Honorable Prime Minister has also proclaimed the global commitment to fight Climate Change; hence the importance of creating the facilities to achieve highest energy efficiency in core sector industries is also very essential.

In view of these facts, the proposed expansion Integrated Steel Plant with Sponge Iron Plant, Ferro Alloys Plant, Captive Power Plant and change in configuration of existing still melting shop along with addition of Pellet Plant.. All these production technologies make the project as a better energy efficient project due to which a substantial amount of GHG emission would be avoided or reduced than the baseline emission.

(A) For Sponge Iron Plants

- Use of hi-grade coal in sponge iron making, can reduce the prevailing coal consumption of 1.2 MT/MT sponge iron to less than 1.0 MT coal per ton of sponge iron production.

- The metallization of sponge iron is drastically improved. - The campaign life of sponge iron kiln is greatly improved. - Water consumption in cooling of sponge iron in cooler portion is reduced. - Waste generation in form of AFBC bottom ash and CFBC bottom ash and ESP

dust is reduced. - The overall productivity of sponge iron plant and steel plant is improved.

(B) For Power Plants

Power companies benefit from better efficiency, less coal consumption, lower transportation cost, lower maintenance cost, better thermal efficiency, higher plant availability and less waste disposal cost.

- The country benefits from greater electricity supply and economic growth. - Environment benefits – less CO2, ash and better air quality. - Reduced load on constrained transportation system, rail and road- giving more

coal supply for India.

Strong Environmental Case for Coal Washing



- According to study from US department of Energy, the use of washed coal reduced CO2 emission by as much as 11%.

- Use of washed coal can increase generation from existing plants by at least 10% which effectively reduced CO2 emission.

- India is likely to be one of the most impacted countries from climate change. - According to the IFPRI, India will face the highest number of climate change

related casualties. - With the implementation of carbon credit, companies using washed coal would

benefit from lower emission and higher profits. - Washing will lower particulate air pollution- as India industrializes, this will become

a major problem.

Mandatory Washing of All Coal

- Today, it is only mandatory to wash coal transported above 1000 KM enforcement is unclear.

- 100% coal washing should be mandatory within 5-7 years in the phased manner. - India has been slower than other countries in implementing washed coal due to

lack of emission standards and a misleading perception that coal washing adds to the cost of electricity generation.

- Unwashed coal encourages power companies to operate inefficient and highly polluting power plant.

- Washed coal encourages the use of efficiency in super critical power plants which are better for the environment and for India‟s goal of more electricity production.

Advantages of the project

Value addition project by gainful utilization of wastes and converting intermediate products into End-use product.

- Improved productivity of the existing process. - Reduced operation cost due to sharing of infrastructures and manpower with

existing unit reducing overhead by almost 30% - Since the materials handling will be similar to existing operation, synergy of

activities will bring economies to the unit. - Dedicated and experienced workforce is available. - Ready market for the supply of finished products. Easy accessibility to the thriving

markets of Chhattisgarh, Madhya Pradesh, Bihar, UP and Odisha form another major locational advantage factor.

- Technology is not new and has already been successfully tried in existing plant.

State Growth Policy

New Industrial policy of the state is to derive maximum value from resources and create jobs by setting up industries in all the districts. The state government has realized that Chhattisgarh can become a “developed State” only if its industrial growth rate increases substantially and that can only happened with a favorable



environment for investment. Hence, attempts are on to make the administration investor-friendly and to provide the necessary infrastructure. Special importance is given to private sector participation as well as industrial development in the backward regions. The proposed expansion will help in increasing the employment opportunities to the local people and also it will help in the industrial growth of the country.

2.4 Demand-Supply Gap

The scenario of Steel Industry is clearly looking upward and the latest data on Steel Industry is as follows:- Steel is traditionally considered the backbone of national economic development. It is a major input into sectors which support economic growth such as infrastructure, machinery, power and railways, as well as being important for fast growing sectors, in particular automobiles and consumer durables.

India is the fourth (4th) largest steel producer in the world, presently producing about 90 Million Tonnes of saleable finished steel products in the ratio of about 40-60% in the category of Flat Products and Long Products.

Per capita consumption of steel in India is only about 60 Kg as compared to a world average of 217 Kg and China‟s 510 Kg. Being a developing country, the consumption in the country shall increase every year creating a good demand over the coming years.

The country‟s steel production and consumption is likely to remain higher in 2017-18 from 89.79 MT of crude steel during 2015-16 backed by an increase in infrastructure allocation in the budget, a report said.

In 2017-18, steel production is expected to remain higher. This will be backed by an expected revival in consumption. An increase in infrastructure allocation by the government in the Union Budget 2017-18 is expected to drive the pace of construction and infrastructure in the country, Care Ratings said in its report.

The National Steel Policy 2017, released by the government, also aims to increase steel production. Thus, both production and consumption of steel is expected to remain buoyant in 2017-18. The country has gained the position of third largest crude steel producer in the world and is largely focusing on increasing production. However, focus at the same time should be on increasing consumption of steel and reducing the dependence on cheap imports.

The government had supported the industry in 2016 by providing protectionist measures. But the protection cannot be expected to last forever and the industry has to gear itself to face competition in the normal course, Care Ratings said. In 2014-15, India surpassed the US to become the third largest steel producer in the world. India continued with this position in 2015-16 as well. The country produced 88.97 million tonnes and 89.79 million tonnes of crude steel during 2014-15 and 2015-16, respectively.



Steel production in the world is dominated by China followed by Japan. During 2015-16, crude steel output of China stood at 789.04 MT and for Japan it stood at 104.23 MT. In 2016-17, production of these steel producing countries (excluding India) remained subdued even during April-December 2016 on a y-o-y basis. While crude steel output in China, Japan and Russia grew by mere 0.5-3%, output in US remained flat and that in South Korea declined by 1.3%.

In contrast, crude steel production in India rose by 8.8% to 72.35 MT during this period. This was on account of higher output by the major Indian steel companies. The imposition of Minimum Import Price (MIP) encouraged the producers to increase their output. Care Ratings said that the consumption of steel, on the other hand, grew by just 3.2% to 73.75 MT during April-December 2016.

Post-demonetization, steel consumption is expected to remain under pressure in the coming few months to a certain extent. This is because it is likely that the demand for steel from the user industries like construction, real estate will take some time to strengthen. However, government push towards infrastructure will compensate for this reduction in demand, it added. Source: Live Mint E paper

Major Objectives of the National Steel Policy 2012 are as follows

a) To attract investments in Indian steel sector from both domestic and foreign sources and facilitate speedy implementation of investment intentions on board so far so as to reach crude steel capacity level of 300 million tonnes by 2025-26 to meet the domestic demand fully.

b) To ensure easy availability of vital inputs and necessary infrastructure to achieve a projected production level of 275 million tonnes by 2025-26.

2.5 Imports vs. Indigenous production

Iron ore is available in abundance in India as non-coking coal, but coking coal is not available much. Thus steel production facilities added during last 10 years in India are well established based on coal based rotary sponge iron kilns. Prior to implementation of the sponge iron kiln based steel making the gap between demand and supply was fulfilled by import of steel. The Chinese manufacturers are giving tough competition to Indian steel producers because of their cheaper production cost mainly due to abundantly availability of coking coal in their country. Therefore, in order to face the competition being poised by the Chinese manufacturer, it is important to provide good quality washed coal to existing sponge iron plants in India and also provide good quality Iron ore / Pellets to the existing sponge iron plants. In view of this, it is necessary to have good quality washery. The Indian infrastructure sector is likely see a massive growth due to increasing economic status thus in order to keep the supply ready to match the demand of construction steel, the additional capacity of TMT steel bars is most immediate requirement of time.

2.6 Export possibility

Export of Steel is always possible, the Government of India is also encouraging export of steel, however proposed quantity will be domestically consumed. The world steel market is for about 1500 Million Tonnes, out of which about 50% is being



produced by China, the global demand even if increased by 2% per annum then it requires addition of 30 Million Tonnes additional production capacity. Since China has already reach to saturation level of increasing the production therefore India has better chance to share the world market by increasing its production in an energy efficient manner. The unit being located in the eastern sector can export the steel to Bangladesh; Bhutan; and Burma and Nepal also.

2.7 Domestic/ Export Markets

Domestic market with real estate, infrastructure project, industrial projects are available for purchase of steel which is estimated to be around 80 million tonnes per annum. The estimated growth in infrastructure is likely to increase the demand of steel to more than 150 million tonnes by the year 2020. In view of this it is required to make advance planning for creating the facility and infrastructure to meet this demand. The domestic market as well as export market both will require good quality steel, produced with minimum energy consumption and minimum cost of production. In order to achieve these objectives, the proposed project has been designed to utilize waste resources to generate power and provides high grade beneficiated coal to the existing sponge iron plants, steel plants and power plants.

The project has potential to cater to the domestic demand as well as export demand of steel and to provide washed coal to domestic as well as export oriented sponge iron / steel plants. The tunnel kiln based reduced Iron Powder production technology is likely to open new energy efficiency vista to the steel plants in India; by which the step of pelletization or sinter can be done and directly produces the Reduced Iron Powder in most environment friendly manner. The same can also be used for experimenting to produce other reduced metals too. The Ferro Alloys plant will be able to meet the internal requirement of the Ferro Alloys as well as it is proposed to produce Pig Iron on trial basis; in case the trial is successful then it will be used to transfer the liquid Iron to produce steel in SMS.

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

The list of likely employment due to project after expansion is given in Table 2, as per which following direct and indirect employment potential is likely to be generated

TABLE 2: EMPLOYMENT GENERATION

Particulars Existing Proposed

Admin Staff : 750 100

Production staff

:

3.0 PROJECT DESCRIPTIONS 3.1 Type of project including interlinked and interdependent projects, if any.

The project is an existing Metallurgy project falling under “A” category. The project already has sponge iron manufacturing through Iron Ore, Coal and Dolomite. Steel Melting Shop with configuration of 6 x 8T of Induction Furnace. These 6x8 T furnaces



will be replaced with new 3x15Tonnes furnaces which are more energy efficient Ferro Alloys with existing capacity of 14,400 TPA (2 x 4 MVA SAF) along with Captive Power plant having capacity of 26 MW capacity in which 18 MW power generated through WHRB and rest of 08 MW generated through bio mass. Similarly the company has also taken combined environmental clearance for Coal washery and rolling mill having capacity of 1.2 MTPA and 0.15 MTPA respectively within the same plant premises. Now, the said proposal for expansion of production capacity with change in configuration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to 2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MW captive power plant since availability of Rice Husk is not consistent as per our requirements hence coal/coal fines will also be used in addition to Rice Husk & Dolochar.The expansion of Submerged Arc Furnace involves the enhancement of capacity and modernization. The existing SAF production capacity is 14,400 TPA (2 No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase in production capacity of 19,800 TPA (1 No. x 5 MVA +1 No. x 6 MVA Transformer).

Existing Steel Melting Shop (SMS) production capacity of 1, 29,600 TPA will be enhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which will have additional production capacity of 81,600 TPA. Existing 6x8 Tonnes furnaces will be replaced with 3x15Tonnes furnaces. Rolling mill capacity will be enhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due to curtailment of Idle Running Hours since it is to run in synchronization with SMS as we have adopted direct rolling technology. A new Pellet plant (0.6 MTPA) is proposed.

3.2 Location (map showing general location, specific location and project boundary and project site layout) with coordinates.

Details about the Project area are presented in Table 3.

TABLE 3: DETAILS ABOUT THE PROJECT AREA

State Chhattisgarh

District/ Tehsil Tehsil- Raipur, District- Raipur

Village Borjhara, Sarora & Urla (Urla Industrial Complex)

Khasara No. CSIDC Allotted Land and Private Purchased Diverted Industrial Land Khasra No. 173, 174, 175, 176, 177 & 178

Area 27.8 Hectare (after expansion)

Toposheet No. 64G/11

Geo-coordinates

Latitude 21018'23" to 21018'46"

Longitude 81035'09" to 81035'44"

The index map and location is presented in Annexure-I, Location map showing 10 km radius of study area shown in Annexure-II

Annexure – I

INDEX MAP



Annexure – II STUDY AREA MAP

(10 KM RADIAL DISTANCE FROM THE PROJECT SITE)

3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Expansion of integrated steel plant within the existing plant premises, hence, alternative sites are not examined. The existing and proposed production capacity with details regarding configuration are presented in Table 4

3.4 Size or Magnitude of Project

TABLE 4: PROPOSED EXPANSION OF INTEGRATED STEEL PLANT



configuration)

TOR granted


Remark





Total Power Plant – 26 MW





configuration)

TOR granted


Remark

(CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler 60 TPH Fuel : Rice Husk & Dolo Char



No change in capacity Change in fuel Mix for CPP. To include coal/ coal fines as fuel in addition to Rice Husk& Dolochar


SMS – 2, 11, 200 TPA

SMS – 2, 11, 200 TPA

Existing 6 X 8 T furnace will be changed to 3 X 15 T capacity furnaces to get the present production of 129600 TPA Two more induction furnace of 15 T each along with continuous casting machine and LRF to will be installed for additional production 81,600 TPA.





Rolling Mill – 0.15 MTPA Rolling Mill - 0.21 MTPA



Coal Washery- 1.2 MTPA Coal Washery- 1.2 MTPA






New Pellet Plant will be installed with coal gasifier of 9000 Nm

3/hr

3.5 Project description with process details:

Description about process/sub-process M/s. Shri Bajrang Power & Ispat Ltd. is having various sections for manufacturing the following products:

1. Sponge Iron Plant, Capacity 2,10,000 TPA 2. Captive Power Plant, Capacity 26 MW 3. Steel Melting Shop, Capacity 1,29,600 TPA 4. Ferro Alloy, Capacity 14400 TPA 5. Coal Washery Plant 1.2 MTPA 6. Rolling Mill, capacity 150000 TPA 7. Fly Ash Bricks Plant 3,00,00,000 NPA



The process flow diagram is enclosed for reference.

Each sub–process of sponge iron division is described as under:

A. SPONGE IRON PLANT M/s. Shri Bajrang Power & Ispat Ltd. is having rotary kiln of (2 x 350) TPD Sponge Iron Plant. DRI or Sponge iron, as it is often referred to, is the substitute for melting scrap (scrap steel) in the steel making process. DRI is the process of converting iron ore to metallic iron without the smelting process. The process of sponge iron making aims to remove oxygen from iron ore. When that occurs, the departing oxygen causes micro pores in the ore body making it porous, looking spongy in texture; hence, the name sponge iron. Sponge iron is better in quality than scrap and is also cheaper than scrap.

In Sponge Iron Division, the process of manufacturing starts from the stage of crushing of Iron Ore, Coal & Dolomite to smaller size. The kiln feed size of iron ore is 4-20 mm, coal 4-18 mm & dolomite 2-6 mm. They are sieved & brought to the conveyor belts to carry to the rotary kiln system. The sized raw materials, viz. iron ore, coal & dolomite, stored in different bins are fed after weighing into the rotary kiln. The ore mixture is continuously rotated with the help of motors, gear boxes for movement of the material placed in it. Air is supplied by the fans mounted on the kiln for burning the charge. Air is continuously supplied into the kiln for burning the charge. The air is continuously supplied into the kiln through several air injection tubes fitted in the kiln to assist the reduction of iron ore into sponge iron resulting in the conversion of iron ore into sponge iron. The material is cooled in the cooler, which is attached to the kiln. The product from the kiln discharge consists of hot sponge iron and char (ash & un-burnt coal particle) which is transferred into rotary cooler where it is cooled down by indirect water spray arrangements. The Sponge Iron is separated from the dust & non-ferrous impurities in magnetic separation system by the process of magnetic separation. The cooled product is further magnetically separated to pick up sponge iron & separate kiln waste. The sponge iron is then sieved to separate the sponge iron lumps, fines & brought to their respective storage areas. The sponge iron is then sieved to separate the sponge iron lumps, fines & brought to their respective storage areas. The process flow diagram of sponge iron plant is shown in Figure 1, whereas the product view (sponge iron) is shown in Figure 2.



FIGURE1: PROCESS FLOW OF SPONGE IRON PLANT

FIGURE 1a: PROCESS FLOW DIAGRAM OF SPONGE IRON SECTION



FIGURE 2: PICTORIAL VIEW OF SPONGE IRON

a. CAPTIVE POWER PLANT

Waste Hot Gas Based Captive Power Plant

The power requirement for SBPIL steel plant is being met by the waste heat recovery based power plant providing a clean environment by restricting the emission of the CO2 and SO2 gases in the environment. The DRI gas, as it comes out after burning chamber, contains sufficient quantity of Heat-Energy (if it‟s not properly harnessed will go to waste and will contribute to atmospheric pollution). 350 TPD DRI Kiln for sponge iron production emits normally around 90000 Nm3/hour of hot gas at a temperature of 950oC-1000oC that contains Heat Energy of 29,000,000 kilocalories/ hour. Such energy waste is abated by installing Waste Heat Recovery Boiler (WHRB) at the tail end of each DRI Kiln, which in fact works as a cooler for the high temperature gas. Heat that is extracted from the hot gas is utilized in the transforming water to high temperature to high pressure steam, to run conventional condensing type Steam Turbo Generator for generation of electricity as a part of forward and backward integration process. SBPIL Captive Power Plant (CPP), comprises of two WHRB, one compatible for 38TPH of steam generation installed at the tail end of second number 350TPD DRI Kiln and another WHRB of 38TPH capacity at the tail end of first number of 350 TPD Kiln along with one AFBC Boiler of 60 TPH steam generation capacity equipped with Water Cooled Condenser. Accordingly, provision has been kept for momentary paralleling of CPP and DG source for transfer of CPP auxiliaries from DG to CPP after startup. Though CPP when running in full capacity can cater steel plant requirement by full energy requirement, but at the time of any power shortage due to non-availability of any of



the power plant unit, CSEB power will be used along with the generation to meet the steel plant requirement. The process flow diagram of power generation is given in Figure 3.

FIGURE 3: PROCESS FLOW DIAGRAM OF POWER PLANT SECTION

B. STEEL MELTING SHOP

Manufacturing Process The induction furnace continuous casting route is adopted for steel melting. The DRI from Sponge Iron Plant is transported to Steel Melting Shop through dumpers and is unloaded in the charging bay of the steel melting shop. There with the help of magnet crane the DRI is fed into the Sponge Iron Bins on over the furnace platform. Below these bins there are Weigh Feeders which is used to fed the DRI in controlled manner into the furnaces. Plant return scraps from various generating points and purchased scrap is transported to the scrap bay of steel melting shop. One crane is provided in the scrap bay for unloading and loading of scrap and pig iron in scrap buckets. These are transported to the furnace bay by electrically driven scrap bucket transfer car. The scrap buckets are weighed in the scrap bay. Scrap is stored on furnace working platform near the furnace for charging. The scrap is charged into the crucibles for generating the hot heel for DRI charging. Necessary carbon in the form of pig iron/petroleum coke is added into the crucibles to ensure the availability of necessary carbon in the bath. Once the molten bath has been formed and minimum temperature of the bath has been achieved, sponge iron is charged in small batches and the slag formed is removed periodically. After the completion of charging sponge iron a sample is drawn to determine the composition of the bath. After achieving the desire malt analysis, temperature is raised to the



tapping temperature and taking into account additions of predetermined amount of ferroalloys; to achieve the required tapping composition of the melt.

Continuous Casting The continuous casting technology has gained worldwide acceptance because of high yield, economics of operation and better product quality. Hence, this technology is adopted for our steel plant casting the liquid steel into billets. The continuous casting machine is equipped with moulds, mould oscillating mechanism, secondary cooling segments, straightening unit and withdrawals, gas cutting unit, rigid dummy bar insertion system, run out roller tables, cross transfer mechanism and cooling bed. The caster is controlled from the pendant control panels and also from main control room, located on the casting platform and the auxiliary control room near the gas cutting unit. The tap to tap time of the induction furnaces is matched with the casting cycle time so as to have maximum number of sequential cast. The ladle is picked up by ladle handling crane and placed on the ladle stand. A refractory lined tundish, fully dried and fitted with preheated nozzles mounted on tundish, car is moved from the reserve position to the casting position. Prior to the start of the casting operation, the dummy bar will be introduced into the mould. The gap between the dummy bar and mould walls is sealed with asbestos cords and small pieces of steel scraps are placed over the dummy bar head for chilling of initial metal. Water supply to mould, secondary cooling zone and machine cooling is switched on at this stage. When the liquid steel level in the tundish reaches a predetermined level, the tundish nozzles are opened. When the metal level in the mould reaches about 100-150 mm from its top, the drive of the mould oscillating mechanism as well as withdrawal and straightening unit is switched on. The withdrawal of dummy bar begins at the minimum speed and gradually increased to normal speed within few minutes. The mould is lubricated with liquid lubricant. During casting operation the metal level in the mould is maintained within predetermined limits by adjusting flow of metal into the mould or by adjusting the withdrawal speed. The partially solidified billets after leaving the mould pass through strand guide roller segment where intensive but controlled cooling of billets is affected by water spray nozzles. The solidified billets are guided through withdrawal and straightening units before entering the gas cutting zone. The dummy bar is separated from the billet for the gas cutting unit and is stored till its introduction is required for the next hit. The cast billet is cut to predetermined length by gas cutting torches. The sized billets are delivered to the cooling bed through run out roller table and cross transfer mechanism. The billets are marked on cooling bed by the marking unit for identification/tracking. The billets are marked on cooling bed by the marking unit for identification/tracking. The process flow diagram of SMS is shown in Figure 4 whereas the pictorial view of M.S. Billets is shown in Figure 5.



FIGURE 4: PROCESS FLOW DIAGRAM OF SMS

FIGURE 5: PICTORIAL VIEW OF M. S. BILLETS

C. FERRO ALLOYS PLANT

Ferro & Silico Manganese is an alloy of Manganese and Iron along with Silicon, Carbon and other elements. Ferro Alloys are basically used in the manufacturing of mild steel, alloy steel and special steels. It is one of the important alloying materials and is widely used in various applications. Ferro/Silico Manganese is produced in one type submerged arc furnaces by smelting manganese ore, redutant and fluid materials. The raw material in a pre-fix ratio is charged into submerged arc furnace where furnace taps holes at regular intervals.



After cooling the tapped materials, the finished product is separated out from slag, made to required sizes, packed and dispatched. Ferro/Silico manganese is smelted at about 1600-18000C. This achieved by a conventional open submerged electric arc furnace. There are three carbon electrodes, which are partially submerged into charge and are supported by the hydraulic cylinders that provide upward and downward movements in order to maintain the desired electrical conditions in the furnace. The body of the furnace is cylindrical in shape and is lined with firebricks, silicon carbide bricks and carbon tampling paste. Tap holes are provided for draining out the molten alloy and slag The raw material mixture is thoroughly mixed in a defined proportion before being charged into the furnace. Manual „pocking‟ rods are used for stroking the charge on the furnace top. As this charge enters the smelting zone, the alloy is formed by the chemical reactions of the oxides and the reductant. This alloy is heavier hence gradually settles at the bottom. The slag is produced by the non-reduced metal oxide and reflects, being relatively lighter floats on the alloy surface. The furnace is tapped at regular intervals and its tap hole is opened by oxygen lancing pipe and after tapping is completed it is closed by a clay plug. After cooling the alloy is separated from the slag, is sized and packed. The process flow diagram of Ferro Alloys section is presented below (Figure 6).

FIGURE 6: PROCESS FLOW DIAGRAM OF FERRO ALLOY SECTION ROLLING MILL SHRI BAJRANG POWER AND ISPAT LTD. (BORJHARA DIVISION) also an ISO: 9001-2008company, manufactures Round, TMT Bars up to 40 mm adopting the most modern advance technology. The company‟s products are ISI approved and are being marketed under the brand name “GOEL TMT”.



The Company has pioneered the methodology of direct charging of HOT BILLETS directly from CCM to Re Rolling Mill and thus stopped the use of reheating furnace and hence saving fuel & protecting Environment. Ingot/ Billet are required as a raw material for Re Bar Mill to Produce CTD/TMT Bar. The red hot raw material from CCM is fed directly to Re-Rolling Mill of the first stand of the Roughing Mill. After the primary reduction at Roughing mill the material goes to intermediate mill for further reduction. Finally the product goes to the finishing mill for attaining the final shape & size.

Manufacturing Process

Raw Material required for the Rolling Mill is generally Ingot and Billets, produced in Steel Melting Shop.

Roughing Mill

The Red Hot Raw material namely Ingot/Billet from CCM is fed directly to the first stand of the Roughing Mill. The Roughing Mill comprises of 3 X 3 Nos. roughing stand having roll size of 450 mm max. The roughing mill is used for primary reduction of the raw material. This is being done by rolling the material through various passes of the roughing mill. The roughing mill runs by drive system comprising of 1500 HP AC motor, high speed fly wheel, reduction Gear Box, pinion Gear Box etc. After the primary reduction the material goes to intermediate mill for further reduction.

After the raw material comes out from roughing mill, both the ends of the material will be shared by Rotary Shearing for free entry into further passes. The material passes through Intermediate Mill comprising of six stands having individual DC drive.

The stands are arranged in continuous line with DC motors & Drives enabling to roll at high speed. DC motors and Thyristor Drive will drive these stands. The Flying Shear is installed in between the stand for cutting the cobbles (misroll) efficiently. Each stand has different passes wherein the hot material is further reduced.

Finally the product goes to the Finishing Mill for attaining the final shape and size.

Finishing Mill

The Finishing Mill consists of stands in continuous configuration. All these stands are equipped with DC motor and Thyristor drive. The material passes through these entire stands and finally comes out in the desired size and section.

After leaving the last roll stand of the finishing mill, the material passes through special water-cooling system for quenching with the well-defined penetration depth. Quenching results into a hardened surface structure of the material. After leaving cooling line, the remaining heat of the core of the Bar reheats the surface up to the equalizing temperature, thus tempering the hardened surface. The resulting heat-treated structure has high strength and good toughness properties. This entire process is the manufacturing process for TMT Bar.



Quenching system

The Quenching system consists of cooling pipes of different length having motorized valves for controlling the flow of water. The system is also equipped with pressure and temperature gauges. High pressure water pumps are provided with butterfly valves so that water at desired pressure is available for rapid water quenching of bar to obtain the desired properties.

The cooling pipes also have air and water inlet system for better cooling. Installing a suitable compressor will generate compressed air of about 300 Cu NM/hr. at 0.5 Mpa.

The water used for water Quenching is collected in a scale pit. It is then cooled at cooling tower for re-use in the Quenching system. The entire system is equipped with various temperature gauges for measurement of the rolling temperature and equalizing the temperature for better quality control. The entire system is being controlled by PLC system, which helps in maintaining accuracy of various process parameters such as flow of water, pressure, temperature. Once the material leaves the quenching system, it passes through a pinch-roll unit, i.e., a machine having 2 nos. cantilevered pinch roll. This machine is used for driving the Bar through the dividing shear after the Bar leaves the last stand. This is done with the help of a photo cell located just before the pinch roll unit which detects the Bar nose. A solenoid valve actuates the air cylinder of the pinch roll unit and the top pinch roll comes down to the Bar and keeps the Bar at mill speed after it leaves the last stand. A Cooling tower with matching capacity is installed to ensure availability of cold water. Thereafter, the flying shear is installed for cutting the material into desired length. The Flying shear is operated with DC motor and is capable of cutting various sizes with best accuracy. The shear has a digital drive, which will control the machine to follow the rolling speed so as to divide the bar suitable to cooling bed length. After cutting, the finished material moves inside the Twin Channel installed on the cooling bed. The twin channel is installed all along the length at the side of the cooling bed. It consists of alternately opening flaps through a hydraulic cylinder. The Bar enters the closed flaps, which opens when the full bar has been received. The cooling bed is an Automatic Rake type Moving Cooling Bed. The Automatic cooling bed moves the finished bar to the discharge end with the help of walking beam. This system has advantage of getting a straight length material, thereby giving better finish to the material. This system has less involvement of labour. The cooling bed is provided with one Aligning device, which consists of 30 nos. individual driven Rollers, which is arranged in the stationary rake system of the cooling bed in front of discharge device. The main function of the aligning device is to align the nose of the rolled bar in direction of forward transportation, ensuring 100% fix length material. The material is then finally sheared by Shearing machine in the length of 11-12 meters and shifted to the loading area. It is then bundled and packed. After proper internal inspection, the material is released for dispatches. The process flow diagram of rolling mill is shown in Figure 7.



FIGURE 7: PROCESS FLOW DIAGRAM OF ROLLING MILL

Brick Manufacturing: The wastes (residues) in the form of Ash, Lime Powder,Gypsum are mixed together in a raw material mixing machine, transferred to Brick moulding machine and dried in open atmosphere. The process flow diagram is shown in Figure 8

FIGURE8: PROCESS FLOW DIAGRAM OF BRICK PLANT



Coal Washery Washing of coal is a process of up-gradation of Coal. There are number of methods/process by which the quality of coal can be improved. Out of several methods/processes available, the dry upgrading of coal through all air Jigging Machine is one of them. This is a tested method and number of plants is running successfully under this technology. The major description and process is given below: The All air jig was invented for the dry upgrading of coal. The advantages of jigging process are combined with the advantages of dry beneficiation process e.g. no need for process water, clarified water or water purification, no fines dewatering and no slurry impoundment. Separation of minerals in jigging machine is based on the fact that particles will stratify in pulsating air the upward and downward currents fluidize and compact air the upward and currents fluidize and compact the grains into relatively homogenous layers. Low density pieces stratify on the surface, while specifically heavy grains settle to the lower level of the bed. The most precise stratification of particles requires pulsation of proper frequency and amplitude- which can be adjusted during operation and can be optimized according to feed characteristics. Allair- jigging machines are driven by vibrating motors and operates within wide range of stroke motion (frequency and amplitude) as required. The Allair – jig mainly consists of

Surge Hopper Weigh Feeder Feed star gate Jig frame with vibrating motors and screen

plates Nuclear density measuring

device Discharge star gate

Working air fan Pulse air fan Flutter valve for air pulsation Bag filter

The sequences of the process of coal washery are as follows:

The E & F Grade Coal received from the Mines are fed into the Sizer to get the 0 to 75 mm size coal.

The same further fed in to crusher to crush the coal and crushed coal is further screened to get 6-20 mm coal for washing.

6-20 mm coal is collected in surge hopper through a belt conveyor from the existing screen house.

This coal is fed to allair jig through washery feed conveyor

After jigging the clean coal is fed to the existing stock house feed conveyor through clean coal conveyor.

Similarly the reject discharge is controlled by reject star gate and conveyed to reject stock yard through reject conveyor.

There is also a provision of bag filter with ID fan and chimney for collection of fines from Air Jig. The reject coal i.e. high density coal at the bottom of the jig bed flows through the reject star gate.

The coal fines collected at bag filter during suction from Jig and different dust generating points are fed to the reject coal conveyor through screw conveyor.



The characteristic of raw coal, clean coal, and reject coal are presented in Table 5, and Schematic diagram for the manufacturing of coal washery is shown in Figure 9.

TABLE 5: CHARACTERISTICS OF RAW COAL, CLEAN COAL AND REJECT COAL

Sl. No.

Particulars Raw Coal Clean Coal Reject Coal

1 GCV (Kcal/Kg) 2800 – 2900 3800 – 4000 2000 – 2200

2 Ash (%) 43 – 47 34 – 36 58 – 62

3 Yield (%) -- 60 – 62 38 – 40

4 Sulphur (%) 0.4-0.6 0.4-.0.5 0.4-0.5

FIGURE 9: SCHEMATIC DIAGRAM FOR THE MANUFACTURING PROCESS OF COAL

WASHERY

Pellet Plant

1) Process Description:

Complete process from receiving of Iron Ore fines to the dispatch of finished product comprising of several stages and operating sections. The same are described below:

2) Raw Material Handling & Storage:

This comprises unloading hoppers, Vibro feeder and belt conveyors, diverting gates. Stock pile & storage hoppers. All raw materials are received by Dumpers. These are unloaded into ground hoppers from where these are transferred to respective storage hoppers in various sections. Three circuits are provided for the various raw materials, as follows:

Iron ore – Stockpile, ground hopper, screening, drying, conveyors, stock house.



Coke breeze & Limestone – stockpile, ground hopper, conveyor stock house.

Coal – storage shed, ground hopper, conveyor, Coal Mill

3) Drying : Iron Ore Fines received contain moisture which need to be reduced before grinding. Drying is performed in a 3 mtr dia X 30 mtr long co-current rotary drum drier. The heat energy to the drier is generated by firing pulverized coal in a combustion chamber / hot air generator. Indian coal containing up to 35% ash is to be used after grinding it in a Coal Mill. Suitable de dusting system has been included to meet the environment / pollution norms. Provision is kept to by –pass the drier if dry material is available. The product is dried to less than 1.5% moisture level. Dried fines are conveyed to the iron ore hoppers in the grinding section through Heat Resistant Belt Conveyor.

4) Screening : Green balls are received on a swing belt conveyor and fed to the oversize reject screen. Thereafter, green balls are passed over a wide belt conveyor feeding to the under size roller screens. Under size reject and over size reject after crushing are recycled to the raw mix hoppers. The sized green balls between 8-16 mm are conveyed through a belt conveyor to the travelling grate.

5) Induration:

Induration process is carried out in three stages viz, drying, preheating and sintering. The first & second stage is performed in the traveling grate. The green balls are passed through the travelling grate which is 2.8 m W X 36 m long and divided three zones viz. 1 drying and 2 pre-heating. The green balls are dried and preheated up to 1000°C. Since there is no relative motion between the balls and the grate, the drying & heating is in the physically static condition. During this process the pellets balls gain sufficient strength to withstand the conditions of the rotary kiln. The hot air from kiln and cooler are used in the travelling grate utilizing and recovering maximum heat from waste gases.

In the third stage, the preheated pellets are fed into the rotary kiln of 4 m dia X 30 m long. The kiln is fired from the discharge end. The pre-heated pellets are further heated and roasted up to the temperature of 1250 to 1350°C and discharged into circular cooler. Imported coal containing less than 15% ash is considered as fuel for the kiln. The coal is pulverized in a ball mill and fired into the kiln through suitable firing burners. The secondary air for burning of fuel is (pre-heated air) available from the cooler.

6) Cooling:

Rotary cooler receives hot pellets with temperature up to 1300°C coming from Rotary kiln. Rotary cooler has 9 air blast boxes divided in 3 zones. Every zone has its own blower to blast the air from bottom. The hot air from the first zone is used as a combustion air in kiln. The hot blast of the second zone is used in the pre-heating zone-I of travel grate and the air from the 3rd zone is discharged to the atmosphere through chimney as its dust concentration is well within the permissible limits of pollution norms. Volume of cooling air in all the three zones is regulated automatically through the temperature control loops as per the requirement. Cold pellets at about



100°C are discharged on apron conveyor, heat resistant conveyors and conveyed to the stockpile/ loading hoppers.

7) Stacking and Shipment:

The pellets are subsequently natural cooled in air and transported to Bunkers or stockyard for further shipment.

8) Waste Gas treatment and dust recovery:

The hot gas exhausted from wind boxes at two sides of the preheating zone of traveling grate are sent for cyclic utilization, these two parts of waste gas are respectively cleaned by No. 1 and No. 2 de-duster (highly efficient multi-cyclone de-duster). The exhaust gas from traveling grate is passed through ESP (Electro Static Precipitator), and it is discharged to atmosphere via induced fan and stack. The chimney discharge is well within the national emission standards. Dust from the wind-box of traveling grate and dust collected through de-dusters & ESPs are conveyed to a Dust Hopper. This is ground together with iron ore fines at grinding mill. Almost all the dust and spillages are re-circulated and recovered.

9) Process Controls and Automation:

A microprocessor based centralized control system are considered for process monitoring, control, safety, data logging and management information. Process flow diagram is shown in Figure 10.

FIGURE 10: SCHEMATIC DIAGRAM FOR THE MANUFACTURING PROCESS OF PELLET PLANT



3.6 Raw material required along with estimated quantity, likely source, marketing

area of final product/s, Mode of transport of raw Material and Finished Product.

Estimated raw materials quantity likely to be sourced from outside, mode of transportation is given in table 6.

RAW MATERIAL QUANTITY EXISTING AND PROPOSED

SPONGE IRON PLANT- 2,10,00 TPA TO PROPOSED- 2,64,000 TPA

S.No. Existing Capacity-2,10,000 TPA

Raw Materials in TPM

Proposed Capacity-2,64,000 TPA Raw Materials in TPM

01. Coal 21000 Coal 22000

02. Iron Ore 26250 Iron Ore 33000

03. Dolomite 700 Dolomite 880

Total 47950 Total 55880

08 MW Biomass Based Power Plant

S.No. Existing Raw Materials in

TPM

Proposed Raw Materials in TPM

01. Dolochar 4350 Dolochar 2175

02. Rice Husk 10417

Rice Husk

2350

03. Coal Fines - Coal Fines

7000

Total 14767

Total 11525

Existing Proposed

S.No.

Quantity(MT) Ash Generatio

n (In MT)

Quantity (MT) Ash Generation

(In MT)

01. Dolochar

4350 3045 Dolochar

2175

1305

02. Rice Husk

10417

1823 Rice Husk

2350 411

03. Coal Fines

- - Coal Fines

7000 2450

Total 14767

4868 Total 11525

4166



STEEL MELTING SHOP -1,29,600 TPA TO PROPOSED- 2,11,200 TPA

S.No. Existing Capacity-1,29,600 TPA


Proposed Capacity-2,11,200 TPA


01. Sponge Iron 11014 Sponge Iron 17352

02. Pig Iron 449 Pig Iron 732

03. MS Scrap 1134 MS Scrap 1834

04. Ferro & Non Ferro alloys

108 Ferro & Non Ferro alloys

176


FERRO ALLOYS PLANT- 14,400 TPA TO PROPOSED 19,800 TPA

S.No.

Existing Capacity-14,400 TPA


Proposed Capacity-19,800 TPA Raw Materials in TPM

01. Manganese Ore

2160 Manganese Ore

2970

02. Coke 240 Coke 330

03. Coal 720 Coal 990

04. Dolomite 120 Dolomite 165

05. Ferro Manganese Slag

1200 Ferro Manganese Slag

1650


PROPOSED PELLETIZATION PLANT- 6,00,000 TPA

S.No.

Existing Capacity Raw Materials in TPM

Proposed Capacity-6,00,000 TPA Raw Materials in TPM

01. - - Iron Ore fines

51,000

02. - - Coke 1750

03. - - Limestone 750

04. - - Bentonite 400

05. - LDO or 625

Coal 2250

LDO/FO will be used as fuel and/or Producer Gas (coal Gasifier ) as alternative fuel.

Detail of mass balance for each process is given as below: (Table 7 to 11) Sponge Iron Plant

Existing Capacity = 2, 10,000 TPA Capacity after Expansion = 2, 64,000 TPA

The mass balance for the production of sponge iron is presented in Table 7.



TABLE 7: MASS BALANCE FOR SPONGE IRON PLANT (2, 64,000 TPA)

S. No. INPUT (TPM) OUTPUT (TPM)

1. Coal 22000 Sponge Iron 22000

2. Iron Ore 33000 Dolochar 4400

3. Dolomite 880 ESP Dust 3373

4. Accretion 192

5. Wet Scrapper Slurry 259

6. Ash 4273

7. Gases 21383


Captive Power Plant Existing capacity of CPP (WHRB – 18 MW + Biomass – 08 MW) = 26

TABLE 8: RAW MATERIAL USED IN BIOMASS BASED POWER PLANT (8 MW)

vis-à-vis Mass Balance

S. No. Material Input (TPM) OUTPUT (TPM)

1. Rice Husk 2350

Gases and Fumes

7359

2. Char/Dolochar 2175 Fly ash 4166 3. Coal fines 7000

Total 11525 11525

Note: 18 MW Power will be generated through WHRB. Steel Melting Shop (SMS) Existing Capacity = SMS – 1, 29,600 TPA (6 x 8T Induction Furnace) Total Capacity after Expansion = SMS – 2, 11,200 TPA (NEW 3 x 15 T Induction Furnace)

TABLE 9: MASS BALANCE FOR STEEL MELTING SHOP (B ILLETS & BLOOMS) (2,11,200 TPA)

S. No.

INPUT (TPM) OUTPUT (TPM)

1. Sponge Iron 17949 Billets & Blooms 17600

2. Pig Iron 732 Slag 2112

3. MS Scrap 1848 Gases & Fumes 993

4. Ferro & Non ferro Alloys

176


Ferro Alloys Plant Existing Capacity = Ferro Alloys – 14,400 TPA [2 x 4 MVA (SAF)] Total Capacity after Expansion = Ferro Alloys – 19,800 TPA [1 x 5 MVA + 1 x 6 MVA (SAF)]



TABLE 10: MASS BALANCE FOR FERRO ALLOYS PLANT (19,800 TPA)

S. No. INPUT (TPM) OUTPUT (TPM)

1. Manganese Ore 2970

Silico Manganese

1650

2. Coke 330 Slag 1980

3. Coal 990 Gases & Fumes 2475

4. Dolomite 165 0

5. Ferro Manganese Slag 1650 0

Total 6105 6105

Pellet Plant (Newly proposed) Proposed Capacity = 0.6 MTPA

TABLE 11: PROPOSED CAPACITY (PELLET PLANT)

S. N. INPUT (TPM) OUTPUT (TPM)

1. Iron Ore Fines 51,000 Pellet 50000

2. Coke 1750

Lost to Atmosphere 3900

3. Lime Stone 750

4. Bentonite 400

Total = 53900 53900

3.7 Resource optimization/ recycling and reuse envisaged in the project, if any,

should be briefly outlined.

No wastewater generation from coal washery, as it is dry separation process. For re-rolling mill and workshops discharged water, settling tank with oil and grease trap is installed and clear water is being used for plantation and dust suppression. No wastewater is being discharged into drains or natural water course. No water will be extracted from the ground water sources. All the acidic and alkaline effluent is being neutralized in neutralization tank and treated effluent is recycled/ reused in the dust suppression in fuel handling, fly ash loading/unloading area and green belt development. Subsequently cooling tower blow down is being used for dust suppression in fuel handling area. Domestic wastewater treated in septic tank followed by soak pit. No wastewater is being discharged outside the factory premises and zero discharged norms are adopted.

3.8 Availability of water its source, Energy/ Power requirement and source:

Availability of water and its source: Present water consumption of the plant is 2442 m3/day. The total water requirement will be about 2823 m3/day. This will be met from River Kharun. SBPIL has already obtained consent for drawl of water through Kharun River (1,25,000 m3/month) from Water Resources Department, Govt. of Chhattisgarh, vide letter No. 5010/302/JS/TS/AJP/03-D-4 dated 26/10/2004. No water will be abstracted from groundwater.



Energy/ Power requirement and source: The electric power requirement for the project will be fulfilled from captive power plant. The additional power requirement after expansion shall be met by wheeling of power from other unit and/or from CSPDCL.

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal:

Generated Char is being used in 8 MW Biomass power plant and surplus quantity of Dolochar is being supplied to 16 MW AFBC power plant at Gondwara plant of M/s. SBPIL unit.

Generated slag after crushing and screening being used in brick manufacturing plant

100% of waste water will be recycled and Zero discharge condition will be maintained.

Reject coal generated from coal washery 100% will be used for captive consumption in power plant

100% Mill scale is used for captive consumption in Ferro Alloys Plant as raw material.

Miss-Roll and End Cuts 100% are used in captive consumption in Steel Melting Shop as raw materials.

The fly ash generated shall be utilized in Fly Ash Bricks Plant and remaining if any, shall be supplied to other Bricks manufacturing units and Cement plant.

The Ferro Alloy slag will be used in Fly Ash Bricks manufacturing unit after crushing & screening.

The liquid steel produced will be used in a manner to produce hot billet suitable for rerolling, thus online hot rerolling practice will be adopted.

Generated waste heat will be used in WHRB for generation of power TABLE 13: QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID)

Source and type of solid waste

Qty. MT/Year Existing

Qty.MT/Year (Total Capacity

after expansion)

Utilization /disposal method

Fly ash from Power Plant

108816 90468 Bricks manufacturing unit & Cement Plant

Slag from SMS unit 17000 25344 Bricks manufacturing

Slag from Ferro Alloys unit

21000 23760 Bricks manufacturing

Dolochar from SID 66000 52800 Used in our AFBC based power plant (Gondwara unit) as a Raw material.



3.10 Schematic representations of the feasibility drawing which give information of EIA purpose.

S. No.

Particulars Impacts Remediation Proposed

1. Change in land use.

The possible greenery on the land and natural recharge is affected

The project is already in an Industrial area and additional land of 6.8 Ha will be used for the proposed expansion will be within plant premises, devoid of vegetative tree cover and having only the grass cover. Part of the land will be covered by tree plantation to the extent of 33% of area being brought under industrial activity. The greenbelt development is aken up within the plant boundary and additionally outside the plant boundary.

Water will be sourced from Kharun river, no groundwater will be abstracted for the project activities hence, natural recharge of groundwater level will not be affected through proposed project activities.

2. Transportation of material

The existing network of transport gets pressurized

The proposed expansion will marginally increase in Traffic density. The project lies within Urla Industrial Complexes thus, infrastructural facilities/road accessibility are already developed.

3. Gaseous and Particulate Emission to The atmosphere

Air quality All necessary steps will be followed to minimize the emission from point sources as well as line sources. Thus the standards of Stack Emission and Ambient Air quality will be maintained as per prescribed limits.

4. Discharge of effluent

Impact of water quality. Zero discharge is proposed.

5. Withdrawal of ground / surface water

Availability of ground/surface water is affected.

Water will be sourced from Kharun River, no ground water will be abstracted for the project activities hence, natural recharge of ground water level is not affected through project activities. Permission regarding drawl of river water is granted from water resource department.

6. Operation of equipment and vehicles likely to

Impact on human health due to excess noise level beyond permissible level.

All the process equipment will be installed on anti-vibration pad with sufficient provisions to minimize generation of noise. The high noise



S. No.

Particulars Impacts Remediation Proposed

generate noise.

generating equipment like turbine and generator will be enclosed with noise suppressing enclosures. The buildings as well as boundary wall and green belt will ensure the attenuation of noise outside the boundary within the prescribed limits.

7. Fire Hazard due to storage of fuel etc.

Risk to the surrounding habitation.

Necessary precautions to prevent fire and all the provisions to control fire shall be Provided.

8. Employment to outsiders

Socio-economic disparity with local community

Priority of employment will be given to local people, as already sufficient qualified and trained local youth are available.

9. Cultural impact

Local population feels isolated

The promoters proposed to employ local masses in the project hence no such impact on cultural diversity is likely to take place.

10. Disposal of solid and hazardous wastes

Create odorous problem, nuisance condition related to the disposal of solid wastes. Deterioration of soil, productivity pollution in ground water/surface water due to leaching and surface runoff.

Domestic wastes will be segregated for organics and Inorganics. Organic wastes will be used for composting and inorganics for approved vendors. Disposal of hazardous wastes will be done as per hazardous wastes handling and disposal rule.

4.0 SITE ANALYSIS 4.1 Connectivity.

The proposed project is situated at Borjhara village, Raipur district and Tehsil, State of Chhattisgarh. The project is located within the Urla Industrial Growth Centre. The site is well connected with Road/Rail. The details are as follows:

Nearest Road: Durg-Raipur-Bilaspur Highway (NH-6)about 5.0 km, S Nearest railway station- Raipur ~7.5 Km, SE Nearest airport- Raipur 21 Km, SE

4.2 Land Form, Land use and Land ownership.

The proposed activities will be within the existing Industrial Complex of SBPIL. The total land area for the project is 27.80 hectare in villages- Borjhara, Urla & Sarora. It is Private Industrial Land. Khasra No. 173, 174, 175, 176, 177 & 178 in village-Borjhara. Present activities are covered under 21.0 Ha and for expansion additional area of 6.8 Ha will be used. The breakup of the land for the various activities for the proposed project will be as follows:



TABLE 14: LAND BREAKUP

S.NO. DETAILS AREA(Hectare) 01. Total Built up area 6.8697

02. Area for green belt 9.238

03. Open area 9.5453

04. Area under road 1.4000

05. Parking Bay 0.747

Total 27.8



4.3 Topography (along with map)

The project area located in the Urla Industrial Growth Centre within the Raipur region is typically flat, with low undulating plain and the plant site having gentle slope toward North. Dominant features of the land is being the lateritic, sandy loamy plain and broad alluvial plain of Kharun River. The project site lies at the 21018'23" to 21018'46” North Latitude and 81035'09" to 81035'44" East longitude on the Topo sheet No. 64, G/11. The site specific Topography map is given in Figure 11.

FIGURE 11: SITE SPECIFIC TOPOGRAPHY MAP (10 KM Radius)



4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (distance from HFL to the river), CRZ. In case of notified industrial area, a copy of Gazette Notification should be given:- The project is located within the notified Urla Industrial Growth Centre. Existing land use is private industrial land. The land is being used for Industrial Purpose. Land allotment letter is enclosed as Appendix – I.

5.0 PLANNING BRIEF 5.1 Planning concept (type of industries, facilities transportation Town and

Country Planning Development authority Classification.

Project concept: The project is conceptualized in accordance to the present challenge of minimizing Green House Gas (GHG) emissions from core sector of industries like steel, power, mining etc. It is known that, India is not having coking coal therefore it largely depends on imported stock of coking coal to meet the coke requirement of blast furnaces, which drains valuable foreign currency of the nation. During last 15 years of industrial growth largest capacity addition had been in steel making through sponge iron route, which was quite successful in bailing out the nation from wrath of costly steel import if these facility would have not be created. However, for sponge iron, industries are also facing a great limitation of good quality coal from the non coking coal mines due to which the energy efficiency of these sponge iron plants were badly affected and therefore the financial viability also got badly affected. It is a known technological limitation in sponge iron making process that poor quality coal results in to faster accretion in the kiln resulting in to poorer capacity utilization and frequent breakdowns. The simplest solution for this is to utilization only high grade coal, which is obtained from beneficiation of poor grade raw coal available from Indian mines. The second problem faced by the sponge iron industry was non availability of good quality iron ore at consistent prices. This bottleneck has been now overcome by inception of a large number of iron ore beneficiation cum pelletisation plant. This has made ample availability of well sized and well defined and sustained availability of proper quality of ore in the form of pellets at much reasonable rates. In the backdrop of this scenario, the project proponent planned for proposed expansion of Integrated Steel Plant. Now, the said proposal for expansion of production capacity with change in configuration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to 2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MW captive power plant since availability of Rice Husk is not consistent as per our requirements hence coal/coal fines will also be used in addition to Rice Husk & Dolochar.The expansion of Submerged Arc Furnace involves the enhancement of capacity and modernization. The existing SAF production capacity is 14,400 TPA (2



No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase in production capacity of 19,800 TPA (1 No. x 5 MVA +1 No. x 6 MVA Transformer).

Existing Steel Melting Shop (SMS) production capacity of 1, 29,600 TPA will be enhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which will have additional production capacity of 81,600 TPA.. Rolling mill capacity will be enhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due to curtailment of Idle Running Hours since it is to run in synchronization with SMS as we have adopted direct rolling technology. A new Pellet plant (0.6 MTPA) is proposed.

Type of Industries: Sponge Iron Plant: Crushed raw materials (Iron ore, coal & dolomite) are fed to the kiln. Coal provides the source of heat and also acts as reducing material to turn iron ore into iron. Sponge iron produced is separated from waste materials in magnetic separator, screened and sent to steel making shop. Steel Melting Shop (SMS): Pig iron, sponge iron, lime and ferroalloy is charged from the top of Electric Arc Furnace / Induction Furnace. Arcing melt the contents. Oxygen blowing is done. Steel is tapped and chemistry correction is done in laddle refining furnace. Liquid steel is casted into billets in continuous casting machine. Slag is taken out from slag tap hole. Rolling Mill: State of art technology is developed for Steel billet/blooms are rolled into different products in the Structural Mill. M/s. SBPIL has bagged the National Energy Conservation Award in the steel rolling mills sector. Under the energy efficiency measures, the company had invented a state of art technology of direct rolling of hot continuous cast billet to produce TMT bars without any intermediated reheating arrangement. It contributes towards conservation of energy and environment as well. The ministry had also recognized the company as inventor of direct rolling technology which is a remarkable achievement. Power Plant: Waste heat from Sponge Iron Plant, Ferro Alloys Plant, and other processes shall be used in WHRB to generate 18 MW electricity. Biomass mainly rice husk as fueling component for the power plant as the region of this area of Chhattisgarh as rice bowl of India. Rice husk and dolochar is being used Biomass based power plant to generate 8 MW electricity; Electricity shall be used for captive consumption. It is proposed to use coal as part of fuel mix in boiler. Coal Washery: The existing coal washery is 1.2 MTPA, coal washery is based on dry process unit, hence no water will be required. Pellet Plant: The pelletisation process consists of forming green balls out of a very finely ground mixture of Iron ore fines, Limestone, coal and a binder like bentonite. These balls are then fired in an indurating furnace to get hardened balls called pellets. The hot air from kiln and cooler will be used in the travelling grate utilizing and recovering maximum heat from waste gases. Town and Country Planning Development authority Classification: The project falls under Urla Industrial Complex surrounded by a few Industries. Town and country planning department has already classified land as industrial. Adequate



road facilities are already available for transportation of raw materials as well as finished products.

5.2 Population Projection.

The existing industry is providing employment to about 750 people and on completion of the expansion, there will be addition of 100 people. Since the plant is located in the Raipur district in which trained manpower are already available therefore the employment will be mostly given to local people therefore there will not be any substantial increase in the population of local villages. However, due to increase economic growth, the local youth will be benefited with respect to employment. And additional population influx of around 100 people within the 10 KM radius of plant can at best be estimated, which includes the addition of persons dependent on the job seeking persons

5.3 Land use planning (breakup along with green belt etc.). Around 9.238 Ha. of industrial land will be used for green belt development. The existing plantation is more than 50,000 proposed plantation by M/s. SBPIL in year 2017-18 was 3000, and so for 3000 plant is already planted in the year 2017-18. The breakup of the land for the various activities for the proposed project will be as follows:

TABLE 15: LANDUSE BREAKUP ALONG WITH GREENBELT

S.NO. DETAILS AREA(Hectare) 01. Total Built up area 6.8697

02. Area for green belt 9.238

03. Open area 9.5453

04. Area under road 1.4000

05. Parking Bay 0.747

Total 27.8

5.4 Assessment of Infrastructure Demand:

The proposed project is expansion of integrated steel complex activity for which no substantial additional infrastructure is required. The available road network and natural sources of water supply and drainage system are adequate.Water will be sourced from Kharun river. There is no other major infrastructural requirement for the project.

5.5 Amenities/Facilities:

The project expansion does not require additional large amenities o

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