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Pre-Feasibility Report (PFR) Shri Bajrang Power and Ispat Ltd. PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated Steel Plant at Urla Industrial Area, Village Borjhara, District Raipur, Chhattisgarh By SHRI BAJRANG POWER & ISPAT LIMITED

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Page 1: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

PRE FEASIBILITY REPORT

Of

Proposed Expansion of IntegratedSteel Plant

atUrla Industrial Area,

Village Borjhara, District Raipur,Chhattisgarh

By

SHRI BAJRANG POWER & ISPAT LIMITED

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

1.0 EXECUTIVE SUMMARY1.1 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

1.4Existing Installed Capacity and Total Capacity after expansion

Existing Productioncapacity andconfiguration

Total capacity afterexpansion andconfiguration

Remark

Sponge Iron - 2,10,000TPA2 x 350 TPD x 300 days

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

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

Total Power Plant – 26 MW(CPP)

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk & DoloChar

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk &Dolochar

No change in capacityChange in fuel Mix for CPP. To include coal as fuel inaddition to Rice Husk & Dolochar

SMS – 1, 29,600 TPA6 x 8T Induction Furnace

SMS – 2, 11, 200TPA

Two more induction furnace of 15 T each along withcontinuous casting machine and LRF to be installedfor additional production 81,600 TPA.

Ferro Alloys – 14.400 TPA2 x 4 MVA (SAF)(Combined EC of Ferro &Biomass)

Ferro Alloys – 19,800TPA1 x 5 MVA + 1 x 6MVA (SAF)

Existing furnaces 4 MVA – 2 Nos. will be replaced byhigher capacity transformer1X5 MVA1X6 MVA

Rolling Mill – 0.15 MTPA Rolling Mill - 0.21MTPA

Optimization of production capacity of Rolling Mill bycurtailing Idle running hours.

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

Proposed - PelletPlant (0.6 MTPA)

New unit – Applying for EC

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

1.6 No. of Working Days : 330 Days1.7 Cost of Project : Proposed expansion : Rs. 120 crores1.8 Man Power Utilization : Present Manpower – 750

Additional manpower – 100

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

2.0 INTRODUCTION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

GOEL GROUP is one of the leading business houses in Chhattisgarh. The Grouphaving diversified business activities, but mainly engaged in manufacturing of Steeland generation of power and has interest in manufacturing of Sponge Iron, Iron OreBeneficiation, Pellets, Induction/ Arc Furnace with Continuous Casting Machine forproduction of Steel Billets and Blooms, Hot Re-Rerolled Steel products, Ferro Alloys,Fly Ash Bricks and Captive Power Plant together with their backward and forwardintegration. The Group is totally integrated to produce finished steel under one roofand selling all products under the Brand Name “GOEL” which is well-established andwell-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 backwardintegration, the company has established mega project with the investment of Rs. 230Crores. Presently the company has established the existing production capacity of2x350 TPD Sponge Iron Plants with 26 MW Captive Power Plant, 6 x 8 MT InductionFurnace with Continuous Casting machine, 2 x 4 MVA Ferro Alloys plant and 1.2MTPA Coal Washery and 0.15 MTPA Rolling Mill at village Borjhara, in Urla Industrialcomplex, Raipur. The company proposed to add the following production/ generationcapacity and change in configuration with existing EC: (Table 1)

TABLE 1: PRODUCTION/ GENERATION CAPACITY EXPANSION AND CHANGE INCONFIGURATION

Existing Installed Capacity and Total Capacity after expansionExisting Production capacity

and configurationTotal capacity after

expansion andconfiguration

Remark

Sponge Iron - 2,10,000 TPA2 x 350 TPD x 300 days

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

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

Total Power Plant – 26 MW(CPP)

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk & Dolo Char

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk & DoloChar

No change in capacityChange in fuel Mix for CPP. To include coal asfuel in addition to Rice Husk& Dolochar

SMS – 1, 29,600 TPA6 x 8T Induction Furnace

SMS – 2, 11, 200 TPA Two more induction furnace of 15 T each alongwith continuous casting machine and LRF to beinstalled for additional production 81,600 TPA.

Ferro Alloys – 14.400 TPA2 x 4 MVA (SAF)(Combined EC of Ferro &Biomass)

Ferro Alloys – 19,800TPA1 x 5 MVA + 1 x 6 MVA(SAF)

Existing furnaces 4 MVA – 2 Nos. will be replacedby higher capacity transformer1X5 MVA1X6 MVA

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

Pellet plant (0.6 MTPA) CTEgranted by CECB, but plant yetnot installed

Proposed - Pellet Plant(0.6 MTPA)

New unit – Applying for EC

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

2.2 Brief Description and Nature of the Project:

The project already has sponge iron manufacturing through Iron Ore, Coal andDolomite. Steel Melting Shop with configuration of 6 x 8T of Induction Furnace. FerroAlloys with existing capacity of 14,400 TPA (2 x 4 MVA SAF) along with CaptivePower plant having capacity of 26 MW capacity in which 18 MW power generatedthrough WHRB and rest of 08 MW generated through bio mass. Similarly thecompany has also taken combined environmental clearance for Coal washery androlling mill having capacity of 1.2 MTPA and 0.15 MTPA respectively within the sameplant premises.

Now, the said proposal for expansion of production capacity with change inconfiguration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MWcaptive power plant since availability of Rice Husk is not consistent as per ourrequirements hence coal/coal fines will also be used in addition to Rice Husk &Dolochar.The expansion of Submerged Arc Furnace involves the enhancement ofcapacity and modernization. The existing SAF production capacity is 14,400 TPA (2No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase inproduction 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 beenhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which willhave additional production capacity of 81,600 TPA.. Rolling mill capacity will beenhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due tocurtailment of Idle Running Hours since it is to run in synchronization with SMS as wehave 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 strategicimportance for any industrial nation. Historically, all nations during theirindustrialization phase have been supported by a strong steel industry of theirown. From construction, industrial machinery to consumer products, steel finds awide variety of applications. It is also an industry with diverse technologies basedon the nature and extent of use of raw materials.

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

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

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

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

(A) For Sponge Iron Plants

- Use of hi-grade coal in sponge iron making, can reduce the prevailing coalconsumption of 1.2 MT/MT sponge iron to less than 1.0 MT coal per ton of spongeiron 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, lowertransportation cost, lower maintenance cost, better thermal efficiency, higher plantavailability 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 coalreduced 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 enforcementis 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 tothe cost of electricity generation.

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

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

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Advantages of the project

Value addition project by gainful utilization of wastes and converting intermediateproducts 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 anothermajor 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 andcreate jobs by setting up industries in all the districts. The state government hasrealized that Chhattisgarh can become a “developed State” only if its industrialgrowth rate increases substantially and that can only happened with a favorableenvironment for investment. Hence, attempts are on to make the administrationinvestor-friendly and to provide the necessary infrastructure. Special importance isgiven to private sector participation as well as industrial development in the backwardregions. The proposed expansion will help in increasing the employmentopportunities to the local people and also it will help in the industrial growth of thecountry.

2.4 Demand-Supply Gap

The scenario of Steel Industry is clearly looking upward and the latest data on SteelIndustry is as follows:-

Steel is traditionally considered the backbone of national economic development. It isa 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 about90 Million Tonnes of saleable finished steel products in the ratio of about 40-60% inthe category of Flat Products and Long Products.

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

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

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

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

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

The government had supported the industry in 2016 by providing protectionistmeasures. But the protection cannot be expected to last forever and the industry hasto 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. Indiacontinued with this position in 2015-16 as well. The country produced 88.97 milliontonnes 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 104.23MT. 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 crudesteel output in China, Japan and Russia grew by mere 0.5-3%, output in USremained 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 thisperiod. This was on account of higher output by the major Indian steel companies.The imposition of Minimum Import Price (MIP) encouraged the producers to increasetheir output. Care Ratings said that the consumption of steel, on the other hand, grewby just 3.2% to 73.75 MT during April-December 2016.

Post-demonetization, steel consumption is expected to remain under pressure in thecoming few months to a certain extent. This is because it is likely that the demand forsteel from the user industries like construction, real estate will take some time tostrengthen. However, government push towards infrastructure will compensate forthis 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 foreignsources and facilitate speedy implementation of investment intentions onboard so far so as to reach crude steel capacity level of 300 million tonnes by2025-26 to meet the domestic demand fully.

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

b) To ensure easy availability of vital inputs and necessary infrastructure toachieve 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 notavailable much. Thus steel production facilities added during last 10 years in Indiaare well established based on coal based rotary sponge iron kilns. Prior toimplementation of the sponge iron kiln based steel making the gap between demandand supply was fulfilled by import of steel. The Chinese manufacturers are givingtough competition to Indian steel producers because of their cheaper production costmainly due to abundantly availability of coking coal in their country. Therefore, inorder to face the competition being poised by the Chinese manufacturer, it isimportant to provide good quality washed coal to existing sponge iron plants in Indiaand 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 infrastructuresector is likely see a massive growth due to increasing economic status thus in orderto keep the supply ready to match the demand of construction steel, the additionalcapacity 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 encouragingexport of steel, however proposed quantity will be domestically consumed. The worldsteel market is for about 1500 Million Tonnes, out of which about 50% is beingproduced by China, the global demand even if increased by 2% per annum then itrequires addition of 30 Million Tonnes additional production capacity. Since Chinahas already reach to saturation level of increasing the production therefore India hasbetter chance to share the world market by increasing its production in an energyefficient manner. The unit being located in the eastern sector can export the steel toBangladesh; Bhutan; and Burma and Nepal also.

2.7 Domestic/ Export Markets

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

The project has potential to cater to the domestic demand as well as export demandof steel and to provide washed coal to domestic as well as export oriented spongeiron / steel plants.

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

The tunnel kiln based reduced Iron Powder production technology is likely to opennew energy efficiency vista to the steel plants in India; by which the step ofpelletization or sinter can be done and directly produces the Reduced Iron Powder inmost environment friendly manner. The same can also be used for experimenting toproduce other reduced metals too. The Ferro Alloys plant will be able to meet theinternal requirement of the Ferro Alloys as well as it is proposed to produce Pig Ironon trial basis; in case the trial is successful then it will be used to transfer the liquidIron 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, asper which following direct and indirect employment potential is likely to be generated

TABLE 2: EMPLOYMENT GENERATIONParticulars Existing ProposedAdmin Staff : 750 100Productionstaff

:

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 projectalready has sponge iron manufacturing through Iron Ore, Coal and Dolomite. SteelMelting Shop with configuration of 6 x 8T of Induction Furnace. Ferro Alloys withexisting capacity of 14,400 TPA (2 x 4 MVA SAF) along with Captive Power planthaving capacity of 26 MW capacity in which 18 MW power generated through WHRBand rest of 08 MW generated through bio mass. Similarly the company has alsotaken combined environmental clearance for Coal washery and rolling mill havingcapacity 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 inconfiguration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MWcaptive power plant since availability of Rice Husk is not consistent as per ourrequirements hence coal/coal fines will also be used in addition to Rice Husk &Dolochar.The expansion of Submerged Arc Furnace involves the enhancement ofcapacity and modernization. The existing SAF production capacity is 14,400 TPA (2No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase inproduction 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 beenhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which willhave additional production capacity of 81,600 TPA.. Rolling mill capacity will beenhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due tocurtailment of Idle Running Hours since it is to run in synchronization with SMS as wehave adopted direct rolling technology. A new Pellet plant (0.6 MTPA) is proposed.

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Shri Bajrang Power and Ispat Ltd.

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

Details about the Project area are presented in Table 3.

TABLE 3: DETAILS ABOUT THE PROJECT AREAState ChhattisgarhDistrict/ Tehsil Tehsil- Raipur, District- RaipurVillage Borjhara, Sarora & Urla (Urla Industrial Complex)Khasara No. CSIDC Allotted Land and Private Purchased Diverted

Industrial LandKhasra No. 173, 174, 175, 176, 177 & 178

Area 27.8 Hectare (after expansion)Toposheet No. 64G/11Geo-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 10km radius of study area shown in Annexure-II

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Shri Bajrang Power and Ispat Ltd.

Annexure – IINDEX MAP

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Shri Bajrang Power and Ispat Ltd.

Annexure – IISTUDY AREA MAP

(10 KM RADIAL DISTANCE FROM THE PROJECT SITE)

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Shri Bajrang Power and Ispat Ltd.

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

Expansion of integrated steel plant within the existing plant premises, hence,alternative sites are not examined. The existing and proposed production capacitywith details regarding configuration are presented in Table 4

3.4 Size or Magnitude of Project

TABLE 4: PROPOSED EXPANSION OF INTEGRATED STEEL PLANTExisting Installed Capacity and Total Capacity after expansion

Existing Productioncapacity andconfiguration

Total capacity afterexpansion andconfiguration

Remark

Sponge Iron - 2,10,000TPA2 x 350 TPD x 300 days

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

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

Total Power Plant – 26MW (CPP)

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk & DoloChar

WHRB – 18 MW

CPP – 8 MWAFBC Boiler 60 TPHFuel : Rice Husk &Dolochar

No change in capacityChange in fuel Mix for CPP. To include coal as fuel inaddition to Rice Husk & Dolochar

SMS – 1, 29,600 TPA6 x 8T Induction Furnace

SMS – 2, 11, 200TPA

Two more induction furnace of 15 T each along withcontinuous casting machine and LRF to be installedfor additional production 81,600 TPA.

Ferro Alloys – 14.400TPA2 x 4 MVA (SAF)(Combined EC of Ferro &Biomass)

Ferro Alloys – 19,800TPA1 x 5 MVA + 1 x 6MVA (SAF)

Existing furnaces 4 MVA – 2 Nos. will be replaced byhigher capacity transformer1X5 MVA1X6 MVA

Rolling Mill – 0.15 MTPA Rolling Mill - 0.21MTPA

Optimization of production capacity of Rolling Mill bycurtailing Idle running hours.

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

Proposed - PelletPlant (0.6 MTPA)

New unit – Applying for EC

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 thefollowing products:

1. Sponge Iron Plant, Capacity 2,10,000 TPA2. Captive Power Plant, Capacity 26 MW3. Steel Melting Shop, Capacity 1,29,600 TPA4. Ferro Alloy, Capacity 14400 TPA5. Coal Washery Plant 1.2 MTPA6. Rolling Mill, capacity 150000 TPA7. Fly Ash Bricks Plant 3,00,00,000 NPA

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Shri Bajrang Power and Ispat Ltd.

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 SpongeIron Plant. DRI or Sponge iron, as it is often referred to, is the substitute for meltingscrap (scrap steel) in the steel making process. DRI is the process of converting ironore to metallic iron without the smelting process. The process of sponge iron makingaims to remove oxygen from iron ore. When that occurs, the departing oxygencauses 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 alsocheaper than scrap.

In Sponge Iron Division, the process of manufacturing starts from the stage ofcrushing of Iron Ore, Coal & Dolomite to smaller size. The kiln feed size of iron ore is4-20 mm, coal 4-18 mm & dolomite 2-6 mm. They are sieved & brought to theconveyor belts to carry to the rotary kiln system. The sized raw materials, viz. ironore, 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 formovement of the material placed in it. Air is supplied by the fans mounted on the kilnfor burning the charge. Air is continuously supplied into the kiln for burning thecharge. The air is continuously supplied into the kiln through several air injectiontubes fitted in the kiln to assist the reduction of iron ore into sponge iron resulting inthe 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 hotsponge iron and char (ash & un-burnt coal particle) which is transferred into rotarycooler where it is cooled down by indirect water spray arrangements. The SpongeIron is separated from the dust & non-ferrous impurities in magnetic separationsystem by the process of magnetic separation. The cooled product is furthermagnetically separated to pick up sponge iron & separate kiln waste. The spongeiron is then sieved to separate the sponge iron lumps, fines & brought to theirrespective storage areas. The sponge iron is then sieved to separate the sponge ironlumps, fines & brought to their respective storage areas. The process flow diagramof sponge iron plant is shown in Figure 1, whereas the product view (sponge iron) isshown in Figure 2.

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FIGURE1: PROCESS FLOW OF SPONGE IRON PLANT

FIGURE 1a: PROCESS FLOW DIAGRAM OF SPONGE IRON SECTION

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Pre-Feasibility Report (PFR)

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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 recoverybased power plant providing a clean environment by restricting the emission of theCO2 and SO2 gases in the environment.

The DRI gas, as it comes out after burning chamber, contains sufficient quantity ofHeat-Energy (if it’s not properly harnessed will go to waste and will contribute toatmospheric pollution). 350 TPD DRI Kiln for sponge iron production emits normallyaround 90000 Nm3/hour of hot gas at a temperature of 950oC-1000oC that containsHeat Energy of 29,000,000 kilocalories/ hour.

Such energy waste is abated by installing Waste Heat Recovery Boiler (WHRB) atthe tail end of each DRI Kiln, which in fact works as a cooler for the high temperaturegas. Heat that is extracted from the hot gas is utilized in the transforming water tohigh temperature to high pressure steam, to run conventional condensing type SteamTurbo Generator for generation of electricity as a part of forward and backwardintegration process.

SBPIL Captive Power Plant (CPP), comprises of two WHRB, one compatible for38TPH of steam generation installed at the tail end of second number 350TPD DRIKiln and another WHRB of 38TPH capacity at the tail end of first number of 350 TPDKiln along with one AFBC Boiler of 60 TPH steam generation capacity equipped withWater Cooled Condenser.

Accordingly, provision has been kept for momentary paralleling of CPP and DGsource for transfer of CPP auxiliaries from DG to CPP after startup. Though CPPwhen running in full capacity can cater steel plant requirement by full energyrequirement, but at the time of any power shortage due to non-availability of any of

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

FIGURE 3: PROCESS FLOW DIAGRAM OF POWER PLANT SECTION

B. STEEL MELTING SHOP

Manufacturing ProcessThe induction furnace continuous casting route is adopted for steel melting.

The DRI from Sponge Iron Plant is transported to Steel Melting Shop throughdumpers and is unloaded in the charging bay of the steel melting shop. There withthe help of magnet crane the DRI is fed into the Sponge Iron Bins on over thefurnace platform. Below these bins there are Weigh Feeders which is used to fed theDRI in controlled manner into the furnaces.

Plant return scraps from various generating points and purchased scrap istransported to the scrap bay of steel melting shop. One crane is provided in the scrapbay for unloading and loading of scrap and pig iron in scrap buckets. These aretransported to the furnace bay by electrically driven scrap bucket transfer car. Thescrap buckets are weighed in the scrap bay. Scrap is stored on furnace workingplatform 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 cruciblesto ensure the availability of necessary carbon in the bath. Once the molten bath hasbeen formed and minimum temperature of the bath has been achieved, sponge ironis charged in small batches and the slag formed is removed periodically. After thecompletion of charging sponge iron a sample is drawn to determine the compositionof the bath. After achieving the desire malt analysis, temperature is raised to the

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

Continuous Casting

The continuous casting technology has gained worldwide acceptance because ofhigh yield, economics of operation and better product quality. Hence, this technologyis adopted for our steel plant casting the liquid steel into billets. The continuouscasting machine is equipped with moulds, mould oscillating mechanism, secondarycooling segments, straightening unit and withdrawals, gas cutting unit, rigid dummybar 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 controlroom, located on the casting platform and the auxiliary control room near the gascutting unit.

The tap to tap time of the induction furnaces is matched with the casting cycle timeso as to have maximum number of sequential cast.

The ladle is picked up by ladle handling crane and placed on the ladle stand. Arefractory lined tundish, fully dried and fitted with preheated nozzles mounted ontundish, 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 themould. The gap between the dummy bar and mould walls is sealed with asbestoscords and small pieces of steel scraps are placed over the dummy bar head forchilling of initial metal. Water supply to mould, secondary cooling zone and machinecooling is switched on at this stage. When the liquid steel level in the tundish reachesa predetermined level, the tundish nozzles are opened. When the metal level in themould reaches about 100-150 mm from its top, the drive of the mould oscillatingmechanism as well as withdrawal and straightening unit is switched on. Thewithdrawal of dummy bar begins at the minimum speed and gradually increased tonormal speed within few minutes. The mould is lubricated with liquid lubricant. Duringcasting operation the metal level in the mould is maintained within predeterminedlimits 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 rollersegment where intensive but controlled cooling of billets is affected by water spraynozzles. The solidified billets are guided through withdrawal and straightening unitsbefore entering the gas cutting zone. The dummy bar is separated from the billet forthe gas cutting unit and is stored till its introduction is required for the next hit. Thecast billet is cut to predetermined length by gas cutting torches. The sized billets aredelivered to the cooling bed through run out roller table and cross transfermechanism. The billets are marked on cooling bed by the marking unit foridentification/tracking. The billets are marked on cooling bed by the marking unit foridentification/tracking. The process flow diagram of SMS is shown in Figure 4whereas the pictorial view of M.S. Billets is shown in Figure 5.

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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 ofmild steel, alloy steel and special steels. It is one of the important alloying materialsand is widely used in various applications.

Ferro/Silico Manganese is produced in one type submerged arc furnaces by smeltingmanganese ore, redutant and fluid materials. The raw material in a pre-fix ratio ischarged into submerged arc furnace where furnace taps holes at regular intervals.

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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 aconventional open submerged electric arc furnace. There are three carbonelectrodes, which are partially submerged into charge and are supported by thehydraulic cylinders that provide upward and downward movements in order tomaintain the desired electrical conditions in the furnace. The body of the furnace iscylindrical in shape and is lined with firebricks, silicon carbide bricks and carbontampling 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 beingcharged into the furnace. Manual ‘pocking’ rods are used for stroking the charge onthe furnace top. As this charge enters the smelting zone, the alloy is formed by thechemical reactions of the oxides and the reductant. This alloy is heavier hencegradually settles at the bottom. The slag is produced by the non-reduced metal oxideand reflects, being relatively lighter floats on the alloy surface. The furnace is tappedat regular intervals and its tap hole is opened by oxygen lancing pipe and aftertapping is completed it is closed by a clay plug. After cooling the alloy is separatedfrom the slag, is sized and packed. The process flow diagram of Ferro Alloys sectionis 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 mostmodern advance technology. The company’s products are ISI approved and arebeing marketed under the brand name “GOEL TMT”.

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The Company has pioneered the methodology of direct charging of HOT BILLETSdirectly from CCM to Re Rolling Mill and thus stopped the use of reheating furnaceand 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 standof the Roughing Mill. After the primary reduction at Roughing mill the material goes tointermediate mill for further reduction. Finally the product goes to the finishing mill forattaining the final shape & size.

Manufacturing Process

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

Roughing Mill

The Red Hot Raw material namely Ingot/Billet from CCM is fed directly to the firststand of the Roughing Mill. The Roughing Mill comprises of 3 X 3 Nos. roughingstand having roll size of 450 mm max. The roughing mill is used for primary reductionof the raw material. This is being done by rolling the material through various passesof the roughing mill. The roughing mill runs by drive system comprising of 1500 HPAC motor, high speed fly wheel, reduction Gear Box, pinion Gear Box etc. After theprimary 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 willbe shared by Rotary Shearing for free entry into further passes. The material passesthrough Intermediate Mill comprising of six stands having individual DC drive.

The stands are arranged in continuous line with DC motors & Drives enabling to rollat high speed. DC motors and Thyristor Drive will drive these stands. The FlyingShear 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 areequipped with DC motor and Thyristor drive. The material passes through theseentire stands and finally comes out in the desired size and section.

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

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Quenching system

The Quenching system consists of cooling pipes of different length having motorizedvalves for controlling the flow of water. The system is also equipped with pressureand temperature gauges. High pressure water pumps are provided with butterflyvalves so that water at desired pressure is available for rapid water quenching of barto obtain the desired properties.

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

The water used for water Quenching is collected in a scale pit. It is then cooled atcooling tower for re-use in the Quenching system. The entire system is equipped withvarious temperature gauges for measurement of the rolling temperature andequalizing the temperature for better quality control. The entire system is beingcontrolled by PLC system, which helps in maintaining accuracy of various processparameters such as flow of water, pressure, temperature. Once the material leavesthe quenching system, it passes through a pinch-roll unit, i.e., a machine having 2nos. cantilevered pinch roll. This machine is used for driving the Bar through thedividing shear after the Bar leaves the last stand. This is done with the help of aphoto cell located just before the pinch roll unit which detects the Bar nose. Asolenoid valve actuates the air cylinder of the pinch roll unit and the top pinch rollcomes 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 coldwater. Thereafter, the flying shear is installed for cutting the material into desiredlength. The Flying shear is operated with DC motor and is capable of cutting varioussizes with best accuracy. The shear has a digital drive, which will control the machineto 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 thecooling bed. The twin channel is installed all along the length at the side of thecooling bed. It consists of alternately opening flaps through a hydraulic cylinder. TheBar 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 Automaticcooling bed moves the finished bar to the discharge end with the help of walkingbeam. This system has advantage of getting a straight length material, thereby givingbetter finish to the material. This system has less involvement of labour. The coolingbed is provided with one Aligning device, which consists of 30 nos. individual drivenRollers, which is arranged in the stationary rake system of the cooling bed in front ofdischarge device. The main function of the aligning device is to align the nose of therolled bar in direction of forward transportation, ensuring 100% fix length material.The material is then finally sheared by Shearing machine in the length of 11-12meters and shifted to the loading area. It is then bundled and packed. After properinternal inspection, the material is released for dispatches. The process flow diagramof rolling mill is shown in Figure 7.

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FIGURE 7: PROCESS FLOW DIAGRAM OF ROLLING MILL

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

FIGURE8: PROCESS FLOW DIAGRAM OF BRICK PLANT

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Coal Washery

Washing of coal is a process of up-gradation of Coal. There are number ofmethods/process by which the quality of coal can be improved. Out of severalmethods/processes available, the dry upgrading of coal through allair JiggingMachine is one of them. This is a tested method and number of plants is runningsuccessfully under this technology. The major description and process is givenbelow:

The All air jig was invented for the dry upgrading of coal. The advantages of jiggingprocess are combined with the advantages of dry beneficiation process e.g. no needfor process water, clarified water or water purification, no fines dewatering and noslurry impoundment.

Separation of minerals in jigging machine is based on the fact that particles willstratify in pulsating air the upward and downward currents fluidize and compact airthe upward and currents fluidize and compact the grains into relatively homogenouslayers. Low density pieces stratify on the surface, while specifically heavy grainssettle to the lower level of the bed. The most precise stratification of particles requirespulsation of proper frequency and amplitude- which can be adjusted during operationand can be optimized according to feed characteristics. Allair- jigging machines aredriven 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 jigbed flows through the reject star gate.

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

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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 COALSl.No.

Particulars Raw Coal Clean Coal Reject Coal

1 GCV (Kcal/Kg) 2800 – 2900 3800 – 4000 2000 – 22002 Ash (%) 43 – 47 34 – 36 58 – 623 Yield (%) -- 60 – 62 38 – 404 Sulphur (%) 0.4-0.6 0.4-.0.5 0.4-0.5

FIGURE 9: SCHEMATIC DIAGRAM FOR THE MANUFACTURING PROCESS OF COALWASHERY

Pellet Plant

1) Process Description:

Complete process from receiving of Iron Ore fines to the dispatch of finished productcomprising 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 areunloaded into ground hoppers from where these are transferred to respective storagehoppers in various sections. Three circuits are provided for the various raw materials,as follows:

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

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• 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. Theheat energy to the drier is generated by firing pulverized coal in a combustionchamber / hot air generator. Indian coal containing up to 35% ash is to be used aftergrinding it in a Coal Mill. Suitable de dusting system has been included to meet theenvironment / pollution norms. Provision is kept to by –pass the drier if dry material isavailable. The product is dried to less than 1.5% moisture level. Dried fines areconveyed to the iron ore hoppers in the grinding section through Heat Resistant BeltConveyor.

4) Screening :

Green balls are received on a swing belt conveyor and fed to the oversize rejectscreen. Thereafter, green balls are passed over a wide belt conveyor feeding to theunder size roller screens. Under size reject and over size reject after crushing arerecycled to the raw mix hoppers. The sized green balls between 8-16 mm areconveyed 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 arepassed through the travelling grate which is 2.8 m W X 36 m long and divided threezones viz. 1 drying and 2 pre-heating. The green balls are dried and preheated up to1000°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 ballsgain sufficient strength to withstand the conditions of the rotary kiln. The hot air fromkiln and cooler are used in the travelling grate utilizing and recovering maximum heatfrom waste gases.

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

6) Cooling:

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

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

7) Stacking and Shipment:

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

8) Waste Gas treatment and dust recovery:

The hot gas exhausted from wind boxes at two sides of the preheating zone oftraveling grate are sent for cyclic utilization, these two parts of waste gas arerespectively 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 StaticPrecipitator), and it is discharged to atmosphere via induced fan and stack. Thechimney 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 atgrinding 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 processmonitoring, control, safety, data logging and management information. Process flowdiagram is shown in Figure 10.

FIGURE 10: SCHEMATIC DIAGRAM FOR THE MANUFACTURING PROCESS OFPELLET PLANT

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3.6 Raw material required along with estimated quantity, likely source, marketingarea of final product/s, Mode of transport of raw Material and Finished Product.

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

RAW MATERIAL QUANTITY EXISTING AND PROPOSED

SPONGE IRON PLANT- 2,10,00 TPA TO PROPOSED- 2,64,000 TPAS.No. Existing Capacity-

2,10,000 TPARaw Materials in TPM

Proposed Capacity-2,64,000 TPARaw Materials in TPM

01. Coal 21000 Coal 2200002. Iron Ore 26250 Iron Ore 3300003. Dolomite 700 Dolomite 880

Total 47950 Total 55880

08 MW Biomass Based Power PlantS.No. Existing

Raw Materials inTPM

ProposedRaw Materials in TPM

01. Dolochar 4350 Dolochar 2175

02. Rice Husk 10417 Rice Husk 235003. Coal Fines - Coal Fines 7000

Total 14767 Total 11525

Existing ProposedS.No. Quantity(MT) Ash

Generation(In MT)

Quantity (MT)Ash Generation

(In MT)

01. Dolochar 4350 3045 Dolochar 2175 1305

02. RiceHusk

10417 1823 RiceHusk

2350 411

03. CoalFines

- - CoalFines

7000 2450

Total 14767 4868 Total 11525 4166

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STEEL MELTING SHOP -1,29,600 TPA TO PROPOSED- 2,11,200 TPAS.No. Existing Capacity-1,29,600

TPARaw Materials in TPM

Proposed Capacity-2,11,200 TPARaw Materials in TPM

01. Sponge Iron 11014 Sponge Iron 1735202. Pig Iron 449 Pig Iron 73203. MS Scrap 1134 MS Scrap 183404. Ferro & Non

Ferro alloys108 Ferro & Non

Ferro alloys176

Total 12706 Total 20094

FERRO ALLOYS PLANT- 14,400 TPA TO PROPOSED 19,800 TPAS.No. Existing Capacity-14,400

TPARaw Materials in TPM

Proposed Capacity-19,800 TPARaw Materials in TPM

01. ManganeseOre

2160 ManganeseOre

2970

02. Coke 240 Coke 33003. Coal 720 Coal 99004. Dolomite 120 Dolomite 16505. Ferro

ManganeseSlag

1200 FerroManganeseSlag

1650

Total 4440 Total 6105

PROPOSED PELLETIZATION PLANT- 6,00,000 TPAS.No. Existing Capacity

Raw Materials in TPMProposed Capacity-6,00,000 TPA

Raw Materials in TPM01. - - Iron Ore

fines51,000

02. - - Coke 175003. - - Limestone 75004. - - Bentonite 40005. - 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 TPACapacity after Expansion = 2, 64,000 TPA

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

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

S. No. INPUT (TPM) OUTPUT (TPM)1. Coal 22000 Sponge Iron 220002. Iron Ore 33000 Dolochar 44003. Dolomite 880 ESP Dust 33734. Accretion 1925. Wet Scrapper Slurry 2596. Ash 42737. Gases 21383

Total 55880 Total 55880

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 41663. 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 2 x 15 T InductionFurnace)

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 176002. Pig Iron 732 Slag 21123. MS Scrap 1848 Gases & Fumes 9934. Ferro & Non ferro

Alloys176

Total 20705 Total 20705

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 6MVA (SAF)]

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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 19803. Coal 990 Gases & Fumes 24754. Dolomite 165 05. 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 500002.

Coke 1750Lost toAtmosphere 3900

3. Lime Stone 7504. 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 isinstalled and clear water is being used for plantation and dust suppression. Nowastewater is being discharged into drains or natural water course.

No water will be extracted from the ground water sources. All the acidic and alkalineeffluent is being neutralized in neutralization tank and treated effluent is recycled/reused in the dust suppression in fuel handling, fly ash loading/unloading area andgreen belt development. Subsequently cooling tower blow down is being used fordust suppression in fuel handling area. Domestic wastewater treated in septic tankfollowed by soak pit. No wastewater is being discharged outside the factorypremises 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 requirementwill be about 2823 m3/day. This will be met from River Kharun. SBPIL has alreadyobtained consent for drawl of water through Kharun River (1,25,000 m3/month) fromWater 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 fromgroundwater.

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Energy/ Power requirement and source:

The electric power requirement for the project will be fulfilled from captive powerplant. The additional power requirement after expansion shall be met by wheeling ofpower from other unit and/or from CSPDCL.

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

• Generated Char is being used in 8 MW Biomass power plant and surplusquantity ofDolochar is being supplied to 16 MW AFBC power plant at Gondwara plant ofM/s. SBPIL unit.

• Generated slag after crushing and screening being used in brick manufacturingplant

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

• Reject coal generated from coal washery 100% will be used for captiveconsumption in power plant

• 100% Mill scale is used for captive consumption in Ferro Alloys Plant as rawmaterial.

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

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

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

• The liquid steel produced will be used in a manner to produce hot billet suitablefor 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 ofsolid waste

Qty. MT/YearExisting

Qty.MT/Year(Total Capacity

afterexpansion)

Utilization /disposal method

Fly ash from PowerPlant

108816 90468 Bricks manufacturing unit &Cement Plant

Slag from SMS unit 17000 25344 Bricks manufacturingSlag from FerroAlloys unit

21000 23760 Bricks manufacturing

Dolochar from SID 66000 52800 Used in our AFBC based powerplant (Gondwara unit) as a Rawmaterial.

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

S.No.

Particulars Impacts Remediation Proposed

1. Change inland use.

The possible greenery ontheland and natural rechargeis affected

• The project is already in anIndustrial area and additional landof 6.8 Ha will be used for theproposed expansion will be withinplant premises, devoid ofvegetative tree cover and havingonly the grass cover. Part of theland will be covered by treeplantation to the extent of 33% ofarea being brought under industrialactivity. The greenbeltdevelopment is aken up within theplant boundary and additionallyoutside the plant boundary.

• Water will be sourced from Kharunriver, no groundwater will beabstracted for the project activitieshence, natural recharge ofgroundwater level will not beaffected through proposed projectactivities.

2. Transportationof material

The existing network oftransport getspressurized

The proposed expansion willmarginally increase in Traffic density.The project lies within Urla IndustrialComplexes thus, infrastructuralfacilities/road accessibility are alreadydeveloped.

3. Gaseous andParticulateEmission toTheatmosphere

Air quality All necessary steps will be followed tominimize the emission from pointsources as well as line sources. Thusthe standards of Stack Emission andAmbient Air quality will be maintainedas per prescribed limits.

4. Discharge ofeffluent

Impact of water quality. Zero discharge is proposed.

5. Withdrawal ofground /surface water

Availability ofground/surfacewater is affected.

Water will be sourced from KharunRiver, no ground water will beabstracted for the project activitieshence, natural recharge of groundwater level is not affected throughproject activities. Permissionregarding drawl of river water isgranted from water resourcedepartment.

6. Operation ofequipmentand vehicleslikely to

Impact on human healthdue to excess noise levelbeyond permissible level.

All the process equipment will beinstalled on anti-vibration pad withsufficient provisions to minimizegeneration of noise. The high noise

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S.No.

Particulars Impacts Remediation Proposed

generatenoise.

generating equipment like turbine andgenerator will be enclosed with noisesuppressing enclosures.The buildings as well as boundarywall and green belt will ensure theattenuation of noise outside theboundary within the prescribed limits.

7. Fire Hazarddue to storageof fuel etc.

Risk to the surroundinghabitation.

Necessary precautions to prevent fireand all the provisions to control fireshall be Provided.

8. Employmentto outsiders

Socio-economic disparitywithlocal community

Priority of employment will be given tolocal people, as already sufficientqualified and trained local youth areavailable.

9. Culturalimpact

Local population feelsisolated

The promoters proposed to employlocal masses in the project hence nosuch impact on cultural diversity islikely to take place.

10. Disposal ofsolid andhazardouswastes

Create odorous problem,nuisance condition relatedto the disposal of solidwastes. Deterioration ofsoil, productivity pollutionin ground water/surfacewater due to leaching andsurface runoff.

Domestic wastes will be segregatedfor organics and Inorganics. Organicwastes will be used for compostingand inorganics for approved vendors.Disposal of hazardous wastes will bedone as per hazardous wasteshandling and disposal rule.

4.0 SITE ANALYSIS

4.1 Connectivity.

The proposed project is situated at Borjhara village, Raipur district and Tehsil, Stateof Chhattisgarh. The project is located within the Urla Industrial Growth Centre. Thesite 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. Thetotal land area for the project is 27.80 hectare in villages- Borjhara, Urla & Sarora. Itis 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 additionalarea of 6.8 Ha will be used.

The breakup of the land for the various activities for the proposed project will be asfollows:

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TABLE 14: LAND BREAKUPS.NO. DETAILS AREA(Hectare)

01. Total Built up area 6.869702. Area for green belt 9.23803. Open area 9.545304. Area under road 1.400005. Parking Bay 0.747

Total 27.8

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4.3 Topography (along with map)

The project area located in the Urla Industrial Growth Centre within the Raipur regionis typically flat, with low undulating plain and the plant site having gentle slope towardNorth. Dominant features of the land is being the lateritic, sandy loamy plain andbroad alluvial plain of Kharun River. The project site lies at the 21018'23" to21018'46” North Latitude and 81035'09" to 81035'44" East longitude on the Toposheet No. 64, G/11. The site specific Topography map is given in Figure 11.

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

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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 copyof Gazette Notification should be given:-

The project is located within the notified Urla Industrial Growth Centre. Existing landuse is private industrial land. The land is being used for Industrial Purpose. Landallotment letter is enclosed as Appendix – I.

5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities transportation Town andCountry Planning Development authority Classification.

Project concept:

The project is conceptualized in accordance to the present challenge of minimizingGreen 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 onimported stock of coking coal to meet the coke requirement of blast furnaces, whichdrains valuable foreign currency of the nation.

During last 15 years of industrial growth largest capacity addition had been in steelmaking through sponge iron route, which was quite successful in bailing out thenation 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 qualitycoal from the non coking coal mines due to which the energy efficiency of thesesponge iron plants were badly affected and therefore the financial viability also gotbadly affected.

It is a known technological limitation in sponge iron making process that poor qualitycoal results in to faster accretion in the kiln resulting in to poorer capacity utilizationand frequent breakdowns.The simplest solution for this is to utilization only high grade coal, which is obtainedfrom beneficiation of poor grade raw coal available from Indian mines.

The second problem faced by the sponge iron industry was non availability of goodquality iron ore at consistent prices. This bottleneck has been now overcome byinception of a large number of iron ore beneficiation cum pelletisation plant. This hasmade ample availability of well sized and well defined and sustained availability ofproper quality of ore in the form of pellets at much reasonable rates.In the backdrop of this scenario, the project proponent planned for proposedexpansion of Integrated Steel Plant.

Now, the said proposal for expansion of production capacity with change inconfiguration of sponge iron from 2, 10, 000 TPA (2 x 350 TPD x 300 days) to2,64,000 TPA (2 x 400 TPD x 330 days). Similarly change in fuel mix of 8 MWcaptive power plant since availability of Rice Husk is not consistent as per ourrequirements hence coal/coal fines will also be used in addition to Rice Husk &Dolochar.The expansion of Submerged Arc Furnace involves the enhancement of

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capacity and modernization. The existing SAF production capacity is 14,400 TPA (2No. x 4 MVA SAF) replaced by higher capacity transformer of SAF to increase inproduction 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 beenhanced to 2,11,200 TPA by installation of two more furnaces of 2 X 15 T which willhave additional production capacity of 81,600 TPA.. Rolling mill capacity will beenhanced from 0.15 to 0.21 MTPA by production Capacity optimization taken due tocurtailment of Idle Running Hours since it is to run in synchronization with SMS as wehave 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 thekiln. Coal provides the source of heat and also acts as reducing material to turn ironore into iron. Sponge iron produced is separated from waste materials in magneticseparator, screened and sent to steel making shop.

Steel Melting Shop (SMS): Pig iron, sponge iron, lime and ferroalloy is charged fromthe top of Electric Arc Furnace / Induction Furnace. Arcing melt the contents. Oxygenblowing is done. Steel is tapped and chemistry correction is done in laddle refiningfurnace. Liquid steel is casted into billets in continuous casting machine. Slag istaken out from slag tap hole.

Rolling Mill: State of art technology is developed for Steel billet/blooms are rolledinto different products in the Structural Mill. M/s. SBPIL has bagged the NationalEnergy Conservation Award in the steel rolling mills sector. Under the energyefficiency measures, the company had invented a state of art technology of directrolling of hot continuous cast billet to produce TMT bars without any intermediatedreheating arrangement. It contributes towards conservation of energy andenvironment as well. The ministry had also recognized the company as inventor ofdirect rolling technology which is a remarkable achievement.

Power Plant: Waste heat from Sponge Iron Plant, Ferro Alloys Plant, and otherprocesses shall be used in WHRB to generate 18 MW electricity. Biomass mainlyrice husk as fueling component for the power plant as the region of this area ofChhattisgarh as rice bowl of India. Rice husk and dolochar is being used Biomassbased power plant to generate 8 MW electricity; Electricity shall be used for captiveconsumption. 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 ondry process unit, hence no water will be required.

Pellet Plant: The pelletisation process consists of forming green balls out of a veryfinely 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 calledpellets. The hot air from kiln and cooler will be used in the travelling grate utilizingand 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. Townand country planning department has already classified land as industrial. Adequate

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

5.2 Population Projection.

The existing industry is providing employment to about 750 people and oncompletion of the expansion, there will be addition of 100 people. Since the plant islocated in the Raipur district in which trained manpower are already availabletherefore the employment will be mostly given to local people therefore there will notbe any substantial increase in the population of local villages. However, due toincrease economic growth, the local youth will be benefited with respect toemployment. And additional population influx of around 100 people within the 10 KMradius of plant can at best be estimated, which includes the addition of personsdependent 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. Theexisting plantation is more than 50,000 proposed plantation by M/s. SBPIL in year2017-18 was 3000, and so for 3000 plant is already planted in the year 2017-18. Thebreakup of the land for the various activities for the proposed project will be asfollows:

TABLE 15: LANDUSE BREAKUP ALONG WITH GREENBELTS.NO. DETAILS AREA(Hectare)

01. Total Built up area 6.869702. Area for green belt 9.23803. Open area 9.545304. Area under road 1.400005. 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 nosubstantial additional infrastructure is required. The available road network andnatural sources of water supply and drainage system are adequate.Water will besourced from Kharun river. There is no other major infrastructural requirement for theproject.

5.5 Amenities/Facilities:

The project expansion does not require additional large amenities or facilities. As italready has necessary arrangement for proposed expansion for meeting watersupply for drinking purposes, toilet facilities for workers as well as inward/outwardtransport operators, parking facilities, as well as small canteen for workers andguests. The septic tank has been built for disposal of domestic effluent generated. Acanteen with rest room is also available for the workers and drivers, visitors etc.Sufficient parking space is already created for the parking of Trucks; cars etc.

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6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

Out of the total 27.80 Ha. about 6.8967 Ha. land is being used as a construction aswell as open area in battery limit of plant area. An area of 1.4000 Ha. is dedicated forarea under road. Remaining area will be for open space as well as roaddevelopment, water storage and green belt development, parking bay, etc. as givenin land use statement.

6.2 Residential Area (Non Processing Area)

There is no residential area proposed in the plant area; as the existing villages haveadequate facilities accommodate the additional manpower residential requirements.Most of the local people will only be employed so the need of the additionalresidential colony in the plant is not there.

6.3 Green Belt.

A greenbelt in around 9.238 Ha. is being planted, having local species with broadleaves and higher canopy. The ever green plants will be selected for the purposed ofgreen belt. The existing plantation is around 50,000 proposed plantation by M/s.SBPIL in year 2017-18 was 3,000 and so for 3000 plant is already planted as pertarget in the year 2017-18.

6.4 Social Infrastructure:

The project area lies within the district of Raipur. There is no requirement to build anysocial infrastructure within the plant area, however, a small temple already exists andthe infrastructure for amenities to the workers such as kitchen, canteen, rest roometc. is already provided which will be further augmented with the expansion of theproject.

6.5 Connectivity (Traffic and Transportation Road, Rail/Metro/Waterways etc.).

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

Nearest Road: Durg-Raipur-Bilaspur Highway (NH-6) about 8.0 km, S Nearest railway station- Raipur ~10 Km, SE Nearest airport- Raipur 30 Km, SE

6.6 Drinking Water Management (Source & Supply of water)

The total water requirement will be about 2,823 m3/day. Water required for domesticpurposes will be 75 m3/day. This will be met from River Kharun. SBPIL has alreadyobtained consent for drawl of water through Kharun River (1,25,000 m3/month) fromwater Resources Department, Govt. of Chhattisgarh, vide letter No.5010/302/JS/TS/AJP/03-D-4 dated 26/10/2004. No groundwater will be abstracted.

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6.7 Sewerage system

Infra-structural services including water supply, sewage, drainage facilities andelectrification will be made. The existing toilet facilities will be available to the workersto allow proper standards of hygiene. These facilities are connected to a septic tankand soak pits. Waste water drainage system of the plant is well connected to thesewerage channel facilities of Urla Industrial Growth Complex (UIGC) to ensureminimum impact on the environment.

6.8 Industrial Waste/ Solid Waste Management.

100% of Industrial Solid waste will be used in the following manner:

6.9 Solid Waste Management

• The disposal of solid waste is planned by utilizing safely and according to thescientific procedures for its handling, storage and disposal activities. Ash will beextracted and disposed off in wet form.

• The rejects generated in coal washing will be used in Captive AFBC (Coal Based)Power Plant of SBPIL (sister concern) situated at a distance of 4 KM.

• Thick green belt will be developed all around the periphery of the plant andvacant places within the premises so as to reduce the pollution load and improvethe aesthetics of the area.

TABLE 16: DISPOSAL OF SOLID WASTESource and type of

solid wasteQty. MT/Year

ExistingQty.MT/Year

(TotalCapacity after

expansion)

Utilization /disposal method

Fly ash from PowerPlant

108816 90468 Bricks manufacturing unit &Cement Plant

Slag from SMS unit 17000 25344 Bricks manufacturingSlag from FerroAlloys unit

21000 23760 Bricks manufacturing

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

6.10 Power Requirement & Supply/source.

The electric power requirement for the project will be fulfilled from 26 MW CaptivePower plant. Additional power will be obtained from the grid or from our sisterconcern.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

7.1 Policy to be adopted (Central/ State) in respect of the project affected personsincluding home oustees, land oustees and landless laborers (a brief outline tobe given):

The proposed project does not have any directly displaced persons, due toacquisition of land. There are also no land oustees or project affected persons or

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home oustees, thus R&R plan is not applicable here. However, the priority foremployment will be given to local persons living in the adjoining villages. In additionto this promoter will also contribute for the welfare of the people of local surrounding.

DETAILS OF CORPORATE SOCIAL RESPONSIBILITY BY GOEL GROUP OFINDUSTRIES

The company is actively involved in CSR activities for the welfare of the surroundingareas and budgetary provision is made every year. In 2015-16. The company hasspent Rs. 92.45 lakhs for different activities as a part of CSR activities.For the year2016-17 a budgetary provision of Rs. 70.75 lacs has been spent by the company(Table 17-18)

TABLE 17: CSR ACTIVITIES DURING THE YEAR 2016-17

S. No. Particulars Cost (in Lacs Rs.)1 Promoting Education 54,34,9942 Environment sustainability 4,00,0003 Rural Development 1,55,4914 Promoting Healthcare facilities 6,18,9305 Making available Safe Drinking water 4,65,940

TOTAL 70,75,355

TABLE 18: CSR ACTIVITIES DURING THE YEAR 2015-16 (RS. IN LACS)S. NO. PARTICULARS COST1 Providing educational facilities 60,19,4622 Providing drinking water facilities & pond cleaning 17,21,9333 Providing healthcare and medical facilities 6,15,8394 Work for environment sustainability and protection of flora 28,7455 Vocational training programmes for employment 8,59,375

TOTAL (IN LACS Rs) 92,45,354

8.0 PROJECT SCHEDULE & COST ESTIMATES

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

SCHEDULE FOR APPROVAL AND IMPLEMENTATION

Proposed Project

Activities at the site will be carried out after grant of Environmental clearance fromMinistry of Environment & Forests and Consent to establish from ChhattisgarhEnvironment Conservation Board (CECB). The schedule for implementing theproposed project is given in Table 19.

TABLE 19: PROJECT IMPLEMENTATION SCHEDULEParticulars Implementation Date/Time PeriodStart of Construction After Receipt of Environmental Clearance

And NOC

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Construction Period(Submerged Arc Furnace, PelletPlant, Expansion of Induction Furnace, Rerolling expansion etc.

03 Months

Commercial Production PeriodCommercial Production will be started After 03 Months

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

The project cost is estimated to be Rs. 120 crores.

TABLE 20: PROJECT COSTExisting Project Cost

(Rs. In Cr.)Proposed expansion

cost(Rs. In Cr.)

Total Cost(Rs. In Cr.)

238.31 120 358.31

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and social benefits with special emphasis on the benefit to the localPeople Including Tribal Population, If Any, in The Area.

On overall assessment of the project with technical and financial aspects, it isconcluded that the proposed expansion of integrated steel plant is technically highlyfeasible and financially highly profitable.

The project is of utmost importance as it is going to be drastically reduced the GHGemission & promote sustainable development with a great saving in energyconsumption. M/s. SBPIL has bagged the National Energy Conservation Awardin the steel rolling mills sector. Under the energy efficiency measures, thecompany had invented a state of art technology of direct rolling of hotcontinuous cast billet to produce TMT bars without any intermediatedreheating arrangement. It contributes towards conservation of energy andenvironment as well. The ministry had also recognized the company asinventor of direct rolling technology which is a remarkable achievement.

The strength of the project lies on the use of washed coal in Sponge Iron making,and use of thermal energy in liquid steel to maintain rerollable temperature in rollingof steel along with Captive Power generation technology based on the Waste Coaland Char, Dolochar and the technical strength of the promoters.

The abundance of raw material in surrounding areas at very cheaper rate will givethe company a great financial strength, which is further substantiated by CaptivePower Generation at cheaper rates.

Waste heat from various processes is being used in WHRB to generate electricity.Electricity shall be used for captive consumption subsequently biomass mainly ricehusk as fueling component for the power plant as the region of this area ofChhattisgarh is known as the rice bowl of India. Rice husk is being used for Biomass

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based power plant to generate electricity; Electricity shall be used for captiveconsumption.

A sincere approach adopted for the Air Pollution Control and Resource conservationby recycling the 100% waste water also gives the additional advantage to thecompany. Power generation from Waste Coal/Waste hot gases will give financialstrength to the Company and Protect Environment.

The project proponents have decided to give top most priority for employment to localpeople within the plant, and outside the plant in direct and indirect employments. Outof over 750 people employed by the company, employing more than 500 peoplefrom local area, which would naturally involve tribal people also, who are more than40% in population and also are now well qualified as well as competent to take theemployment in the proposed industry. The local population is likely to be benefited bypayment of salary and wages to the local community employed.

In view of these above factors, it is thought that the project is technically feasible,environmentally safe and financially viable.

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Appendix -ILAND ALLOTMENT LETTER

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Appendix IIAPPROVAL LETTER FROM WATER RESOURCES DEPARTMENT

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Appendix IIIEXISTING EC LETTER

Date 17th January, 2008

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Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 52: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 53: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 54: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 55: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 56: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 57: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 58: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 59: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.

Page 60: PRE FEASIBILITY REPORT Of Proposed Expansion of Integrated … · 2017. 8. 31. · use of good quality coal Total Power Plant – 26 MW (CPP) WHRB – 18 MW CPP – 8 MW AFBC Boiler

Pre-Feasibility Report (PFR)

Shri Bajrang Power and Ispat Ltd.