setting up of a greenfield integrated steel plant of …€¦ · power plant which will utilize...

PRE-FEASIBILITY REPORT

ON

SETTING UP OF A GREENFIELD INTEGRATED STEEL PLANT OF 0.7 MTPA WITH CAPTIVE POWER PLANT OF 70 MW

TO

SPINTECH TUBES PRIVATE LIMITED

SEPTEMBER 2018

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report

TABLE OF CONTENTS

Page

- i -

1 - EXECUTIVE SUMMARY...................................................1-1

2 - INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION...............................................................2-1

2.1 Identification of the Project and Project Proponent ............... 2-1

2.2 Brief Description of the Nature of the Project ....................... 2-2

2.3 Need for the Project and Its Importance to the Country ........ 2-3

2.4 Demand-Supply Gap, Imports vs. Indigenous production, Export possibility & Domestic/ Export Markets ............................................................................. 2-5

2.5 Employment Generation (Direct and Indirect) due to the Project ............................................................................... 2-8

3 - PROJECT DESCRIPTION.................................................3-1

3.1 Type of Project ................................................................... 3-1

3.2 Location ............................................................................ 3-1

3.3 Details of alternate sites considered and the basis of selecting the proposed site.................................................. 3-3

3.3.1 Suitability of the Site for Integrated Steel Plant................. 3-3

3.4 Size or Magnitude of Operation ........................................... 3-6

3.5 Layout ............................................................................... 3-6

3.6 Project Description with Process Details .............................. 3-6

3.6.1 Iron Ore Grinding Unit for Pellet Plant.............................. 3-7

3.6.2 Pellet Plant ..................................................................... 3-9

3.6.3 Direct Reduction (DR) Plant ........................................... 3-12

3.6.4 Sinter Plant................................................................... 3-12

3.6.5 Blast Furnace ............................................................... 3-15

3.6.6 Pig Casting Machine ...................................................... 3-18

3.6.7 Steelmelt Shop .............................................................. 3-18

3.6.8 Annual Production from SMS ......................................... 3-22

3.6.9 Major Equipment and Facilities...................................... 3-22

3.6.10 Rolling Mills .................................................................. 3-22

3.7 Briquetting Plant for Ferrochrome Production.................... 3-29

3.7.1 Ferro-Alloy Plant ........................................................... 3-30

3.7.2 Air Separation Plant ...................................................... 3-32

3.7.3 Captive Power Plant....................................................... 3-34

3.7.4 Raw Materials ............................................................... 3-37

3.8 Road Logistics for Raw Material Transportation ................. 3-40

3.9 Resource Optimization/Recycle & Reuse envisaged in the project ............................................................................. 3-41

3.10 Availability of Water and Power ......................................... 3-41


TABLE OF CONTENTS

(Continued)

Page

- ii -

3.10.1 Water............................................................................ 3-41

3.10.2 Power ........................................................................... 3-42

3.11 Waste Generation and Management................................... 3-43

3.11.1 Waste Water Management .............................................. 3-43

3.11.2 Solid Waste Management ............................................... 3-44

3.11.3 Air Pollution.................................................................. 3-45

3.12 Schematic representations of the feasibility drawing which give information of EIA purpose .............................. 3-47

4 - SITE ANALYSIS..............................................................4-1

4.1 Connectivity....................................................................... 4-1

4.2 Land Form, Land Use and Land Ownership ......................... 4-2

4.2.1 Land Use of Project site ................................................... 4-2

4.3 Topography ........................................................................ 4-2

4.4 Existing Infrastructure ....................................................... 4-4

4.5 Soil Characteristics ............................................................ 4-4

4.6 Climatic Conditions ............................................................ 4-5

4.7 Social Infrastructure Available ............................................ 4-6

5 - PLANNING BRIEF ...........................................................5-1

5.1 Planning Concept ............................................................... 5-1

5.2 Population Projection ......................................................... 5-1

5.3 Land use planning.............................................................. 5-2

5.3.1 Integrated Steel Plant ...................................................... 5-2

5.4 Assessment of Infrastructure Demand ................................. 5-3

6 - PROPOSED INFRASTRUCTURE .......................................6-1

6.1 Industrial Area (Processing Area) ........................................ 6-1

6.2 Residential Area (Non Processing Area) ................................ 6-1

6.3 Greenbelt........................................................................... 6-1

6.4 Social Infrastructure .......................................................... 6-2

6.5 Connectivity....................................................................... 6-2

6.6 Drinking Water Management............................................... 6-2

6.7 Drainage and Sewerage System........................................... 6-3

6.8 Industrial Waste Management............................................. 6-3

6.9 Solid Waste Management .................................................... 6-3

6.10 Power Requirement and Supply/Source ............................... 6-4

7 - REHABILITATION AND RESETTLEMENT..........................7-1


TABLE OF CONTENTS

(Continued)

Page

- iii -

8 - IMPLEMENTATION SCHEDULE AND COST ESTIMATE .......8-1

8.1 Implementation Schedule ................................................... 8-1

8.2 Capital Cost Estimate......................................................... 8-4

8.3 Annual Manufacturing Expenses......................................... 8-5

8.4 Annual Sales Reasilsation................................................... 8-5

8.4.1 Return on Investment (ROI) ............................................. 8-6

9 - ANALYSIS OF PROPOSAL................................................9-1

9.1 Financial and Social Benefits of the Project ......................... 9-1

TABLES

Table 2-1 - Forecasted capacity and demand of steel by 2030-31.......... 2-5

Table 2-2 - Major Market Segments - 2030 .......................................... 2-7

Table 3-1 - Evaluation of SiteS based on Multiple Indicators ................ 3-5

Table 3-2 - Major plant units and facilites........................................... 3-7

Table 3-3 - Design Basis of Pellet Plants ............................................. 3-9

Table 3-4 - Typical Analyses of Raw Materials for Pellet Production ...... 3-9

Table 3-5 - Analyses of Raw Materials ............................................... 3-12

Table 3-6 - Design Basis of Sinter Plants........................................... 3-13

Table 3-7 - Typical Analyses of Raw Materials for Sinter production ... 3-13

Table 3-8 - Design Basis of Blast Furnace ......................................... 3-16

Table 3-9 - Typical Raw Materials Analysis (Dry Basis) ...................... 3-16

Table 3-10 - Characteristics of Molasses and Hydrated Lime .............. 3-29

Table 3-11 - Briquette Characterisitcs............................................... 3-30

Table 3-12 - Specific Power Consumption for Ferro-Alloy ................... 3-31

Table 3-13 - Specific Consumption of Raw Materials (Dry Basis)......... 3-31

Table 3-14 - Purity and Pressure of Oxygen, Nitrogen and Argon ........ 3-33

Table 3-15 - Estimated Annual requirements of Major Raw Materials ................................................................ 3-38

Table 3-16 - Unitwise requirement of Water....................................... 3-42

Table 3-17 - Solid Waste Generation ................................................. 3-44

Table 4-1 - Land use of Core Area ....................................................... 4-2

Table 4-2 - Summarised Meteorological Data ....................................... 4-6

Table 5-1 - Land use Break-up of the Project Area ............................... 5-2

Table 8-1 - Capital Cost Estimate ....................................................... 8-4

Table 8-2 - Annual Manufacturing Expenses (At rated Capacity Level) ....................................................................... 8-5


TABLE OF CONTENTS

(Continued)

Page

- iv -

FIGURES

Fig. 3-1 - Site Location Map................................................................ 3-2

Fig. 3-2 - Google Map showing Location of the Project.......................... 3-3

Fig. 3-3 - Schematic Diagram for Steps of EIA ................................... 3-48

Fig. 4-1 - Site Connectivity ................................................................. 4-1

Fig. 4-2 - Topographic Map of the Proposed Steel Plant Site ................. 4-4

Fig. 8-1 - Implementation Schedule .................................................... 8-3

DRAWINGS

Drg 11485-97A-000-LTL-0001 - Plant General Layout Drg 11485-97A-000-PRS-0002 - Process Flow Diagram


1-1

1 - EXECUTIVE SUMMARY

Spintech Tubes Private Limited (STPL) is one of the flagships

Company of M/S Gagan Group, well known in eastern India for their

quality products viz. TMT bars, billets, ingots, sponge iron etc. Gagan

Group is one of the fastest growing steel making company in eastern

India, started as a manufacturing company for iron & steel products in

2000 in Durgapur, West Bengal under the name of Shakambhari

Overseas Trades Pvt. Ltd (SOTPL). SOTPL established an ingot

manufacturing plant with a capacity of 72,000 TPA in Durgapur, West

Bengal. Gagan group is multiplying its business in terms of sales &

production by setting up an integrated steel plant at Jamuria, West

Bengal.

As a result, Gagan Ferrotech Limited (GFL) started

manufacturing sponge iron at Jamuria Industrial Area, Ikra in Burdwan

district in 2007. Now, STPL being incorporated as Private Limited

Company on 14th February 2017, intends to set up 0.7 MTPA Integrated

Steel Plant (ISP) with captive power plant of 70 MW capacity in Dhasal,

Jamuria at Paschim Bardhaman in West Bengal with an objective to

expand its operation in eastern India.

The major production facilities envisaged for this integrated

iron and steel plant of STPL will comprise pellet plant, sinter plant, DR

plant, blast furnace, steelmelt shop, long product mills, structural mill

and wire drawing facility. Ferro-alloy plants have also been envisaged in

order to produce FeMn, SiMn and FeCr. The plant will have its captive

power plant which will utilize surplus blast furnace gas, waste heat off

gas of DR plant, in-plant char and purchased coal to produce power. The

plant will also have its captive air separation plant for producing oxygen,

nitrogen and argon required by various units.

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 1 - Executive Summary (cont’d)

1-2

The following section presents a brief outline of the

Pre-feasibility report for the proposed plan for setting up of the

aforementioned proposed projects.

Project Profile - Hot Metal .. 0.367 MTPA - DRI .. 0.495 MTPA - Liquid Steel .. 0.729 MTPA - Semis .. 0.712 MTPA - Captive Power .. 70 MW

Products for Sale Pellet .. 0.300 MTPA Pig Iron .. 0.046 MTPA Wire Rods .. 0.219 MTPA TMT Bars .. 0.250 MTPA Plain Structural .. 0.100 MTPA TLT Structures (Galvanised TLT Section) .. 0.100 MTPA Drawn Wires .. 0.030 MTPA Ferro Alloys .. 0.036 MTPA

Location Dhasal, Bahadurpur & Mamudpur villages of Jamuria Block, Paschim Bardhaman District

Iron Ore Grinding Unit 1.186 MTPA

Pellet plant 1.13 MTPA

Sinter plant 0.62 MTPA

DRI plant (coal based) 0.495 MTPA

Blast furnace 0.367 MTPA

Submerged Arc Furnace 0.0466 MTPA Chrome Ore Briquetting Plant 0.041 MTPA

Steelmaking Shop (SMS) 0.729 MTPA

Caster Shop 0.712 MTPA

Mill 0.699 MTPA

Captive Power Plant 70 MW

Major Facilities with Production capacity

Air Separation Plant 180 TPD

Major Raw Materials Coke, anthracite, non-coking coal, iron ore fines, PCI coal, steam coal, lime stone, dolomite, chrome ore (lump & fines), manganese ore, quartzite

Water consumption 276 cu m/hr

Water Source Ajay River of approx 7 km distance & Asansol Municipal Corp.

Power source & requirement

Annual energy consumption - 851 X 106 kWh, sourced from captive generating units & India Power Corporation Limited

Land details Around 240 acres

Employment generation

Construction phase - Around 1,200-1,500 casual and contract workers,

Operation phase - Approximately 1,150 direct employment & another 4,000 indirect employment

Implementation Schedule

27 months from ‘Go-ahead’ date

Capital Cost Around INR 3,200 Crore

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 1 - Executive Summary (cont’d)

1-3

The proposed Greenfield project would generate employment

opportunities, enhance local income and contribute to applicable

government revenues. Consequently the growth of allied small-medium

scale industries, trade & commercial establishments and local

entrepreneurship may be envisaged.

The peripheral development activities that would be

undertaken by the proposed project under Corporate Environment

Responsibility (CER) will focus on marginal communities and attempt to

bring forward an overall socioeconomic development with special

emphasis in the areas of education, training, health and infrastructure.


2-1

2 - INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

Spintech Tubes Private Limited (STPL) is one of the flagship

companies of M/S Gagan Group, well known in eastern India for their

quality products viz. TMT bars, billets, ingots, sponge iron etc. Gagan

Group is one of the fastest growing steel making company in eastern

India, started as a manufacturing company for iron & steel products in

2000 in Durgapur, West Bengal under the name of Shakambhari

Overseas Trades Pvt. Ltd (SOTPL). SOTPL established an ingot

manufacturing plant with a capacity of 72,000 TPA in Durgapur, West

Bengal. Gagan group is multiplying its business in terms of sales &

production by setting up an integrated steel plant at Jamuria, West

Bengal. As a result, Gagan Ferrotech Limited (GFL) started

manufacturing sponge iron at Jamuria Industrial Area, Ikra in Burdwan

district in 2007. Now, STPL being incorporated as Private Limited

Company on 14th February 2017, intends to set up 0.7 MTPA Integrated

Steel Plant (ISP) with captive power plant of 70 MW capacity in Dhasal,

Jamuria at Paschim Bardhaman in West Bengal with an objective to

expand its operation in eastern India.

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 2 - Introduction of the Project/Background Information (cont’d)

2-2

2.2 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT

The brief profile of the projects is as follows:

Iron Ore Grinding Unit .. 1.186 MTPA Pellet Plant .. 1.13 MTPA Sinter Plant (1 x 60 sq m) .. 0.62 MTPA DR Plant (3 x 500 tpd) .. 0.495 MTPA Blast Furnace (1 x 350 cum) .. 0.367 MTPA Steel Melt Shop .. 0.729 MTPA EAF (1 x 50 T) IF (4 x 25 T) LF (2 x 50 T) Caster Shop .. 0.712 MTPA Rolling Mill .. 0.7 MTPA Bar Mill .. 0.25 MTPA Wire Rod Mill .. 0.25 MTPA Structural Mill .. 0.2 MTPA Ferro Alloy Plant Submerged Arc Furnace .. 20,854 Ton (1 x 12 MVA - FeCr Plant) Submerged Arc Furnace .. 25,659 Ton (1 x 12 MVA) - FeMn Plant .. 20,391 Ton - SiMn Plant .. 5,268 Ton Captive Power Plant .. 70 MW Air Separation Plant .. 180 TPD Intermediate products

Hot Metal .. 0.367 MTPA DRI .. 0.495 MTPA Liquid Steel .. 0.729 MTPA Semis .. 0.712 MTPA Saleable products

Pellet .. 0.300 MTPA Pig Iron .. 0.046 MTPA Wire Rods .. 0.219 MTPA TMT Bars .. 0.250 MTPA Plain Structural .. 0.100 MTPA TLT Structures .. 0.100 MTPA (Galvanised TLT Section - 50,000 T) Drawn Wires .. 0.030 MTPA Ferro Alloys .. 0.036 MTPA


2-3

This chapter describes the major facilities envisaged for this

project. The major production facilities envisaged for this integrated iron

and steel plant will comprise pellet plant, sinter plant, DR plant, blast

furnace, steelmelt shop, long product mills, structural mill and wire

drawing facility. Ferro-alloy plants have also been envisaged in order to

produce FeMn, SiMn and FeCr. The plant will have its captive power

plant which will utilize surplus blast furnace gas, waste heat off gas of

DR plant, in-plant char and purchased coal to produce power. The plant

will also have its captive air separation plant for producing oxygen,

nitrogen and argon required by various units.

The integrated steel plant would falls under Category ‘A’ of

item 3(a) “Metallurgical Industries (ferrous & non-ferrous)” of the

Schedule to the EIA Notification 2006 and amendments thereunder vide

Notification No. S.O 3067 (E) dated 1st December 2009under the

Environment (Protection) Rules 1986.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

In 2016-17, production of crude steel in India was about

101.0 MTPA with a growth of approximately 10.5% over 2015. India’s per

capita steel consumption is 61 kg, much lower than the global average of

208 kg. The Government of India has set pragmatic target of achieving

per capita steel consumption of 160 kgs by 2030-31 requiring a crude

steel production of 255 MT and capacity of 300 MT.

Indian economy is rapidly growing with key focus on

infrastructure and construction sector. Several initiatives mainly,

affordable housing, expansion of railway networks, development of

domestic shipbuilding industry, opening up of defence sector for private

participation, and the anticipated growth in the automobile sector, are

expected to create significant demand for steel in the country.


2-4

Major factors which carry the potential of raising the per

capita steel consumption in the country are listed below:

i) Infrastructure improvement initiatives, such as ‘Smart

Cities project’, 'Housing for All by 2022', ‘Atal Mission for Rejuvenation and Urban Transformation (AMRUT)’

ii) Manufacturing growth driven by Make-in-India

initiative iii) Encouraging use of Made in India steel for various

projects and levying of anti-dumping duties on certain steel products from Brazil, Russia, China, Korea, Japan and Indonesia.

iv) National Mineral Development Corporation expected to increase the iron ore production favoring steel production

v) Emergence of the rural market for steel buoyed by projects like MGNREGS, development of ‘Rurban Clusters’ under the Shyama Prasad Mukherjee Rurban Mission, Pradhan Mantri Gram Sadak Yojana, among others.

As per the National steel policy (NSP) 2017, in order to

achieve expected demand of 300 MT and per capita consumption of

160 kg of finished steel by 2030-31, steel demand would need to grow at

a CAGR of around 7-7.5 per cent during the period against a CAGR of

3.5 per cent -4 per cent over the last 5 years. This would mean that

capacity additions planned by most of the major steel players need to

come on stream in next few years.

As per NSP 2017, it is aimed to domestically produce value

added steel- special steel and alloys and focuses on pelletisation based

on BF/DR- IF/EAF technology.

The concept of the proposed project is aligned with the

current progress plan of the country.


2-5

2.4 DEMAND-SUPPLY GAP, IMPORTS VS. INDIGENOUS PRODUCTION, EXPORT POSSIBILITY & DOMESTIC/ EXPORT MARKETS

Total consumption of finished steel was 83.5 MT in FY16.

Driven by rising infrastructure development, growing demand for

automotives and lower per capita consumption compared to international

average, steel consumption is expected to reach 104 MT by the end of

2017. World Steel Association (WSA) has projected a growth of Indian

steel consumption of 7.1% at 94.91 MT in 2018, one of the highest

growing among the global steel producers.

The projected demand and capacity as per NSP 2017 would

be is as shown in Table 2-1.

TABLE 2-1 - FORECASTED CAPACITY AND DEMAND OF STEEL BY 2030-31

Sl. No. Parameters

Projections (2030-31), MT

1 Total crude steel capacity 300 2 Total crude steel demand/production 255 3 Total finished steel demand/production 230 4 Per capita finished steel consumption, kg 158

The import vs export of steel for the last few years is

presented below:

Industry Steel Industry: Import vs Export, MT

2013-14 2014-15 2015-16 2016-17 2017-18 Total Finished

Steel 5.45 5.99 9.32 5.59 11.71 4.08 7.23 8.24 7.482 9.62

Source : Joint Plant Committee Website : Ministry of Steel

From the above table it can be seen that over the last few

years, the gap between imports and exports have gradually declined due

to various factors like increase in Minimum Import price &


2-6

implementation of a more stringent anti-dumping policy and there has

been a net export of steel in the last financial year. The National Steel

Policy (NSP) 2017 aims to increase export of steel and reduce import by

2030-31. As of March 2017, the capacity utilisation of steel producers is

set to increase with strong export demand and signs of revival in

domestic sales.

Steel products find application in multifaceted sectors

mainly dominated by areas of infrastructure & transport. Among the

many drivers of demand, the following are having maximum influence in

triggering consumption of finished steel products like Bars & Rods,

Structural and Plates:

Product/Category Application

Bars & Rods

Infrastructure - House Building

Fasteners & Wires

Bright Bars

Industry

Structural Infrastructure - High rises

Industrial Construction

Plates

Infrastructure - Bridges

Railways - Wagons, Coaches, Tankers

Industrial Construction

Defence Sector

Energy - Boilers, Pressure Vessels, Penstocks

HR Products

Tube making industry

Railways - Wagon & Coach

Automobiles

Industrial Machinery

Galvanized products

& Ferro alloys

Automobiles – Body panels & structural

members

Electrical Appliances & machine

Electronic equipment

Construction – Building panels, equipment &

machinery

Metallurgical Industries


2-7

The NSP 2017 provides an overview of the segmental

composition of the projected Indian market for the year 2030-31 with

quantitative estimates of the likely demand and their associated growth

rates adopted for the study. A summary of the leading segments of the

domestic market is furnished in the Table 2-2.

TABLE 2-2 - MAJOR MARKET SEGMENTS - 2030

Market Segments Demand

(Million Tons) % Share

Infrastructure (Project Construction)

90 39%

Construction (Real Estate & Buildings)

45 20%

Engineering & Fabrication 43 19%

Energy 11 5%

Automotive 10 4%

Sub-total (Major Segments) 199 87%

Other Segments (Railways, Ship Building, Defence, Gas Pipelines, Packaging etc.)

31 13%

Total 230 100%

Source: NSP 2017

Barring project construction, other ‘heavy-weight’ or steel

intensive market segments like building construction, engineering and

fabrication etc. need not necessarily grow at rates faster than those of

the other comparatively less steel intensive segments. The segments like

automotives, defence sector, ship building, and gas pipelines hold out lot

of promise for the future of steel demand with near double digit annual

growths.


2-8

2.5 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

In the construction & operation phases of the proposed

projects, both direct & indirect deployment of local work force would be

facilitated.

With respect to the proposed Integrated Steel Plant, it is

estimated that there would be a requirement of around 1,200 to 1,500

casual and contract workers, during the phase of construction.

Subsequently in the operation phase, approximately 1,150 personnel

would be directly employed with another 4,000 of indirect employment.


3-1

3 - PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed greenfield project would comprise the

following:

Integrated Steel Plant of 0.7 MTPA rolled capacity via BF/DRI-IF/EAF-Caster route and rolled through wire rod, bar and structural mill. This also includes:

i)) Captive generation of 70 MW of power ii)) Air separation plant of 180 TPD capacity iii) Ferro Alloy plant to produce 46,600 TPA ferro-alloys

3.2 LOCATION

The proposed ISP would be sited in Dhasal, Jamuria at

Paschim Bardhaman in West Bengal. The project site is located within

23040’45” to 23041’21” North latitude and 87007’45” to 87008’22” East

longitude.

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 3 - Project Description (cont’d)

3-2

FIG. 3-1 - SITE LOCATION MAP


3-3

FIG. 3-2 - GOOGLE MAP SHOWING LOCATION OF THE PROJECT

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE

3.3.1 Suitability of the Site for Integrated Steel Plant

The site selection criteria for the proposed 0.7 MTPA

integrated steel complex have been established considering the following

major factors:


3-4

i) Availability of adequate land for installation of the units

ii) Availability of suitable infrastructure in terms of connectivity and grid power

iii) Proximity of the site from Ajay River as water source iv) Availability of iron ores due to proximity to the mineral

belts of Odisha v) Ease of raw materials acquisition and products

transportation vi) Availability of economical labour force vii) The site does not require any Rehabilitation &

Resettlement (R&R) issues viii) No eco-sensitive zone and no wild life corridor within

10 km radius of the Project area ix) The area does not come under the critically polluted

area as identified by CPCB and no polluted stretch of river nearby

x) Scope for regional development

Three sites were primarily selected for the proposed project:

i) Site A - Dhasal ii) Site B - Seikhpur iii) Site C - Borjora. The analysis of

various criteria for selecting the most suitable location is shown in

Table 3-1.


3-5

TABLE 3-1 - EVALUATION OF SITES BASED ON MULTIPLE INDICATORS

Indicators Site A - DHASAL Site B - SEIKHPUR Site C - BORJORA

Village/Town Tehasil District

Dhasal, Bahadurpur Jamuria Paschim Bardhaman

Sekpur Jamuria Paschim Bardhaman

Borjora town Bankura Sadar Bankura

Availability of land

240 acres 22 acres 45 acres

Status of land availability

Purchased - 113 acres Under process of

acquisition - 127 acres i) Govt. land - 35 acres ii) Private land - 92 acres

Purchased - 22 acres Yet to purchase any land

Type/category of land

Single crop land, barren land and water body

Industrial land Under West Bengal Govt. Land Bank

Distance from the nearby Railway Stations

Ikrah - around 2 km Tapasi - around 1.5 km Jamuria - around 6.8 km

Ikrah - around 0.3 km Tapasi - around 6.7 km Jamuria - around 1.4 km

Durgapur Railway Station - About 8.3 km

Distance from the National Highway

Around 4.7 km from NH-2 & around 700 m from NH-60

Around 4.5 km from NH-2 & around 6.8 km from NH-60

Around 11.0 km from NH-2

Whether homestead involved

No No Yes

Requirement of R&R issues

No No Yes

Water source

Ajay river at a distance of around 7.3 km and Asansol Municipal Corporation (AMC)

Ajay river at a distance of around 8.7 km

Damodar river at a distance of around 5 km

Power availability

India Power Corporation Limited (IPCL) - Power Agreement is available

IPCL - Power Agreement to be made

Damodar Valley Corporation (DVC) - No power agreement is available

Proximity to the ecological sensitive zone

No No No

Raw material source & linkage

Possible source of major raw material (iron ores) is Joda - Barbil and Koira & Sundergarh mines region of Odisha



Conclusion

Most suitable due to availability of adequate land, water, power and suitable from logistics point of view

Acquired land is inadequate for the proposed steel plant

Available land is not meeting the requirement for setting up of steel plant

Hence, Site A i.e. Dhasal site would be selected for the

proposed project.


3-6

3.4 SIZE OR MAGNITUDE OF OPERATION

The proposed project would include production of the

following saleable products:

i) 0.7 MTPA long rolled products ii) 0.3 MTPA pellets iii) 0.05 MTPA pig iron iv) About 0.036 MTPA ferro-alloys

3.5 LAYOUT

The plant general layout of the proposed ISP is shown in

Drg. 11485-97A-000-LTL-0001.

3.6 PROJECT DESCRIPTION WITH PROCESS DETAILS

The plant would be designed for a capacity of 0.7 MTPA

crude steel, which, would be cast into long products namely bars, wire

rods, structural sections, etc. for sale.

The proposed production of liquid steel and subsequent

rolling would be accomplished via Blast Furnace (BF)-Induction Furnace

(IF)-Electric Arc Furnace (EAF)-Caster route, followed by hot rolling for

production of long products.

The facilities at the production stage of 0.7 MTPA crude steel

are shown in Table 3-2.


3-7

TABLE 3-2 - MAJOR PLANT UNITS AND FACILITES

Sl. No. Unit Facility

Production MTPA

1 Iron Ore Grinding Unit 1.2 MTPA 1.186

2 Pellet plant 1 x 1.13 MTPA 1.13

3 Sinter plant 1 x 60 sq. m 0.62

4 DRI plant (coal based) 3 x 500 TPD 0.495

5 Blast furnace 1 x 350 cum 0.367

6 Submerged Arc Furnace

1 x 12 MVA (FeCr), 1 x 12 MVA (FeMn, SiMn)

0.0466

7 Chrome Ore Briquetting Plant

1 x 10 TPH 0.041

8 Steelmaking Shop (SMS)

4 x 25 t IF 1 x 50 t LF

1 x 50 t EAF 1 x 50 t LF

0.729

9 Caster Shop Billet Caster - 1 x 3 strand Billet/Bloom Caster - 1 x 3 strand

0.712

10 Mill Bar mill - 1 x 0.25 MTPA Wire Rod Mill - 1 x 0.25 MTPA Wire drawing facility with 50% hot dip galvanizing - 0.03 MTPA Structural Mill with hot dip galvanizing - 1 x 0.2 MTPA

0.699

11 Captive Power Plant BF gas based - 10 MW DR kiln off gas based WHRB - 37.5 MW Char & Coal based AFBC boiler - 22.5 MW

70MW

12 Air Separation Plant 1 x 180 TPD 180 TPD

The production facilities would be adequately supported by

necessary auxiliary facilities such as raw materials unloading and

storage, proportioning of raw materials, electric power receiving and

distribution stations, various utility facilities, water treatment and

distribution system, etc.

The preliminary process flow sheet is shown in Drg.

11485-97A-000-PRS-0002. The following write-up lays down details of

the various process units.

3.6.1 Iron Ore Grinding Unit for Pellet Plant

The wet grinding unit of the 1.2 MTPA pellet plant is

designed to grind the iron ore fines of 62 to 63% Fe having top size

(-) 5 mm and to produce pellet feed material of size d80 (-) 45 microns.

The design basis is as follows:


3-8

Annual requirement of pellet feed, MTPA .. 1.2 Operating days per year .. 330 Operating hours per day .. 20

Based on the above assumptions, the annual operating

hours and rated throughput to the grinding system work out to around

6,600 and 182 ton per hour (tph) respectively.

The iron ore of top size (-)5 mm from the day bins will be

ground in one number of ball mill having capacity of 182 tph to the size

required for pelletization. The ball mill will be working in close circuit

with a set of classifying hydrocyclones. The overflow obtained from the

classifying hydrocyclones at size d80 45 microns will report to one

number concentrate thickener of around 22 m diameter for partial

dewatering. The clarified water obtained as overflow from the thickener

will be recycled back to the grinding system as process water. The

thickened slurry obtained as underflow from the thickener will be

pumped to two numbers pressure filter for final dewatering. The cake

obtained from the pressure filters having moisture content of 9 to 10%

will be conveyed to the pellet plant.

The list of major equipment for the overall plant is indicated

below:

i) Ball mill ii) Hydrocyclone clusters iii) Hydrocyclone feed pumps iv) Concentrate thickener

v) Concentrate thickener underflow pumps vi) Slurry holding tanks with agitator vii) Pressure filter feed pumps viii) Pressure filter process water pumps


3-9

3.6.2 Pellet Plant

It is envisaged to install one Pellet plant of capacity

1.13 MTPA to cater to the pellet requirement in DR kilns and mini blast

furnace (MBF) the additional 30,000 TPA pellet would be either sold off

or transferred to GFL plant.

The design basis considered for pellet plant is given in

Table 3-3.

TABLE 3-3 - DESIGN BASIS OF PELLET PLANTS

Parameters Value Requirement of pellet in MBF, tpy 94,100

Requirement of pellet in DR plant, tpy 737,600

Pellet for sale/inter-plant transfer, tpy 300,000

Total requirement of product pellet (>6 mm), tpy 1,131,700

Fines generation at pellet plant screen house(<6 mm), % 3

Annual generation of pellet fines, tpy 33,900

Gross pellet production, tpy 1,165,600

Operating days/year 330

The raw material (dry basis) and their typical analyses are

given in Table 3-4.

TABLE 3-4 - TYPICAL ANALYSES OF RAW MATERIALS FOR PELLET PRODUCTION

Fe,% SiO2,,% Al2O3,% CaO,% MgO,% LOI,% Pellet feed concentrate 62.50 3.25 3.10 - - 3.75

Bentonite 13.00 47.06 14.94 1.68 3.57 10.00

Dolomite 0.35 1.50 0.75 26.00 18.00 42.00

Limestone 0.56 1.55 1.65 48.00 2.70 41.00

Coal 0.50 3.50 1.75 0.23 0.13 91.00

Coke breeze 1.74 7.02 3.64 0.80 0.45 85.00


3-10

The indicative chemical analysis of pellet produced would be

as follows:

Fe, % .. 63.80 CaO/SiO2 ratio .. 0.15 CaO .. 0.60 SiO2 .. 3.90 Al2O3, % .. 3.40 MgO, % .. 0.17

Envisaged physical and metallurgical properties of pellet

would be as follows:

Size range, mm .. 6-18 Compressive strength, kg/pellet .. 250 Tumbling index: +6.3 mm, % .. 92 -500 micron, % .. 6

It is suggested that attainment of the above properties

should be ensured by adopting appropriate process parameters

established through necessary test work before implementation of the

project.

Filter cake, limestone, bentonite and coal fines will be stored

in separate bins. The materials from these bins will be drawn out in

requisite proportions and fed into high intensity mixer for thorough

mixing. Iron bearing dust collected by waste gas handling system and

plant dedusting system shall be recycled back to the mixer. Controlled

spray of water shall be provided for wetting the mix with approximately

8.5 to 9 per cent moisture.

The pre-wetted mixed material shall be transported by belt

conveyors to mixed material bins installed directly above the pelletising

discs. The wet-mix material shall be drawn from each bin into the disc

feeding chute via weigh feeder.


3-11

Green pellets produced will be fed to a double deck roller

screen. While the sized green pellets are discharged across the width of

the traveling grate, the oversize and undersize factions are disintegrated

in a shredder and recycled to the plant.

Heat treatment of green pellet is carried out in the

induration furnace in stages comprising drying, pre-heating, induration

and cooling. Green pellets shall be dried and pre heated on the

travelling grate, hardened and indurated in the rotary kiln and cooled in

the annular cooler. The green pellets from the balling unit will be laid

across the full width of the chain grate. The green balls are dried and

preheated on the chain grate and pre-heating with exhaust gas from the

kiln and hot air from the cooler. The dried and preheated pellets from the

chain grate will be discharged to the rotary kiln for completion of

induration. After firing, fired pellets shall be cooled in a cooler. The

recuperated heat shall be utilised in the process by recycling the hot air

in drying and preheating zones.

The hardened and cooled pellets will be screened as per

requirement.

The pellet plant would comprise following facilities: i) Storage handling and preparation of coal, dolomite and

bentonite ii) Storage, Proportioning and mixing, Balling, induration

and cooling iii) Product pellet storage iv) Auxiliary facilities like fuel storage, laboratory, etc. v) Plant de-dusting system vi) Cranes, hoists and elevator vii) Plant electrics viii) Instrumentation and Level-1 ix) Plant communication system x) Utility system xi) Air-conditioning and ventilation system

xii) Fire fighting system


3-12

3.6.3 Direct Reduction (DR) Plant

For the production of Directly Reduced Iron (DRI),

3 x 500 TPD rotary kilns will be installed. The annual production from

all three numbers of kiln will be about 495,000 ton of DRI based on

300 days operation using iron ore pellets.

The rotary kiln charge will consist of iron ore pellets, non

coking coal and dolomite. The typical analyses of input raw materials

(dry basis) considered for DRI production is given in Table 3-5.

TABLE 3-5 - ANALYSES OF RAW MATERIALS

Fe,% SiO2,,% Al2O3,% CaO,% MgO,%

Pellet 63-64 3-4 3-4 0.5-1 0.1-0.2

Dolomite 0.35 1.50 0.75 26.00 18.00 FC,% Ash,% VM,% Non coking coal 52-54 22-24 23-25

Product DRI will contain about 86 per cent of Fe (total),

around 0.15 per cent carbon and the degree of metallization will be

about 90 per cent.

The facilities within the DR plant will comprise the following

major units:

i) Raw materials feeding system ii) Rotary kiln iii) Rotary cooler iv) Product (DRI) handling system v) Waste gas system

3.6.4 Sinter Plant

Sinter would constitute around 85% of the ferrous burden to

the blast furnaces. To meet the requirement of charge sinter one sinter

plant of around 60 sq m would be installed.


3-13

The design basis considered for the sinter plant is given in

Table 3-6.

TABLE 3-6 - DESIGN BASIS OF SINTER PLANTS

Parameter Value Product sinter, tpy 623,000 Charge sinter, tpy 529,200 Screening at BF stock house, % 15 Operating days/year 330 Daily product sinter, tpd 1,886 No. of strand 1 Appx. suction area, sq m 60 Product sinter size, mm 5-50 Temperature of sinter at cooler discharge, oC

100

The raw material (dry basis) and their typical analyses are

given in Table 3-7.

TABLE 3-7 - TYPICAL ANALYSES OF RAW MATERIALS FOR SINTER PRODUCTION

Fe,

% SiO2,

% Al2O3,

% CaO,

% MgO,

% LOI,

%

Iron ore fines 62.50 3.25 3.10 0.09 0.06 3.50

Limestone 0.56 1.55 1.65 48.00 2.70 41.00

Coke breeze 1.74 7.02 3.64 0.80 0.45 85.00

Flue dust 36.30 9.75 1.55 6.20 1.60 37.50

Mill scale 69.50 1.23 1.22 0.68 0.25 5.00

Lime 0.00 3.0 2.50 83.00 3.20 4.00

Dolomite 0.35 1.50 0.75 26.00 18.00 42.00

The indicative chemical analysis of sinter produced would be

as follows:

Fe, % .. 54.64 CaO/SiO2 ratio .. 2.04 Al2O3, % .. 3.23

MgO, % .. 2.16

CaO, % .. 9.66


3-14

Envisaged physical and metallurgical properties of sinter

would be as follows:

ISO tumbler index (+6.3 mm) .. 76% (min) Reducibility index .. 65% (min) RDI (-3.15 mm) .. 28% (max) Sinter size range .. 5 to 50 mm Sinter mean size .. 18 mm

It is suggested that attainment of the above properties

should be ensured by adopting appropriate process parameters

established through necessary test work before implementation of the

project.

For various types of input materials, adequate number of

proportioning bins mounted on load cells to ascertain material level in

each bin and electronic weigh feeders under each bin will be provided to

draw required materials in proportions.

Mixing and nodulizing drum with internals and water

proportioning system for intimate mixing and nodulizing of sinter mix

will be provided for each sinter plant. Calcined lime will also be added

before entering to the mixing drum.

Sinter machine will be complete with hearth layer feeding

system, raw mix feeding system comprising anti segregation filling

method at the top of raw mix feed bin and drum feeder and segregation

device below it, ignition furnace, sinter breaker, crash deck, segregation

chute and the sinter strand proper comprising lifting wheel assembly,

lowering wheel assembly, support structure, sliding bars, thermal

compensation device, wind boxes with compensators, spillage chute, SG

iron pallet assembly with spring loaded sealing and high chrome grate

bar, lubrication system etc. Sintering will be performed during the

movement of the bed from ignition furnace to the discharge end.


3-15

A suitable forced draft type circular cooler comprising

adequate number of fans, drives, cooler troughs, sealing etc will be

provided in order to discharge sinter below 100OC from cooler.

Waste heat recovery system from cooler for ignition furnace

combustion system and post heating of sinter bed will be optional for the

sinter machines.

Cooled sinter from sinter cooler will be fed to screening

system for separation of hearth layer material (10-20 mm), plant return

fines (0-5 mm) and product sinter (5-50 mm).

The sinter plant would comprise following facilities:

i) Proportioning system ii) Flux and fuel crushing iii) Mixing and nodulizing system iv) Sinter machine section v) Sinter cooler section vi) Sinter stabilizing section vii) Sinter storage and despatch viii) Waste gas system ix) Plant de-dusting system x) Cranes, hoists and elevator xi) Plant electrics xii) Instrumentation and Level-1 xiii) Plant communication system xiv) Utility system xv) Air-conditioning and ventilation system xvi) Fire fighting system 3.6.5 Blast Furnace

It has been envisaged that a mini blast furnace (MBF) of

350 cu m (useful volume, U.V.) will be installed for production of

367,500 ton of hot metal per year, out of which 58,900 tpy will be used

in induction furnaces and 259,400 tpy will be used in electric arc

furnace. Balance hot metal, i.e. 49,200 tpy will be cast in pig casting

machine. About 46,800 tpy of pig iron will be available for sale/inter

transfer.


3-16

The blast furnace would incorporate all the modern

technological features. The design basis of blast furnace is given in

Table 3-8.

TABLE 3-8 - DESIGN BASIS OF BLAST FURNACE

Parameter Phase

Hot metal production, tpy 367,500 Daily production of hot metal, ton/day (avg.) 1,050 Useful volume, cu m (appx.) 350 Operating days 350 Burden: - Sinter, % 85 - Pellet, % 15 - Ore, % Nil O2 enrichment, % 4 Coke rate (including nut coke), kg/thm 465 PCI rate, kg/thm 100 Slag rate, kg/thm 400

The major raw materials for blast furnace comprise of sinter,

pellet, fluxes and coke. Pulverised coal will be injected through tuyeres

as auxiliary fuel. The typical analysis of raw materials envisaged is given

in Table 3-9.

TABLE 3-9 - TYPICAL RAW MATERIALS ANALYSIS (DRY BASIS)

Fe, % SiO2, % Al2O3, % CaO, % MgO, % Sinter 54.64 4.74 3.23 9.66 2.16

Pellet 63.8 3.90 3.4 0.60 0.17

Quartzite - 97.00 1.00 - -

Ash,% CSR CRI

Coke 12.50 62 25

Ash, % Fixed Carbon,%

PCI 15.00 70.00

The hot metal quality is expected to be as follows:

C, % .. 4.3 (max.) S, % .. 0.045 (max.) P, % .. 0.10 (max.)


3-17

The sinter from sinter plant, pellet, coke, quartzite etc. from

the raw material storage yard will be received on separate conveyors and

will be distributed to the stock house of blast furnace. The furnace will

be provided with conveyor belt charging system.

The furnace will be self-supporting free standing type. The

top equipment and platform at various levels around the furnace will be

supported by an independent tower structure. The blast furnace will be

provided with bell less top charging system and with modern facilities,

like above burden probe, heat flux and pressure profile measurement etc.

The cooling system will comprise of staves.

Automation and control system, which will include control of

hot blast temperature, charging etc., will be provided to take care of

smooth operation of blast furnace.

The blast furnace will be served by three internal combustion

chamber type stoves provided with ceramic burners to supply hot blast

at a temperature of about 11500C. The stoves will be fired with blast

furnace gas.

The blast furnace will be provided with one cast house,

having one taphole and one slag notch. Hydraulic mudgun & drilling

machine will be provided. One slag granulation system and dry slag pit

will be provided along with granulated slag handling system.

The plant comprises following facilities:

i) BF proper ii) Cast house iii) Slag granulation plant iv) Hot blast stoves v) Gas cleaning plant vi) Stock house and charging system


3-18

vii) Hot metal handling system viii) Cranes and hoists ix) Coal dust injection system x) Pig casting machine and ladle repair shop xi) Stockhouse and casthouse de-dusting system xii) Air blowing system xiii) Plant electrics xiv) Instrumentation, automation and control system xv) Communication system xvi) Water system xvii) Utility system xviii) Fire fighting system xix) Air conditioning and ventilation system

3.6.6 Pig Casting Machine

A double strand pig casting machine (PCM) of 2 x 700 tpd

capacity will be installed for production of pig iron. Necessary facilities

for preparation of lime wash required for coating the moulds will be

provided. Re-circulating water system for cooling of pigs including a

settling tank will be installed. Cold pig will be stored in pig storage yard

and further sold to the market/transferred internally.

3.6.7 Steelmelt Shop

Steelmelt shop will consist of Induction Furnace (IF), Electric

Arc Furnace (EAF), Ladle Furnace (LF), billet casting machine and billet

cum bloom casting machine with associated shop auxiliaries for

production of about 712,200 tpy of billet and blooms. The production of

liquid steel from induction furnaces will be around 288,000 tpy which

will be cast through billet caster to produce around 282,200 tpy of

billets. The production of liquid steel from electric arc furnace will be

around 441,000 tpy which will be cast through billet cum bloom caster

to produce around 235,900 billets and 194,000 tpy of blooms. However,

the liquid steel so produced by EAF and IF can be cast in either of the

casters as required. The billets so produced will cater to the wire rod and

bar mill whereas the blooms will cater to structural mill.


3-19

Induction Furnace (IF) : It is proposed to install four

25-ton/12 MVA capacity IFs, with the combined heat size of

50 ton for this purpose, heats from two 25-ton IFs will be combined into

50 ton ladle for further processing. Any of the two induction furnaces out

of four Nos. will be operated in synchronized manner. The estimated

quantity of liquid steel from the IFs works out to be around 288,000 tpy

as per below basis.

Computation of annual production: No of furnaces .. 4 Capacity of IF .. 25 ton/12MVA Net operating days .. 320 Charge mix .. 68% DRI 17% Pig iron 15% scrap Tap-to-time, mins .. 160 Average number of heats/IF .. 9 Average number of heats/day from 4 IFs .. 36 Average number of heats/day after combining into 50 ton ladle .. 18 Liquid steel, ton/year .. 288,000 Major technical parameters are given as follows: No. of units .. 4 No. of crucibles .. 2/furnace Capacity .. 25 ton/12 MVA Metallic charge .. 68% DRI, 17% pig, 15% scrap

Electric Arc Furnace (EAF): In order to achieve the balance

liquid steel production, it is proposed to install one No. 50 ton/40 MVA

capacity EAF. The estimated quantity of liquid steel from the EAF works

out to be around 441,000 tpa as given below.


3-20

Computation of annual production:

No of furnaces .. 1 Capacity of EAF .. 50 ton/40 MVA Number of operating days .. 315 Charge mix .. 50% hot metal 50% DRI Tap-to-Tap time, mins .. 52 Average number of heats/day/EAF .. 28 Liquid steel, ton/year .. 441,000

The salient features of the EAF are indicated below:

Number of furnaces .. 1, EBT type Furnace capacity .. 50 ton Furnace transformer .. 40 MVA Metallic charge, appx. .. 50% Hot metal, 50% DRI

Ladle furnace (LF): It is proposed to provide two Nos.

matching capacity LF i.e. 50 ton equipped with arc heating, inert gas

stirring and alloy addition facilities to treat the combined heats tapped

from two IFs simultaneously and heat tapped from EAF.

All the 46 heats coming from EAF and IFs can be

conveniently treated in two LFs with an average treatment cycle time

varying between 35 to 45 minutes per heat depending on the extent of

treatment required.

The relevant parameters of the LF are as follows:

No. of units .. 2 Nominal capacity, ton .. 50 Heating rate, deg C/min .. 4 to 5 Transformer rating, MVA .. 12 Type of unit .. Lift/lower roof type This unit will also be utilized to hold the heats for an

extended period of time, should it be necessary for any reason, such as,

sequencing of casting in CC machine, hold up in CC machine etc. All the

required features including both top and bottom rinsing, multi-strand

wire feeding, automatic temperature measurement and sampling

facilities will be provided.


3-21

Billet Casting Machine: It is proposed to install

one 3-strand billet continuous casting unit in order to cast 288,000 tpy

of liquid steel produced from IFs. The caster will be designed to cast

100 mm, 130 mm and 160 mm sq billets. However, this caster will be

used to cast 100 mm sq and 130 mm sq billets as required by the wire

rod and bar mill. A casting time of 45 to 50 mins will be adopted to

match with the synchronized operation of two groups of IFs being

operated in staggered timing of 40 to 45 mins considering each IF

tap-to-tap time of 140 mins, thus making one combined 50 ton heat

available in every 50 mins to match a casting sequence of 2 heats.

One 3-strand billet caster will be able to cast the entire quantity of

288,000 tpa of liquid steel on the basis of casting 18 heats/day.

Assuming a yield of 98% from liquid steel to cast billets, the annual

quantity of billets will be 282,240 tpa.

The salient features of the billet caster are indicated below:

No. of machines .. 1 No. of strands .. 3 Type of machine .. Conventional billet

caster, radial bow type Mould .. Tubular mould Casting practice .. Open Ladle capacity, ton .. 50 Billet size, mm sq .. 100 to 160

Billet cum Bloom Casting Machine: It is proposed to install

one 3-strand billet cum bloom casting machine in order to cast the

envisaged liquid steel production. The caster will be designed to cast

130 mm-250 mm sq billets/blooms. A casting time of 48-50 mins is

adopted to match with EAF tap-to-tap time of 52 mins. One No. 3-strand

billet cum bloom caster will be able to cast the entire quantity of

441,000 tpa of liquid steel on the basis of casting 28 heats/day.

Assuming a yield of 97.5% from liquid steel to cast billets, the annual

quantity of billets will be 429,975 tpa.


3-22

The salient features of the billet cum bloom caster are

indicated below:

No. of machine .. 1 No. of strands .. 3 Type of machine .. Conventional billet cum bloom caster, radial bow type Mould .. Tubular mould Casting practice .. open/closed Ladle capacity, ton .. 50 Billet/Bloom Size, mm sq .. 130 to 250

3.6.8 Annual Production from SMS

The annual production of SMS will be as below: Liquid steel, tpy .. 729,000 Semis, tpy .. 712,200

3.6.9 Major Equipment and Facilities

i) 4 x 25T/12 MVA IFs ii) 2 x 25T / 12 MVA LFs iii) 1 x 50T/40MVA EAF iv) IF & LF gas cleaning system v) EAF & LF gas cleaning system vi) Billet casting machine vii) Billet cum bloom casting machine viii) Raw Material handling system ix) Shop auxiliaries and maintenance facilities x) Shop cranes

3.6.10 Rolling Mills

Wire Rod Mill: The mill will be designed to produce of

0.25 MTPA wire rod. The input billet size will be as follows:

Section, sq mm .. 130x130, 160x160 Length, mm .. 6,000 Annual requirement, MTPA .. 0.26

Output from the mill will be as follows:

Wire rod, mm .. 5.5 to 16


3-23

Mill availability:

Calendar days .. 365

Maintenance (shutdown days .. 45 and holidays) No. of operating days per year .. 320 Yield:

Average Mill yield, % .. 96.5

The hot billets from the billet caster will be charged into

the induction furnace for temperature homogenization or cold billets

will be transferred from the cold charging grid through charging roller

table into the reheating furnace. The cold billets will be reheated to the

required rolling temperatures. The mill configuration will comprise

roughing stands, intermediate stands, finishing stands and finishing

block. The wire rods delivered from finishing block will pass through in-

line water cooling section, air cooling section, pinch roll and loop type

cooling conveyor system. The convoluted wire rod shall proceed to coil

reformers and down-enders and shall be loaded in conveyor. The coil

shall be compacted and tied by compacting machine, weighed by on-line

weighing machine, tagged and transferred to collecting tables.

Major equipment and facilities would be as follows:

i) Reheating furnace (For off-line charging of billets) ii) Induction furnace (For hot charging of billets) iii) Roughing stands iv) Intermediate stands v) Finishing stands vi) Finishing block vii) Water box cooling section viii) Loop cooling conveyor ix) Coil conveyor & tying station x) Weighing & collecting station

This mill will also be provided with roll and guide shop,

re-circulating water treatment facilities, laboratory etc.


3-24

Rebar Mill: The mill is designed to produce of 0.25 MTPA

Rebar

The input billet size will be as follows:

Section, sq mm .. 130x130, 160x160 Length, mm .. 6000 Annual requirement, MTPA .. 0.26


Rebar, mm .. 8 to 32

Mill availability:

Calendar days .. 365 Maintenance (shutdown days and holidays) .. 45 No. of operating days per year .. 320

Yield:

Average Mill yield, % .. 96.5

The hot billets from the billet caster will be charged into the

induction furnace for temperature homogenization followed by rolling

mill. The mill configuration will comprise roughing stands, intermediate

stands, and finishing stands. The bars delivered from finishing stands

will be passing through inline-water boxes cooling system. The finished

bars will be cut to cooling-bed lengths by dividing shears located

downstream of the water cooling lines. The cold shear placed after the

cooling bed will cut the bar layers into commercial lengths of 6 to 12 m.

Batches of finished length rebar will be transferred to the layer formation

area and automatic bar bundling stations which will count and sort the

rebars and form the bundles.


3-25


i) Induction furnace (For hot charging of billets) ii) Roughing stands iii) Intermediate stands iv) Finishing stands v) Water box cooling section vi) Dividing Shear vii) Cooling bed viii) Cold shear ix) Layer formation area x) Weighing & collecting station

This mill will also be provided with roll and guide shop, re-

circulating water treatment facilities, laboratory etc.

Structural Mill: The mill is designed for production of

0.2 MTPA structural products. The mill will have the facility of

0.05 MTPA of Zn coated products.

Billets of 160 x 160 mm size from caster will be fed to the

induction furnace followed by rolling mill. Bloom sizes of 250 x 250 mm

will also be rolled and charged into the reheating furnace. The input

billet/bloom size will be as follows:

Section, sq mm .. 160x160, 250x250 Length, mm .. 6,000 Annual requirement, MTPA .. 0.210


Equal Angles, mm .. 45x4/5 to 200x8/10/12 Unequal Angles, mm .. 45x30x4 and 45x30x5 ISMB, ISMC, Flats, mm .. 125, 150, 175, and 200

Mill availability:


Yield:

Average Mill yield, % .. 95


3-26

Input material (bloom/billet) from caster will be transferred

from the cold charging grid through charging roller table into the

reheating furnace. The input material which will be heated in the

reheating furnace will be rolled in Break-down mill, followed by 3-high

reversing mill. The mill will also be able to take billet directly from caster

which will be fed into the mill trough induction furnace. The mill

configuration will comprise Break-down mill, 3-high reversing roughing

stands, intermediate stands and finishing stands. The finished products

will be cut to the cooling-bed lengths by dividing shears. The material

after cooling bed is straightened in horizontal straightener. After

straightener the material will be cut in commercial length by cold saw.

After that the product will passes through magnetic stackers, bundling

and unloading station.


i) Reheating furnace (For off-line charging of billets) ii) Roughing stands iii) Break-down mill iv) Induction furnace (For hot charging of billets) v) Roughing stands vi) Intermediate stands vii) Finishing stands viii) Section cooling and diving shear ix) Cooling bed x) Multi-strand straightener xi) Cold Saw xii) Stacking section xiii) Strapping station xiv) Weighing and collecting station

This mill will also be provided with roll and guide shop, re-

circulating water treatment facilities, laboratory etc.


3-27

Galvanizing Facility of TLT Sections: The galvanizing

facilities will be installed for processing structural products.

Product to be galvanized .. TLT section Capacity, MTPA .. 0.05

The size range of TLT section will be as follows:

Equal angles, mm .. 45x4/5 to 200x8/10/12 Unequal angles, mm .. 45x30x 4 and 45x30x5

Wire Drawing Facility: The wire drawing facility is designed

to produce 100 ton per day (tpd) of finished wires. The production will

consist of 50 tpd of galvanized wires and black wires each. Annually,

30,000 tpy of drawn wires will be produced out of which 15,000 tpy of

wires will be galvanized.

Wire rod coils will be directly fed to the pickling section

followed by wire drawing and galvanizing facilities. The input wire rod

size and other details will be as follows:

Dia., mm .. 5.5 to 8.0 Coil OD, mm .. 1250 Requirement, tpd .. 101.5 Steel Grade .. Mild steel

Output (Wires) sizes will be as follows:

Sl. No. Sizes 1. 20 gauge (0.81 mm)

2. 18 gauge (1.02 mm)

3. 14 gauge (1.63 mm)

4. 12 gauge (2.06 mm)

5. 10 gauge (2.65 mm)

Machine availability:



3-28

Yield:

Average yield, % .. 98.5

The processes involved in producing the wires of above

grades or quality from wire rods mainly consist of pickling,

rinsing, boraxing/phosphating (depending on product requirement),

drying, feeding, drawing, annealing or stress relieving, galvanizing

etc depending upon the sizes and types of wires to be finished.

All wire rods will be either pickled or passed through mechanical

descaler for scale removal before drawing. The wire rod coils will be

pickled in hydrochloric acid and rinsed in water. After water rinsing

lime or borax coating will be given, followed by drying in the baking oven.

Phosphating will be done for specific types of wires depending on the end

use envisaged for the processed wires. The pickled wire rods are drawn

to required size in multiple block continuous wire drawing machine

depending on the starting wire rod size and finished wire size.

The number of blocks required for drawing varies with the number of

passes to be given for producing the specific size of wire from wire rod

which in turn depends on the starting wire rod size, finished wire

size, grade of finished wire etc. Intermediate annealing or patenting

may be required to avoid work hardening. Facilities for galvanizing

have also been provided.

The wire drawing facilities will be complete with storage

yard, Effluent Treatment Plant (ETP), re-circulating water treatment

facilities, ECR, laboratory, die shop, electrical and mechanical

maintenance/workshop facilities, automation control rooms etc.


3-29

3.7 BRIQUETTING PLANT FOR FERROCHROME PRODUCTION

Briquetting plant will be installed to produce about

41,200 ton of finished briquettes per year suitable for production of

ferrochrome. The plant will be designed based on the following

assumptions:

No. of working days per year .. 330 No. of working shifts per day .. 2 No. of working hours per shift .. 8

Based on the above assumptions, the effective annual

operating hours work out to 5,280 and the capacity of the briquetting

plant is estimated to around 10 ton per hour (tph).

Chrome ore fines of size (-) 7 mm will be fed to the plant. 6 to

7% molasses and 3 to 4% hydrated lime will be used as binders for

briquetting chrome ore fines. The characteristics of molasses and

hydrated lime proposed to be used in the plant are given in Table 3-10.

TABLE 3-10 - CHARACTERISTICS OF MOLASSES AND HYDRATED LIME

A. Molasses Specific gravity 1.4 Sugar content, % 50 Viscosity at 200/400 C (cP) 5500/800

B. Hydrated lime Ca (OH)2, % (min) 80 Size, d90 200 mesh Moisture, % (max.) 1 Bulk density 0.5-0.7

The product will be chrome ore briquettes suitable for

production of ferro-chrome in submerged arc furnaces. The

characteristics of the briquettes envisaged to be produced in the plant

are given in Table 3-11.


3-30

TABLE 3-11 - BRIQUETTE CHARACTERISITCS

Briquette size, (L x B x H), mm 70 x 45 x 25 pillow shaped Bulk density of briquette 1.5-2.2 ton/cu m Angle of repose, degree 38 Compressive strength, N: - After pressing - After 24 hours

150 400

The run of mines (r.o.m.) chrome ore fines will be screened

at 7 mm and delivered to the briquetting plant by conveyor system. The

chrome ore fines will be fed to a rotary dryer for reducing the moisture

content to about 1 to 2 per cent for proper briquetting. The dried ore

from the rotary dryer will be stored in a storage bin. Hydrated lime will

be screened at 1 mm to separate the tramp oversize and will be stored in

a lime silo.

Dried chrome ore fines and hydrated lime drawn from the

respective storage bins will be intimately mixed in a Muller mixer.

Molasses will be added at controlled rate to the muller mixer and will be

mixed with ore-lime mixture.

The mixture will be fed to a briquetting machine. The

briquettes thus produced will be screened in a rubber deck vibrating

screen with 10 mm opening. The undersize from screen will be recycled

back to the mixer. The finished green briquettes obtained as oversize of

the screen will be delivered to a slow moving conveyor and stacked in a

new store house for complete curing to achieve the desired strength.

3.7.1 Ferro-Alloy Plant

In order to fulfill the internal requirement of ferrochrome

(FeCr), ferromanganese (FeMn), and silicomanganese (SiMn) in house and

for sale, it is proposed to install 2 x 12 MVA semi closed submerged arc

furnaces (SAF) with necessary facilities to produce 46,513 tpa

ferro-alloys comprising 20,854 tpy FeCr; 20,391 tpy FeMn and 5,268 tpa

SiMn.


3-31

Operating days of the furnace has been considered as 350.

Different parameters of design basis considered for the plant are given in

Tables 3-12 & 3-13.

TABLE 3-12 - SPECIFIC POWER CONSUMPTION FOR FERRO-ALLOY

Specific Power Consumption SiMn FeMn FeCr

kWh/ton kWh/ton kWh/ton 3,800 2,700 3,600

TABLE 3-13 - SPECIFIC CONSUMPTION OF RAW MATERIALS (DRY

BASIS)

Specific Consumption(1) Raw Materials SiMn FeMn FeCr

kg/ton kg/ton kg/ton Chrome ore briquette - - 1,977 Cr chips - - 347 Mn ore 750 2,600 - FeMn slag 1,500 - - Quartzite 400 - 220 Coke 400 400 520 Magnesite - - 81 Dolomite - 30 71 Electrode paste 25 18 13

The likely analysis of ferro-chrome is indicated below:

C, % .. ~8 Cr, % .. 60-61 Fe, % .. 27-29 The likely analysis of ferro-manganese is indicated below:

C, % .. 6-8 Mn, % .. 65-70 Fe, % .. 24-26 The likely analysis of silico manganese is indicated below:

C, % .. 1-2 Mn, % .. 65-68 Si, % .. 18-21


3-32

The facilities within the ferro alloy plant will comprise the

following major units:

i) Reheating furnace ii) SAF iii) Furnace transformer iv) Furnace electrode assembly v) Furnace cover vi) Gas cleaning plant vii) Furnace tapping viii) Casting ix) Product separation and storage x) Weighing and collecting station

3.7.2 Air Separation Plant

To meet the requirement of industrial gases like oxygen,

nitrogen and argon for various process facilities, Cryogenic type Air

Separation Plant of 180 ton per day (tpd) capacity is envisaged to be

installed. The oxygen plant will have adequate liquid generation and

storage capacity so as to supply the gases for 72 hours in an event of

stoppage of ASP. Oxygen will be available at pressure levels of 40 kscg

which will be reduced to 16 kscg and 8 kscg through pressure reducing

station as per the need. Nitrogen will be available at pressure 20 kscg.

Argon will be available at pressure 10 to 12 kscg.

Buffer vessels and pressure reducing stations for oxygen,

nitrogen and argon will be provided to cater to various peak

requirements of the process.

Oxygen: Oxygen will be required mainly for EAF refining

operation, and heating, cutting operation in the caster and other general

purpose usage. Oxygen will also be required for enrichment of cold blast

to the stoves of the blast furnace. The hourly requirement of oxygen will

be around 4,270 N cu m/hr.


3-33

Nitrogen: Nitrogen will be mainly required for gas cleaning,

cooling of the blast furnace bell-less top, PCI coal conveying, gas line

purging and general purpose along with instrumentation applications.

The hourly requirement of nitrogen will be around 1120 N Cum/hr.

Argon: Argon will be mainly required for ladle stirring,

tundish nozzle shrouding, etc. The hourly requirement of argon will be

around 40 N Cum/hr.

Pressure of product oxygen, nitrogen and argon will be

raised by internal compression without the need of booster compressor.

The purity and pressure of product oxygen, nitrogen and argon available

from the air separation plant are given in Table 3-14.

TABLE 3-14 - PURITY AND PRESSURE OF OXYGEN, NITROGEN AND ARGON

Medium Pressure Purity kscg % Oxygen 40 99.5 Nitrogen 20 99.99 Argon 10 to 12 99.999

The plant can be turned down to a level of 60% without any

change in the purity of the products.

The low pressure internal compression design is envisaged

for this 180 tpd air separation plant. The plant will consist of feed air

compressors, air pre-cooling and purification unit, heat exchangers and

expansion turbines, rectification column, hydrogen and acetylene

removal system, cryogenic pumping and purification facilities, pipework

etc.


3-34

The cryogenic section of the air separation plant will be

designed for outdoor installation. A positive pressure inside the cold box

will be maintained by nitrogen to restrain the diffusion of air into the

cold box. The cold box will be designed for the prevention of explosions

from acetylene and other hydrocarbon accumulation.

The liquid oxygen, nitrogen and argon storage tanks will be

of double-walled construction. The annular space for liquid oxygen and

nitrogen tanks will be filled with non-inflammable insulating material

(perlite) and maintained under positive nitrogen pressure. For the argon

liquid storage tanks, the interspace is evacuated and filled with nitrogen.

3.7.3 Captive Power Plant

A Captive Power Plant of 70 MW capacity is envisaged. The

total power will be generated from BF gas fired boilers, Waste Heat

Recovery Boilers (WHRB) working on off gas of DR Plant, and coal and

char fired Atmospheric Fluidized Bed Combustion (AFBC) Boilers. About

10 MW of power will be generated from BF Gas fired boilers, 37.5 MW of

power will be generated from WHRB working on off gas of DR Plant and

22.5 MW power will be generated from char and purchased coal fired

AFBC Boilers. Five (5) Nos. 70 tph boilers, 2 x 35 MW turbo-generators

and other auxiliaries are envisaged.

The off gas from the DRI Kiln, will be utilized in a set of

WHRB for generation of high pressure steam. The steam thus generated

will be utilized for generation of electric power in turbine generator sets.

The non magnetics (char) from the DR Kiln, will be charged

in Atmospheric Fluidized Bed Combustion (AFBC) Boiler, along with

purchased coal for generation of high pressure steam.


3-35

The BF Gas which is in excess after catering to the various

mill furnaces and stove heating will be burnt in gas fired boilers to raise

high pressure steam which in turn will be utilized in turbo-generators to

generate electric power.

All the boilers will raise steam at a fixed pressure and

temperature. The entire steam will be fed into a steam boiler. This will

carry the steam to the turbo-generator sets.

The excess power, after meeting the plant requirements, will

be exported to the external grid.

The power plant will have four WHRBs, two AFBC Boilers,

one gas fired boiler and two Turbo-generator (TG) sets of 35 MW capacity

each, along with other accessories. Each WHRB boiler will have a

normal capacity of 24.5 tons per hour and the normal capacity of the

AFBC boiler will be around 100 t/hr. The normal capacity of Gas fired

boiler will be 50 tph.

Waste Heat Recovery Boilers (WHRB): The major technical

parameters of WHRB are given below:

Type .. Single drum, natural circulation, multi-pass, semi-outdoor Number of WHRB .. 4 Normal continuous rating, ton/hr .. 24.5 Steam pressure at superheater .. 66 outlet, ksca Steam temperature at superheater .. 485+5 outlet, OC Feed water temperature at economiser outlet, OC .. 130 Inlet temperature of DR Kiln flue gas OC .. 900 Exit temperature of flue gas, OC .. 180


3-36

Atmospheric Fluidized Bed Combustion (AFBC) Boiler:

The major technical parameters of AFBC boilers are given below:

Steam output, max continuous rating (MCR), tph .. 100 Steam pressure at superheater outlet, ksca .. 6 Steam temperature at superheater outlet, OC .. 85 Feed water temperature at economiser inlet, OC .. 40 Exit temperature of the fuel gas, OC .. 60 Quanity of AFBC Boilers .. 2

Gas fired Boiler and Auxiliaries: There will be one gas

fired boiler of capacity 50 tph for burning of BF Gas and generation of

high pressure steam.

Type .. Single drum, natural circulation, multi-pass, semi-outdoor Number of gas fired boiler .. 1 Normal continuous rating, ton/hr .. 50 Steam pressure at superheater .. 67 outlet, ksca Steam temperature at superheater .. 540+5 outlet, OC Feed water temperature at economiser outlet, OC .. 130

Steam Turbine: The steam turbine will be of bleed cum

condensing type with two bleeds suitable for deaerator and LP heater for

feed water heating. The rated capacity of the turbine will be 35 MW as

measured at generator terminals. Major technical parameters of the

turbine are given below:

Type .. Single cylinder, multistage straight condensing machine Maximum rated capacity .. 35 x 2 of turbine, MW Steam conditions at turbine inlet

Pressure, ksca .. 67 Temperature, OC .. 535+5 No. of bleeds .. 2 (one for deaerator & one for LP heater) Condenser pressure, ksca .. 0.1 Circulating cooling water .. 34/42 temperature at inlet to condenser, OC


3-37

Steam turbine will be complete with auxiliaries like lube oil

system, governing system, condenser, condenser vacuum system,

condenser extraction pumps, condensate and feed water heating system

etc.

The major system/equipment in the power plant is given

below:

i) Waste Heat Recovery Boilers (WHRB) and its

auxiliaries ii) Atmospheric Fluidized Bed Combustion (AFBC) Boiler and its auxiliaries iii) Gas fired Boilers iv) Steam Turbo Generator (TG) and its auxiliaries v) Water system vi) Fire fighting system vii) Power generation, distribution and evacuation viii) Instrumentation and controls ix) Compressed air system x) Air conditioning & ventilation system xi) TG building crane

3.7.4 Raw Materials

Integrated Steel Plant: The estimated annual requirements

of major raw materials for the integrated steel plant are presented in

Table 3-15.


3-38

TABLE 3-15 - ESTIMATED ANNUAL REQUIREMENTS OF MAJOR RAW MATERIALS

Sl. No.

Major Raw materials

Estimated Quantity,

tons Indicative

Analysis, % Likely source Mode of

transport

1 Coke 219,920 FC - 90 Merchant cokery in

India/abroad Rail/Sea/

Road

2 Anthracite 18,384 Ash - 9 VM - 4 FC - 87

International market Sea

3 Non coking Coal

400,950 Ash - 23 VM - 24 FC - 53

International market Sea/Rail/ Road

4 Iron ore fines 1,597,228 Fe - 62.0-63.0 SiO2 - 3.0-3.5 Al2O3 - 3.0-3.2 LOI - 3.5-4.0

Procured from the Joda-Barbil and Koira & Sundargarh mines region, Odisha

Rail/Road

5 PCI coal 36,750 Ash - 10-15 VM - 15-20 FC - 71

International market Sea

6 Limestone 73,287 SiO2 - 1.55 Al2O3 - 1.65 CaO - 48 MgO - 2.7 LOI - 41

Purchased from mines in Sundergarh district, Odisha or quarries in Jukehi-Katni-Niwar area in Central India

Rail/Road

7 Calcined lime 48,132 CaO Domestic Rail/Road

8 Dolomite 82,698 SiO2 - 1.6 Al2O3 - 0.6 CaO - 28 MgO - 19 LOI - 45

Purchased from mines in Sundergarh district, Odisha & Baradwar regions in Chattisgarh

Rail/Road

9 Chrome Ore Fines

37.106 Cr2O3 - 46-49 FeO - 17-19 SiO2 - 2-4 Al2O3 - 10-11

Procured from the mines in Sukinda regions, Odisha

Rail/Road

10 Chrome Ore lump

7,236 Cr2O3 - 50-51 FeO - 18-19 SiO2 - 3-4 Al2O3 - 11-12

Procured from the mines in Sukinda regions, Odisha

Rail/Road

11 Manganese Ore

56,968 Mn - 45-47 SiO2 - 6-8 Al2O3 - 4.3-6.3

Procured from the mines of Manganese Ore India Limited (MOIL) in MP & Odisha.

Rail/Road

12 Steam coal 143,416 FC - 40-45 Ash - 40-45 S - 0.4-0.5

Domestic Rail/Road

13 Bentonite 11,724 Fe - 13.0 SiO2 - 47.0 Al2O3 - 15.0 MgO - 3.6 LOI - 10.0

International market Sea/Rail/ Road

14 Quartzite 21,395 SiO2 - 97.0 Al2O3 - 1.0

Procured from Chaibasa, Ranchi and Hazaribagh areas of Jharkhand

Sea/Rail)/ Road

Apart from the major raw materials mentioned below, other

materials like hydrated lime, molasses, quartz fines, electrode paste,

fluorspar, zinc would also be required.


3-39

Raw Material handling & Storage system: Raw materials

(viz. ore fines, non coking coal, purchase coke and flux) will be received

in plant by road through trucks from various sources. The raw materials

will be unloaded directly to stockyard. Roads all around the pile has

been considered for to and fro movement of trucks for the same.

The raw materials hence received will be stacked in regular

piles with excavator or payloader. Iron ore fines required for Pellet plant

and Sinter plant will be stored in same piles. PCI coal will be unloaded

and stored in the within the blast furnace area. Raw materials required

for ferro-chrome plant will be unloaded and stored separately in the

vicinity of plant.

There will be two weighbridges for incoming materials and

one weighbridge for dispatch of finished products, slags etc. for weighing

of trucks.

List of major facilities of raw material handling system is

presented in below.

i) Road weigh bridge ii) Flux crusher iii) Coal crusher (non coking coal) iv) Vibrating screen v) Coke screen vi) Coke breeze crusher vii) Rod gate viii) Rack and pinion gate ix) Flap gate x) Vibrating feeder xi) Belt scale xii) Sampler xiii) Metal detector xiv) Magnetic separator xv) Belt scale xvi) Reversible shuttle conveyor xvii) Belt feeder xviii) Belt conveyors xix) Hoist xx) Dust suppression system


3-40

3.8 ROAD LOGISTICS FOR RAW MATERIAL TRANSPORTATION

Road logistics has been considered for transportation of raw

materials required for the proposed plant. Gagan Ferro Tech Limited

(parent company of STPL) is located in the vicinity of the proposed plant

site. It is served by a railway siding at Topsia for handling iron ore and

another railway siding at Asansol for handling coke & coal. The same

railway sidings are envisaged to cater to the requirement of the proposed

plant.

Around 2.8 MTPA of raw material would be transported by

road (NH-60) to the plant. About 0.75 MTPA of coke & coal would be

received at Asansol siding and 1.9 MTPA at Topsia siding. The balance

would be transported by road from the nearest sea port and/or local

market. Considering dumpers of 20 T capacity, it is estimated that

400 nos. dumpers would be required per day i.e. 20 dumpers/hour. The

above estimated dumper movement will be accommodated conveniently

as planned for plant logistics.

Considering installation of railway yard within the plant,

total incoming rakes would be three Nos. per day, i.e. two rakes from

Topsia and one rake from Asansol. In order to accommodate all three

rakes, three railway tracks would be required along with one additional

track for engine escape line and two wagon tipplers. The total length of

the yard would be around 2.0 km. Adequate space for providing the

above mentioned yard is not available within the plant. Also, future

expansion of the plant is not envisaged.

In view of the above, road logistics for raw material

transportation has been found suitable and railway yard has not been

considered. However, adequacy study regarding the capacity of existing

railway sidings and traffic load study for NH-60 would be carried out to

ensure sufficient handling capacity for the proposed plant.


3-41

3.9 RESOURCE OPTIMIZATION/RECYCLE & REUSE ENVISAGED IN THE PROJECT

The steel plant would be designed with state-of-art

technology for optimum consumption of energy & other resources. By

product BF gas would be reused within the plant as in-plant fuel and

also to produce power in the CPP. Waste heat from DR off gas would be

used to produce power in WHRB. One of the major solid waste, Char

from DR would be used to generate power in AFBC boiler in addition to

purchased steam coal. In addition, adopting a compact layout for the

Plant would enable to optimise the utilisation of land, which is another

critical resource. By utilising the fines and scrap generated during the

process within the plant for the production process, usage of raw

materials is optimised. Water consumption would also be optimised by

treatment of water to the extent possible and recycle of treated water as

make-up in the network. Solid byproducts would be reused to the extent

feasible.

3.10 AVAILABILITY OF WATER AND POWER

3.10.1 Water

The estimated requirement of raw water to the reservoir will

be at a rate of 276 cu m/hr. Water is proposed to be sourced from Ajay

River by laying a pipeline of approx 7 km & Asansol Municipal

Corporation. For the requirement of makeup water as above, M/S

Spintech Tubes have already applied to Municipality and Irrigation

Departments.

An earthen raw water storage reservoir of about

100,000 lakh cu m water holding capacity has been considered to meet

about 15 days’ make-up water requirement. From the reservoir raw

water shall be pumped to the Raw Water Treatment Plant (RWTP). The

treated raw water would be distributed in the plant’s make-up water

circuit. The unit wise requirement of water is shown in Table 3-16.


3-42

TABLE 3-16 - UNITWISE REQUIREMENT OF WATER

Sl. No.

Consumer Plants Make-up Water Requirement

(cu m per hour) 1. Pellet plant 20

2. Grinding unit of pellet plant 12

3. DRI plant 53

4. Raw material handling and storage system 8

5. Sinter plant 15

6. Blast furnace (including pig casting M/C and slag granulation plant)

30

7. Ferro alloy plant 12

8. Induction furnace 10

9. EAF 10

10. Ladle Furnace - 1 5

11. Ladle Furnace - 2 5

12. Billet caster 17

13. Billet cum bloom caster 20

14. Wire rod mill 14

15. Bar mill 14

16. Structural mill 12

17. Air separation (oxygen) plant 16

18. In-plant captive power plant 22 19. Softening plant 13

20. DM water 13

21. Drinking and sanitation 3

22. Wire drawing facility 2

23. Miscellaneous requirements including losses from reservoirs

2

24. Total Make-up Water (Sl. Nos. 1 to 23) 328

25. Recovery as treated effluent from CETP and reused in RWTP

54

26. RWTP reject Loss, Raw water reservoir evaporation loss etc.

2

Grand Total (Sl. No. 24 - Sl. No. 25 + Sl. No. 26) 276

3.10.2 Power

The estimated power requirements of various plant units

including utilities and auxiliary facilities for the Plant is indicated below:

Annual energy consumption, kWh x 106 .. 851 15-min maximumdemand, MW .. 141


3-43

The power requirement would be met from the following

sources:

i) India Power Corporation Limited at 132kV/220 kV as per requirement

ii) Captive power Plant based on surplus BF Gas, WHRB & AFBC boiler

The sent out captive generation would be 64 MW and the

power sourced from the grid would be 77 MW.

DG sets of adequate capacities are proposed for the plant

units as well as CPP auxiliaries to cater to the requirement of safe

shutdown and safety of personnel during total black-out condition when

power supplies to plant network from both the sources viz. grid and CPP

have failed.

3.11 WASTE GENERATION AND MANAGEMENT

3.11.1 Waste Water Management

Waste water generated from the different areas of the plant

will be treated in suitable treatment facilities and recycled back to the

process, facilitating adequate re-use of water in the respective

recirculating systems and economizing on the make-up water

requirement. The blow down from various direct/indirect cooling water

(DCW/ICW) circuits of pellet plant, sinter plant, oxygen plant, waste

effluent from power plant and DM-softening plant, EAF, IF and LF,

Caster and Mill shall be collected in a blow-down sump, treated in the

Central Effluent Treatment Plant (CETP) and reused within the plant.

Water required for toilet flushing, floor washing etc. shall be provided

from CETP after primary treatment. Other effluents will be further

treated to the desired extent with suitable treatment facility in CETP and

recycled back to make-up water reservoir and re-used. Reject Water

generated in CETP will be used for slag quenching in SMS. Blow-down

water from the Blast-Furnace circuits will be used in slag granulation

Plant and other low-end applications.


3-44

Sewage generated from toilet blocks etc would be collected by

means of suitable sewer system for treatment in Sewage Treatment Plant

(STP). Biological solid waste generated from STP would be used as

manure for development of greenery. Chemical sludge and salt would be

sent to near-by secured landfill site.

3.11.2 Solid Waste Management

The estimated generation of major solid wastes and its

utilization as envisaged for the production of 0.7 MTPA steel is presented

in Table 3-17. It may be seen that maximum effort would be taken to

reutilize & reuse of the by-products either for various in-plant use or

sold to outside agencies for value recovery & reuse.

TABLE 3-17 - SOLID WASTE GENERATION

Solid Wastes Expected

generation, TPA Management Scheme

Char 89,100 Used to generate power in AFBC boiler along with purchased steam coal

BF Slag 1,47,000 Granulation in Slag granulation plant and sell to cement manufacturers for production of Slag cement

Steelmaking Slag 1,59,318 Use in construction purposes mainly for filling of low-lying areas & road sub grade preparation.

BF Flue Dusts 5,513 Reuse in Agglomeration

Mill Scales 8,339 Reuse in agglomeration

Ferro alloy & SiMn Slag

39,769 Used for filing of low-lying area after recovery of metallics

Caster scale 3,645 Reuse in agglomeration

Caster scrap 13,140 Recycle in induction furnace

Fly Ash 95,788 Sell to agencies for manufacture of pozzolona cement, bricks, etc

Bottom Ash 23,948 Would be stored in ash pond and used for road making

Besides the above, there would be other solid wastes like

clarifier sludges, ESP/Bag Filter dust, refractory debris etc. generated

from the proposed steel plant. These would be reused/recycled within

the plant to the extent possible and the balance would be transferred to

Authorised agencies for reuse/recovery of materials/disposal as per

prevailing regulations.


3-45

3.11.3 Air Pollution

Various process operations would generate particulate dusts,

oxides of sulphur and nitrogen and carbon dioxide to the environment.

The emission would be from the stacks as well as there would be fugitive

emission of dusts from open & closed areas.

Fugitive dust emissions generating from the handling and

stockpiling of raw material in open stockyards would be controlled by

water sprinkling at regular intervals. All closed zone working areas

such as raw materials handling zone, conveyor transfer points, dust

generation points at screen would be provided with dust extraction (DE)

systems/dry fogging (DF) at several emission points to control the

fugitive dust emissions. DE system shall consist of suction hood followed

by bag filter/ESP, ducts, extraction fans and stack of appropriate height.

Sinter plant: There would be cleaning of waste gas in dry

type ESP before venting it off to the atmosphere through a stack of

adequate height. Dust generated in the material & product handling and

in various transfer points would be mitigated with DE system based on

dry type ESP. Partial recirculation of waste gas would be adopted for

heat recovery and energy conservation measures.

Pellet Plant: Emissions from Pellet Plant would mainly be

from Induration Process, which are controlled by installation of ESP with

adequate height of chimneys.

Blast furnace: In addition to cleaning of BF gas in gas

cleaning plant (GCP), the main sources of air pollution would be stock

house and cast house. The BF stock house would be provided with DE

systems complete with dust extraction hoods, ESP/ Bag Filter, ID fan

and stack of adequate height. Similarly, the cast house would have

separate fume collection system during taping of hot metal and slag,

equipped with bag filter/ESP for separation of particulates before venting

through a stack of appropriate height.


3-46

Heat recovery from stove waste gas shall be installed for

preheating of BF Gas and combustion air for stoves. In addition, energy

conservation would be carried out through installation of TRT and

pulverized coal injection.

DR Plant: At the kiln inlet, a dust settling chamber (DSC)

will be provided for allowing the dust to settle before passing through the

after burning chamber (ABC). The ABC will be supplied with additional

air by a fan for burning the combustible matter contained in the kiln

off-gas.

The waste gas from the ABC would be cleaned in dry type

ESP and would be further used to generate steam in a waste heat

recovery boiler (WHRB).

Steel Melting Shop: There would be two combined gas

cleaning facilities and FE system for EAF & LF and IF & LF. The gas

cleaning system would be complete with water cooled duct, combustion

chamber, fume and gas cooler, bag house, ID fan and stack for venting

off to the atmosphere.

Secondary fumes would be generated at several points

during ladle transfer, raw materials charging, liquid steel tapping and

secondary refining points. All the fumes from each of the process

operation would be collected by FE systems and taken through bag filter

before venting out clean air into the atmosphere through a stack of

appropriate height.

Rolling Mills: The off-gases generated from the reheating

furnace would contain particulates, CO2 and NOx. NOx emissions would

be controlled by optimising the excess air supply and proper burner

design. In addition fume extraction (FE) system would be installed. The

flue gas, which is fairly clean, would be vented through a stack of

adequate height.


3-47

The structural products & a fraction of the wire rods would

undergo hot dip galvanisation in molten zinc baths. These processes

would generate vapours and fumes which would be controlled by fume

extraction systems.

Captive Power Plant:

Waste heat recovery type power plant: The sensible heat of

the hot flue gas from coke oven would be utilised for generation of

electrical power. The off-gas from the power plant containing SO2 and

NOx would be vented to the atmosphere through a stack of adequate

height.

BF gas fired power plant: There would be generation of power

based on combustion of BF gas. The flue gas from boilers mainly

containing NOx would be vented off to the atmosphere through stack of

adequate height.

AFBC Boiler: Char and steam coal would be burnt in the

boiler for generation of power. The flue gas thus generated from the

boiler would be vented through stack of appropriate height. ESPs would

be provided to capture the fly ash.

3.12 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY

DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE

As per the Environment Impact Assessment (EIA)

notification dated 14th September 2006 and subsequent amendments,

this project falls under category A. It would be required to prepare

EIA/EMP report to obtain the Environmental Clearance (EC) for the

project from the MoEFCC. The schematic diagram given in Fig. 3-4

represents the steps required for EIA to obtain the EC.


3-48

FIG. 3-3 - SCHEMATIC DIAGRAM FOR STEPS OF EIA


4-1

4 - SITE ANALYSIS

4.1 CONNECTIVITY

The site is located in Dhasal, Mamudpur & Bahadurpur

villages of Jamuria block of Paschim Bardhaman district in West Bengal.

The location is well connected by road and rail. The nearest railway

station is Ikrah Junction. Asansol junction and Raniganj stations are

two other major railway stations in the area. Jamuria Road is the access

road for reaching the plant site. NH 60 runs in South East direction at

an distance of approx 2 km from the project site. Kazi Nazrul Islam

International Airport, Andal is around 15 km in South East direction

while NSC Bose International Airport at Kolkata is around 160 km from

the project site. The nearest sea port Haldia is within 300 km away from

the site. The site connectivity is shown in Fig. 4-1.

FIG. 4-4 - SITE CONNECTIVITY

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 4 - Site Analysis (cont’d)

4-2

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The major land use in the study area is agriculture followed

by collieries operation. No reserve or protected forest is present within

the study area however scattered vegetation patches covering small areas

are present in the south and South West direction of the project site.

Approx 113 acres land have already purchased by STPL.

4.2.1 Land Use of Project site

The proposed site for setting up of the Greenfield ISP project

is located within the jurisdiction of Jamuria Block of Paschim

Bardhaman District of west Bengal. The geographical location of the

project site lies within 23040’45” to 23041’21” North latitude and

87007’45” to 87008’22” East longitude.

240 acres of land would be required for the proposed ISP

project. The proposed site primarily consists of a mixture of single crop

land, poor crop land, water logged area, pond & barren land as shown in

Table 4-1.

TABLE 4-1 - LAND USE OF CORE AREA

Land use Area (Acres) % use Agricultural land 21.36 8.9 Poor Crop land 98.16 40.9 Water logged area 45.31 18.8 Pond 13.37 5.6 Barren land 61.80 25.8

Total 240.00 100.0

4.3 TOPOGRAPHY

Jamuria is characterized by undulating topography with

rugged hilly terrains in the western parts. The western half of the area

resembles a promontory jutting out from the hill ranges of Chottnagpur

plateau and consists of barren, rocky and rolling country with a Laterite


4-3

soil rising into rocky hillocks, the highest being 227 m. Ajay-Barakar

divide is a convex plateau, the average altitude being 150 m from the

mean sea level. The gradient is westerly to the west and to the east it is

northerly towards Ajay and southerly towards Damodar below the

latitude. The average elevation of Bardhaman plain is about 104 m above

the Mean Sea Level (MSL). This area is a low lying alluvial plains with

riverine aggregates.

The rocky undulating topography with laterite soil found in

Paschim Bardhaman district is a sort of extension of the Chota Nagpur

plateau. For ages the area was heavily forested and infested with

plunderers and marauders. The discovery of coal in the 18th century led

to industrialization. Most of the forests in the coal-bearing areas have

been cleared but some areas in the eastern part of the district remained

thickly forested till more recent times and some are still there. The

eastern part of the district gradually slopes down to the rice plains of the

agriculturally rich Purba Bardhaman district.

The study area is mainly drained by River Ajay which flows

along northern side at a distance of about 7.3 kms. The direction of flow

of the river is controlled by slope which in general is from North to South

East. Ajay River is of high significance in the region as it caters to the

water requirements to most of the villages and the majority of the

industrial units in the region.

The general topography of the project site is pediplain. The

other areas are divided into shallow weathered buried pediplain, Flood

plain, and valley hill & rivers. The topographic features of the study area

may be seen from Survey of India Topo Sheet No. 73 M2. The

Topographic map is shown in Fig 4-2.


4-4

FIG. 4-5 - TOPOGRAPHIC MAP OF THE PROPOSED STEEL PLANT SITE

4.4 EXISTING INFRASTRUCTURE

The site is located at Dhasal under Jamuria block in district

Paschim Bardhaman of West Bengal. The location is well connected by

road & rail. The proposed site is only 2.0 km away from NH 60. Ikrah

Railway station is about 2.0 km away & Kazi Nazrul Islam Airport is

around 15.0 km away for the proposed site.

4.5 SOIL CHARACTERISTICS

Soil of the project site is red lateritic soil with high Fe, sandy

loamy texture with medium water holding capacity. The pH level found to

in the range of 5.5 to 6.0, which indicate moderately acidic soil which

870 15’

230 45’

230 40’

230 35’

870 05’ 870 10’ 870 00’

Topo Map No - 73 M2

Proposed Project Site


4-5

has deficient available nutrients to plants for growth. The presence of

nutrients like nitrogen, phosphate, potash, manganese and humus are

insufficient. Hence, the soil is non fertile and low productive for

cultivation.

4.6 CLIMATIC CONDITIONS

The Paschim Bardhaman experiences a mixed transitional

climate between the tropical wet and dry climate and the more humid

subtropical climate. The winter season starts from about the middle of

November and continues till the end of February. The monsoon is

followed by a mild, dry winter. March to May is dry summer intervened

by tropical cyclonic storms. June to September is wet summer while

October is autumn.

Average temperature during summer season is 31OC while at

the cold season is 22OC. Average annual rainfall is around 1,350 mm, of

which the bulk of rainfall occurring around the July-September period.

The wind blows predominantly from South (S)/South West

(SW) during the period from March to August and for rest part of the

year wind generally blows from North (N) and North West (NW) directions.

The summarized meteorological data of Burdwan district is shown in

Table 4-2.


4-6

TABLE 4-2 - SUMMARISED METEOROLOGICAL DATA Location .. Burdwan

Lat/Long .. 23O14′ N; 87O51′ E Elevation above MSL .. 32 m

Parameters Summer Monsoon Post-

Monsoon Winter Max. DB temperature (OC) 46.8 45.6 38.0 38.8

Average DB temperature (OC) 31.2 29.7 27.1 22.0

Relative Humidity (%) 56.0 79.3 74.8 55.8

Average Wind Speed (kmph) 7.7 8.4 5.0 3.2

Predominant wind direction S, SW S, SE,SW E, SE N, NW

Total rainfall (mm) 131.2 819.7 359.8 27.8

Source: IMD - Climatic Normals (1951-1980)

4.7 SOCIAL INFRASTRUCTURE AVAILABLE

i) The economy of Paschim Burdwan district is divided into the agricultural sector (52%) and non agricultural sector (48%).The primary crop grown in the district is that of Paddy followed by Jute, Mesta, Sugarcane, Potato and Oil seeds

ii) Small & Medium scale manufacturing units have mushroomed around the Iron and Cement Industries. The economic activities within these manufacturing units facilitate employment to the local populace

iii) Educational institutions like Bahadurpur High School, Dhasal F.P School (Primary) and Kazi Nazrul Islam Mahavidyalaya at Churulia are operational in the district

iv) Transport & Communication infrastructure in district is characterized by Ikrah Railway Station and bus routes from Jamuria to Raniganj/Asansol/Haripur/ Kolkata. Kutcha road connects Dhasal and Jamuria to NH 60. The nearest arirport is Kazi Nazrul Islam Airport located in Durgapur

v) Financial institutions like Axis Bank, State Bank of India, Bank of India and HDFC Bank are operational in Jamuria

vi) Primary Health Centres are located in Jamuria and Bahadurpur and Churulia


5-1

5 - PLANNING BRIEF

5.1 PLANNING CONCEPT

The proposed steel plant would be located near Dhasal,

Jamuria Block, Paschim Bardhaman. The total land area of the

proposed project would be 240 acres spread across 3 villages (Dhasal,

Mamudpur & Bahadurpur) in Jamuria block of Paschim Bardhaman.

Most of the raw materials would be transported through

covered trucks by road after unloading at railway station. The raw

materials and products would be covered fully during the transportation

to avoid spillage & fugitive emissions. The transportation load would not

add much to the existing load on the said road network.

The proposed steel plant involving semi-mechanized

operations would be a labour intensive one. Local construction labourers

as well as direct & indirect labourers would be engaged for the operation.

Suitable plantation programme would be undertaken to cover

the boundary areas with thick & tall plants tom arrest the air-borne

pollutants within the plant premises.

5.2 POPULATION PROJECTION

The census data of 2011 for district of Burdwan indicates a

total population of 7,717,563. In the year 2017, the erstwhile district of

Burdwan was divided into Purba Bardhaman and Paschim Bardhaman.

The proposed Greenfield project currently falls under the

block of Jamuria in the district of Paschim Bardhaman.

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 5 - Planning Brief (cont’d)

5-2

The total population of Jamuria block (as indicated in the

census data) for the years 2001 and 2011 are 1,12,799 and 1,23,176

respectively. The computed decadal growth is that of 9.20 %. Hence the

projected population of Jamuria block for the year 2018 is calculated to

be around 1,31,110.

5.3 LAND USE PLANNING

5.3.1 Integrated Steel Plant

The total area for steel plant would be 240 acres, consisting

of government and private land. The area would house the following

facilities:

i) Raw material storage yard ii) Sinter plant iii) Pellet plant iv) DRI plant v) Ferro alloy & Briquetting plant vi) Blast Furnace vii) Steel Melt Shop with casters viii) Air separation plant ix) Mills (Structural, Bar & Wire rods) x) Wire drawing facilities xi) RWTP, STP & CETP xii) Captive power plant

The land use break-up of the project area (240 acres) is

shown in Table 5-1.

TABLE 5-1 - LAND USE BREAK-UP OF THE PROJECT AREA

Land Use Acres % Use Built up area 108.4 45.2 Raw Material Storage area 24.9 10.4 Waste Disposal area 2.7 1.1 Water Body 3.2 1.3 Greenery 79.2 33.0 In-plant Roads 21.6 9.0

Total 240.0 100.0

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 5 - Planning Brief (cont’d)

5-3

The total greenbelt, comprising of about 33% of total plant

area of about 79.2 acres, would be reserved in the layout. The layout

would also house canteen, administrative buildings, workshop, stores

etc.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

i) Support towards adequate sanitation facilities and awareness programmes (in the areas of hygiene, vector borne diseases and HIV) for the local population

ii) Support towards industrial and vocational training (for

both local male & female youth members) and adult education of the marginal communities

iii) Support towards provision of adequate mobile medical

facilities


6-1

6 - PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The site is located at Dhasal under Jamuria block in district

Paschim Bardhaman of West Bengal. The location is well connected by

road & rail. The proposed site is 2.0 km away from NH 60. Ikrah

Railway station is about 2.0 km away & Kazi Nazrul Islam Airport is

around 15.0 km away for the proposed site.

The existing infrastructure for the proposed steel plant as

well as connectivity has been discussed in Chapter-4.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No residential facilities have been considered for the

proposed project.

6.3 GREENBELT

It is obligatory to develop dense greenbelt area in proposed

project plant as per CPCB guidelines. Green belt is proposed to be

developed in compliance with the regulatory norms. This would not only

prevent the fugitive dust emissions but also improve the peripheral

appearance of the plant from aesthetics point of view. Unpaved areas, if

any, within the plant boundary would be provided with grass/tree cover.

Depending on the type of soil suitable for growth, higher

survival rate in the region, large leaf index area, nativity of the species

and pollution load, following are the proposed species of trees which may

be planted as greenbelt at the steel plant site at Jamuria:

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 6 - Proposed Infrastructure (cont’d)

6-2

List of selected tree species for greenbelt development: 1. Akashmoni - Acacia moniliformis (Fabaceae) 2. Arjun - Terminalia arjuna (Combretaceae) 3. Kassod - Cassia siamea (Fabaceae) 4. Chatim - Alstonia scholaris (Apocynaceae) 5. Jamun - Syzygium cuminiin (Myrtaceae) 6. Kanchan - Bauhinia acumiata (Fabaceae) 7. Kath badam - Terminalia catappa (Combretaceae) 8. Neem - Azadirachta indica (Meliaceae) 9. Siraish - Albizia lebbeck (Fabaceae) 10. Sisoo - Dalbergia sisso (Fabaceae)

6.4 SOCIAL INFRASTRUCTURE

i) Support towards government initiatives relating to sanitation

ii) Support towards industrial and vocational training for youth of marginal communities

iii) Support towards strengthening of existing medical facilities & allied camps/awareness programmes to cater to the local population

iv) Support towards repairing of local approach and link roads for better communication

6.5 CONNECTIVITY

The project location has good connectivity in respect of road

& rail. The site is only 2.0 km away from the NH 60. Ikrah Railway

station is 2.0 km away. Nearest Airport (Kazi Nazrul Islam Airport) is

about 15 km away from the project site. The connectivity has been

described in detail in chapter 2.

6.6 DRINKING WATER MANAGEMENT

The total water requirement for drinking & sanitation would

be 3 cu m/hr approximately, which is proposed to be drawn from the

plant water system and the total water requirement of the plant would be

sourced from Ajay River approximately 7 km away from the plant site

and Asansol Municipal Corporation.


6-3

The drinking and sanitary water system will be provided to

meet the water requirement of the plant personnel. Drinking quality

water also will be required at the quality control laboratory. Clarified

water received from the plant make-up water system will be filtered and

chlorinated to convert it into drinking quality water. The drinking water

will be collected in a 50 cu m overhead storage tank from which drinking

water will be distributed to the various consumers.

6.7 DRAINAGE AND SEWERAGE SYSTEM

Open type drain has been envisaged for the plant storm

water drainage. The drains will be laid generally by the side of the roads.

Storm water run-off, collected through arterial and trunk drain, will be

discharged to water treatment plant for treatment and treated water will

be discharged to pond. Overflow water from pond will be discharged to

the existing re-routed canal of the plant. Sanitary faecal sewage will be

collected from the ablution blocks through pipeline and the same will be

connected to a sewage treatment plant. The effluent from sewage

treatment plant will be utilized for the development and maintenance of

greenery.

6.8 INDUSTRIAL WASTE MANAGEMENT

The proposed project would generate various types of wastes

including liquid effluents and solid wastes, which have been detailed in

Chapter-3.

6.9 SOLID WASTE MANAGEMENT

Major solid wastes produced in the ISP would be namely

blast furnace slag, SMS slag, char and coal ash among others. The solid

waste management has been discussed in details in Chapter-3.


6-4

6.10 POWER REQUIREMENT AND SUPPLY/SOURCE

Power sources at two different voltage levels are available in

Asansol area, 132 kV and 220 kV. M/s India Power Corporation Limited

(IPCL) will arrange for the required power supply from their 132 kV

substation located within a km from this project site. Necessary grid

strengthening, if required, for meeting the short circuit fault level, will be

done by grid authority before implementation of the project. Power

supply from 220kV line can also be adopted if 132 kV line/grid

strengthening is not found suitable. The estimated power requirements &

supply/source for the proposed integrated steel plant has been stated in

more details in Chapter-3.


7-1

7 - REHABILITATION AND RESETTLEMENT

The land acquisition process for the proposed Greenfield

project does not entail issues of ‘Rehabilitation and Resettlement’ of local

human settlements including those of encroacher and squatter groups.


8-1

8 - IMPLEMENTATION SCHEDULE AND COST ESTIMATE

This chapter indicates the overall implementation schedule

of the project and the capital cost estimate.

8.1 IMPLEMENTATION SCHEDULE

It is envisaged that the project will be completed within a

period of twenty seven months from “Go Ahead”.

The schedule has been developed on the basis of the

estimated quantum of work, expected delivery and installation period of

equipment and commissioning of the plant facilities in shortest possible

time.

Completion of major activities from “Go Ahead”:

Pellet Plant .. 24 months Sinter Plant .. 24 months DR Plant .. 25 months Blast Furnace .. 27 months Steel Melt Shop .. 27 months Wire Rod Mill .. 24 months Bar Mill .. 24 months Structural Mill .. 24 months FeMn and FeSi Plant .. 23 months Ferro Chrome Plant .. 23 months Captive Power Plant .. 22 months Air Separation Plant .. 22 months

The preliminary overall implementation schedule for the

project, indicating the time period required for completing the major

activities like ordering of main process equipment, basic & detail

engineering for the project, manufacturing & supply to site, construction

(civil & structural work and erection including cold trials/testing) and

readiness of the plant is presented below in the form of a Bar Chart in

Fig. 8-1.

SPINTECH TUBES PVT LIMITED Greenfield Integrated Iron & Steel Plant of 0.7 MTPA with Captive Power Plant of 70 MW in Jamuria Pre-Feasibility Report 8 - Implementation Schedule and Cost Estimate (cont’d)

8-2


8-3

FIG. 8-6 - IMPLEMENTATION SCHEDULE


8-4

8.2 CAPITAL COST ESTIMATE

This section presents the capital cost estimates,

manufacturing expenses and return on investment (ROI) for the project.

The order-of-magnitude capital cost is projected in this

section. This comprise as erected mechanical and electrical equipment

including related civil and structural steelwork and cost towards design,

engineering and consultancy and administration during construction.

Provision has also been considered for contingency, margin money,

preliminary & preoperative expenses and IDC for arriving at the total

capital cost.

The estimate is based on information available with

CONSULTING ENGINEERS for similar facilities. Applicable taxes and

duties have been considered in all of the estimated costs.

The breakdown of order-of-magnitude plant cost is indicated

in Table 8 -1.

TABLE 8-1 - CAPITAL COST ESTIMATE

Item Amount Rs. crore

Land and land development 89 Plant and equipment (as erected) including civil and structural work

2,400

Infrastructure and construction facilities 16 Design, engineering and administration during construction

118

Contingency 262

Total Plant Cost 2,885

Margin money, Preliminary & pre-operative expenses & IDC

315

Total Capital Cost 3,200


8-5

It is seen from the table above that the order-of-magnitude

plant cost (Gross of GST) of the plant will be about Rs 3,200 crore.

8.3 ANNUAL MANUFACTURING EXPENSES

The annual manufacturing expenses for the project have

been estimated at rated capacity level under the following heads:

a) Raw materials, b) Utilities and services, c) Consumables and refractories, d) Repair and maintenance, f) Salaries and wages g) Admin and sales overhead.

The estimated annual manufacturing expenses for the plant

at the rated capacity level are given in Table 8-2.

TABLE 8-2 - ANNUAL MANUFACTURING EXPENSES (AT RATED CAPACITY LEVEL)

Item description Amount, Rs. crore

Raw materials 1,772 Utilities and services 241 Consumables and refractories 253 Repair and maintenance 44 Salaries & wages 50 Overhead expenses 32

Annual manufacturing expenses 2,392

8.4 ANNUAL SALES REASILSATION

The annual sales realisations at rated capacity level have

been estimated at about Rs. 3,028 crore.


8-6

8.4.1 Return on Investment (ROI)

Return of investment has been calculated based on the gross

profit at first year of 100 per cent capacity utilization and capital cost of

the Project and given below.

A. Sales realization, Rs crore 3,028

B. Manufacturing expenses 2,392

C. Gross profit (A-B) 636

D. Capital cost 3,200

E. ROI, % (C/D) 20


9-1

9 - ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS OF THE PROJECT

The proposed Greenfield project would

i) generate local direct & indirect employment opportunities and improve local income

ii) augment the development of ancillary small-medium

scale industries, trade & commercial establishments and local entrepreneurship

iii) promote diversification in skill set amongst young

adults iv) enhance local land prices v) contribute to the district and state revenue

The peripheral development activities that would be

undertaken by the proposed project under Corporate Environment

Responsibility (CER) will focus on marginal communities and attempt to

bring forward an overall social development with emphasis in the areas

of education, training, health and social & physical infrastructure.


i

setting up of a greenfield integrated steel plant of …€¦ · power plant which will utilize...

Documents