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SWATI CONCAST & POWER PVT. LTD. ENVIRONMENTAL APPRAISAL REPORT FOR EXISTING PIG IRON MANUFACTURING UNIT CAP 120 MT/DAY AT

VILLAGE MOHANPUR, TUNDI ROAD, GIRIDIH(JHARKHAND) ----------------------------------------------------------------------------------------------------------------------------- --------------------

© 2017 PECS all rights reserved of 32

EXECUTIVE SUMMARY

1. GENERAL DETAILS:

This is an existing plant having facilities for pig iron manufacturing and a non-

operational Hard Coke plant established in 2010 at village Mohanpur, District Giridih

(Jharkhand). Plant was established after due environmental clearance vide letter no

EC file No. J-11011/866/2007/IA-II(I) dated 18/06/2010. JSPCB has accorded consent

to operate on regular basis. During recent consent to operate, JSPCB asked the plant

authority to establish on-line ambient air quality monitoring station as per specific

condition of EC issued to plant or get the condition waved off from MOEF&CC. ours is

a very small unit with a capital budget of 14.0 Cr with mandate to spend Rs 11.0Cr on

environmental management. The commercial cost of on-line AAQ station equipment

and maintenance start from 75 lakhs on wards. Currently plant is monitoring AAQ via

off-line monitoring through JSPCB approved third party monitoring and submitting

regularly to JSPCB. The unit has provided employment to about 90 persons in various

categories for production.

Name of Project: SWATI CONCAST & POWER PVT. LTD. (Formerly Swati Sponge

& Iron Pvt. Ltd.)

Plant Location & Administrative office: Village-Mohanpur, P.S. & P.O. Giridih, Dist.

Giridih, Jharkhand

Project: Manufacturing of Pig Iron is working & Hard Coke(Non-Operative)

Total Investment in Plant: Rs. 14.00 Crores

Investment in EMP: Rs. 11.00Lakhs

Budget for Peripheral Development: Rs. 14.65 Lacs

Employment: the total employment provided to 90 Nos of persons .

Land Details: Plant is constructed over 6.93 acres of land acquired at Village:

Mohanpur, P.S. & P.O. Giridih, Dist. Giridih, Jharkhand.

Location Details

Topo Sheet No.: 72 L / 8

Latitude: 240 08’ 05” N

Longitude:860 21’ 26” E




Approach Road / Highway: State Highway– 0.5 Km

Nearest Major River: Ushri River – 2.5 Km, Barakar River – 9.5 Km

Nearest habitation: Giridih - 4 Km

Densely populated or built-up area: Giridih - 4 Km

TYPES AND MAJOR SOURCES OF POLLUTION & MITIGATION MEASURES

Measures adopted for minimizing and/or offsetting adverse impacts:

The following measures has been adopted for minimizing adverse impact on the

environment:

➢ Dust extraction system is installed for extraction of dust from all material

handling points.

➢ Adequately designed Bag Filter is installed for Pig iron plant De-Dusting.

➢ All de-dusting units is connected to a stack of height 30 m. Particulate matter

emission is maintained below 100 mg/Nm3.

➢ The fugitive emissions of suspended particulate matter (SPM) are maintained

below 5000 μg/m3 at a distance of 10 m from the sources.

➢ Water is used only for shell cooling in closed circuit system and only

evaporation losses is added as fresh makeup. Hence no industrial effluent is

generated. Domestic waste water treated in soak pit and septic tank and finally

used for horticulture after primary treatment.

Solid waste generated are reused as follows:

➢ Dust from bag filters are used for land filling.

➢ Slag from Pig Iron plant is granulated and sold to cement manufacturers.

➢ Rain Water Harvesting has been implemented for recharge of ground water

➢ Peripheral development activities has been continuously undertaken and

detailed later.

➢ Green Belt development is carried out over 30% of total land area available.

Some photo graphs are attached with this appraisal.

➢ Workers are issued ear plugs and google and also ensured about their use.

Enclosures are provided for heavy noise generating equipment’s.

Quantity of solid waste generation is significant. The solid waste is not hazardous

in nature. The main Solid waste generated as follows:

➢ Dust from Bag filter system - 1.7 MT / day

➢ Slag from Blast Furnace - 55.20 MT / day




GREEN BELT DEVELOPMENT PLAN

As per MOEF&CC/CPCB guidelines, a 5 m wide green belt surrounding plant

boundary inside and outside both has been developed and trees are also planted

both side of road. Fast growing, strong, and pollutant resistant species of tree are

planted in consultation of forest department.

A three-tier plantation scheme comprising of:

• Outer ring of tall, thick canopy trees

• Middle ring of less taller trees

• Inner core layer of tolerant species.

OCCUPATIONAL SAFETY AND HEALTH SYSTEM

Occupational safety and health is very closely related to productivity and employee –

employer relationship. The main factors of occupational health in the plants are dust

and noise. To prevent any adverse effect on the health of workers the following

measures relating to health and safety are adopted:

i. Training of employees for use of safety appliances and first aid.

ii. Regular maintenance and testing of all equipment and machineries.

iii. Periodical health check-up of employees.

iv. Provision of dispensary/first aid in the plant premises.




CHAPTER – 1: INTRODUCTION

1.1 PURPOSE OF THE REPORT

The Swati Concast & Power Private Limited is engaged in manufacturing of Pig Iron

through MBF. The unit was accorded environmental clearance vide letter no EC file

No. J-11011/866/2007/IA-II(I) dated 18/06/2010. The EC was granted to establish Pig

Iron Unit capacity (39,900 MT/Year) and a Hard Coke Unit (cap-33,000 MT/year). At

present the Pig Iron Unit is working and producing Pig Iron with rated capacity.

However, the Hard Coke unit remain un-operative due to technical and commercial

reasons since last three years.

The objective of this environmental appraisal report is to describe of those aspects of

the plant, which are causing environmental impacts in/around the existing plant. To

delineate the existing level of environmental quality and measures adopted by plant

management to contain them within Regulatory frame work prescribed by

JSPCB/CPCB and comply all the standards and norm applicable on plant by authority.

The environmental appraisal is carried out to know, if there is any serious violation of

applicable norm and standards and based on this EAR requesting honourable EAC to

grant us permission to monitor Ambient Air Quality(AAQ) monitoring in off-line mode

by third party Laboratory instead of on-line mode. Here, we have to submit to

Honourable EAC that Swati Concast & Power Pvt Ltd is a very small unit in comparison

of integrated steel plants and managing to operate the pig iron plant with great

difficulty. The Hard Coke unit remain in-operative due to technical reason.

1.2 project & project proponent

Pig Iron is one of the basic raw materials required by the foundry and casting industry

for manufacture of various types of castings for the engineering sector. Pig Iron & Cast

Iron is essential to maintain the carbon content of the product. Demand for Pig Iron is

on the increase in the region.

M/S SWATI CONCAST & POWER PVT. LTD. had set up the Pig Iron plant as well as

a Hard Coke Unit keeping in view of this development. Accordingly, a 65 M3 mini blast

furnace of 120 MT per day with an annual capacity of 39,600 MT and a Hard Coke

Plant with annual capacity of 33000 MT was established. Hard coke unit remain shut

down since last three year due to technical reason and therefore we are purchasing

the coke from market as per requirement. The project was implemented with estimated

cost of Rs 14.00 Crores at that time.

Company Details




Name: SWATI CONCAST & POWER PVT. LTD.

Plant Location and Registered Office: Village: Mohanpur, P.S. & P.O. Giridih

Dist. Giridih, Jharkhand.

Existing Plant: Pig Iron & Hard Coke(non-functional)

Sector: Iron & Steel

Constitution: Private Limited Co.

Promoters of the Project:

1. Mr. Amit Kejriwal

2. Mr. Sumit Kejriwal

Installed name plate Capacity:

Pig Iron: 39600 TPA

Hard Coke: 33000 TPA

Brief description of nature, size, location of the project and its importance

to the country, region

Nature

Pig Iron is reduced molten metallic form of Iron Ore. The natural iron ore has chemical

composition Fe2O3, which is reduced in the process of iron making and the oxygen is

eliminated by oxidation of carbon monoxide to carbon dioxide by burning coke in front

of the tuyeres to produce Iron i.e. Fe. Hence, the pig iron is a refined form of the natural

iron ore. The pig iron is the basic raw-material for manufacture of grey iron casting;

malleable iron and S.G. iron castings. It is used in the induction furnace, foundry and

casting units etc. Pig Iron contains 3.5 to 4.5 percent carbon. Pig Iron Classes are as

below: -

Grade of Pig Iron

I Gray pig iron

II Molten pig iron

III White Pig Iron

Gray pig iron has a crystalline appearance, a dark iron grey colour, in soft and easily

chipped or filed. It has a large proportion of carbon, which separates in flakes as

graphite. It requires high temperature to melt than white iron. White pig iron has the

appearance of matrix of white iron with Grey spots. It’s carbon which present in both

free and combined state.

Size

The existing plant had set up one Mini Blast Furnaces of 65 m3 – 120 TPD (39,600

TPA) Pig Iron and one Hard Coke unit of 100 TPD (33,000 TPA) only. The total cost

of the project as estimated to be that time was Rs 14.00 Crores. The promoters had

setup its plant in the state of Jharkhand at Village: Mohanpur in Giridih district. The

Company had acquired land measuring 6.93 acres at Village: Mohanpur in the district




of Giridih for this plant. The land use changed from fallow to industrial after this plant

established.

Location

The existing plant site is located at Village: Mohanpur, P.O. Giridih, District Giridih, of

Jharkhand State and is about 0.5 KM from State Highway.

Latitude: 240 08’ 05” N.

Longitude: 860 21’ 26” E.

MSL level - 281 m above sea level.

Details of the plant site:

1 Village, District and State: Mohanpur, P.S. & P.O. Giridih Dist. Giridih, Jharkhand

2 Survey of India Topo. sheet covering the plant and surroundings 72 L / 8

3 Nearest Highway State Highway (Tundi Road) – 0.5 KM

4 Nearest Railway Station Giridih - 5 km

5 Nearest major habitation Giridih - 4 km

6 Nearest River Ushri – 2.5 KM, Barakar River – 9.5 KM

7 Forest Reserve Forest – NIL, P F - beyond 2.5 Km

8 National Park NIL within 10 KM

Importance

Pig Iron is one of the basic raw materials required by the foundry and casting industry

for manufacture of various types of castings for the engineering sector. There exists a

growing demand for pig iron in the international market, which has resulted in the

international price of pig iron to soar up. Brazil, currently one of the major suppliers of

pig iron in the world market has started to tighten the supply because of high inflation

rate and severe shortage of coal. Even other suppliers like Japan and China have

become buyers. This coupled with the government’s desire to export more value-

added pig iron than iron ore has bettered the prospects of pig iron export.




CHAPTER-2: EXISTING PROJECT DESCRIPTION

TYPE OF THE PROJECT

The existing project has been established as Greenfield industrial project for

manufacture of Pig Iron from various raw materials like iron ore, coke,

dolomite/limestone etc. The project is listed in the EIA Notification S.O. 1533, dated

14.09.06 as category A at Serial No. 3(a). the plant has obtained environmental

clearance in 2010 from Ministry of Environment and Forest, Government of India, New

Delhi. Pig Iron plant generates air pollution, solid waste and noise pollution to a great

extent. Water pollution is not of great concern in this type of unit. Pig Iron is reduced

molten metallic form of Iron Ore. The natural iron ore has chemical composition

Fe2O3, which is reduced in the process of iron making and the oxygen is eliminated

by oxidation of carbon monoxide to carbon dioxide by burning coke in front of the

tuyeres to produce Iron i.e. Fe. Hence, the pig iron is a refined form of the natural iron

ore. The pig iron is the basic raw-material for manufacture of grey iron casting;

malleable iron and S.G. iron castings. It is used in the induction furnace, foundry and

casting units etc. Pig Iron contains 3.5 to 4.5 percent carbon. Iron is a metallic element

whose physical properties render it an excellent material for making tools and

implements. Cast irons and pig iron contain amounts of carbon varying from 2 to 4 per

cent. The carbon here is present both as iron carbide and elemental carbon in the form

of graphite. Steel is now produced in greater quantity than any other man-made

material except concrete. The decontrol of the steel sector in 1992 has ushered in a

revolution in the creation of capacity in the industry. Moreover, with the abolition of the

freight equalisation scheme, regional concentration of demand centres has emerged,

opening up this vital core sector to smaller players in their backyard markets using the

Mini Blast Furnace methods of steel making.

Review of the Plant

Pig Iron

The Pig Iron is one stage advance of the Sponge Iron where the iron ore reduces to

the “molten metallic iron”. The iron ore (Fe2O3) is reduced to Iron (Fe) through different

chemical reactions to form molten metallic iron, which is called “PIG IRON”. The Pig

Iron is the raw material for casting and steel making units. There is huge demand for

pig iron in this region. The pig iron is used in the induction furnaces & casting unit for

the production of M.S. and Alloys and other casting jobs as per requirement.

The concept of Mini Blast Furnace is well established in China where iron is produced

through the Mini Blast Furnace just like induction furnace in India. The existing plant




is located in the state of Jharkhand and close to the area which is rich in both coal and

iron ore being the basic raw materials for manufacture of Pig Iron. Pig Iron is essential

raw material for the induction furnaces. There is a rapid growth of steel industry in the

state. The company is to take advantage of the growing market trend in respect to

demand of finished steel and hence demand for Pig iron is expected to increase day

by day.

This plant has contributed to improve the socio-economic conditions of the region by

raising the gross economic output of the area. The enterprise has also contributed

through additional avenues of employment and improved infrastructural facilities and

living standards in terms of housing, water supply, medical facilities, transport, schools

etc.

Hard Coke Plant (facility exist but non-operational)

Hard coke is carbonized coking coal in deficient air and is a very good fuel for

manufacturing pig iron through mini blast furnace route. Besides the imported Prime

Coking Coal, suitably designed fast coking beehive coke ovens can successfully

carbonise even the inferior coking coals which fail to produce satisfactory coke in by-

product coke ovens. The plant was established due to availability of both imported

Prime Coking Coal and indigenous inferior coking coal. The capital investment of the

beehive coke oven plant is only about one-tenth of that for a by-product coke oven

plant of same capacity. Beehive coke ovens can be installed as small scale industrial

units generating considerable employment opportunities. Coke making through non-

recovery technology (beehive) due to its inherent features of carbonisation at negative

pressure and complete burning of all hydrocarbons with large excess air has got the

distinct advantages over conventional coke ovens in respect of pollution control.

Factors taken into consideration while selecting the site earlier:

➢ Availability of land, present land use / conditions & geography

➢ Communication facility for procurement of raw materials & supply of finished

goods.

➢ Availability of resources for such project.

➢ Overall impact on environment

➢ Socio – economic background

➢ Other infrastructural facilities




Land and Plant Lay Out

The Company had acquired land measuring 6.93 acres at Village Mohanpur, District:

Giridih which is bounded and developed for this plant. The vicinity of the plant unit is

occupied by very thin human habitation, but some industries like Steel, Refractory,

Coke etc. are present in the vicinity. The general layout of the plant had been

developed keeping in the view the following factors:

❖ Uninterrupted flow of materials in accordance with the technological

requirements.

❖ Contours and gradient of the site

❖ Optimum lead for transport of materials and for service lines

❖ Predominant wind direction

❖ Logistic approach in location of technological units as well as service facilities

❖ Safety clearances & statutory provisions

Topography and Drainage

The topography of the site is flat. Ushri River flows from north-west to south-east on

the eastern part of the site. It is a perennial water source of the area and also the sink

for industrial and domestic waste water from the area. A large number of ponds,

reservoirs are present in the area. Number of dug-wells and tube wells are present in

the 10-km study area. The important rock types are sandstones, shales, traps and

coal seams. The entire region is a plain area having a gentle slope from the south to

the north

LAND USE BREAKUP

The total area of land in the company possession for the project is about 6.93 acres

at Village: Mohanpur, Giridih, Jharkhand

Land Use Breakup

SL No Type of use Area (in acres)

1. Plant Area 1.39

2. Stock yards 0.94

3. Green belt 2.90

4. Road & Infrastructure 0.60

5. Open Land 1.10

TOTAL LAND AREA 6.93




SIZE OR MAGNITUDE OF OPERATION

PRODUCTION CAPACITY

The existing plant has one 65 M3 blast furnace, which produces 120 MT per day

(annual capacity 39,600 TPA) pig iron and a Hard Coke Plant of 100 TPD (annual

capacity 33,000 TPA) which is currently shut down due to technical reason.

QUANTITY OF INCOMING MATERIALS FOR PIG IRON (120 TPD – 39600 TPA)

SL

No

ITEM Per MT of

Product

MT / DAY MT / YEAR

1. IRON ORE 1.55 186.00 61380

2. COKE 0.75 90.00 29700

3. DOLOMITE 0.095 11.40 3762

4. LIME STONE 0.10 12.00 3960

5. QUARTZ 0.045 5.40 1782

GENERAL AVERAGE 2.54 304.80 100584

SOURCE OF RAW MATERIALS

SL No ITEM SOURCE

1 IRON ORE Barajamda & Barbil area of Jharkhand & Orissa

2 COKE Purchase from market

3 DOLOMITE Jharkhand / Bhutan

4 LIME STONE Katni (MP), Sonebhadra (UP)

5 QUARTZ Jharkhand

RESOURCE RECOVERY OF INPUT MATERIALS

SL

No

ITEM

Per MT of

Product

Utility as

Finished

Product

Unutilized

output

as slag

Unutilized

output with

gaseous

emission

1. Iron Ore 1.55 0.94 0.18 0.43

2. Coke 0.75 0.03 0.12 0.60

3. Dolomite 0.095 0.01 0.065 0.02

4. Limestone 0.10 0.01 0.07 0.02

5. Quartz 0.045 0.01 0.025 0.01

General

Average

2.54 1.00 0.46 1.09




The operational efficiency and quality of product are mainly dependent upon the

quality and size of raw material, hence utmost care is taken in procuring and storage

of the raw materials.

PROJECT COST

The total cost of the project as estimated at Rs. 14.00 Crs at the time of plant

implementation. It includes cost of land, building & sheds, plant & machinery, electrical

and other fixed investment

MANPOWER REQUIREMENT

The total man power employed for the project has been about 90, inclusive of

managerial, supervisory, administrative, skilled /unskilled workers, and security staff.

POWER

The power requirement for the unit is 525 KVA. The power is currently sourced through

DVC.

WATER

The existing plant is operated based on ground water source. The circulating water

requirement of the plant is 23-25 m3 .Total fresh makeup water is required at 240

m3/day (10 m3/hr).

Plant Section Make up Water Quantity:

Blast furnace 5 m3/hr

Slag granulation 1.5 m3/hr

Hard coke plant quenching 1.5 m3/hr (currently not in operation)

Domestic use 0.5 m3/hr

Water sprinkling system 0.5 m3/hr

Pollution control system 1.0 m3/hr

total make up requirement 10.0 m3/hr (240 m3/day)

TRANSPORTATION SYSTEM

All the materials required for operation of the plant is transported through road. State

Highway is at a distance of nearly 0.5 Km from the site, which connects Giridih to

Dhanbad and NH 2. The plant site has also good connectivity with other major cities.

Hence transportation of materials by road is feasible as the existing network of roads

is adequate to accommodate the traffic due to the project. Buses are provided for

manpower logistic. Most of the workers are local and located in the nearby villages

and town on lease for accommodating outside manpower. Other major industrial towns




like Asansol, Raniganj, Durgapur of West Bengal, Jamshedpur of Jharkhand, Rourkela

of Orissa are within an approachable distance from the Plant site.

TECHNOLOGY AND PROCESS DESCRIPTION

The project envisaged manufacture of Pig Iron by Mini Blast Furnace technology.

Selection of suitable production process and the capacity of the production units form

the nucleus around which the basic concept of a plant has been developed. While the

selection of a process takes into account factors like type of product, availability of

local raw material, process status, specific energy consumption, level of energy

required, environment and pollution etc., the capacity selection of major units would

depend on the volume of production, available unit sizes, economies of scale etc.

The basic materials used for the manufacture of pig iron are iron ore, coke, and

limestone. The coke is the reducing agent and is partly burnt as a fuel to heat the

furnace; but to reduce consumption of this expensive commodity, additional fuels,

such as pulverized coal are added to the air blast injected near the bottom of the

furnace. By doing this, coke consumption has been halved since the 1980s to an

average 500 kg (1,100 lb) per tonne of metal produced. The air reacts with the carbon

in the coke to produce carbon monoxide, which combines with the iron oxides in the

ore, reducing them to metallic iron. This is the basic chemical reaction in the blast

furnace; it has the equation Fe2O3 + 3CO = 3CO2 + 2Fe. The limestone in the furnace

charge acts as a flux to combine with the infusible silica present in the ore to form

fusible calcium silicate slag. Without the limestone, iron silicate would be formed, with

a resulting loss of metallic iron. Calcium silicate and other impurities form a slag that

floats on top of the molten metal at the bottom of the furnace. Ordinary pig iron as

produced by blast furnaces has the composition: iron, about 92 per cent; carbon, 3 to

4 per cent; silicon, 0.5 to 3 per cent; manganese, 0.25 to 2.5 percent; phosphorus,

0.04 to 2 per cent; with a trace of sulphur. A typical blast furnace consists of a

cylindrical steel shell lined with a refractory, which is any non-metallic substance such

as firebrick. The shell is tapered at the top and at the bottom and is widest at a point

about one quarter of the distance from the bottom. The lower portion of the furnace,

called the bosh, is equipped with several tubular openings or tuyères through which

the air blast is forced. Near the bottom of the bosh is a hole through which the molten

pig iron flows when the furnace is tapped, and above this hole, but below the tuyeres,

is another hole for draining the slag. The top of the furnace, which is about 27 m(90 ft)

in height, contains vents for the escaping gases, which are collected, dedusted, and

then blended with natural gas for use as a fuel within the plant. The blast furnace top

is fitted with a charging device such as a pair of round hoppers closed with bell-shaped

valves through which the charge is introduced into the furnace, or a movable chute

that is continuously adjusted to direct the charge to the required spot in the top of the

furnace. The materials are brought up to the top of the furnace by conveyor or in small




dump cars or skips that are hauled up an inclined external skip hoist. Blast furnaces

operate continuously. The raw material to be fed into the furnace is divided into a

number of small charges that are introduced into the furnace at10- to 15-minute

intervals. Slag is drawn off from the top of the melt about once every 2 hours, and the

iron itself is drawn off or tapped about five times a day. An important development in

blast-furnace technology, the pressurizing of furnaces, was introduced after World War

II. By “throttling” the flow of gas from the furnace vents, the pressure within the furnace

may be built up to 1.7atmosphere or more. The pressurizing technique makes possible

better combustion of the coke and higher output of pig iron. The output of many blast

furnaces can be increased by 25 per cent in this way. Experimental installations have

also shown that the output of blast furnaces can be increased by enriching the air blast

with oxygen, a level of 2.5 to 5 per cent being common.

The process of tapping consists of knocking out a clay plug from the iron hole near the

bottom of the bosh and allowing the molten metal to flow into a clay lined runner and

then into a large, brick-lined metal container, which may be either a ladle or a rail car

capable of holding as much as 100 tonnes or more of metal. Any slag that may flow

from the furnace with the metal is skimmed off before it reaches the container. The

molten pig iron is then transported to the steel-making shop. Modern blast furnaces

are operated in conjunction with basic oxygen furnaces and occasionally an electric

arc furnace, or in a few countries the older open-hearth furnaces, as part of a single

steel-producing plant. In such plants the molten pig iron is used to charge the steel

furnaces. The molten metal from several blast furnaces may be mixed in a large mixer

vessel before it is converted to steel, to minimize any irregularities in the composition

of the individual melts.

TECHNOLOGY FOR MANUFACTURE OF HARD COKE (currently non operative)

Coking coal contributes to approximately 50% of the cost of hot metal. Therefore, it is

logical that coke quality and price needs to be kept under control in the iron and steel

industry to be competitive. The two primary variables that influence the price and

quality of BF coke are – coke making technology and raw materials used. Some of the

technological developments that have improved performance of industry are:

❖ Stamp Charging of Coal

❖ Partial Briquetting of Coal Charge (PBCC)

❖ Selective Crushing of Coals

❖ Dry Coke Quenching

Non-Recovery/ Heat Recovery Coke Production:

Non-Recovery coke plants, originally referred to as beehive ovens, have large oven

chambers. The carbonization process takes place from the top by radiant heat transfer




and from the bottom by conduction. Primary air for combustion is introduced into the

oven chamber through several ports located above the charge level in both pusher

and coke side doors of the oven. Combusted gases exit through common tunnel via a

stack which creates natural draft. Since by-products are not recovered, the process is

called Non-Recovery Coke making. The waste gas is fed into a waste heat recovery

boiler to convert excess heat into steam for power generation; hence, the process is

also called Heat Recovery Coke making.

Non-Recovery Coke Oven Technology

The Non-Recovery Coke Ovens are considered eco-friendly in comparison to

recovery type. It is less capital intensive and has short construction periods of

approximately 6 months. Main features are:

❖ Energy of carbonisation is supplied by burning the gaseous volatile products

released from the coal charge during carbonisation.

❖ Heat generated by the combustion of the volatile matter, produces high

temperature zone in the free space above the coal charge. This radiates back

into the coal charge downwards.

❖ The products of combustion are drawn through the various points in the oven

arch and passed through side wall off-take flues into a series of sole flues

located below the oven floor.

❖ Application of heat takes place from above, sides and below the charge.

Temperature at the point where burning gases are drawn into the side off take

ports is of the order of 1200 oC.

Advantages of Non-Recovery Coke Oven

❖ Low Capital cost; low operating and maintenance cost; and hence low cost per

ton of coke conversion.

❖ High coke yield and flexibility of operation; No external heating required

❖ Heat transfer is in vertical direction against horizontal as in case of by-product

or recovery type oven design

❖ Exhaust flue gas can be utilized for power generation.

❖ No effluent discharge, all volatiles are fully burnt resulting in clean flue gas with

minimal environmental impact.

❖ Ovens of non-recovery type are being operated under suction to avoid any

explosion during operation and to prevent pollution.

❖ Extensive flue system ensuring complete combustion of all hydrocarbons

leaving a clean stack gas with in permissible limit.

MANUFACTURING PROCESS - PIG IRON




The concept of Blast Furnace in India means big Blast Furnace giving capacity above

200 TPD but Mini Blast Furnace of less than 100 TPD capacity is relatively new in

India. There has been much improvement in the process in last 3 – 4 decades. The

most important are higher hot blast temperature, prepared burden like sinter and

pellets, high top pressure, slag granulation, injection of coal / gas through tuyers etc.

The project has installed a Mini Blast Furnace of much smaller size. It has only adopted

only those techniques, which are less capital oriented and provides relatively more

benefits. It is going to have higher hot blast temperature, use of lump ore and pellets,

slag granulation system etc. With the introduction of Blast Furnace, it has become

possible to manufacture iron in a continuous process. The features of the blast furnace

are as below:-

➢ An arrangement for charging material in blast furnace.

➢ An arrangement for taking out molten metal.

➢ An arrangement to blow air into the furnace.

Important points of the Mini Blast Furnace manufacturing process are:

❖ Hearth at the base which serves the purpose of crucible to store molten metal

and slag.

❖ A high shaft formed by joining two cones. The one on the lower side is known

as “Bosh” and upper one as “Stack”.

❖ A double cup and cone arrangement to close the throat of furnace.

❖ Tapping out the molten metal from one outlet in the lower portion of the

hearth. Let out for lighter slag – another “Slag notch”.

❖ Introducing Blast of air, tuyeres and

❖ Out let for gases of the Furnace.

The other important equipment’s of Blast Stoves which contains high alumina bearing

balls. The heat of the air is increased by passing through brick work generators, heated

by burning the waste gases collected from the top of the furnace. The waste gases

collected at the throat of the furnace is burnt in the stove and the products of the

combustion passes through the brick work and then to the chimney. The heat is thus

observed by the balls and by passing the blast through the stove balls in a direction

opposite to that taken by products of combustion it attains the desired temperature. At

least three stoves are required, two on gas and one on the blast in a sequence.

Advantages of hot air blast areas under:-

➢ The raw coal powder can be used through tuyeres replacing some coke.

➢ Less fuel is now required in the furnace, owing to the heat already conveying

the air.

➢ The temperature in front of the tuyeres is increased and the fusion zone or the

furnace brought lower down.

➢ The furnace works with lesser irregularity and is more easily controlled.




➢ Foundry grade pig iron can be easily produced.

In the blast furnace, the iron ore lumps and pellets are charged from top of the blast

furnace along with the Coke, Limestone & Dolomite by the help of skip car moving up

and down by the electric hoist. It keeps the furnace continuously full to the required

level by keeping a watch on the stack gauge rod. The hot air is blown inside the furnace

through the tuyeres. This air provides necessary oxygen for combustion of the coke

inside the furnace which generates carbon dioxide. This gas travels upwards, comes

across more hot coke and is reduced to the carbon monoxide which helps in

preheating and reducing iron ore in successive stages to iron (Fe). The ash of the coke

is fluxed with limestone to form slag. The slag and the molten metal accumulate in the

hearth of the blast furnace which are subsequently tapped from time to time. It is

proposed that the lag will be granulated and the same will be sold as a raw-material

for the cement plants. The gas is released from the top of the blast furnace containing

calorific value of approx. 900 kilo calories/Nm3. The gas is passed through dust catcher

and the other Gas Cleaning Systems so that it is finally clear enough to be used as a

fuel for preheating the air in the Blast Furnace. The liquid hot metal will be directed

towards the pig casting machine and it will provide the pig iron shed to the molten

metal. Finally, the Pig Casting Machine will transport the finished product at the end

of the machine. The cooling arrangement of Pig Casting Machine will convert the

molten metal into solid pig iron.

CHEMICAL REACTIONS IN THE BLAST FURNACE

Considering the chemical change taking place in the blast furnace, the conditions

under which it works must be borne in the mind. In the furnace the temperature varies

continuously from throat to the hearth. Near the throat the temperature is2000C max.

Next is the stack where the reduction takes place and the temperature is up to 8000

C. Next is the zone of slag formation with temperature from 8000C to 12000C and

finally near the hearth is the zone of fusion with a temperature of 12000C to

15000C.After charging the materials, it takes a considerable time in descending to the

lower part of the furnace. In its descent, the ore meets carbon-mono-oxide produced

from the coke at the hearth and air blast.

2C + O2 = 2 CO

Above the boshes, at a dull red heat, the reaction takes place in two stages, as under:-

Between 4000C - 7000C:Fe2O3 + CO = 2 FeO + CO2

Between 7000C - 9000C:FeO + CO = Fe + CO2

The ore is thus reduced to metallic iron. Further, in the upper zone limestone charged

as flux is reduced to lime. CaCO3 = CaO + CO2

Carbon dioxide is expelled in the upper part of the furnace and calcium oxide combines

with the gangue and produces slag consisting of calcium silicate:

CaO + SiO2 = Ca SiO3




Near the centre of the furnace where the temperature is of a bright red heat (1000 -

1200), the following reaction also takes place simultaneously:

2CO = CO2 + C

The liberated carbon is utilized for the completion of the reduction process. The norms

of consumption of raw materials differs from plant to plant depending upon the health

of the plant, technology followed, nature of important input raw materials, melting

practice extent to which fuel injection is practiced, design of plant, resources used

efficiency, type of steel manufacture etc. The requirement of raw materials differs from

one plant to another depending upon technological route followed. For example, raw

material needed for integrated steel plants differs very much from those of Electric Arc

Furnace (EAF) or Sponge Ironmaking units. The steel melting scrap in International

market is depleting. Therefore, manufacturing of sponge iron, which is a partial

substitute, is being encouraged. But all others units need Iron ore as starting materials,

irrespective of process and technology followed. Several units in private sector are

engaged in Sponge Iron and merchant Pig Iron making which is eventually used for

steel making. Therefore, it is difficult to summarize precisely the pattern of raw

materials consumption in the country. Never the less the Iron ore, manganese ore,

coal &coke, flux & refractory, etc are invariably used in Iron and Steel making. The

growth in domestic demands (plus expected level of export demand) for Iron and Steel

items leads to growth in investment in steel sector and eventually results in increased

domestic production. This eventually leads to grow in demand for inputs including raw

materials. The forecasting of demand helps industry to gear its activities for expansion

of production capacities or locate new source of supply.

MANUFACTURING PROCESS – HARD COKE

Coking is the process of heating coal in coke ovens to drive volatile matter from it.

Ovens are heated by coke-oven gas, which burns in heating flues in an oven’s side

walls. Waste gases from this combustion pass out through a stack or chimney. At

either 20- or 30-minute intervals, the flows of gas, air and waste gas are reversed to

maintain uniform temperature distribution across the wall. The design of heating

systems varies from battery to battery. Approximately 40 percent of the total coke oven

gas produced from coking is returned to the heating flues for burning after having

passed through various cleaning and coproduct recovery processes.

The process of filling the oven with coal is called charging. The actual coking process

begins with coal charging. 'Larry cars’ atop the batteries ‘take on’ coal from storage

bins and carries it to the ovens. Currently it is planned to carry the coal manually to

the oven. The coal is dropped through four charging holes in the top of an oven.

Charging-hole lids, taken off before charging, are then replaced. After nearly all the

coal has been dropped into an oven, a pusher machine extends a large steel ram to




level the coal within the oven to a height that provides a space above the bed of coal

to allow for the collection of gases emitted during the coking process. The gases driven

from the coal during coking are carried away from the oven through refractory- lined

standpipes or ascension pipes. refractory is a special type of brick. Pipes from each

oven are connected to a 'collecting main,' which runs the length of a battery, and which

carries the gases and waste ammonia liquor to the coal chemical processing facilities.

During a charge, steam aspirators located in gas off take pipes are turned on to

maintain negative pressure in the oven chamber and thus contain charging emissions.

After charging, a worker turns off the steam aspirators, replaces the charging lids and

seals them. These designs plus careful work practices minimize emissions. Once

charged, coal is allowed to 'coke' for from, for example, from 24 to 36 hours depending

on the battery and the way it is operated. Times may vary even wider depending on

the battery. The coking time can be changed depending on production requirements.

When coking is finished, the oven is dampened from the collecting main and the oven

doors are removed. A coke guide on the coke side directs the coke across a bench

and into a 'quench car. ‘A quench car is equipped with emission control devices that

spray water over the hot coke to suppress release of particulate emissions.

Preparing Coke for Use

After quenching, the temperature of coke is about 300 0F to 400 0F. The quench car

dumps the coke onto a coke wharf, which feeds the coke onto conveyer belts that

transport it to a coke screening station. The screening station is a processing point

that either diverts the coke to a truck ‘load-out' bin or sends it to be separated

according to size. Th load-out bin holds the coke for dump trucks to transport it to

storage piles. Coke is fed onto a single deck scalping screen where large pieces of

coke are separated for crushing before re-joining the smaller coke for screening.




CHAPTER-3: ENVIRONMENTAL MANAGEMENT IN THE PLANT

Types and Major Sources of Pollution

Proposed

production

facilities

Process

operation

Pollutants

released

Type of

environmental

pollution

Mitigation

adopted

Raw Material

Handling

Unloading,

Stocking

Dust

Air Pollution Water

suppression

Raw Material

Feeding

Feeding RM in

stock Bin of

MBF & Hard

Coke Ovens

Dust Air Pollution

Fugitive

Emission

Control system

Production

Process

Melting of Raw

material,

Chemical

Reaction in

Furnace/ ovens.

Fume & Dust Air Pollution

Air Pollution

Control system

Product

Processing

Molten Metal

Discharge,

Slag Discharge

and

Hard Coke

Discharge

Solid Waste in

form of Slag

Air Pollution

Land pollution

Disposal and

Sale of Solid

Waste

Product

handling

Sizing, Storage,

Loading

& Transporting

of Product

Dust Air Pollution

Covering of

Trucks,

dumpers and

water

Suppression

a) Ambient Air Quality Management:

❖ Fume extraction system for suction of fugitive emissions from raw material

charging area and then to bag filter

❖ Water sprinkling and green belt development for maintenance of other areas

❖ Fugitive emissions can also be kept low by making pucca haul roads within the

premises and making arrangements for water spraying at all the dusty places in

the premises and during loading, unloading process.




❖ Control of Stack Emissions and Fugitive Emissions will have a direct impact on

the ambient conditions.

❖ Development of planned green belt in the industry will also control ambient

Conditions

For Pig Iron Division:

Bag filter system for control of emissions from Blast furnace and dust from charging

section of mini blast furnace

Hard Coke Division:(non operative)

Hard Coke Manufacturing Units accounts for a significant amount of Particulate and

Gaseous Emissions from the process. Components of suitable pollution control

system are:

❖ Wet Scrubber

❖ Venturi Scrubber

❖ Cyclone Separator

❖ I. D. Fan

❖ Recycle Water Cleaning System

b) Waste Water Management

Water requirement is only for cooling purpose. There would be no discharge of any

effluent to the outside area. Hence at present there appears no requirement for any

Effluent treatment plant. Domestic discharge from canteens and toilets must be

channelled through proper sewage channels and soak pits. Should any situation arise

for discharge for liquid effluents, necessary treatment will be undertaken.

c) Solid Waste

Solid wastes generated in the plant are non-hazardous in nature. Slag from MBF will

be granulated and sold to cement manufacturing plant. Dust from APC system is used

for land filling. Waste from hard coke unit is usable by briquette manufacturers.




Budget for Peripheral Development CSR (Next 5 Years)

SL No

Programme Villages Amount

(Rs. In Lacs)

1

Education: - Supply of study materials construction/

extension of village school buildings, financial aid to

village schools

3.75

2

Health & Hygiene: - One new ambulance (higher

capacity); mobile health camps, free supply of medicine,

insecticides, etc.

4.25

3

Promotion of cultural and social welfare activities: -

Construction of community hall, extension of village club,

supply of furniture financial aid to encourage local cultural

heritage, regular film shows

2.55

4

Training to villages through self-help group: -

Tailoring, knitting, papad, pickle making etc for women

4.10

TOTAL Mohanpur & Tirukdiha 14.65

CONCLUSION

On the basis of the overall results of the present impact assessment the following

conclusions are drawn:

❖ The project is not going to cause any damage to the existing agricultural situation.

Instead, it is likely to provide the farmers with on-farm income.

❖ The project has strong positive effect on average consumption in the study area,

and is likely to increase average income through multiplier effect.

❖ The project has very strong positive employment and income effects, both direct

as well as indirect.

❖ There is a possibility of increase in industrial development in the vicinity. This is

likely to bring more skill diversification among local people.

❖ The project is going to have positive impact on health care and occupational safety.

❖ The project will have positive impact on educational status of people of the study

area.

❖ Overall community development is envisaged due to this project.




Photograph of Greenbelt surrounding Plant




Photograph of on-line Stack Monitoring connected to JSPCB through Server




Photograph of dust suppression through water Sprinkler




CSR ACTIVITY IN BLIND SCHOOL DISTRIBUTION OF BOOKS AND CLOATHS




ENVIRONMENTAL MONITORING REPORT

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