th to, director & member secretary...

Date: 13th October, 2018 TO, DIRECTOR & MEMBER SECRETARY (INDUSTRY-I) MINISTRY OF ENVIRONMENT, FOREST & CLIMATE CHANGE, GOVT. OF INDIA, INDIRA PARYAVARAN BHAWAN, ALIGANJ, JORBAGH ROAD, NEW DELHI - 110003

Subject: Additional Document Submission (ADS) for getting Environmental Clearance

of Proposed Expansion of existing Steel Plant by installation of Sponge Iron

Plant with 2x200 TPD DRI Kilns, 2x15 T + 2x20 T Induction Furnaces, 400 TPD

Rolling Mill and 8 MW capacity WHRB based Captive Power Plant at Jamuria,

Mouza Ikra, Jamuria Industrial Estate, Dist. Paschim Burdwan in West Bengal

Sir, This has reference to the 36th meeting of Reconstituted Expert Appraisal Committee

(Industry-1) of Ministry of Environment, Forest and Climate Change (MoEF&CC), Govt.

of India dated 9th October 2018. The ministry has raised the Additional Document

Submission (ADS) against our proposal which states that “After detailed

deliberations, the Committee deferred the consideration of the proposal and

asked the project proponent to submit revised unit configuration details of

induction furnaces along with revised Form-I and pre-feasibility Report” for further

consideration of our proposal for the appraisal to grant Terms of Reference (TOR).

As advised, we are submitting herewith revised Form-I & Pre-feasibility Report based on

the revised of project configuration.

We hope this will serve your purpose. We hereby request you to take the necessary action so that an early Environmental Clearance could be issued for our proposed expansion project. Thanking you, Yours faithfully, for Calstar Sponge Limited

Vikas Agarwal (Director) Enclo: Revised Form-I & Pre-feasibility Report.

at Jamuria, Mouza Ikra, Jamuria Industrial Estate,

Dist. Burdwan, West Bengal

Project Proponent

Calstar Sponge Limited18, R. N. Mukherjee Road, Kolkata-700 001

forProposed Expansion of existing Steel Plant by

installation of Sponge Iron Plant with 2x200

TPD DRI Kilns, 2x15 T + 2x20 T Induction

Furnaces, 400 TPD Rolling Mill & 8 MW

capacity WHRB based Captive Power Plant

SUBMITTED TO

MINISTRY OF ENVIRONMENT, FOREST &

CLIMATE CHANGE, GOVT. OF INDIA

M/s CALSTAR SPONGE LTD.

Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill & Captive Power Plant at Jamuria, Mouza Ikra,

Jamuria Industrial Estate, Dist. Burdwan, West Bengal FORM 1

1

FORM-1

(I) Basic Information:

Sl. No Item Details

1 Name of the project/s: Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant with 2x200 TPD DRI Kilns, 2x15 T + 2 x20 T Induction Furnaces, 400 TPD Rolling Mill & 8 MW capacity WHRB based Captive Power Plant.

2 S. No. in the schedule Item 3(a) & 1(d), Category A of the Schedule of the EIA Notification 2006.

3. Proposed capacity/area/length/tonnage to be handled/command area/lease area/number of Wells to be drilled.

The units/capacities for which Environmental clearance has been accorded from SEIAA, West Bengal & MoEF&CC, the existing unit in operation, the units which are under implementation / to be implemented, the proposed units are presented below,

Unit

Existing

Unit under

Operation

as per NOC

dated

21.02.2007

Units under implementation / to be Implemented

Proposed

Units

Capacity

Total Units

Capacity Product

As per EC

obtained from

SEIAA, West

Bengal dated

07.08.2009 &

03.02.2010

As per EC

obtained

from

MoEF&CC,

New Delhi

dated

20.05.2011

Sponge

Iron Plant 2x100 TPD

(72,000 TPA) -

2x100 TPD (60,000 TPA)

(Under

Construction)

2x200 TPD

(1,20,000

TPA)

4x100 TPD + 2x200 TPD

(2,52,000

TPA)

Sponge

Iron

SMS -

Induction

Furnaces

(with

matching

LRF &

CCM)

-

1x8 T (24,000 TPA)

(Being

Dropped)

-

2x15 T + 2x20 T

(2,10,000

TPA)

2x15 T + 2x20 T

(2,10,000

TPA)

Liquid

Steel

Rolling

Mill

-

Rolling Mill 1 –

240 TPD

(72,000 TPA)

-

Rolling Mill 2 - 400 TPD

(1,20,000

Rolling Mill 1 – 240 TPD


Rods,

Bars, Light

Structural




2

TPA)

(1,92,000

TPA)

Ferro

Alloy Plant

-

-

2 x 9 MVA Submerged

Arc Furnaces (30,000 TPA)

-

2 x 9 MVA Submerged


Ferro

Manganes

e & Silico

Manganes

e

Captive

Power

Plant

-

9 MW - Under Construction

(4 MW WHRB

based & 5 MW

AFBC based)


(4 MW WHRB

based & 4

MW AFBC

based)

8 MW

(WHRB

based)

25 MW

(16 MW

WHRB

based & 9

MW AFBC

based)

Power

The proposed expansion project will be installed on 7.81 hectares (19.29 acres) of land

within the existing plant premises within Notified Jamuria Industrial Estate.

Total Capital Cost of the Project: Rs. 92 Crores

4. New/Expansion/Modernization Expansion

5. Existing Capacity Area etc. As mentioned in the above Table.

6. Category of Project i.e.' A' or 'B' Category “A” Project

7. Does it attract the general condition? If yes, please specify.

No

8. Does it attract the specific condition? If 'yes, please specify.

No

9. Location Latitude 23°41'41.94"N to 23°41'52.43"N and Longitude 87° 6'19.11"E to 87° 6'29.98"E.

(Above Mean Sea Level (AMSL): 122 m (400 ft))

Plot / Survey /Khasra No. Plot No. 6, 9, 10, 20, 21 J.L. No. 38 Khatian No. 1473

Village Jamuria

Tehsil Ikra

District Burdwan

State West Bengal

10. Nearest railway station/airport along with Distance in kms.

➢ Ikra Railway station – 0.7 km (approx.) from project site.

➢ NSCBI Airport, Kolkata – 180 km (approx.) from the project site.




3

11. Nearest Town, city, District Headquarters Along with distance in kms.

➢ Raniganj Town - Within 10 km in south direction w.r.t the project site.

➢ Burdwan town (Dist. H.Q) - within 92 km in south-east direction w.r.t the project site.

12. Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal Address with telephone nos. to be given)

Jamuria, P.O. Nandi, Dist-Burdwan, West Bengal

13. Name of the applicant M/s Calstar Sponge Limited

14. Registered Address M/s Calstar Sponge Limited 18, R. N. Mukherjee Road, Kolkata-700 001

15. Address for correspondence: M/s Calstar Sponge Limited 18, R. N. Mukherjee Road, Kolkata-700 001

Name Shri Vikas Agarwal

Designation (Owner/Partner/CEO) Director

Address 18, R. N. Mukherjee Road, Kolkata-700 001

Pin Code 700 001

E-mail [email protected]

Telephone No. 033-22109542 / 9543

Fax No. +91-33-2248-6987

16. Details of Alternative Sites examined, if any. Location of these sites should be shown on a topo sheet.

Not applicable as it is an existing industry.

17. Interlinked Projects No

18. Whether separate application of interlinked Project has been submitted?

NA

19. If yes, date of submission NA

20. If no, reason NA

https://maps.google.com/?q=18,R.N.Mukherjee+Road,+Kolkata-700+001&entry=gmail&source=g




mailto:[email protected]




4

21. Whether the proposal involves approval/clearance under: if yes, Details of the sameand their status to be given. (a) The Forest (Conservation) Act,

1980? (b) The Wildlife (Protection) Act, 1972 (c) The C.R.Z. Notification, 1991?

No No No

22. Whether there is any Government Order/ Policy relevant/ relating to the site?

No

23. Forest land involved (hectares) No

24. Whether there is any litigation pending against the project and /or land in which the project is propose to be set up? (a) Name of the Court (b) Case No. (c) Orders/directions of the Court, if

any and its relevance with the proposed project.

No

• Capacity corresponding to sectoral activity (such as production capacity for manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.,)




5

(II) Activity

1. Construction, operation or decommissioning of the Project involving

actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

S.No.

Information/Checklist confirmation

Yes/No

Details thereof (with approximate quantities /rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

Yes The proposed expansion project

will be installed on 7.81 hectares

(19.29 acres) of land in the

existing plant premises within

Notified Jamuria Industrial Estate.

The land is generally flat and does

not come under flood zone. Said

plot of land will be reformed

/developed from its existing land

use.

This project will be developed following a land use plan, which will be made taking into consideration relevant guidelines /stipulations of the concerned Authorities. Moreover, the planning of the project, development of green belt and other landscape on the proposed site would enhance the aesthetics of the area.

1.2 Clearance of existing land, vegetation and buildings?

Yes Site clearing and preparation activities will involve removal of scanty vegetation on the proposed plant site.

1.3 Creation of new land uses?

No -

1.4 Pre-construction investigations e.g. bore houses, soil testing?

No -

1.5 Construction works?

Yes The civil works for the construction and development of the proposed




6

expansion project include bulk earthworks; construction of factory sheds & utilities; internal roads & parking areas; drainage system; underground & overhead tanks etc.

1.6 Demolition works?

No -

1.7 Temporary sites used for construction works orhousing of construction workers?

Yes Suitable temporary accommodation for workers will be made within the project site.

1.8 Above ground buildings, structures or earthworks including linear structures, cut andfill or excavations

Yes Please refer Pre-feasibility Report.

1.9 Underground works including mining or tunneling?

No -

1.10 Reclamation works?

No -

1.11 Dredging?

No -

1.12 Offshore structures? No -

1.13 Production and manufacturing processes?

Yes Please refer Pre-feasibility Report.

1.14 Facilities for storage of goods or materials?

Yes All construction materials will be handled through site store within the project boundary.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

Yes Wastewater: The plant will be designed as a zero discharge plant as far as the process effluents are concerned. The water will be re-circulated through cooling and treatment. The entire wastewater after necessary treatment will be recycled for various purposes inside the plant. Domestic wastewater will be treated in septic tank-soak pit system.




7

Solid Waste: Dolochar from Sponge iron plant will be used in power generation. Slag from Induction Furnaces will be used for Land filling / Road Construction purpose. End cuts, scales and scraps etc. from CCM & Rolling Mill will be used in the Induction Furnaces.

1.16 Facilities for long term housing of operational workers?

No Most of the workers employed shall be from nearby villages.

1.17 New road, rail or sea traffic during construction or operation?

No The site will be developed with all infrastructure facilities and is well connected to main road way. No new road, rail or sea traffic during construction or operation.

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

No -

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in trafficmovements?

No -

1.20 New or diverted transmission lines or pipelines?

No -

1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?

No -

1.22 Stream crossings?

No -

1.23 Abstraction or transfers of water form ground or surface waters?

Yes Daily water requirement in the proposed project for industrial purpose will be around 222 m3/day and 10 m3/day for drinking and sanitary use, which will be supplied by Jamuria Municipality.

1.24 Changes in water bodies or the land surface affecting drainage or run-off?

No -

1.25 Transport of personnel or materials for Yes The plant location has proper road




8

construction, operation or decommissioning?

and rail linkages. These systems will be used for transportation of materials, equipment and personnel during construction operation phases.

1.26 Long-term dismantling or decommissioning or restoration works?

No -

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

No -

1.28 Influx of people to an area in either temporarily or permanently?

Yes The proposed project shall increase the employment potential and hence may lead to migration to surrounding villages. Manpower, to the tune of 220 persons will be required for the plant operations. Attempt will made to maximize utilization of local population during the construction activities.

1.29 Introduction of alien species?

No -

1.30 Loss of native species or genetic diversity?

No -

1.31 Any other actions?

No -

2. Use of Natural resources for construction or operation of the Project (such as

land, water, materials or energy, especially any resources which are non-renewable or in short supply):

S.No.

Information/checklist confirmation

Yes/No

Details thereof (with approximate quantities /rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

Yes The proposed expansion

project will be installed on 7.81

hectares (19.29 acres) of land

in the existing plant premises

within Notified Jamuria

Industrial Estate. The land is

generally flat and does not




9

come under flood zone.

2.2 Water (expected source & competing users) unit: KLD

Yes 232 KLD water will be required for the project which will be supplied by Jamuria Municipality.

2.3 Minerals (MT) No -

2.4 Construction material – stone, aggregates, sand / soil (expected source – MT)

Yes The construction materials such as cement, MS, sand, aggregates etc. will be sourced locally.

2.5 Forests and timber (source – MT) No -

2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes Around 35.5 MW power will be required for the proposed expansion project, which will be sourced from Captive Power Plant & rest from state Grid.

2.7 Any other natural resources (use appropriate standard units)

No -




10

3. Use, storage, transport, handling or production of substances or materials, which

could be harmful to human health or the environment or raise concerns about actual

or perceived risks to human health.

4. Production of solid wastes during construction or operation or

Decommissioning (MT/month)

S.No.


Yes/ No

Details thereof (with approximate quantities / rates, wherever possible) with source of information data

4.1 Spoil, overburden or mine wastes No -

4.2 Municipal waste (domestic and or commercial wastes)

Yes Solid waste of domestic / commercial origin that would be generated in the Plant will be disposed of suitably in consultation with the concerned Civic body.

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

No -

S.No.


Yes/No


3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

No -

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)

No -

3.3 Affect the welfare of people e.g. by changing living conditions?

No The implementation of the proposed expansion project will increase the employment potential for locals with the improvement in their living conditions.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

No -

3.5 Any other causes No -




11

4.4 Other industrial process wastes

Yes Dolochar from Sponge iron plant will be used in power generation. Slag from Induction Furnaces will be used for Land filling / Road Construction purpose. End cuts, scales and scraps etc. from CCM & Rolling Mill will be used in the Induction Furnaces.

4.5 Surplus product No -

4.6 Sewage sludge or other sludge from effluent treatment

Yes Sewage sludge will be disposed off-site in consultation with the concerned local authority.

4.7 Construction or demolition wastes No Small quantity of construction waste only would be generated and same will be reused for filling.

4.8 Redundant machinery or equipment No -

4.9 Contaminated soils or other materials No -

4.10 Agricultural wastes No -

4.11 Other solid wastes No -

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)

S. No.


Yes/No


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

No -

5.2 Emissions from production processes

Yes Electrostatic Precipitator (ESP) & Bag filter system will be installed to control the particulate emission from the process.

5.3 Emissions from materials handling including storage or transport

Yes Bag filter & dust suppression system will be installed in the raw material handling site.

5.4 Emissions from construction activities Yes Water sprinkling arrangement




12

including plant and equipment

will be provided to reduce dust during construction.

5.5 Dust or odours from handling of materials including construction materials, sewage and waste

Yes Dust suppression system will be provided. There will be no odour problem from handling of construction materials, sewage and other wastes.

5.6 Emissions from incineration of waste

No -

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

No -

5.8 Emissions from any other sources

No -

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities / rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines, ventilation plant, crushers

Yes Mainly Noise and vibration. However, all the machinery will be of highest standard of reputed make and will comply with national / international standards that take care of air and noise pollution control / vibration control.

6.2 From industrial or similar processes Yes Noise and vibration

6.3 From construction or demolition Yes Best practices will be followed during all construction and installation activities to maintain noise level within permissible limit.

6.4 From blasting or piling

Yes Traffic movement will generate sound. However, best practices will be followed to maintain noise level within 75 dB (A).

6.5 From construction or operational traffic Yes Best noise abatement




13

measures will adopted to control noise from the cooling systems.

6.6 From lighting or cooling systems No -

6.7 From any other sources No -

7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:

S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

7.1 From handling, storage, use or spillage of hazardous materials

No -

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

No No effluent or treated sewage will be let out into any water body or land. Sewage will be treated in septic tank and soak pit.

7.3 By deposition of pollutants emitted to air into the land or into water

Yes Dust will be generated to some extent due to different project activities. During the construction phase, proper care will be taken to reduce dust emission, wherever possible.

7.4 From any other sources No -

7.5 Is there a risk of long term build up of pollutants in the environment from these sources?

No -

8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment

S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data




14

8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

No -

8.2 From any other causes No -

8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, Cloud burst etc)?

Yes The area falls under Earthquake Zone-III as per Indian Standard Seismic Zoning Map.

9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data

9.1 Lead to development of supporting. facilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.:

• Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)

• housing development • extractive industries • supply industries • other

No The project will have insignificant impact on the road network around the project site. The project is not expected to have any impact of concern on the power supply system, housing and wastes management system of the area.

9.2 Lead to after-use of the site, which could havean impact on the environment

No -

9.3 Set a precedent for later developments Yes Best practices will be followed during all construction and installation activities to maintain noise level within




15

permissible limit.

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

No -

(III) Environmental Sensitivity

S.No. Areas Name/Identity Aerial distance (within 15 km.) Proposed project location boundary

1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

None -

2 Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

None -

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

None -

4 Inland, coastal, marine or underground waters

Ajay River 7.3 kms. (approx..) from the Project Site

5 State, National boundaries State Boundary between West Bengal & Jharkhand

Around 12 kms.

6 Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas

None -

7 Defense installations None -

8 Densely populated or built-up area

Raniganj Asansol Jamuria

10.0 Kms (approx). 15.5 Kms (approx). 2.5 Kms (approx).




16

9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)

▪ Ikra Hospital ▪ Kanustoria High

School ▪ Jamuria Boys

School ▪ Dhasna Shiva

Mandir

3 Kms (approx). 7 Kms (approx). 4 Kms (approx). 1 Kms (approx).

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

Ajay River

7.3 kms. (approx..) from the Project Site.

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)

None

-

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

None -

(IV) Proposed Terms of Reference for EIA studies Refer Annexure.




17

I hereby given undertaking that the data and information given in the application and enclosure are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and clearance give, if any to the project will be revoked at our risk and cost. Date: 13th October, 2018 Place: Kolkata

Vikas Agarwal Director

Address: M/s Calstar Sponge Ltd. 18, R. N. Mukherjee Road, Kolkata – 700 001 NOTE:

1. The projects involving clearance under coastal Regulation zone Notification, 1991 shall submit with the application a CRZ map duly demarcated by one of the authorized agencies, showing the project activities, w.r.t. C.R.Z (at the stage of TOR) and the recommendations of the State coastal zone Management Authority (at the stage of EC). Simultaneous action shall also be taken to obtain the requisite clearance under the provisions of the C.R.Z. Notification, 1991 for the activities to be located in the CRZ.

2. The projects to be located within 10 km of the National parks, sanctuaries,

Biosphere Reserves, Migratory corridors of wild Animals, the project proponent shall submit the map duly authenticated showing by chief wildlife warden showing these features vis-a-vis the project location and the Recommendation or comments of the Chief Wildlife Warden 'thereon (at the stage of EC)."

3. All correspondence with the Ministry of Environment &Forests including

submission of application for TOR / Environment Clearances, subsequent Clarifications, as may be required from time to time, participation in the EAC Meeting on behalf of the project proponent shall be made by the authorized signatory only. The authorized signatory should also submit a document in support of his claim of being an authorized signatory for the specific project.

Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill & Captive Power Plant at Jamuria, Mouza Ikra, Jamuria Industrial Estate, Dist. Burdwan, West Bengal by M/s Calstar Sponge Ltd.

PROPOSED TOR

ANNEXURE

PROPOSED TERMS OF REFERENCE FOR EIA STUDIES The EIA shall cover the following: Description of the proposed project:

The first task:” Description of the proposed project” forms a vital component of the

Environmental Impact Assessment (EIA) as it provides the basis for evaluating the likely

causes of Environmental Impacts.

Existing Environment and Baseline Conditions:

The base line assessment will be carried out to identify potentially sensitive and critical

areas that may be affected by the project in an area of 10 km surrounding the project

location. The critical and sensitive targets shall be plotted on land use map of project

impact area.

The existing environment and baseline conditions should be established from:

- Analysis of existing information published and secondary data.

- Consultation with relevant statutory authorities, and Field visits for

supplementation of missing gaps.

The key subject areas which the EIA shall address include Ecology and Nature

conservation. Air quality, surface and water quality in project impact area, soil quality,

cultural heritage, landscape, land use, noise quality, etc. Natural habitats like national

parks, wildlife reserves, sanctuaries, sacred grove, protected areas, forests, wetlands,

major rivers and waterways if any, shall also be identified and marked.

Assessment of Environmental Impacts:

Based upon the results from the review of existing information, field visits, site data

collection and consultation, for each component of environment (physical, biological and

socio economic) the positive, negative, direct and indirect, temporary and permanent

impacts will be evaluated along with an indication of the degree of impact, i.e., whether

the impact is significant, moderate, minor or negligible. The degree of impact shall also

be quantified by using state of the art air quality impact prediction models based on

ISCST3 algorithms.

Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill & Captive Power Plant at Jamuria, Mouza Ikra, Jamuria Industrial Estate, Dist. Burdwan, West Bengal by M/s Calstar Sponge Ltd.

PROPOSED TOR

Environment Management Plan and Mitigation Plan:

For each significant negative impact identified, specialist shall work closely with the

engineering team / technical consultants to suggest practicable measures to avoid or

mitigate the impact. The mitigation of environmental impacts will be by three

mechanisms.

• Introduction of mitigation features through the engineering practices.

• Implementation of environmental controls during construction and operation.

• Legislative control involving compliance with Indian environmental laws.

The Environmental management plan shall include an estimate of capital and recurring

costs of mitigation measures and will identify the institutional framework for

implementation.

Monitoring Plan:

Having identified the significant environmental impacts that are likely to arise as a result

of the project, the project team shall specify what monitoring is required during the

various phases of the project cycle.

The monitoring plan will identify parameters and frequency of monitoring and

responsible organization.

at Jamuria, Mouza Ikra, Jamuria Industrial Estate, Dist.

Burdwan, West Bengal

Project Proponent

Calstar Sponge Limited18, R. N. Mukherjee Road, Kolkata-700 001

forProposed Expansion of existing Steel Plant by

installation of Sponge Iron Plant with 2x200 TPD

DRI Kilns, 2x15 T + 2x20 T Induction Furnaces,

400 TPD Rolling Mill & 8 MW capacity WHRB

based Captive Power Plant

PRE-FEASIBILITY REPORT

CALSTAR SPONGE LTD.

Proposed Expansion of existing Steel Plant by installation of Sponge Iron Plant, Induction Furnaces, Rolling Mill & Captive Power Plant at Jamuria, Mouza – Ikra, Jamuria Industrial

Estate, Dist. Burdwan, West Bengal

Pre-feasibility Report Page-1

CONTENTS

1.0 INTRODUCTION

2.0 THE PROJECT

3.0 INDUSTRY SCENARIO

4.0 SITE LOCATION

5.0 PROCESS OF MANUFACTURING

5.1 Sponge Iron Plant 5.2 Induction Furnaces

5.3 Rolling Mill

5.4 Captive Power Plant

6.0 RAW MATERIALS & UTILITIES

6.1 Raw Material 6.2 Fuel 6.3 Raw Water Demand 6.4 Power

7.0 ENVIRONMENTAL ASPECTS

7.1 Steel Plant 7.2 Water Pollution Control 7.3 Solid Waste Management 7.4 Noise Pollution Control

8.0 FIRE PROTECTION SYSTEM

9.0 LAND

10.0 GREEN BELT DEVELOPMENT OBJECTIVE

11.0 RAIN WATER HARVESTING

12.0 MANPOWER REQUIREMENT

13.0 PROJECT PERIOD

14.0 ESTIMATED COST

15.0 COMMERCIAL & FINANCIAL FEASIBILITY EVALUATION

16.0 CONCLUSION

CALSTAR SPONGE LTD.




PRE-FEASIBILITY

REPORT

1.0 INTRODUCTION

M/s Calstar Sponge Ltd., a private Company, was incorporated on 1st

March, 2004, has its registered office at 18, R.N. Mukherjee Road,

Kolkata – 700001, West Bengal.

The company’s current activity involves production of Sponge Iron

(72,000 TPA by installation of 2x100 TPD DRI Kiln) at Mouza – Ikra,

Jamuria Industrial Estate, Dist. Burdwan, West Bengal.

The chronology of events and the various units for which

Environmental Clearance (EC) / validity of EC extension / Consent to

operate (CTO) was obtained by the Company for the same plant, has

been given below.

Sr.

No.

Application

Date

Date

of

Issue

Certificate

obtained

Reference

Number

Name of

Proposed

Units

Obtained from

1

10-5-2006 21-2-2007

Consent to Establish

(NOC)

Memo No. 1002-2N-175/2006(E)

dated 21.02.2007

• 2 x 100 TPD Rotary Kilns - 6000 TPM Sponge Iron (Project Cost: Rs. 17.11 Crores)

West Bengal Pollution Control Board

2

3-6-2009

7-8-2009

Environmental Clearance

(EC)

No. EN/2098/T-II-1/045/2009

• Induction Furnace (1x8 MT),

• Continuou

s Casting Machine (24000 TPA)

• Waste Heat based Captive Power Plant (4 MW)

State Level Environment

Impact Assessment Authority

(SEIAA), West Bengal

CALSTAR SPONGE LTD.




3

22-8-2009 3-2-2010


(EC)

EN/332/T-II-1/045/2009

5 MW Captive

Power Plant (AFBC Boiler

- 30 TPH)




4

15-7-2017 18-8-

2017

Extension of validity of

Environmental Clearance dated 7-8-

2009 & 3-2-2010

1782/EN/T-II-1/045/2009

As per Serial No. 2 & 3 of this Table




5

9-9-2010

20-5-

2011


(EC)

F. No. J-11011 / 655 /

2009- IA II (I) dated

20.05.2011

• DRI Kiln (2x100 TPD) – 60000 TPA Sponge Iron

• 8 MW Captive Power Plant – WHRB 4 MW + AFBC 4 MW

• Ferro Alloys (2x9 MVA) – 30000 TPA Ferro Alloys

Ministry of Environment

& Forests, Govt. of

India

6

27-03-2018

23-7-

2018

Extension of validity of


F. No. J-11011 / 655 /

2009- IA II (I) dated

20.05.2011

• DRI Kiln (2x100 TPD) – 60000 TPA Sponge Iron

• 8 MW

Captive Power Plant – WHRB 4 MW + AFBC 4 MW

• Ferro Alloys (2x9 MVA) – 30000 TPA Ferro

Ministry of Environment

& Forests, Govt. of

India

CALSTAR SPONGE LTD.




Alloys

7

- 30-

11-2017

Valid Consent to Operate

(CTO) – upto 31-7-2022

Memo No. 1974/WPBA/Red

(Bwn)/ Cont (595)/08 (Part-II)

2 x 100 TPD Rotary Kilns - 6000 TPM Sponge Iron

West Bengal Pollution Control Board

Now, the company intends to expand its activity by setting up Sponge

Iron Plant and Induction furnaces with matching LRF & CCM

including WHRB based Captive Power Plant within the premises of the

existing Steel Plant.

2.0 THE PROJECT

Encouraged by the anticipating better future market, the company has

decided to install Sponge Iron Plant (2x200 TPD DRI Kilns) and

Induction furnaces (2x15 T + 2X20 T) with matching LRF & CCM, 400

TPD Rolling Mill and 8 MW capacity WHRB based Captive Power Plant

at Jamuria, Mouza – Ikra, Jamuria Industrial Estate, Dist. Burdwan,

West Bengal.

The proposed expansion project will be installed on 7.81 hectares

(19.29 acres) of land within the existing plant premises. The land is

generally flat and does not come under flood zone. There is no human

settlement in the project site. Said plot of land has already been

earmarked as an industrial land. So, setting up of the expansion

project would not alter the current land use pattern. The existing unit

as well as units to be implemented and proposed units are presented in

Table-1.0.

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TABLE-1.0 OVERALL PROJECT SCENARIO

Unit

Existing Unit under

Operation as per NOC dated

21.02.2007

Units under implementation / to be Implemented

Proposed Units Capacity

Total Units Capacity

Product

As per EC obtained from SEIAA, West Bengal dated 07.08.2009 & 03.02.2010

As per EC obtained from MoEF&CC, New

Delhi dated 20.05.2011

Sponge Iron

Plant

2x100 TPD (72,000 TPA)

-

2x100 TPD (60,000 TPA)

(Under Construction)

2x200 TPD

(1,20,000 TPA)

4x100 TPD + 2x200 TPD

(2,52,000

TPA)

Sponge Iron

SMS - Induction Furnaces

(with matching

LRF & CCM)

-

1x8 T (24,000 TPA)

(Being Dropped)

-

2x15 T + 2x20 T

(2,10,000 TPA)

2x15 T + 2x20 T

(2,10,000

TPA)

Liquid Steel

Rolling Mill

-

Rolling Mill 1 –

240 TPD

(72,000 TPA)

-


(1,20,000 TPA)

Rolling Mill 1 – 240 TPD

Rolling Mill 2 -

640 TPD

(1,92,000 TPA)

Rods, Bars, Light

Structural

Ferro Alloy Plant

-

- 2 x 9 MVA Submerged


-

2 x 9 MVA Submerged


Ferro Manganese

& Silico Manganese

Captive Power Plant

-


(4 MW WHRB based & 5 MW AFBC based)


(4 MW WHRB based &

4 MW AFBC based)

8 MW

(WHRB based)

25 MW

(16 MW WHRB based

& 9 MW AFBC based)

Power

3.0 INDUSTRY SCENARIO

Indian steel industry plays a significant role in the country’s economic

growth. It now occupies the position of 4th largest steel producer at the

global front and struggling to become the 2nd largest producer of crude

steel in the world by 2015-16. India has taken over a central position

on the global steel map with its giant steel mills, acquisition of global

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scale capacities by players, continuous modernization and up gradation

of old plants, improving energy efficiency, and backward integration

into global raw material sources. Global steel giants from across the

world have shown interest in the industry due to its phenomenal

performance in the recent years.

Demand-Supply Gap

On a conservative estimate, the steel demand in India is expected to

touch around 90 MTPA by 2015 and around 150 MTPA by 2020. Steel

supply is, however, expected to reach only around 88 MTPA by 2015

and around 145 MTPA by 2020. While the demand for steel will

continue to grow in traditional sectors, specialized steel is also

increasingly being employed in various hi-tech engineering industries.

Globally, a relation can be observed between steel consumption and the

GDP growth rate. Overall, India, being in a high growth phase with

huge planned infrastructure development, is bound to witness

sustained growth in steel requirement in the years to come.

M/s Calstar Sponge Ltd. has drawn up a growth plan with the

objective of increasing its market share in Indian steel industry.

Keeping all these in mind, the Company has planned to set up the

proposed expansion project in a more environment friendly way.

CALSTAR SPONGE LTD.




4.0 SITE LOCATION

The proposed project will be located at J.L. No. – 38, Jamuria, Mouza –

Ikra, Jamuria Industrial Estate, P.S. – Jamuria, Dist. Burdwan, Pin –

713362 in West Bengal. Its geographical co-ordinates are Latitude

23°41'41.94"N to 23°41'52.43"N and Longitude 87° 6'19.11"E to

87°6'29.98"E with mean sea level as 400 ft. Ikhra Railway Station is

about around 0.7 km from the project site. National Highway-60 (NH-

60) and National Highway-2 (NH-2) are around 5 and 6.5 km

respectively, from the project site.

The proposed site area is well developed and has all necessary

infrastructure facilities such as motorable road upto the plant site,

close proximity to rail head, telephone facilities etc. The nearby

industrially developed towns are Raniganj, Asansol and Durgapur

which are around 9.5, 16 and 29 km respectively, from the project site.

Kolkata city is located at a distance of about 182 km from the project

site. Distance from Howrah Railway station to the project site is about

174 km. The nearest airport is Andal (Durgapur) which is about 16 km

from the project site and Netaji Subhash Chandra Bose International

Airport, Kolkata is around 180 km from the project site. Kolkata Port is

around 100 km away and Haldia Port is 209 km away from the project

site.

River Ajay is passing approximately at a distance of 7.3 kms from the

project site. There is no National Park & Reserve Forest within 10 km

radius of the project site.

CALSTAR SPONGE LTD.




Location Map & Project site on Google Map is presented in Figure – 1.0

& 2.0 respectively.

Figure – 1.0 : Location Map

J.L. No. – 38, Jamuria, Mouza – Ikra, Jamuria Industrial Estate, P.S. – Jamuria,


Latitude 23°41'41.94"N to 23°41'52.43"N and Longitude 87° 6'19.11"E to 87°6'29.98"E with

mean sea level as 400 ft. (122 m)

CALSTAR SPONGE LTD.




Figure – 2.0 : Project Site on Google Earth

J.L. No. – 38, Jamuria, Mouza – Ikra, Jamuria Industrial Estate, P.S. – Jamuria,


Latitude 23°41'41.94"N to 23°41'52.43"N and Longitude 87° 6'19.11"E to 87°6'29.98"E with mean with mean sea level as 400 ft. (122 m)

CALSTAR SPONGE LTD.




5.0 PROCESS OF MANUFACTURING

5.1 SPONGE IRON PLANT

The project proponent will install 2 nos. of Rotary Kilns having 200 TPD

capacity with rated production of 1,20,000 TPA Sponge Iron (300

working days in a year). The process employs Rotary Kiln as the main

reactor where the reduction of iron ore in the form of iron oxide is

carried out with coal as reductant. The inner of steel frame shell kiln

will be protected by refractory lining. The kiln will have a slope of 2.50

down towards the discharge end. Air blowers having dampers will be

provided on the kiln shell in different heating zones for introducing air

for combustion. Sized iron ore and coal shall be fed in to the kiln at the

feeding end with the help of weigh feeders. Due to the slope and

rotational movement of the kiln the charge will move towards the

discharge end. Temperature measurement and control shall be done

with the help of thermocouples provided in different heating zones of

the kiln. Additional coal requirement shall be met by injecting fine coal

through the discharge end of the kiln.

Kiln discharge consisting of mixture of sponge iron and dolochar,

mixture of unreduced iron, uncalcinated limestone, gangue and semi

burnt coal, will be passed on to a rotary cooler where water will be

sprayed to cool the discharge mix to about 120°C. The cooler discharge

will fall on to a hopper and taken through conveyers for screening of

fines and coarse materials and subsequently subjected to magnetic

separation where sponge iron will be separated from dolochar. The

reducing gases generated from the combustion of the coal will flow in

the counter current direction and emerge from the feed end of the kiln

which will be maintained at a positive pressure of about +5 mm water

column. The flue gases will then pass through a gravitational Dust

Settling Chamber (DSC) and then to the After Burner Chamber (ABC)

where CO will get converted to non-toxic CO2. The flue gas at about

900°C to 1000°C, will be taken to the Waste Heat Recovery Boilers

(WHRB) to utilize the waste heat content of flue gases.

Material Balance for Sponge Iron Plant

An Indicative Material Balance showing input of raw materials and the

resultant output for the Sponge Iron Plant are presented in Table-2.0.

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Table 2.0 : Material Balance for 1.0 Tonne Sponge Iron Production

INPUT QTY (T) OUTPUT QTY (T)

Iron ore 1.600 Sponge Iron 1.000

Coal 1.300 Char 0.371

Lime Stone 0.032 DSC 0.160

Gasified 1.074

Dust 0.032

Back flow 0.021

Handling 0.140

Accretion 0.080

Oversize 0.054

TOTAL 2.932 TOTAL 2.932

An Indicative coal based Sponge Iron Plant process flow diagram is presented below,

CALSTAR SPONGE LTD.




5.2 INDUCTION FURNACE

We are proposing to install 4 (four) numbers of Induction furnaces of

(2x15 T + 2x20 T) capacity for production of 2,10,000 TPA of liquid steel

(considering 300 working days in a year & 10 heats per day).

The plant will produce steel in the form of billets & TMT Bars through

IF-CCM route. Steel making will be done using induction furnaces. A

brief description of the processes is dealt with in the subsequent

paragraphs and the process flow sheet is given below.

Steel Making by Induction Furnace

The greatest advantage of the Induction Furnace is its low capital cost

compared to other types of Melting Units. Its installation is relatively

easier and its operation simpler. Among other advantages, there is very

little heat loss from the furnace as the bath is constantly covered and

there is practically no loss during its operation. The molten metal in an

Induction Furnace is circulated automatically by electromagnetic action

so that when alloy additions are made, a homogeneous product is

ensured in minimum time. The time between tap and charge, the

charging time, power delays etc. are items of utmost importance in

meeting the objective of maximum output in tones/hours at a low

operational cost. The disadvantage of the induction furnace is that the

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melting process requires usually selected scrap because major refining

is not possible.

The process for manufacturing of steel may be broadly divided into the

following stages:

i) Melting the charge mixed of steel & Iron scrap

ii) Ladle teeming practice for Casting (OR)

iii) Direct teeming practice for billet casting unladdable teeming

machine

When the furnace is switched on, the current starts flowing at a high

rate and a comparatively low voltage through the induction coils of the

furnace, producing an induced magnetic field inside the central space

of the coils where the crucible is located. The induced magnetic fluxes

thus generated throughout the packed charge in the crucible, is placed

centrally inside the induction coil.

As the magnetic fluxes generated throughout the scraps complete the

circuit, they generate an induced eddy current in the scrap. This

induced eddy current, as it flows through the highly resistive bath of

scrap, generates tremendous heat and melting starts. It is thus

apparent that the melting rate depends primarily on two things (1) the

density of magnetic fluxes and (2) compactness of the charge. The

charge mixed arrangement has already been described. The magnetic

fluxes can be controlled by varying input of power to the furnace,

especially the current and frequency.

In a medium frequency furnace, the frequency range normally varies

between 150-10 K cycles/ second. This heat is developed mainly in the

outer rim of the metal in the charge but is carried quickly to the center

by conduction. Soon a pool of molten metal forms in the bottom

causing the charging to sink. At this point any remaining charge mix is

added gradually. The eddy current, which is generated in the charge,

has other uses. It imparts a molten effect on the liquid steel, which is

thereby stirred and mixed and heated more homogeneously. This

stirring effect is inversely proportional to the frequency of the furnace

and so the furnace frequency is selected in accordance with the

purpose for which the furnace will be utilized.

CALSTAR SPONGE LTD.




The melting continues till all the charge is melted and the bath

develops a convex surface. However, as the convex surface is not

favorable for slag treatment, the power input is then naturally

decreased to flatten the convexity and to reduce the circulation rate

when refining under a reducing slag. The reduced flow of the liquid

metal accelerates the purification reactions by constantly bringing new

metal into close contact with the slag. Before the actual reduction of

steel is done, the liquid steel which might contain some trapped oxygen

is first treated with some suitable deoxidizer. When no purification is

attempted, the chief metallurgical advantages of the process

attributable to the stirring action are uniformity of the product, control

over the super heat temperature and the opportunity afforded by the

conditions of the melt to control de-oxidation through proper addition.

As soon as the charge has melted clear and de-oxidising ions have

ceased, any objectionable slag is skimmed off and the necessary

alloying elements are added. When these additives have melted and

diffused throughout the bath, the power input may be increased to

bring the temperature of metal up to the point most desirable for

pouring. The current is then turned off and the furnace is tilted for

pouring into a ladle. As soon as pouring has ceased, any slag adhering

to the wall of the crucible is scrapped out and the furnace is readied for

charging again.

As the furnace is equipped with a cover over the crucible very little

oxidation occurs during melting. Such a cover also serves to prevent

cooling by radiation from the surface heat loss and protecting the

metal. Another advantage of the induction furnace is that there is

hardly any melting loss compared to the arc furnace.

CONTINUOUS CASTING MACHINE

The molten steel from the IF is cast in a continuous casting machine to

produce billets. In some processes, the cast shape is torch cut to length

and the hot metal is transported to the rolling mill for further

processing. Other steel mills have reheat furnaces. Steel billets are

allowed to cool, and then be reheated in a furnace prior to rolling the

billets into bars or other shapes.

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The process is continuous because liquid steel is continuously poured

into a ‘bottomless’ mould at the same rate as a continuous steel casting

is extracted.

1) Before casting begins a dummy bar is used to close the bottom of

the mould.

2) A ladle of molten steel is lifted above the casting machine and a hole

in the bottom of the ladle is opened, allowing the liquid steel to pour

into the mould to form the required shape.

3) As the steel’s outer surface solidifies in the mould, the dummy bar is

slowly withdrawn through the machine, pulling the steel with it.

4) Water is sprayed along the machine to cool/solidify the steel.

5) At the end of the machine, the steel is cut to the required length by

gas torches.

5.3 ROLLING MILL-2 The company has planned to set up 2nd Rolling Mill for production of

1,20,000 TPA (400 TPD) TMT Bars as a finished product.

Hot rolling process

Re-Heating Furnace is fired daily 4 hours before start up time of Rolling

Mill. Billets, when in the heating zone, a temperature of 650°C is

achieved, which is measured through Thermo Couples. In soaking zone

a temperature of 1250°C is achieved. Some sized samples of

approximately 1.5 m to 2 m length are put in & fed in every mill. This is

already in running condition with all water circuitry on, to check the

sizes on every pass. If some minute adjustment is required it is made &

again samples are fed to confirm the size of pass in Rolls. Then 1st piece

of billet is passed through. Leader & tail ends are cut in line Rotary

Shears to final size. It is then put on cool bed manually & again size is

reconfirmed.

In the meantime charging grate helpers manually put the cold billet,

which was stacked on charging grate by (EOT) Electromagnetic Crane

from stock yard, on conveyor table. The conveyor table brings the piece

in front of the pusher present on the back side of re-heating furnace.

From here on getting the signal from ejector operator the pusher

operator pushes the piece into the furnace. In front the roughing pull

pot operator gives an electric operated signal to ejector operator for

pushing next piece and rolling of second piece starts. If rolling is going

on without hindrance which is observed upto 10 (approx.) pieces, the

process becomes continuous. On an average when 8 MM size is being

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rolled & 3 Meter billet is used. Approximately 65-70 pieces come in one

hour. Production increases for high sized sections (10 MM & above). On

cooling bed, when the quantity is collected, one piece of 48 M length is

pushed manually/ automatically on pieces conveyor. When it passes

through cold shear, it is cut into 12 M length. Workers make bundles of

these & stack these size wise for checking & dispatching.

5.4 CAPTIVE POWER PLANT

The company intends to set up a Captive Power Plant of 8 MW capacity,

based on WHR Boiler, utilizing waste heat from the proposed 2x200

TPD DRI Kilns.

Waste Heat Recovery Boiler will be installed behind the After burning

chamber (ABC) of proposed DRI kilns in bypass configuration. The flue

gases after ABC will be taken to uni-fired furnace chamber and then

flow over banks of super heater, convective evaporator and economizer

before being discharged to atmosphere through ESP, ID fan and stack.

The flue gases will pass over various heat transfer surfaces to ESP and

then finally discharged into chimney by ID fan. Condensate extraction

pumps will pump the condensate after condenser of STG to a common

deaerator. Feed water from the deaerator will be pumped to the waste

heat recovery boiler by boiler feed pump. The steam generated from the

Waste Heat Recovery boiler will drive the steam turbine.

After burning chamber (ABC) and Dust settling chamber (DSC) will be

located at the exit of DRI Plant Kilns. Part of the dust carried by the

waste gases will settle down at DSC. The DSC and ABC assembly will

be connected to the DRI Plant Kilns through refractory lined duct.

The combustibles in the waste gases are burnt in the After Burning

Chamber which will raise the waste gas temperature thus making the

waste gases free from carbon mono-oxide. Provision for spraying water

will be made to control the temperature if required. From ABC outlet

the WHRB will be connected through a refractory lined duct. An

emergency stack cap on top of ABC will be provided for diverting the

waste gases to atmosphere when WHRB is under shutdown or break

down.

The boiler will be complete with evaporator steam drum, mud drum,

bank of super heaters, economizer, attemperator, air fans, ESP,

internal piping etc. Soot blowing and super heater attemperation

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system will also be provided. Boiler will be provided with blow down

tanks (IBD, CBD etc), sample cooler.

Steam Turbine generator:

There shall be one TG of 8 MW capacity. The board description of the

steam turbine generator envisaged is indicated below:

Indicative process flow diagram of WHRB based captive power plant are

presented below.

6.0 RAW MATERIALS & UTILITIES

6.1 RAW MATERIAL

The major raw material, which will be handled consists of Sponge Iron,

Pig Iron, dolomite, Ferro Alloys, Imported coal etc. The annual

requirement of major raw materials, which will be required additionally

for the proposed project, is presented in Table-3.0.

PROCESS FLOW DIAGRAM – WASTE HEAT RECOVERY BASED

POWER PLANT

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Table-3.0

List of Raw Materials

Raw materials will be received at plant site by rail/road. All the trucks

for raw material and finished product transportation shall comply with

the applicable environmental norms.

6.2 FUEL

For meeting the requirement of Furnace oil and Light Diesel Oil of

various producing modules of the plant, adequate infrastructure in

terms of tanks, pumps, pipe lines and dispensing units have been set

up which shall be further augmented to meet the requirements of the

proposed project. The required fuel is being sourced locally from Indian

Oil Corporation.

6.3 RAW WATER DEMAND

As per an initial estimate water to the tune of 222 m3/day will be

needed for the proposed project. In addition, water around 10 m3/day

will be needed for in-plant domestic use. Thus, total 232 m3/day make

up water will be required for the proposed project.

Water will be supplied by Jamuria Municipality.

The estimated unit wise make up water requirement for the proposed

project are given below:

SL.

NO.

RAW MATERIALS

ANNUAL

REQUIREMENT

( IN TPA )

SOURCE

SPONGE IRON PLANT (2X200 TPD)

1. IRON ORE 2,30,000 ORISSA

2. IMPORTED COAL 1,87,200 SOUTH AFRICA

3. LIME STONE 4,608 MARKET

INDUCTION FURNACES (2X15 T + 2X20 T)

1. SPONGE IRON 1,86,700 IN HOUSE DRI PLANT

2. SCRAPS 30,000 IN HOUSE PLANT & MARKET

3. PIG IRON 35,000 MARKET

4. FERRO ALLOYS 1800 IN HOUSE PLANT

CALSTAR SPONGE LTD.




Sl. No.

Description Daily water Demand (in cum/day)

1. Sponge Iron Plant (2x200 TPD) 50

2.

Steel Melting Shop (Induction Furnaces (2x15 T

+ 2x20 T) + Ladle Furnaces + Continuous Billet Caster)

52

3. 400 TPD Rolling Mill-2 20

4. Captive Power Plant 100

5. Domestic 10

TOTAL 232

6.4 POWER

The estimated power requirement of the proposed unit is around 35.5

MW. The power requirement will be met from proposed captive power

plant and the rest from nearby grid of State. Unit wise power breakup

for the proposed project is as follows.

SL.

No. UNIT

POWER

CONSUMPTION (IN MW)

1. Sponge Iron Plant (2x200 TPD) 2.5

2. Steel Melting Shop (Induction Furnaces (4x15T)

+ Ladle Furnaces + Continuous Billet Caster) 28.0

3. 8 MW capacity Captive Power Plant 1.0

4. 400 TPD Rolling Mill 3.0

4. Auxiliary & other loads 1.0

TOTAL 35.5

CALSTAR SPONGE LTD.




7.0 ENVIRONMENTAL ASPECTS

This chapter covers the genesis of pollution, principal sources of

pollution, nature of pollution and proposed measures required for

meeting the prevailing statutory requirements of gaseous emissions,

waste water characteristics, noise level etc. for environmental

management purpose in connection with the proposed expansion

project.

Pollution prevention and control measures are enumerated as below:

Genesis of Pollution:

The genesis of industrial pollution can be assessed from the project

concept described in earlier paragraphs. The specific aspects, which

need to be looked into for assessing the pollution potential, are:

(i) Physical-chemical characteristics of raw materials,

(ii) Manufacturing technology involving a set of physical and chemical

conversions of raw materials and lastly,

(iii) The generation of all types of wastes, namely, gaseous, liquid and

solid having specific characteristics.

The pollutants in the form of solids, liquids and gases that are expected

to be generated from various Units of the proposed Sponge Iron Plant,

Steel Melting Shop, etc. Release of such pollutants without proper care

may affect the environment adversely. Pollution of the environment not

only adversely affects the human beings, flora and fauna but also

shortens the life of the machinery and equipment. This vital aspect,

therefore, has been taken into account while planning the plant and

equipment and adequate measures have been proposed to limit the

emission of pollutants within the stipulations of statutory norms.

However, the proposed units by and large are less polluting in nature.

7.1 AIR POLLUTION CONTROL

Sources of air pollution can be broadly divided into two groups –

process and non-process. Process emissions would be those which

would be emitted during production/operation of the plant, while non-

process emissions would be due to different material handling facilities.

The main air pollutants from process emissions would be SO2, NOx and

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to some extent PM while for non-process emission the main pollutant

would be PM.

A number of systems have been proposed for air pollution control

which will provide safe environmental conditions in the working area

and will ensure acceptable air quality in the surrounding area of the

steel plant. Different air pollution control facilities / equipments that

would be considered include dry fog dust suppression systems, dust

extraction systems, bag filters, ESP etc. Cleaned waste gases would be

discharged through tall stacks to ensure adequate dispersion and

dilution of pollutants.

Particulate emission from the stack would be governed according to the

Central Pollution Control Board Emission Regulation. Electrostatic

precipitators having efficiency of 99.89% or better will achieve the limit

of particulate emission below 30 mg/Nm3. As far as coal dust

suppression is concerned, water spraying arrangement will be provided

at suitable locations.

7.2 WATER POLLUTION CONTROL

Waste water generated from the different areas of the plant will be

treated to the desired extent in suitable treatment facilities and

recycled back to the process, as far as practicable, facilitating adequate

reuse of water in the respective recirculating systems and economizing

on the make-up water requirement. Sewage generated from toilet

blocks etc. shall be treated in septic tank-soak pit system. The water

thus collected shall be used for dust suppression at raw material

handling system, ash handling, landscaping etc. Thus, Water system

will be designed for “Zero Discharge” wherein all discharges will be

treated and reused in the plant.

The Boiler blowdown will be controlled to maintain system solids

loading within normal limits for proper water chemistry. The effluent

will have less than 100 ppm suspended solids and will be led into the

station sump mix with other station effluents to reduce temperature

and utilized for disposal of ash in slurry form.

Surface run-off will be settled in a settling basin prior to reuse/

disposal.

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7.3 SOLID WASTE MANAGEMENT

Solid wastes that will be generated from IF are slag and dust. The hot

slag generated from IF will be transferred to slag yard after cooling. IF

slag will be used for road construction and land filling purposes.

Dolochar from the existing & proposed Sponge Iron Plans will be used

in power generation.

Solid wastes that will be generated from caster are the scales. The

scales will be collected from the drain and transferred to IF for reuse.

7.4 NOISE POLLUTION CONTROL

Noise generation will be considered while selecting equipment.

Equipment would not generate noise more than 85 dB (A) at 1 m

distance. Wherever required noisy equipment will be placed on

vibration isolators or housed in a separate enclosure or surrounded by

baffles covered with noise absorbing material. As the operator would be

stationed in the control room, there will be minimum chance of

exposure to high noise levels. However personnel working in high noise

zones will be provided with personal noise protection equipments (e.g.

ear muffs, ear plugs) and their duty hours will be regulated to control

noise exposure levels.

8.0 FIRE PROTECTION SYSTEM

In addition to the yard fire hydrant system, the fire protection systems

envisaged for the plant are as follows:

- Internal fire hydrant for storied buildings to be tapped-off from

the outdoor fire water header.

- Fire detection and alarm system for electrical rooms, cable

basements/cellars, cable tunnels, selected oil/hydraulic cellars.

- Portable fire extinguishers such as CO2, foam and dry chemical

powder in all areas of the plant with fire hazard.

CALSTAR SPONGE LTD.




9.0 LAND

The proposed expansion project will be installed on 7.81 hectares

(19.29 acres) of land within the existing plant premises. The plant

layout of the proposed project is presented in Figure-3.0.

10.0 GREEN BELT DEVELOPMENT OBJECTIVE

To capture the fugitive emission, if any, from the plant and to attenuate

the noise generated from the plant machinery and to improve the

aesthetics of the plant site, a green belt will be developed within the

plant area.

The green belt is a set of rows of trees planted in such a way that they

form an effective barrier between the plant and the surrounding areas.

Prevalent wind directions shall be taken into consideration to ensure

adequate capturing of the air pollutants around the plant.

Open spaces, where tree plantation is not possible shall be covered

with shrubs and grass. The plantations shall match with the general

landscape of the area and be aesthetically pleasant. Adequate attention

will be paid to planting of trees and their maintenance and protection.

Out of the total plant area of 7.81 hectares (19.29 acres), 2.58 hectares

(6.36 acres) (33% of the total area) shall be covered under Green Belt.

11.0 RAIN WATER HARVESTING

It is proposed to achieve proper utilization of rain water by harvesting

through rain-water harvesting mechanism in the plant area. Rain

water harvesting will be done following the guidelines of the concerned

Authority.

12.0 MANPOWER REQUIREMENT

Operation and maintenance of the proposed expansion project requires

human resources in different categories like managers, engineers of

different discipline like metallurgical, mechanical, electrical,

electronics, computer, civil, structural, chemical, etc., highly skilled,

skilled and semi-skilled work force in different disciplines, commercial,

accountants and financial managers, unskilled labour force, clerical,

security personal, etc.

CALSTAR SPONGE LTD.




Factory human resources

In order to operate and maintain the plant facilities, including its

technical and general administration needs, the manpower requirement

for the proposed project has been estimated to be 220 persons.

The above estimate covers the top management, middle and junior level

executives and other supporting staff.

13.0 PROJECT PERIOD

The installation of several production units along with utilities and

services require co-operation for procurement of equipment, equipment

foundations, awarding of all contracts and supervision of all

construction jobs at plant site. The factors which are responsible for

timely implementation of the project are :

i) Arrangement of proper finance for the project.

ii) Finalization of layout of the proposed plant.

iii) Designing of utilities and services.

iv) Placement of orders for plant and machinery.

v) Arrangements for Govt. sanctions and supply of power.

vi) Recruitment of personnel.

As per an initial estimate around 36 months will be needed for

implementation of the project.

14.0 ESTIMATED COST

As per initial estimate, the cost of the project works out to around Rs.

92 Crores.

15.0 COMMERCIAL & FINANCIAL FEASIBILITY EVALUATION

The focus of proposed expansion project is cost reduction by producing

quality material as per the required specification. There will be

complete integration right from the beginning to finished products (viz.

TMT bars). The estimated cost of the project is expected to be around

Rs. 92 Crores. There will be substantial savings due to the said project

as company will also be eligible for various incentives. The company

has a good track record of implementing and commissioning capital for

the proposed project as per schedules. The total project is expected to

be commissioned over a period of 36 months in phased manner. The

benefit from the project planned will begin to be acquired from year one

only.

CALSTAR SPONGE LTD.




16.0 CONCLUSION

Here we have examined the feasibility of the expansion project from

3 angles, which is the backbone of any project to succeed -

• Environmental feasibility

• Commercial and financial feasibility and

• Pre and post project scenario in which company will operate.

The outcome shows that results are positive which indicate a positive

feasibility.

th to, director & member secretary...

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