PRE – FEASIBILITY REPORT · Rabana village approx. 0.70 Kms towards SE direction Nearest Airport...

PROJECT NAME: EXPANSION IN MANUFACTURING OF SPONGE IRON, BILLET, TMT Bars AND

CAPTIVE POWER PLANT & WHRB

PRE - FEASIBILTY REPORT

APPLICANT : M/S YAZDANI STEEL & POWER LIMITED

PRE – FEASIBILITY REPORT





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INDEX

1.1 EXECUTIVE SUMMARY .................................................................................................................... 4

1.2 SALIENT FEATURES OF THE PROJECT ........................................................................................ 5

1.3 PROPOSED PLANNING .................................................................................................................... 8

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION ............................... 9

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................ 9

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ............................................................... 9

2.3 NEED FOR THE PROJECT AND ITS PORTANCE TO THE COUNTRY AND OR REGION 10

2.4 DEMAND - SUPPLY GAP ................................................................................................................ 10

2.5 IMPORTS VS. INDIGENOUS PRODUCTION .............................................................................. 10

2.6 EXPORT POSSIBILITY ...................................................................................................................... 10

2.7 DOMESTIC/ EXPORT MARKETS .................................................................................................. 10

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ......... 11

2.8.1 DIRECT EMPLOYMENT .................................................................................................................. 11

2.8.2 INDIRECT EMPLOYMENT ............................................................................................................ 11

3.0 PROJECT DESCRIPTION ................................................................................................................. 11

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY. ..................................................................................................................................................... 11

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND

PROJECT BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES. ................ 11

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

PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN

INTOSHOULDBE HIGHLIGHTED. ............................................................................................... 12

3.4 SIZE OR MAGNITUDE OF OPERATION ..................................................................................... 12

3.5 RAW MATERIAL REQUIREMENTS MATERIAL (Quantity and Source), PRODUCT AND

MODE OF TRANSPORT ................................................................................................................... 12

3.6 PRODUCT ........................................................................................................................................... 14

3.7 SOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT. .. 15

3.8 AVAILABILITY OF WATER, ENERGY/ POWER REQUIREMENT AND SOURCE. ............... 15

3.8.1 WATER DEMAND .............................................................................................................................. 15

3.8.2 POWER DEMAND .............................................................................................................................. 15

3.8.3 MANUFACTURING PROCESS ....................................................................................................... 16

3.8.3.1 Process Description of Sponge Iron Manufacturing Unit ............................................................. 16





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3.8.3.2 Process Description of Captive Power Plant .................................................................................. 20

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR

THEIR MANAGEMENT/ DISPOSAL. ........................................................................................... 30

3.9.1 SOLID ................................................................................................................................................... 30

3.9.2 Hazardous Waste .................................................................................................................................... 31

3.9.3 WASTE WATER ................................................................................................................................. 31

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE................................................................................................ 32

4.0 SITE ANALYSIS ................................................................................................................................. 33

4.1 CONNECTIVITY ................................................................................................................................ 33

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP .............................................................. 33

4.2.1 LANDFORM ....................................................................................................................................... 33

4.2.2 LAND USE .......................................................................................................................................... 33

4.2.3 LAND OWNERSHIP ......................................................................................................................... 33

4.3 TOPOGRAPHY (ALONG WITH MAP) ......................................................................................... 33

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST,

WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM

THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL

PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES (DISTANCE

FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A

COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ........................................... 34

4.5 EXISTING INFRASTRUCTURE ....................................................................................................... 34

4.5.1 BASIC AMENITIES ............................................................................................................................ 34

4.5.2. SOIL CLASSIFICATION ................................................................................................................... 34

4.7 CLIMATE ............................................................................................................................................ 34

4.8 SOCIAL INFRASTRUCTURE AVAILABLE .................................................................................. 35

5.0 PLANNING BRIEF ............................................................................................................................ 35

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND

TRANSPORTATIONETC.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT

AUTHORITY CLASSIFICATION. ................................................................................................... 35

5.2 POPULATION PROJECTION .......................................................................................................... 36

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.) ............................. 36

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL) ................... 36

5.5 AMENITIES/ FACILITIES ............................................................................................................... 37





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6.0 PROPOSED INFRASTRUCTURE .................................................................................................... 37

6.1 INDUSTRIAL AREA (PROCESSING AREA) ................................................................................ 37

6.2 RESIDENTIAL AREA (NON PROCESSING AREA) .................................................................... 37

6.3 GREEN BELT ...................................................................................................................................... 37

6.4 SOCIAL INFRASTRUCTURE .......................................................................................................... 37

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/WATER

WAYS ETC.) ........................................................................................................................................ 38

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER) ...................... 38

6.7 SEWERAGE SYSTEM ........................................................................................................................ 38

6.8 INDUSTRIAL WASTE MANAGEMENT ....................................................................................... 38

6.9 SOLID WASTE MANAGEMENT .................................................................................................... 38

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE ................................................................... 38

7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN) ....................................................... 38

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT

AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS

LABOUR (A BRIEF OUTLINE TO BE GIVEN) ............................................................................. 38

8.0 PROJECT SCHEDULE AND COST ESTIMATES .......................................................................... 39

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

(TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN). ....................................................... 39

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT. ........................................................................................................ 39

9.0 ANALYSIS OF PROPOSAL .............................................................................................................. 39

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFITS TO

THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. ....... 39

10.0 CONCLUSION ................................................................................................................................... 42

**********************





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1.0 EXECUTIVE SUMMARY

1.1 EXECUTIVE SUMMARY

M/s Yazdani Steel & Power Ltd presently operating an integrated steel plant in

Kalinganagar Industrial Complex, Dist-Jajpur, State-Odisha. The Environmental Clearance

for this existing project was accorded by Ministry of Environment Forest and Climate

Change (MoEFCC) on 16.04.2008 in favor of M/s Dinabandu Steel & Power Ltd and later on

dated 27/10/2011 M/s Yazdani Steel & Power Ltd had taken over ownership of companies

from the M/s Dinabandu Steel & Power Ltd. CTO was obtained from State Pollution Control

Board of Odisha for production of 2 x 200 TPD Sponge Iron, IF 2 x 6 T; 2x 12 T for Billet and

Rolling Mill 4000 TPM i.e. 48,000 TPA along with CPP 10 MW (Coal based 6 MW; WHRB 4

MW) which is valid up to 31.03.2019.

M/s Yazdani Steel & Power Ltd has proposed for the expansion of Integrated steel plant

along with captive power plant at Mantira, Kalinga Nagar Growth Centre, District Jajpur,

Orissa. Total land allotted by IDCO Orissa in Kalinga Growth Centre is 170 Acres (687966

SQM). The land is notified industrial area and declared as Industrial Growth Centre by the

Govt. of Orissa. The total cost of the project is Rs. 780.64 Crores (existing cost of the project

is Rs.138.50 Crores) proposed expansion cost Rs.642.14). Followings are the details of the

existing and proposed plants and their capacities:

Sr.

No.

Units Existing

Capacity

(TPA)

Proposed

Capacity

(TPA)

Total capacity

After Expansion

(TPA)

1. DRI Kiln (Sponge Iron

Plant)

2 x 100TPD

2 x 350 TPD

2 x 100TPD 2 x 350TPD

2.

SMS – I

2 x 12 T (IF) 2 x 6 T (IF)

(Billets)

1,10,000 - 1,10,000

3.

SMS – II

4 x 25 T(IF) 1 x 25T (LRF)

(Billets)

- 2,53,500 2,53,500

4 Billet Caster 1x 2 strand 1 x 3 strand 1x 2 strand

1 x 3 strand

5. Reheating

Furnace

10 TPH 60TPH 1 x 10TPH

1 x 60TPH





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6. Rolling Mill -1

(TMT Bars)

48,000 - 48,000

7. Rolling Mill-2

(TMT Bars)

- 3,00,000 3,00,000

8. Captive Power

Plant

WHRB (4 MW)

AFBC (6 MW)

WHRB – 2 x 8 MW

CFBC-2 x 22MW

70 MW

The proposed expansion in capacity is due to increase in market demand. The proposed

expansion is coming up within existing plant area 170 Acres (687966 Sq.m). No additional

land is required for the proposed expansion. The expected capital investment for the

proposed expansion will be Rs. 642.14 Crore and the total project cost will be 780.64

Crores.

The proposed expansion is categorized under 3 (a) of Gazette Notification dated 14th

September, 2006 and its subsequent amendment. Thus, the project is “A” category project.

1.2 SALIENT FEATURES OF THE PROJECT

Particulars Details

Latitude &

Longitude

N E

200 55’ 40.88” 860 02’ 01.85”

200 55’ 52.73” 860 02’ 26.78”

200 55’ 13.72” 860 02’ 46.00”

200 55’ 22.20” 860 02’ 10.86”

Toposheet No. 73G/16, K/04, H/13, L/01

Production Capacity Sr.

No.

Units Existing

Capacity

(TPA)

Proposed

Capacity

(TPA)

Total

capacity

After

Expansion

(TPA)

1. DRI Kiln

(Sponge Iron

Plant)

2 x 100TPD

2 x 350 TPD

2 x 100TPD

2 x 350TPD

2.

SMS – I

2 x 12 T (IF)

2 x 6 T (IF)

(Billets)

1,10,000 - 1,10,000

3.

SMS – II

4 x 25 T(IF)

1 x 25T (LRF)

(Billets)

- 2,53,500 2,53,500


1 x 3 strand





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5. Reheating

Furnace


1 x 60TPH

6. Rolling Mill -1

(TMT Bars)

48,000 - 48,000

7. Rolling Mill-2

(TMT Bars)

- 3,00,000 3,00,000

8. Captive Power

Plant

WHRB (4 MW)

AFBC (6 MW)

WHRB – 2 x 8

MW

CFBC-2 x 22MW

70 MW

Estimated project cost Project Cost Amount (In Cr.)

Existing 138.50

Proposed 642.14

Total 780.64

Man Power Existing – 519 ; Proposed 509; Total – 1028(Approx.)

Elevation Highest – 52 AMSL; Lowest – 40 AMSL.

Land use Industrial Land

Nearest Habitation/

Town

Rabana village approx. 0.70 Kms towards SE direction

Nearest Airport Biji Patnaik Airport Bhubaneshwar approx. 78.50 Kms towards SSW direction

Nearest Highway S. No. Particulars Distance (Km) Direction

(From Project Boundary)

1 NH-200 2.70 SW

NH-215 9.23 ENE

SH-20 4.50 N

MDR 1.10 S

Source: All distances are taken with respect to Google Earth.

Nearest railway track

from project boundary

Jakhapura Junction approx. 2.5 Kms towards SE direction

Power supply

Phase Demand (MW) Expected Source

Operational 8 MW (Existing)

48 MW (Proposed)

58 MW (Total)

Existing & proposed CPP

Nearest Telephone Rabana village approx. 0.70 Kms towards SE direction

Nearest Dispensary and

Govt. Hospital

PHC at Rabana village approx. 0.70 Kms towards SE direction and Hospital facilities at

Jakhapura approx. 3.40 Kms towards SE direction.

Primary education facilities available at village Rabana approx. 0.70 Kms towards SE direction

and higher education facilities available Jakhapura approx. 3.40 Kms towards SE direction and

Jajpur approx. 37 Kms towards SE direction.

Educational facility

Water demand and

supply

S. No. Particulars Water Demand (KLD)

Existing Proposed Total

1. Industrial





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DRI 480 360 840

IF 372 1428 1800

Billet caster 228 876 1104

Rolling Mil - 1560 1560

Power Plant 2088 4488 6576

2. Domestic 36 50 86

3. Plantation and

other purposes

275* (-101*) 174*

Total 3204 8762 (8002 fresh +

760 recycled)

11966(Daily fresh water

11206+ 760Recycled)

Source: - Water from IDCO water supply system.

• Treated water from STP and ETP will be utilized for greenbelt development

Nearest tourist places None within the study area.

Defense installations None within the study area.

Archeological Features None within the study area.

Ecological sensitive

zones

None within the study area.

Nearest Forests S. No. Particulars Distance (Km) Direction


1. Cangadi PF 8.0 NE

2. Ragarhi PF 14.5 NE

3. Sunajhari PF 7.0 NW

4. Balibo RF 13.0 WSW

5. Balipashi 15.0 SW

(Source: All distances are taken with respect to Google Earth.

Nearest streams/

rivers/ water bodies

(from project boundary)

S. No. Particulars Distance (Km) Direction


Water Bodies

1. Brahmani River 4.30 S

2. Gonda Nadi 7.50 ENE

3. Bhabadei Pond 13.10 SE

4. Ara Pond 14.50 SSE

5. Dhaneshwar Pond 13.60 E

6. Hospital pond 15.0 ENE

7. Seksan Pond 14.70 ENE

8. Maszid Pond 14.40 E

9. School Pond 14.0 E

10. Batira Pond 14.20 E

11. Barada Pond 13.0 E

12. Nua Gadiaa Pond 13.30 NE





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(Source: All distances are taken with respect to Google Earth.

Seismic zone As per the 2002 Bureau of Indian Standards (BIS) seismic zone map of India, categorized as

“moderate risk zone” Zone-III.

1.3 PROPOSED PLANNING

Company : M/s Yazdani Steel & Power Limited

Project Cost : Existing – 138.50 Cr; Proposed-642.14 Cr, Total-780.64 Cr

Production : As given below:-

Sr.

No.

Units Existing

Capacity

(TPA)

Proposed

Capacity

(TPA)

Total capacity

After Expansion

(TPA)

1. DRI Kiln

(Sponge Iron Plant)

2 x 100TPD

2 x 350 TPD

2 x 100TPD

2 x 350TPD

2.

SMS – I 2 x 12 T (IF)

2 x 6 T (IF)

(Billets)

1,10,000 -

1,10,000

3.

SMS – II

4 x 25 T(IF) 1 x 25T

(LRF) (Billets)

- 2,53,500 2,53,500


1 x 3 strand

5. Reheating

Furnace


1 x 60TPH

6. Rolling Mill

-1

(TMT Bars)

48,000 - 48,000

7. Rolling Mill-2 (TMT Bars)

- 3,00,000 3,00,000

8.

Captive Power

Plant

WHRB (4 MW)

AFBC (6 MW)

WHRB – 2 x 8 MW

CFBC-2 x

22MW

70 MW





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Table 1: Land Use of Project Site

Sl.

No.

Land Use Area (Acre) Percentage

(%) Existing Proposed Total

1. Plant Area Office Area,

Residential Colony (All

covered area).

15.26 34.4 49.66 29.21

2. Paved Area (Road, Corridor,

Parking and Drainage).

7.15 12.81 19.96 11.74

3. Green Belt Area 51 5.5 56.5 33.24

4. Future for expansion 71.09 18.38 10.81

5. Open area 25.5 25.5 15

Total 170 100

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Yazdani Steel & Power Limited is a Public incorporated on 29 October 2003. It is classified

as Non-govt company and is registered at Registrar of Companies, Cuttack. Its authorized

share capital is Rs. 700,000,000 and its paid up capital is Rs. 416,964,416. It is involved in

Manufacture of Basic Iron & Steel.

Directors of Yazdani Steel & Power Limited are Mansur Ahmed Khan, Mohammed Yusha,

Meraj Yusha, Seraj Yusha, Sarosh Yazdani, Manoj Kumar Mahapatra, Mohammed Odud

Ansari.

Name and address of

the Applicant

M/s Yazdani Steel & Power Limited

Arun Kumar Sahu

5th Floor, "A" Wing, Fortune Tower Chandrasekharpur

Bhubaneswar - 751023.

Telephone No. No. –7381096787

Email:- [email protected],

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed expansion is for manufacturing Sponge Iron – 2x 100 TPD to 2x 100 and 2x

350 TPD; Billets – 1,10,000 to 3,63,500 TPA, TMT Bars -48,000 TPA to 3,48,000TPA; Captive





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power plant of 6 MW to 50 MW; WHRB based power plant 4MW to20 MW, respectively due

to increase in market demand.

2.3 NEED FOR THE PROJECT AND ITS PORTANCE TO THE COUNTRY AND OR

REGION

The need for the expansion unit for Sponge Iron, TMT Bars, Billet and Captive power plant

and WHRB. This is due to the rising infrastructural demand from the existing unit and to

keep its continuous supply, owing to the growth in the region. Captive Power plant will be

installed to meet the demand of electricity.

India is world's largest sponge iron producer with an annual production of about 26-28

MnT against installed capacity of 46-47 MnT. There are over 400 sponge iron units in India.

Indian sponge iron industry is highly fragmented. Top 20 producers contribute about 60-

65% of total production whereas rest contribute 35-40% of the production. Sponge iron

contributes 25% of India's total crude steel production of 90 MnT.

The production for sale of DRI or Sponge Iron has increased from 1.31 mt in 1991-92 to

14.83 mt in 2016-17 (prov). India was the largest producer of DRI in the world during the

period 2003 to 2015 and emerged as the 2nd largest global producer in 2016, based on

provisional ranking released by the World Steel Association.

2.4 DEMAND - SUPPLY GAP

In order to meet the in house demand of raw material for billets and TMT bars and also to

meet the market requirement in timely manner the proposed expansion project is

undertaken.

2.5 IMPORTS VS. INDIGENOUS PRODUCTION

There will be no import for the proposed expansion project. The machinery used is

indigenously manufactured and will be purchased. Local villagers will be employed. There

will be Indigenous production in the entire activity.

2.6 EXPORT POSSIBILITY

The product will be used 50 % in house and 50 % of the product shall be exported in the

nearby region depending on the market demand.

2.7 DOMESTIC/ EXPORT MARKETS

The end products will be sold depending on the market demand shall be exported in

domestic market.





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

2.8.1 DIRECT EMPLOYMENT

The proposed expansion project generates employment for around 509 people (after

expansion). Priority for employment is given to local persons. Following staff & workers are

proposed to be employed:-

Table 4: Manpower Details

S. No. Category No. of Persons


1. Permanent Staff 102 133 235

2. Skilled Workers 179 337 516

3. Semi-Skilled worker 59 18 77

4. Unskilled worker 179 21 200

Total 519 509 1028

2.8.2 INDIRECT EMPLOYMENT

� The vocational training camps and Technical Training of generating skilled manpower

for cement plants will be done to generate potential manpower.

� Available for the proposed & surrounding plants of the Tehsil.

� The proposed employee development and welfare activities already envisaged and

proposed by the expansion project aims to engage many people with various jobs

indirectly.

� There will be development of externalities viz. local logistics, warehousing etc. as

supporting services.

� This would create Indigenous technologies for sustainable development.

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

PROJECTS, IF ANY.

There is no interlinked or interdependent project with the proposed expansion project.

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND

PROJECT BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES.

The proposed expansion project is situated at Mantira, Kalinga Nagar Growth Centre,

District Jajpur, Orissa. The project site falls in Survey of India Toposheet No.- 73G/16, K/04,





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H/13, L/01. The geographical location with respect to boundary pillars of the proposed

expansion project are:-

Table 5: Geographical Position of the Boundary Pillars

N E

200 55’ 40.88” 860 02’ 01.85”

200 55’ 52.73” 860 02’ 26.78”

200 55’ 13.72” 860 02’ 46.00”

200 55’ 22.20” 860 02’ 10.86”

The topo map showing location of the project site is enclosed as Annexure – III.

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING

THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL

CONSIDERATIONS GIVEN INTOSHOULDBE HIGHLIGHTED.

No alternative site was examined or chosen, as the proposed expansion is coming up in

existing land area.

3.4 SIZE OR MAGNITUDE OF OPERATION

The size and magnitude of the project area is as given below:-

Table 6: Size or Magnitude

S. No. Particulars Details

1. Area (Acre) 170Acres (6,87,966 m2)

2. Production (After Expansion) Production details already

given in subsection 1.3

3.5 RAW MATERIAL REQUIREMENTS MATERIAL (Quantity and Source), PRODUCT AND

MODE OF TRANSPORT

The requirement of major raw material is given in Table 7.

Table 7: Details of Raw Material

Sr.

No

Raw Material Existing

Requirement

(TPA)

Proposed

additional

Requirement

(TPA)

Total

After

expansion

(TPA)

Source Mode of

transportation

For DRI Kilns

1 Iron ore (Calibrated

150,000 472,200 622,200 Joda Rail / Road





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2 Imported Coal 75,000 251,000 326,600 Paradeep Port

Rail / Road

3. Dolomite 5300 18000 23,400 Biramitrapur Raipur, Katni

Road

For Steel Melting Shop (Billets)

1 DRI 58,500 281,500 340,000 Captive Belt Conveyor

2 Pig Iron / Scrap

16,350 68,650 85,000 Merchants Road / Rail

3 Ferro Alloys 1400 4200 5600 Merchants Road

For Rolling Mill

1 Billets 60,800 283,900 344,700 Captive mostly

-

For CFBC/AFBC Boiler-CPP and WHRB

1 Coal – Talcher

44,000

262,000

306,000

Talcher Rail / Road

2 Char 16,000 54000 70,000 Inhouse -

Other chemicals and materials required with quantities and storage capacities

Sl.No. Before Expansion After Expansion

1 2000 TPA 10,000 TPA Diesel, fuel oil & Industrial gases

2 20 TPA 100 TPA Water treatment chemicals

Table 8 (A): Material Balance for Sponge Iron Plant

IN PUT OUT PUT

Qty / MT of Sponge Iron Qty. / MT

Sponge

Qty / MT of Sponge

Iron

Qty. / MT Sponge

Iron

Iron ore / Pellet: 1.79 Ton Sponge Iron 100% 1 Ton

Coal: Imported 0.87 Ton Coal Char 20% 0.2 Ton

Ash (Fly Ash from ESP) 0.15

Dolomite 0.06 Ton Waste solids 0.17

Air (3726 Nm3

to Kiln

Process Gas (As waste gas for

Power generation)

5.7





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Total In put 7.22

Total out put 7.22

Table 8 (B): Materials Balance for Billets (Per 100 Tons) INPUT TONS OUTPUT TONS

Sponge Iron 93 Billets 100

Pig Iron / Scrap 23 Slag 15

Ferro Alloys 4.0 Burning Loss 1.5

Other Miscellaneous Losses 3.5

Total 120 Total 120

Table 8(C): Materials Balance for TMT Bars:

IN PUT OUT PUT

Qty / 100 MT of billets, Qty Qty / 100 MT of TMT Qty

Billets : 1.03 103 TMT 100% 97

Waste fines & gases 6

Total Input 103 M T Total Output 103 M T

3.6 PRODUCT

Table 9: Details of Product

Sr.

No.

Units Existing

Capacity

(TPA)

Proposed

Capacity

(TPA)

Total capacity

After Expansion

(TPA)

1. DRI Kiln

(Sponge Iron

Plant)

2 x 100TPD

2 x 350 TPD

2 x 100TPD

2 x 350TPD

2.

SMS – I

2 x 12 T (IF)

2 x 6 T (IF)

(Billets)

1,10,000 -

1,10,000

3.

SMS – II

4 x 25 T(IF)

1 x 25T (LRF)

(Billets)

- 2,53,500 2,53,500


1 x 3 strand

5. Reheating Furnace 10 TPH 60TPH 1 x 10TPH





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1 x 60TPH

6. Rolling Mill -1

(TMT Bars)

48,000 - 48,000

7. Rolling Mill-2

(TMT Bars)

- 3,00,000 3,00,000

8. Captive Power

Plant

WHRB (4 MW)

AFBC (6 MW)

WHRB – 2 x 8 MW

CFBC-2 x 22MW 70 MW

3.7 SOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT.

The unit will utilize all the charcoal as raw material for power generation and fly ash

generated will sold to brick manufacturing unit or used as binding material for land filling.

3.8 AVAILABILITY OF WATER, ENERGY/ POWER REQUIREMENT AND SOURCE.

3.8.1 WATER DEMAND

The fresh water requirement for the proposed expansion will be 8002 KLD and the total

water demand will be 11206 KLD. The detailed breakup of the same is given below:-

Table 10: Water Demand

3.8.2 POWER DEMAND

The total power requirement for the proposed expansion is as given below:-

S. No. Particulars Water Demand (KLD)


1. Industrial

DRI 480 360 840

IF 372 1428 1800

Billet caster 228 876 1104

Rolling Mil - 1560 1560

Power Plant 2088 4488 6576

2. Domestic 36 50 86

3. Plantation and

other purposes

275* (-101*) 174*

Total 3204 8762 (8002 fresh + 760

recycled)

11966(Daily fresh water

11206+ 760Recycled)

Source: - Water from IDCO water supply system.

• Treated water from STP and ETP will be utilized for greenbelt development





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Table 11: Power Demand

3.8.3 MANUFACTURING PROCESS

3.8.3.1 Process Description of Sponge Iron Manufacturing Unit

ROTARY KILN

Existing plant has 2 x 100TPD DRI Modules that shall be kept running. In addition, 2 lines of

Direct Reduction (DR) Plant having 350 TPD modules shall be added.

The Direct Reduction Plant will be based on rotary kiln technology using non-coking coal as the

fuel and reductant. The plant will have a 4.2 m diameter ported rotary kiln of 80 m length with

related systems required for off gas treatment essential for waste heat power generation and

subsequent release to atmosphere.

Major Plant Facilities

Major plant facilities for the sponge iron plants will be as follows:

Day Bins

Rotary kiln and cooler

Offgas system including waste heat power generation

Product processing facilities and product storage bins.

The process of the production of sponge iron consists of the reduction of Pellets with solid

carbonaceous material (coal/coke/lignite) in a rotary kiln at high temperature, cooling to room

temperature in the rotary cooler with indirect water-cooling system, screening and magnetic

separation of the product. Sponge iron, being magnetic, gets attracted and separated from the

non-magnetic char.

In the process for the production of sponge iron, raw materials (pellets, Sponge Iron, feed coal

and dolomite) are fed to the rotary kiln through feed tube in a pre-determined ratio by

electronic weighing equipment. Rotary kiln is generally of 4.2 mts in diameter and 80 Mts. long

and inclined at 2.5% of its length . It is internally lined with refractory of 300 mm thick. It is

rotated by an AC variable speed motor at a steeples variable speed ranging from 0.2 to 1.0 rpm.

Due to inclination and rotary motion of the kiln, the material moves from the feed’s end of the

kiln to the discharge end in approximately 5.5 hrs (Tendency time). Fine coal is blown counter

currently from the discharge end of the kiln to maintain required temperature and carbon

concentration in the bed. Kiln has seven shells, air fans mounted on the top which blow air in

the respective zones to maintain the required temperature profile. Material and hot gasses

Phase Demand (MW) Expected Source

Operational 10 MW (Existing)

48MW (Proposed)

58MW (Total)

Existing & proposed CPP





17 | P a g e

move in the counter current direction and as a result, pellets gets pre-heated and gradually

reduced by the time it reaches discharge end.

Kiln is divided into two zones namely pre-heating zone and reduction zone. The pre-heating

zone is normally 30 per cent of the total length of the kiln and rest is taken as reduction zone.

Material gets heated to the reduction temperature in pre-heating zone up to 200°C, iron ore,

coal and dolomite gets dried and all the moisture is vapourised. Upto 800°C, Iron Ore lumps or

Pellets gets roasted and any carbonates in it get calcinated. In the coal, volatile matter starts

getting released. Limestone also gets calcinated and becomes active. Iron Ore lumps or Pellets,

which are in the form of hematite, gets reduced to magnetite. Afterwards, materials enter to the

reduction zone where the magnetite is reduced to wustite and then to metallic iron.

Coal contains sulphur. During the decomposition of coal, sulphur is released in the form of Iron

sulphide. Iron sulphide (FeS) has deleterious effect in the steel making and has to be

removed. Hence, limestone is used to prevent the sulphur pick up by sponge iron. All the above

reactions are possible only in the presence of CO. Therefore, generation of CO is most important

reaction, which is called as ‘Bouduard reaction’. This reaction is highly endothermic which is

also reversible. Conditions favorable for the forward reaction i.e. generation of CO, is higher

temperature higher the production of CO. Concentration of the reactants has to be high so that

the forward reaction occurs. Low pressure also favors CO generation.

Oxygen required for the burning of these combustibles is supplied from the air tubes and/or

ports placed along the length of kiln. By controlled combustion, temperature in various zones is

maintained so that the reduction is proper and to required degree. Reduction of iron ore is topo-

chemical i.e. reduction proceeds from the surface to core. Iron ore on partial reduction has all

the different stages of reduction.

Hot material, after reduction is complete, is transferred to the rotary cooler via transfer chute.

The rotary cooler is 1.8 Mts. in diameter and 30 Mts. long made up of Mild Steel shell. It is also

inclined at 2.5% approximately and rotates at variable speed from 0.2- 1.2 rpm. It is driven by

an AC variable speed motor. Water is sprayed on the top of the shell, which cools the material

inside the cooler indirectly. Heat from the material is extracted by the shell. In order to increase

the surface area for the heat extraction fins are welded inside. Complete shell is covered by thin

layer of water. Heat is transferred from the shell to the water by convection. By this, the

material gets cooled to 800C and is discharged on the belt conveyor by double pendulum valve.

The double pendulum valve acts as the seal for the prevention of the atmospheric air into kiln

cooler system.

The total kiln cooler system is kept under positive pressure about 0.3-0.5 mbar. This prevents

the atmospheric air from getting into the system. The kiln has to be always operated on positive

pressure, as any leakage into the system will cause the re-oxidation of the sponge iron there by

causing the drop in the quality of the product.

The material after the discharge from the cooler is dropped on to the cooler discharge conveyor.

A diversion chute is provided at head end of this conveyor for diversion of the material in case

of break down in the production separation. The material is then sent to product separation





18 | P a g e

system. In product separation system consisting of double deck screen, material is screened to

0-15 mm size fractions. Oversize i.e. +20 mm obtained is small quantity so it is taken on the

floor or diverted to the sponge iron bin. The 0-3mm size fraction, called as fines, are fed to a

drum type magnetic Concentrator where the magnetic sponge iron fines and the non-magnetic

dolochar separated and fed to the respective bins through the chutes and conveyor. The coarser

fraction is similarly separated by another magnetic separator and fed to respective bins. This

magnetic fraction is called the sponge iron lumps and the non- magnetic as char which is the

unburned coal. This char can be recycled depending on the quality obtained after processing.

The gasses, which flow in the counter current direction of the material, go to the dust-settling

chamber where the heavier particles settle down. These particles are continuously removed by

the wet scrapper system. The gasses then pass to the after burner chamber where the residual

carbon or CO is burned by the excess air available. The gasses are at high temperature and have

lot of heat energy, which can be utilized for the power generation through the waste heat

recovery boiler. The hot gas after the heat recovery boiler gets cooled to 200°C. The gases are

then scrubbed and let-off to the atmosphere through the chimney. Alternatively the hot gasses

are quenched and scrubbed to clean all the dust in it, and then let off to the atmosphere through

the stack.

Chemical reactions taking place in reduction zone is represented by following equation:

Fex Oy + CO FexOy-1 + CO2

The carbon dioxide formed is converted to carbon monoxide by means of the carbon in the

reductant in accordance with the boundary reaction:

C + CO2 2CO

Burning of small amount of carbon and excess carbon monoxide by means of outside air

supplied through tubes to provide heat for the process reactions can be shown by the following

equations:

CO + 1/2 O2 CO20

It is to be noted that a reducing and oxidizing atmosphere prevail side by side in the rotary kiln.

Within the material charge, it is reducing atmosphere accompanied with endothermic reaction

while in the free board above are the oxidizing conditions with the exothermic reactions.

The separation of the two atmospheres is ensured by the pressure generated by CO emerging

from the charge into the kiln free board. This avoids re-oxidation of the reduced particles at the

charge surface.





19 | P a g e

Flow chart for the sponge iron manufacturing process

Raw Material Feeding At

Ground Hopper

Coal Iron Ore

Crushing

Over Size Over Size

Screening Screening

Coal Bin Iron Ore Bin Dolomite Bin

Setting up of Production of Mixed Raw

Materials for Kiln Feed

Processed in Rotary Kiln at 10750C with

Air Control

Indirect Cooling in Rotary

Cooler with Water Spray

Screening of Mixed end Products

(Sponge Iron and un burnt Coal)

Sponge Iron Lumps + Char Sponge Iron Fines + Dolo Char

Drum Type Magnetic

Separator

Drum Type Magnetic

Separator

Sponge Iron

Lumps Bin

Char Bin Fines Bin Dolo Char Bin





20 | P a g e

3.8.3.2 Process Description of Captive Power Plant

Operation of the Plant

Each waste heat recovery boilers will generate around 35 TPH of steam with the outlet

parameters of 95 ata (g) 5050C., while taking in the feed water at 165 Deg.C from the HP heater.

The entire waste gas from the sponge iron kiln will be utilized in the waste heat boiler for the

steam generation.

Circulating Fluidized Bed Combustion (CFBC) / Atmospheric Fluidized Bed Combustion (AFBC)

Boiler

Fluidized bed combustion is a "Clean Technology for a better tomorrow" where technology and

economy have been interwoven harmoniously in quest of a better environment. The

environmentally friendly perspective of this technology are as follows:

At the low combustion temperature of 850°C / 900°C, no Nitrogen Oxides result from the

Nitrogen in the combustion air, with the end result of extremely low NOx emissions even with

fuels rich in Nitrogen.

Formation of SOX is essentially prevented by the addition of limestone. This is both mixed into

the fuel and blown into the combustion chamber. Due to the favourable conditions in the

fluidised bed, about 90 per cent of the resulting Sulphur Oxides can be removed.

100% char is proposed to be utilized in CFBC hence no recycling to DRI

Better Plant flexibility at partial loads of about 25 per cent and quick load changes.Low

Auxiliary Power consumption compared to other coal fired Boiler versions.

The Steam Generator would be semi-outdoor type, natural circulation, balanced draft, Single-

drum, designed for firing different grades of coal. Boiler is of bubbling fluidized bed type to

handle even high ash coal.

Capacity of AFBC in existing plant as well as CFBC in expansion coupled with adjacent WHRB

has been selected to ensure adequate margin over the requirement of turbine at 100% MCR.

CFBC would be designed to operate with "The HP heaters out of service" condition (resulting in

lower feed water temperature at Economiser inlet) and deliver Steam to meet the Turbo-

Generator requirement at 100% MCR. Economiser section of the Boiler would be non-Steaming

type. Super heater sections would be convection type and also bed super heater and designed so

as to maintain rated Steam temperature of 535°C (:i: 5°C) at super heater outlet over the control

range of 60% to 100%, MCR. Attemperator is provided at the outlet of convection super heater

for temperature control at Steam Generator outlet. The Boiler furnace and flue gas passages

would be designed for appropriate low velocities in order to minimize erosion.

Suitable balanced draft System would be provided for the Steam Generator with two (2) forced

draft and two (2) induced draft fans. Each of these fans would be capable of meeting the air

requirement at 60% Boiler MCR load. The forced draft fans would be radial type with inlet vane

control for regulation of airflow. The induced draft fans would be radial type with multi louver

damper control the regulation. The forced draft fans would control total airflow to Boiler and





21 | P a g e

the induced draft fan would control furnace draft of the Boiler through automatic control loops.

In addition to the FD fan, two (2) primary air fan of 60% capacity each shall be provided for

transportation of fuel with one working and one standby.

The Boiler would be top supported type and would be provided with all supporting Steel

platforms, galleries and stairways for easy approach and Maintenance of the Unit. Adequate

weather protection would be provided for instruments and operating personnel. Necessary

insulation along with skin casing to limit outside surface temperature to the safe level would be

provided.





22 | P a g e

Capacity MW 2 x 90TPH ie

40MW

No of Steam Generator No. 02 Nos

Superheated Steam pressure kg/cm2 (a) 95 ata (g)

Superheated Steam, temperature °C 505 0C

Feed water temperature at economizer °C 135

Flue gas temperature at AH outlet °C 140

Fuel used:

Main fuel Char & Coal

Performance fuel Char & Coal

Startup fuel Light Diesel Oil

Char produced by DRI Kilns will have an outlet as fuel to FBC Boiler. Coal and Char will be

fired as a base fuel to FBC Boiler for Steam Generation with consequent proportionate

reduction in fuel cost.

Analysis Report of Char

Characteristics Char

Carbon 40.00%

Hydrogen 0.75%

Oxygen 3.00%

Sulphur 0.30%

N2 0.74%

Ash 55%

Moisture Negligible

GCV 2700 Kcal /kg

Steam Turbine Generators and Auxiliaries

Steam Turbine

The Steam Turbine will be of condensing type. The set will be complete with Condenser, Air

Evacuation System, 2 x 100% Condensate Extraction Pumps, Generator Cooling, System,

Gland Sealing with Gland Vent Condenser, Lube Oil System, LP & HP Re-generative Feed

Heaters, etc.

Generators

Each of the 2 generators will be rated for 30 MW with 0.8 lagging Power Factor, delivering

Power at 12 KV, 3 Phase, 50 Hz Star connected in IP55 enclosure.





23 | P a g e

The Generators will be provided with brush less excitation. It shall be capable of operating in

Isolation or in parallel with the Power grid, with Voltage Variation of (+) 5% to (-) 5% and

Frequency Variation of (+) 3% to (-) 5% with Short Circuit ratio of around 0.8.

The Generator shall have class F insulation with Temperature rise limited to Class "B"

insulation and shall be designed for CACW Cooling.

All Six Terminals of the Generator shall be brought out and shorted, neutral point will be

grounded through a Resistor. Generator shall be connected through Isolated Phase Bus duct

to the 40MVA Generator Transformers which will be provided with an "On-Load" Tap

Changing Gear of :I: 10% range.

Excitation System

The Excitation System envisaged will be brush-less type. The Excitation System shall be

capable of supplying the Excitation Current of the Generator under all condition of Operation

of Load, Voltage and Power. Rated current and Voltage of the Exciter shall be at least 120%

of normal Excitation Current and at least 110% of no Load Excitation.

Voltage with maximum of 140% ceiling. The Exciter response ratio shall be greater than 1.5.

The Field Breaker and Field Suppression System will also be part of Exciter System.

Automatic high speed Thyristorised, Auto Manual AVR capable of maintaining Steady State

Terminal Voltage within :I: 0.5% of the preset Value under all Operating Conditions and

capable of smooth and continuous running over the Operating Range. The Generators shall

be provided with Temperature Detector embedded at different location, i.e. Stampings,

Stator Windings, etc.





24 | P a g e

Process flow chart of Captive Power plant

Figure: Typical Flow Diagram of Steam Based Turbo Generator Set

Steel Melt Shop

The induction melting technology and Arc furnace technology in the Global Steel Scenario

has brought a significant change in technological and revolution where it has been proved

that the steel produced out of sponge iron mixed with Cast Iron and M.S. Melting Scrap/Pig

iron coupled with electric induction furnace, medium frequency, constant power track and

arc furnace rouge has become formidable process and can offer better economics at a

relatively smaller scale operations.

The process involves the charge mix of Raw material mainly Sponge Iron 70% to 90% and

C.I.Scrap/ M.S.Scrap 15% to 30%, into molten bath with constant power track through

Solid State generator converting A.C. Power into D.C. Power and again to convert the same

into A.C. Power after changing the frequency of cycle in between 250 to 500

HZ through thyesisters (an electronic device). This converted A.C. power with a frequency

of 250 to 500 HZ is passed through capacitor Rack after achieving the de-sired voltage and





25 | P a g e

the same is passed through copper Bus Bar into Molten bath having copper coil, cooled

through water circulation, transparent the heat energy into molten bath at constant voltage

to melt the Iron and Steel at a temperature of 1550°C.

The continuous efforts made by technologists in established mini steel plants all over

India, sponge iron manufacturers and Medium Frequency Melting Induction furnace

equipment manufacturer/arc furnace manufacturers have developed the

process parameters by which considerable quantity of sponge iron are used in steel

making. This has brought a new era in steel melting technology in the country where scrap

scarcity can no more be a threat to the mini steel plants. The economy of steel

making rather introduced Induction Furnace/arc furnace to convert sponge iron and scrap

into steel where better productivity could be attained with proportionately lower scale.

Continuous Casting Machine:

Liquid Metal from Induction Furnace is carried in a ladle over the Concast Machine. The

liquid metal flows from the ladle through a slide gate system underneath it into water cooled

copper mould tubes which solidifies the liquid metal into a square shaped mould which we

call as M.S. Billets.

From the considered casting cycle time, the number of strands required to cast 100 mm sq.

and 110 mm sq. billets is worked out to be two (2). Based on the above, 3 strand billet

casting machine suitable for casting up to 160 mm sq. Billets have been selected. Space

provision will be made in the shop for installation of a second billet caster in future.

Table 12: TECHNOLOGICAL PARAMETERS OF MEDIUM FREQUENCY INDUCTION

FURNACE IN EACH SMS

Sl.

No.

Parameter

Unit

SMS-I

Value/Feature

SMS-II

Value/Featu

re

1 Liquid steel production T/Yr 98,000 272,000

2 No. of furnaces No. 3 4

3 Type of furnace - AC, coreless medium

frequency, coreless,

twin shells per furnace

with common power

pack

AC, coreless medium

frequency, coreless,

twin shells per

furnace with common

power pack

4 Nominal

transformer rating

per furnace

MW 5 10

5 Average heat weight T 12 25





26 | P a g e

Sl.

No.

Parameter

Unit SMS-I

Value/Feature

SMS-II

Value/Featu

re

6 Average heat time,

approx.

Min. 150 15

0

7 Heats/day/furnace No. 8.5 8.

5

8 Charge mix, approx.

%

80

80

DRI

Scrap % 20 20

9 Method of charging - Feeder assisted by

Manual prodding

Feeder assisted by

Manual prodding - DRI/scrap

10 Steel grades - Plain carbon

commercial

grades

Special Steels

Table 13: TECHNOLOGICAL FEATURES OF BILLET CASTER IN EXPANSION

Sr. No. Item Parameters

1 Type of machine Curved mould bow type

2 Number of machines 1

3 Number of strands 3

4 Design limit Min. 100 mm.sq

Max. 150 mm.sq

5 Machine equipped to cast 100 mm.sq. – 150 mm sq.

6 Casting Radius 6m/10m

7 Billet length 6m / 9m

8 Type of ladle Bottom pouring with slide gate system

9 Ladle support Ladle stand

10 Heat size 25 t average

11 Type of cutting device Manual

12 Method of discharge On horizontal discharge roller table to cooling beds

13 Steel quality Commercial grades

14 Dummy bar Link type

15 Casting practice Open casting

16 Tundish practice Cold

17 Casting speed for 100 mm.sq. 3.2m/min

18 Mould support Lever arm oscillation

19 Average casting time for

100x100mm size section

40 minutes approx.

20 Preparation time 30 minutes approx.

21 No. of heats/in sequence 3





27 | P a g e

22 No. of heats cast/day 36

23 Billets production, t/yr. 255,000

Flow chart showing Process Flow for Manufacturing Billet

Rolling Mill

The process involves converting the shape stock viz. Ingots/billets to desired finished

section in hot condition by way of passing the material between a pair of grooved rolls and

providing suitable reduction at various stages. Whole operation is conducted at a particular

temperature range and within a limited time span. Stages of rolling operation are comprised

of heating of feed stock to rollable temperature, rolling the feed stock in different mill stands,

cropping the hot bar during process of rolling between stands as applicable and

subsequently finishing in the form of hot rolled deformed bar in straight length. The hot bar

coming out of last pass is then conveyed through TMT line and collecting in a cooling bed

after shearing. The bars at almost ambient temperature are sheared to commercial length

stored and kept ready for dispatch. In TMT process hot bars are subjected to quenching by

means of an intense cooling installation (cooling installation specially designed water spray

BLENDING IN PREDETERMINED RATIO

RAW MATERIAL PREPARATION SPONGE IRON SCRAPS

(SIZING & PROCESSING)

MELTING IN INDUCTION FURNACE

TAPPING OF MOLTEN METAL

CASTING IN CONCAST MACHINE

BILLETS





28 | P a g e

Finishing Mill

CUTTING OF BILLET TO DEFINITE

LENGTH

PREHEATING THE BILLETS IN DOUBLE

ROW REHEATING FURNACE/ DIRECT HOT

CHRGING

Intermediate Mill

Roughing Mill

TMT Bar

Cooling Bed

TMT Rod

system). This step hardens the surface layer to martensite while the core structure remains

austenite. When the bar is free of water chamber heat flows from core to surface and surface

gets tempered to structure called tempered marten site. In the cooling bed due to

atmosphere cooling, the hardened zone is tempered by temperature homogenization in the

cross section and the austenite core is transferred to ducktile-ferrite-pearlite core.

Process flow chart of Rolling Mill

Flow chart showing Process flow chart of Rolling Mill





29 | P a g e

Table 14: FLUE GAS EMISSION AND CONTROL MEASURES FOR EXISTING PROJECT

S. No. Stack attached

to

Stack

Height

from GL,

meters

Exit gas

Velocity,

m/s

Top

Stack

Dia, m

Exit gas

Temp, ºC

APCM

For sponge iron/ WHRB

1 Kiln No 1 & 2 30 Mtr 7-10 m/s 1 m 120 Bag filter

For TMT

2 Reheating

Furnace 30 Mtr 5-8 m/s 1 mtr 150-180

Gas cooler + Bag

filter

For AFBC/CFBC

3 Boiler 30 Mtr 8-10 M/S 2 Mtr 100-120 ESP

For Billets

4 Induction

Furnace No 1 & 4 32 Mtr 5-7 m/s 1 Mtr 100

Bag Filter + Spark

Trapper

5 Induction

Furnace No 2 & 3 32 Mtr 5-7 m/s 1 Mtr 100

Bag Filter + Spark

Trapper

Table 15: PROPOSED PROJECT

S. No. Stack

attached to

Stack Height

from GL, meters

Exit gas

Velocity,

m/s

Top Stack

Dia, m

Exit gas

Temp, ºC

APCM

1 Power Plant

New Stack to be

built

As per norms

8-10 M/S 2 Mtr 100-120 ESP

2 Kiln No. 3 &4 48 MTR 5-10

M/SEC

2 Mtr 100-120 Bag Filter

4 IF No. 1,2 of New Stack to be

built. 5-7 m/s 1 Mtr 100 Bag Filter +





30 | P a g e

S. No. Stack

attached to

Stack Height

from GL, meters

Exit gas

Velocity,

m/s

Top Stack

Dia, m

Exit gas

Temp, ºC

APCM

SMS-II

As per norms

Spark Trapper

4

IF No. 3,4 of

SMS - II

New Stack to be

built.

As per norms

5-7 m/s 1 Mtr 100 Bag Filter +

Spark Trapper

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME

FOR THEIR MANAGEMENT/ DISPOSAL.

3.9.1 SOLID

Particulars Waste Quantity in TPA Treatment/ disposal

Type of

Waste


Solid Waste Slag 11400 31687 43,087 Sold to road construction

Activity after separation of

metallic part

Char 16,000 54000 70,000 Total Char shall be used in

Power Plant

Total Ash 25100 129980 155080 Sold to brick manufacturing

unit and Sold to TSDF

site for utilization of fly ash

as

binding material for

solidification and

stabilization. ESP ash have demand in cement plants.

Nearby Cement plants shall be contacted.

Municipal Solid

Waste generation

rate as

Assuming per

capita solid waste

0.20

kg/capita/day

Organic solid

waste : 60

% of the

total waste

62.4 61.2 123.6 Sent to Municipal Council

Jajpur Orissa

Inorganic

solid waste :

40 % of the

41.6 40.8 82.4





31 | P a g e

total waste

3.9.2 Hazardous Waste

Particulars Hazardous Waste Quantity in TPA Treatment/ disposal

Type of Waste Existing Proposed Total

Hazardous

Waste

Used Oil 2.063 1.13 3.19 As per CPCB/SPCB

guidelines and HWM Rules

2016

Used Ion exchange

resin

0.35 0.19 0.54

Tar residue 1.6 2.0 3.6

3.9.3 WASTE WATER

The plant shall be a zero discharge plant. The effluents source shall be cooling tower blowdown

waters and neutralized water of DM plant regeneration. These shall be suitably utilized for

gardening, dust control and such activities. & 760 KLD water will be recycled in cooling tower

after treatment in ETP followed by RO.

Description Existing (KLD) Total After

Expansion (KLD)

(A) Industrial

IF 57 100

Billet caster &

Rolling Mill 10 250

DRI 70 95

Power Plant (C.T

blow down) 90 600

Boiler blow

down 5 20

Industrial Total 232 1065

(B) Domestic

26 64

(C) Other (DM Rejects)

28 58





32 | P a g e

Total Waste Water

Generation (A)+(B)+ (C) 286 1187

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE

Project Concept

Form 1, Pre-feasibility Project Report with Proposed TOR to MoEF&CC (EAC)

Scoping by EAC (Site visit by sub group of EAC, if necessary)

TOR approved by EAC EC - rejected by MoEF&CC on recommendation of EAC

Draft EIA Report to SPCB

by Project Proponent

Public Consultation process by SPCB

Summary EIA and Form 1 –

display on the Website by SPCB

Proceedings of Public Consultation

Appraisal and Recommendation by EAC

Display on MoEF&CCWebsite

Display at Panchayat, ZP, DM/DC/

Dy. Com & on the SPCB website

To Proponent for Submission of Final EIA

Report/Supplementary Report to Draft EIA

Approval by MoEF&CC

Rejected Approved Display on MoEF&CC Website& Project Proponent Website

Post EC

Monitoring

Submission of half yearly Compliance

Report to MoEF&CC/ RO-MoEF&CC

Display of Compliance Report

on MoEF&CCWebsite





33 | P a g e

4.0 SITE ANALYSIS

4.1 CONNECTIVITY

The existing Plant is situated at Mantira, Kalinga Nagar Growth Centre, District Jajpur,

Orissa. This has all possible amenities that are feasible for industrial projects viability.

Table 16: Connectivity

S. No. Name Distance (Km) Direction


Nearest Railway Station

1 Jakhapura Junction 2.50 SE

Nearest Airport

2 Biji Patnaik Airport

Bhubaneshwar

78.50 SSW

Nearest Highway

3 NH-200 2.70 SW

4. NH-215 9.23 ENE

5. SH-20 4.50 N

6. MDR 1.10 S

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

4.2.1 LANDFORM

The proposed expansion is planned within existing land area of 170 Acre (6, 87, 966 m2). No

additional land is required for the proposed expansion.

4.2.2 LAND USE

The land use pattern is given in point no. 1.2.

4.2.3 LAND OWNERSHIP

The land use is industrial Land declared by the District Collector of Jajpur enclosed as

Annexure- IV.

4.3 TOPOGRAPHY (ALONG WITH MAP)

Topographically, the project area comprises of gently flat land. The highest elevation of the

project area is 52AMSL and lowest elevation of the project area is 40AMSL





34 | P a g e

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST,

WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM

THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL

PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES

(DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED

INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE

GIVEN.

The existing land use pattern is given in point no. 1.2.

4.5 EXISTING INFRASTRUCTURE

The same has been given in point no. 3.8.1, 3.8.2 and 4.0.

4.5.1 BASIC AMENITIES

At the project site first aid center will be set up. Company will provide drinking water

and other sanitary facilities to the workers.

4.5.2. SOIL CLASSIFICATION

Generally four types of soils, viz. Alfisols, Utisols, Vertisols and Entisols occur in the district.

As per agro-climatic classification, the district falls under North Eastern Coastal plain.

4.7 CLIMATE

The district is characterized by humid sub- tropical monsoon climate having three distinct

seasons in a year, viz. winter, summer and rainy seasons. Winter commences from late

November and continues till end of February. Winter is followed by the summer season,

which extends up to mid-June. During the period between April and May, 3 to 4 cyclonic

rains generally occur in the district. The rainy season sets in 3 the district with the advent of

the southwest monsoon, generally from the middle of June and continues till end of

September. Lowest and the highest temperatures- The maximum temperature rises up to

460C in the summer and falls to a minimum of 140C in winter. The December and January

are the coldest and May is the hottest month. The relative humidity is high, on an average,

varies from 40 to 90% during the year and during monsoon it is much more where as in

winter it is less.. The mean monthly potential evapo-transpiration varies from 57 mm

during January to 320 mm during May. Rainfall in the district is caused by the south-west

monsoon. The average rainfall of the district is 1771.8 mm. Maximum rainfall generally

occurs in the month of August. Average nos. of rainy days in a year is 72.The western, south-





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western, eastern southern tract s receive a fairly high rainfall (>1500 mm.) which gradually

decreases to 1300mm towards north-east. The district has experienced an unprecedented

mild to severe drought situation during 1996.

4.8 SOCIAL INFRASTRUCTURE AVAILABLE

• The project area falls under ‘Kalinganagar Industrial Complex’ with the development

of several large and medium scale industries, the study area has witnessed speedy

development of infrastructure with regard to road linkages, black top roads,

communication facilities, trade and commerce. The State Highway (SH-20) connects

Jajpur and Talcher and the Expressway that runs from Daitari and Paradeep Port are

in the study area

• The General Hospital in Jajpur Town is the main health care center in the study area,

equipped with modern facilities. There are few villages having primary health centers

as well

• Socio-economic infrastructure facilities like that of schools (both primary &

secondary), parks, banks, post offices and shopping centers are available in the study

area

• With regard to education, the district of Jajpur is characterized by several educational

and professional institutes namely B.B. High School, Dasarathpur High School, V.N

College, N.C College, Biraja Women’s College, Biraja Law College, B.S. College, Sukinda

College and A.P. College etc.

5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND

TRANSPORTATIONETC.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT

AUTHORITY CLASSIFICATION.

M/s Yazdani Steel & Power Ltd presently operating an integrated steel plant in

Kalinganagar Industrial Complex, Dist-Jajpur, State-Odisha. The existing production

capacity are 2 x 200 TPD Sponge Iron, IF 2 x 6 T; 2x 12 T for Billet and Rolling Mill 4000

TPM i.e. 48,000 TPA along with CPP 10 MW (Coal based 6 MW; WHRB 4 MW)

The proposed expansion is for manufacturing Sponge Iron – 2x 100 TPD to 2x 100 and 2x

350 TPD; Billets – 1,10,000 to 3,63,500 TPA, TMT Bars -48,000 TPA to 3,48,000TPA; Captive





36 | P a g e

power plant of 6 MW to 50 MW; WHRB based power plant 4MW to20 MW, respectively due

to increase in market demand.

5.2 POPULATION PROJECTION

The study area of the proposed expansion falls in the district of Jajpur, Odisha. The total

population of the district as per 2001 & 2011 Census data was 16,24,341 and 18,27,192

respectively. The decadal growth was around 12.49 %. The population projection of the

study area for the year 2017 is estimated to be around 19,64,122.

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.)

The existing unit has approximately 51-acre land area in green belt and plantation. Now, for

the proposed expansion additional 5.5-acre green belt will be developed. Thus, after

expansion the total land area in the green belt will be 56.5Acre (i.e. 33.24 %).

The main aim of the green belt development is to improve the ecosystem to a maximum

possible extent by designing the green cover with the same native species.

However, in order to compensate the loss of vegetation, it is suggested to carry out

extensive afforestation program mainly in and around the project area. Appropriate plant

species of different life forms have been suggested in the following table to grow and to re-

establish the vegetation cover and thereby provide habitat for the faunal species. The list of

plant species suggested includes the following criteria:-

� Tree species which are well adapted to local environmental setting, tall, bearing

larger canopy cover and leaf area.

� Tree species of different size classes (small, medium and larger) were suggested to

maintain the different canopy levels at vertical profile.

� Fruit trees in the selection list would help to attract birds and fruit eating bats which

are locally available.

� Wild species were suggested to provide habitat for faunal species, increase the faunal

species diversity and maintain the naturalness.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)

On the basis of the preliminary site visit, the infrastructure demand in the villages assessed

on the basis of need and priority.

The health infrastructure of the study area requires improvement. The lack of modern and

specialist facilities in hospitals needs improvement.





37 | P a g e

The assessment will be identified in the socio economic survey, after the grant of TOR and

will be submitted at the time of final presentation regarding EC.

5.5 AMENITIES/ FACILITIES

The project expansion envisages improvement in the facilities provided to workers.

Provision for the same has been made as given below:-

Table 17: Facilities provided to workers

S.

No.

Activities Capital Cost

(Rs. In Lacs)

Recurring Cost

(Rs. In Lacs)

1. Shelter/ Housing Facility 50 5

2. Health Facility 12 3

3. Drinking Water 12 02

4. Sanitation Facilities 08 01

5. Education 05 01

Total 87 12

6.0 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The area is very well connected by road network to the site, district headquarter etc. The

area is self-sufficient to cater the needs of the project. Hence, no infrastructure is proposed.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

The unit already has housing facility for operational employee.

6.3 GREEN BELT

The same has been given in point 5.3.

6.4 SOCIAL INFRASTRUCTURE

The existing project is situated at Mantira, Kalinga Nagar District – Jajpur, Odisha. Local

population will be employed by the company in the proposed expansion project. Further,

indirect means of earnings have been created in the area of contractual jobs, vehicle driving,

shops, construction etc. Therefore, this project brought a positive impact on the adjoining

society. The proponent will spend 1% of profit for the development of the area i.e. medical





38 | P a g e

facilities, schools, temples and other social work. There is well developed social

infrastructure in the area.

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/

METRO/WATER WAYS ETC.)

Given in point no. 4.0.

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER)

Given in point no. 3.8.1.

6.7 SEWERAGE SYSTEM

For the treatment of domestic sewage, STP (20 KLD) has already provided with adequate

capacity in existing plant & colony

Installation of 1400 KLD capacity of ETP for industrial waste water treatment & and

upgradation of STP from 20 KLD to 70 KLD are proposed under expansion of the project.

6.8 INDUSTRIAL WASTE MANAGEMENT

After expansion of the project required additional 1400 KLD capacity ETP & and

upgradation of STP from 20 KLD to 70 KLD.

6.9 SOLID WASTE MANAGEMENT

The same has been given in point no. 3.9.

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE

The same has been given in point no. 3.8.2.

7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT

AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND

LANDLESS LABOUR (A BRIEF OUTLINE TO BE GIVEN)

The proposed expansion project does not require additional land and would be housed

within the available plant area. Hence, there would not be displacement of any human

settlement. Hence there are no issues relating to rehabilitation and resettlement.





39 | P a g e

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF

COMPLETION (TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN).

Table 18: Expected Time Schedule for the Project

S. No. Particulars Time Schedule (in month)* Remark If any

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th

1. Environmental

Clearance

2. Consent To Establish Project Establishment Period

3. Consent To Operate Production Start Period

*Time line may vary; subjected to rules & regulation/ & other unforeseen circumstances.

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT.

The expected capital investment for the proposed expansion will be Rs. 642.14 Crore.

Table 19: Expenditure Proposed for Environmental Protection Activities

S. No. Description of Item Capital Cost

(In Lacs)

Recurring Cost

(In Lacs)

1 Air Pollution Control/ Noise 800 80

2 Water Pollution Control 50 05

3 Environmental Monitoring and Management 100 10

4 Green Belt Development 40 04

5 Occupational Health 15 05

Total 1005 104

9.0 ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE

BENEFITS TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN

THE AREA.

There have been many social benefits from the existing manufacturing operations. The

underlying financial and social benefits envisaged through the existing plant have been

listed as follows:-

Table 19: Financial & Social Benefits

S. No. Activities

1. It aims to provide few additional employments to the local population of the proposed study area.





40 | P a g e

Existing Direct employment provided: - 519 Approx.

Proposed Direct employment provided: - 509 Approx.

2. The PP proposes for sustainable development as per the Companies Act 2013 and its subsequent

notifications regarding activities enlisted under the CER. The PP has been undertaking need based

CER activities annually and the same will be given in the EIA / EMP report.

The CSR activity envisaged by the M/s Yazdani Steel & Power Limited has been given as

follows and they shall continue to allocate sustainable welfare activities with an allocated

budget of 2% of the average annual profit of last three years for the forthcoming years CSR.

Year

Particular

Area

Amount

Incurred in RS.

Total

Amount

Year wise in

RS.

2012-13 Avenue Plantation Danagadi Block 120980 120980

2013-14 i) Avenue Plantation Danagadi Block 25875

108875

ii) Donation toward red cross society and

other organization Jajpur 33000

iii) Donation toward development of

Jagannath Temple, Mantira Danagadi Block 50000


199410

ii) Cold & Purified Drinking water

facilities for displaced installed at ADM

office Kalinga Nagar Jajpur Road 54295


803320

ii) Construction of the boundary wall of RN

Sahu UP/ME School at Rabana Danagadi Block 585495

iii) Supply of Bench Desk to of RN

Sahu UP/ME School at Rabana Danagadi Block 70000

iv) Drinking water supply at Mantria

Primary School Danagadi Block 21000

v) Donation toward red cross society Jajpur 20000

vi) Donation toward Jajpur Zilla Mahotsav Jajpur 25000


ii) Installation of Aquaguard Purifier cum

water cooler at Pimpudia Nodal UP Sukinda Block 73000





41 | P a g e

School, Kuhika, Sukinda Block 745220

iii) Drinking water supply project Jatara Pal

Village Danagadi Block 550110

2017-18

i)Supply of Refrigerator & Chairs at Rabana

PHC 30920

795283

ii)Bus Hire charges for Girls students of

KNIC Kalinga Nagar 14363

iii) Donation toward Jajpur Zilla

Mahotsav Jajpur 50000

iv)Contribution to 25th foundation of Jajpur

District formation & 150th foundation day

of Jajpur Municipality Jajpur 50000

v) Contribution to District Aahar Society Jajpur 200000

vi)Contribution to community center at

village Singadia Sukinda Block 450000

2018-19

i)Contribution to community center at

village Kabat

Sukinda Block

350000

(Approx)

Project

Completed

but cost

escalated

ii) Contribution to District Aahar Society

Jajpur for the year 2018-19

Jajpur

200000

Already Paid

iii)Drinking Water Project

Sukinda/

Danagadi Block 450000

Not Yet Start

The CSR of the existing project is enclosed as Annexure-VI.

The proposed expansion project aims to continue the sustainable social development. The

Project authorities are committed towards fulfilling its corporate social responsibility.

After the analysis of the baseline data generation and socio – economic survey, and the

public hearing, the appropriate sustainable development plan will be contributed on the

basis of need based analysis and projected by the corporation.

The appropriate amount of CSR will be proposed by the M/Yazdani Steel & Power Ltd

Limited as per the Companies Act, 2013.

Adequate budgetary provisions have been made by the management for execution of

environmental management plans.





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10.0 CONCLUSION

M/s Yazdani Steel & Power Ltd is proposing expansion of the existing manufacturing Iron,

The plant shall have rolling facility for multi-product Bars, Rods, Sections, Billet and Coal

based Captive Power Plant and WHRB will not only contribute to the growth of Indian

economy but also strengthen the socio-economic values/ status in the area. All the latest

and environment friendly technology will be adopted. The unit will adopt all measures like;

pollution control equipments, effective EMP & DMP to prevent harm/ damage to the

environment. Green belt development in & around the area will increase aesthetic value, as

tool for effective pollution mitigate measure, and will also serve as biological indicators for

that particular site.

*****************

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