Project Proponent: M/s. Maruti Ispat and Energy Pvt. …...in FY09 to 65.25 kgs in FY17. The figure...

Project Proponent:

M/s. Maruti Ispat and Energy Pvt. Ltd. Sy. No. 158,159, 160, 163-168 & 171, village Madhavaram and 13-19

of village Rassamarri Mandal- Mantralyam, District- Kurnool, Andhra

Pradesh.

June 2019

EXPANSION OF INTEGRATED STEEL COMPLEX at

Sy. No. 158,159, 160, 163-168 & 171, village Madhavaram and 13-19

of village Rassamarri

Mandal- Mantralyam, District- Kurnool, Andhra Pradesh.

M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report

1

1.1 Introduction

India is the third-largest crude steel producer in the world. In FY18, India produced

104.98 million tonnes (MT) of finished steel. Crude Steel production during 2017-18

stood at 102.34 MT Steel consumption is expected to grow 5.7 per cent year-on-year

to 92.1 MT in 2018. India’s steel production is expected to increase from 102.34 MT

in FY18 to 128.6 MT by 2021. The Government of India has allowed 100 per cent

foreign direct investment (FDI) in the steel sector under the automatic route. Nearly

301 MoUs have been signed with various states for planned capacity of about 486.7

MT.

India’s per capita consumption of steel grew at a CAGR of 4.75 per cent from 45 kgs

in FY09 to 65.25 kgs in FY17. The figure stood at 68 kgs during April-February 2017-

18. National Steel Policy 2017 seeks to increase per capita steel consumption to the

level of 160 kgs.

M/s. Maruti Ispat and Energy Pvt. Ltd. Is planning to install integrated steel plant at

Village- Madhavaram and Rassamarri , Mandal- Mantralyam, District- Kurnool,

Andhra Pradesh.

The company has obtained Environmental Clearance for the existing units vide F.No.

J-11011/1149/2007-IA II (I) dated 02.01.2009 for integrated steel complex at sy. No.

158,159, 160, 163-168 & 171, village Madhavaram and 13-19 of village Rassamarri.

Company has also taken EC extension on 16.12.2016. But till date company has

installed only 2 x 100 TPD sponge iron plant and 8 MW WHRB Plant. As the validity of

Environment for 10 years lapse, management planned to file the application for

Terms of reference as per the guildliens of EIA notification 2006.

The company already acquired 60.7 ha of land and proposed expansion will be done

within existing plant premises.

The salient features of the project are given Table 1.

Table 1-Salient Features of the Project

Project Name Maruti Ispat and Energy Pvt. Ltd

Total Area 60.7 ha

Location of Project

sy. No. 158,159, 160, 163-168 & 171, village

Madhavaram and 13-19 of village Rassamarri.

Mandal- Mantralyam, District- Kurnool, Andhra

Pradesh

Production Capacity Attached as Annexure-1


2

Raw Material Iron ore, scrab, Coal dolomite, Lime

Water demand Total Water Quantity– 1650 KLD

Sources of water Tungbhadra river

Man power 450 nos.

Electricity Consumption

56.0 MW

Source: Captive Power Plant and Andhra Pradesh

State Electricity Board

Nearest railway station Mantralyam Raod – 7.5 Km

Nearest airport Hyderabad Airport – 180 Km

Project Cost Rs. 700 crores

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent

Maruti Ispat & Energy Pvt. Ltd., established in 2005, is a leading steel company

manufacturing Sponge Iron, MS Billets, Structural Steel and TMT Steel Bars. We are

ISO 9001:2008 certified company and the products what we are manufacturing are

also BIS registered.

With a progressive vision and focus on customer’s interests, the company expanded

its business operations in retail sector by adding MS Life Brand with Fe 500 & Fe 550

grades.

The Manufacturing Process using raw materials, right from Iron ore, coal and

dolomite in our DRI unit to the final product, Steel rebars are in-house manufactured

in our integrated steel plant, gives us that Extra edge required to serve all our clients

with the best quality product at extremely competitive prices. Empowered with the

most qualified and experienced personnel, Maruti Ispat & Energy Pvt. Ltd., Ltd comes

up with the best possible deal for our customers and deliver products that meet their

categorical requirements without compromising on quality. Coupled with prompt

service back up, our products and services have earned M/s. Maruti Ispat & Energy

Pvt. Ltd., a reputation of being a reliable and favored company in the construction

field arena.

2.2 Brief Information about the Project

The company is planning to install integrated steel plant at Village- Madhavaram and

Rassamarri , Mandal- Mantralyam, District- Kurnool, Andhra Pradesh.


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2.3 Need for the Project and Its Importance to the Country or Region

The demands of steel are increasing day by day in India due to rapid Industrialization,

Booming in construction sector and other infrastructure project. Considering the said

scenario M/s. Maruti Ispat & Energy Pvt. Ltd.. is proposing to increase in existing

steel plant capacity.

2.4 Employment Generation

This plant will keep the skilled manpower hence the local village people are exposed

to the skilled jobs and get feeding to their livelihood. The estimated manpower

requirement for expansion is 1350 nos. out of which approx.. 450 will be direct

employee and 900 will be in direct employee. Employment will be provided for the

surrounding village’s people those who are educated also. The status of socio

economic will improve in these rural areas.

3.0 PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked and Interdependent Projects, If Any.

No interlinked projects were associated with this project.

3.2 Location

The Location of the Project is shown in Figure – 1 and study area map is given in

Figure -2.


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FIGURE – 1: LOCATION MAP

Project Site


5


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FIGURE – 2: 10-KM TOPOGRAPHICAL MAP

3.3 Details of Alternate Sites

No alternate site was considered.

3.4 Size or Magnitude of Operation

S.no Unit Plant

Configuration

Production

Capacity

Status of

Implementation

as per old EC

1 Palletization Plant (Pellets) 1 x 3000 TPD 9,00,000 TPA Not Started

2 Sintering Plant (Sinter) 1 x 2000 TPD 6,00,000 TPA Not Started

3 Sponge Iron Kilns (Sponge

Iron)

6 x 100 TPD 1,80,000 TPA 2 x 100 TPD – is

in Operation

Remaining 4 x

100 TPD to be

Implementation

4 Mini Blast Furnace

(Hot Metal/Pig Iron)

1 x 380 m3 2,40,000 TPA Not Started

5 Induction Furnace (Billets

from CCM)

2 x 40 TPH 2,40,000 TPA Not Started

6 Billets Casting Machine/

Continuous Casting Machine

1 x 1000 TPD 3,00,000 TPA Not Started

7 Rolling Mill 1 x 1000 TPD 3,00,000 TPA Not Started

8 Power

Generation

Through

WHRB

6 x 10 TPH 20 MW 8 MW WHRB –

Civil Work

Started

Through FBC 2 x 100 TPH 2 x 18 MW Not Started

9 Ladle Furnace 1 x 40 TPH --- Not Started

10 Oxygen Plant --- 97,92,000

SM3/Annum

Not Started

3.5 Project Description with Process Details

Process Description

The proposed plant will produce steel in the form of billets and rolled products

through DRI/ MBF-IF-CCM-RM route. The iron ore is pelletized and sintered for the

preparation of iron oxide raw material for primary iron and steel making. The

iron oxide in the DRI process is reduced to sponge iron using non-coking coal in kiln.

In the mini blast furnace, the reduction is achieved by use of coke. The heat

requirement is supplied by combustion of coal/ coke. Steel making will be done using

induction furnace. The steel formed is molded into billets and rolled products by

casting mills and rolling mills.


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Pelletization

Pellets are small crystallized balls of iron ore with a size of 9-16 mm. The Pelletization

process consists of grinding and drying or de-watering, balling and induration

followed by screening and handling. Before being fed into the Pelletization plant the

ore is upgraded by several sorting and beneficiation steps with intermediate crushing

and grinding. Af ter hot grinding the material is wetted in paddle type mixers and

combined with additives, then processed in the ball preparation plant. The balling

drum is inclined 6 to go to the horizontal plane. To obtain a well-defined green ball

size, under and oversized fractions are screened off and re-circulated.

Induration, which means thermal treatment, consists of drying, heating and cooling.

It can be carried out in two different systems; in 'straight grate' or 'grate kiln'

systems. During thermal treatment magnetite is almost completely oxidised to

hematite. This contributes to the large amounts of heat needed to operate the

process. At the end of the induration strand, the pellets are collected and screened.

Undersize or broken pellets can be recycled. Significant particulate matter emissions

may occur.

Sintering

The sinter plant essentially consists of a large traveling grate of heat resistant cast

iron. The material to be sintered is placed on top of a 30-50 mm deep layer of

recycled sinter. This bottom layer prevents the mixture from passing through the

slots of the grate and protects the grate from direct heat of the burning mixture.

At the start of the grate a canopy of gas burners ignites the coke breeze in the

mixture.

In the down-draf t process a powerful fan draws process air through the entire length

of the sinter bed into distribution chambers located underneath the grate known as

wind-boxes. The waste gas flow from a sinter plant is 17000 m3/ hr As the sinter

mixture proceeds along the grate, the combustion front is drawn downwards

through the mixture. This creates sufficient heat (1300-1480°C) to sinter the fine

particles together into porous clinker referred to as sinter.

Sponge Iron Manufacturing Process


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Sponge iron can be manufactured either through the coal based route or the gas

based route. The proposed plant uses the coal based process in which iron ore is

reduced with non coking coal in a rotary kiln to make sponge iron. The raw materials

(iron ore, coal and dolomite), in desired quantities and sizes, are fed into the rotary

kiln from the feed end, after the rotary kiln has been fired and reaches the desired

temperature. The rotary kiln is a refractory lined cylindrical vessel on which blowers

and air pipes are mounted to provide combustion air to the kiln. The rotary kiln has -

a downward slope and is mounted on rollers to enable rotation. The angle of

inclination, rotational speed, and length of time the charge is exposed to the

atmosphere and temperature has important bearings on the quality of the

end product. The rotary kiln has three functions as: It is a heat exchanger, Vessel for

chemical reaction, Conveyor for solids.

With the rotation of the kiln, the charge moves down the slope and the surface of the

material is exposed to heat. The heat exchange takes place via the non-refractory

lining of the kiln. The reduction from oxide to metal occurs by gradual removal of

oxygen at various temperatures giving rise to various intermediate oxides.

Hot sponge iron is discharged from the kiln- discharge end and taken into the rotary

cooler. The effluent gas that contains coal volatile, fine carbon particles, iron ore and

sponge iron dust is treated separately in the waste gas handling system. The system

consists of:

(a) Dust settling chamber

(b) After burner chamber

(c) Waste heat recovery boiler

(d) Electrostatic precipitator

(e) ID fan

(f) Chimney

Direct Reduced Iron /Sponge Iron (DRI)

The process of reduction takes place inside the rotary kiln, which is mounted on 4

tyres and supported by 8 support rollers. The transverse motion of the kiln is


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controlled with the help of hydro thruster and thrust rollers. The kiln is rotated at

the rate of 0.35 rpm with the help of a girth gear mounted on the kiln and connected

with 2 pinion drives, which in turn are coupled with gear boxes and motors.

The direct reduction of iron ore inside the kiln is held due to CO gas, which is

generated out of coal at nearly 9500C. Shell air fans are mounted on the kiln, which

inject air in controlled manner into the kiln for creating reducing atmosphere. The CO

reacts with Fe203 and reduces it to Fe. The kiln is lined with refractory for sustaining

the high temperature .

The hot DRI is then cooled by indirect cooling inside a cooler. The rotary cooler is

supported on 2 tyres and 4 support rollers. The cooler is rotated at the rate of 0.6

rpm with the help of a girth gear mounted on the cooler and connected with single

pinion drive, which is coupled with a gearbox and motor. The water is sprayed on the

cooler shell while the sponge iron travels inside the cooler and hence, the material

gets cooled at outlet to 150 0C while discharged on the product conveyor.

Product Separation

The sponge iron along with unburnt coal in the form of char comes out of the cooler.

The sponge iron being magnetic is separated out of the char by passing it through a

magnetic separator. The sponge iron and char, recovered separately, are stored in

the storage bunkers and discharged through trucks.

Off gas cleaning system

The off gases moving in counter current of material flow inside the kiln are at a

temperature of l000 OC and carry coal dust, which is pased through dust settling

chamber and after burning chamber (ABC). Air is added into the ABC for converting

CO to CO2. The hot flue gas stream is taken to the waste heat recovery boiler for

utilization of the sensible heat for making steam. The off gases are then allowed to

pass through ESP for removal of dust so that the concentration of dust is limited to

below 100 mg/ m3 before being discharged from the chimney.


10

In-plant de-dusting system

Air Pollution Control Equipment like bag filter shall be installed for catching the dust

from various conveyors, material handling equipments and-product handling

equipment. The dust collected from the bag filter is sold to cement manufacturers.

Product Separation

The sponge iron along with unburnt coal in the form of char comes out of the cooler.

The sponge iron being magnetic is separated out of the char by passing it through a

magnetic separator. The sponge iron and char, recovered separately, are stored in

the storage bunkers and discharged through trucks.

Off gas cleaning system

The off gases moving in counter current of material flow inside the kiln are at a

temperature of 1000 0C and carry coal dust, which is pased through dust settling

chamber and after burning chamber (ABC). Air is added into the ABC for converting

CO to CO2. The hot flue gas stream is taken to the waste heat recovery boiler for

utilization of the sensible heat for making steam. The off gases are then allowed to

pass through ESP for removal of dust so that the concentration of dust is limited to

below 100 mg/ m3 before being discharged from the chimney.

In-plant de-dusting system

Air Pollution Control Equipment like bag filter shall be installed for catching the dust

from various conveyors, material handling equipments and-product handling

equipment. The dust collected from the bag filter is sold to cement manufacturers.

Requirement of Raw Materials for Sponge Iron manufacture

The main raw materials for sponge iron production are iron ore pellets, coal, and

dolomite.

Pig Iron manufacturing process Mini Blast Furnace Plant

The blast furnace comprise of one furnace of 380 m3 working volume and a

pig- casting machine of 800 TPD capacities. The blast furnace is envisaged to operate

with sized lump iron ore, sinter, coke, fluxes & additives. In the blast furnace, the

burden of iron ore and coke is reduced into hot metal. Coke is used both as reductant

and fuel. To maintain heat in the furnace, stove has been set up. The hot metal

produced shall be either transferred directly for primary refining or cast in pig casting

machine.


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The liquid slag will be granulated at cast house granulation unit. The BF top gas will be

cleaned in dust catcher & gas cleaning system, and distributed to the stoves, burners

for runner drying, boilers for process and process steam supply. The surplus gas will be

exported to the AFBC power plant, where it will be utilized as supplementary fuel.

Steel Making

Steel making and continuous casting shop has been envisaged to produce about

300000 t/ yr of continuously cast billets. Two Induction Furnaces (IF) of 40 T capacities

will be installed to meet the annual requirement of liquid steel. Induction furnaces are

used to melt both ferrous and non-f errous metals. There are several types of

induction furnaces, but all create a strong magnetic field by passing an electric current

through a coil wrapped around the furnace. The magnetic field in turn creates a

voltage across and subsequently an electric current through the metal to be melted.

The electrical resistance of the metal produces heat which melts the metal. Induction

furnaces are very efficient and are made in a wide range of sizes. Induction furnaces

require cleaner scrap than electric arc furnaces; however, they do allow precise

metallurgical adjustments.

Casting & Rolling

Continuous Casting Facility

The Continuous Casting facility consists of three nos. of 2-strand continuous casting

machine for casting billets along with necessary tundish & mould/ segment

preparations and auxiliary facilities. The continuous casting machine will be of radial

type with curved mould design.

The casting ladle after treatment at the induction furnace will be picked up by the

ladle handling crane and placed on the ladle stand of the continuous casting

machine. In the mean time a tundish lined with refractory .materials, preheated to

about noooc and mounted on the tundish car will be moved from the

reserve position to the casting position. The ladle slide gate will be opened to allow

flow of liquid steel into the tundish. The liquid steel stream from the ladle to tundish

will be protected by ceramic tube to avoid oxidation and formation of inclusions in the

steel.

Prior to start of casting operation, dummy bars will be introduced into the moulds.

The gap between dummy bar head and mould walls will be sealed with asbestos


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chord and small pieces of steel scrap will be placed over the dummy bar head for

chilling of initial liquid steel.

Water supply to moulds, secondary cooling zone and machine cooling will be switched

on. When the liquid steel level in the tundish reaches a predetermined level, the

nozzles of the tundish will be opened for flow of metal into the moulds. The liquid

steel stream from tundish to mould will be protected by shroud system to ensure

superior quality of cast products.

When the liquid steel level in the mould reaches about 100-150 mm from its top, the

drives of the mould oscillating mechanisms, withdrawal and straightening units will be

switched on. The withdrawal of dummy bar begins at the minimum speed and

gradually increases to normal casting speed within a few minutes. The lubrication of

mould walls will be done by adding requisite quantity of mould lubrication oil.

During casting operation, the metal level in mould will be maintained within

predetermined limits by adjusting the strand withdrawal speed. The liquid steel level in

the tundish will also be kept within permissible range by adjusting the opening of ladle

slide gate.

The partially solidified strand af ter leaving the mould will pass through the strand

guide rollers segments where intensive but controlled cooling of the strands will be

achieved by direct water spray with the help of nozzles. The solidified strand will be

guided through strand guides, withdrawal and straightening unit before entering in

the cutting zone.

The dummy bars will be separated from the cast strands of billet caster when dummy

bars reach beyond the withdrawal and straightening unit and will be stored in a

dummy bar storage device till their introduction is required for the next cast.

The cast strands will be cut into predetermined length by automatic Oxy-LPG cutting

torches. The cut billets will be delivered to cooling bed through run-out roller tables

Pusher will be provided for pushing billets on the cooling bed where these billets will

be marked. The marked billets will be lifted by billet handling magnet crane for storage

in the billet storage bay.

For chemical analysis of liquid steel, samples will be taken from the tundish and sent to

the laboratory. The samples will also be cut from cast products and sent to the


13

laboratory for macro etching, sulphur prints and to determine other

quality parameters.

At the end of casting, the tundish along with tundish car will be shifted to the reserve

position for drainage of remaining slag and metal. The empty tundish will be lif ted by

the crane and transferred to the tundish preparation area where facilities will be

provided for tundish preparation.

Rolling mill

Rolling mill of 300000 t/ yr capacity has been proposed in the steel complex. Blooms

shall be received in the bloom storage bay and stacked size-wise as well as grade- wise.

These shall be inspected for surface defects. Minor defects, particularly for stainless

steel, shall be rectified by grinding.

Depending on the product being rolled, blooms shall be lifted by the EOT crane and

placed on the charging gate of the reheating furnace. After this, complete operation of

the reheating rolling and cooling of bar is mechanized and automated through stand-

alone automation as well as process control from computers.

Well heated and soaked blooms are discharged from the front end of the reheating

Furnace by an extractor. The bloom then travels toward the reversing mill. On the way,

descaling takes place in a descaler by high pressure water jets. Blooms then enter the

reversing mill. Depending on the final product, a number of to and fro passes are

given at the reversing mill with the help of roller tables, manipulators and turning

device. Heavy rounds & RCS are finish rolled from the reversing mill itself and taken to

hot saw for cropping and dividing into cooling bed lengths.

Cooled bars are then lifted from the cooling bed cradle by the storage bay EOT crane

and taken for inspection or post rolling finishing operations.

Power Generation

Power generation is proposed through two techniques, viz., through WHRB technique

and through AFBC system. The two techniques are briefly discussed below:

WHRB (Waste heat recovery boiler) Technique

Sponge Iron is produced by heating Iron with Coal and other additives under

controlled conditions in Rotary Kiln. The proposed 6 x 100 TPD Kilns would generate


14

approximately 240,000 Nm3/ hr of Flue Gases at 850 - 900°C. To recover the heat of

hot flue gases coming out of the Rotary Kilns, they are passed through Heat Recovery

Boiler (HRB). It consists of radiation chamber with water walls just like conventional

boiler with a drum to evaporate steam at 34-kg/ cm2 pressure. The steam is carried to

super heater system where the temperature is maintained at 430 °C. The boiler has an

economizer, which utilizes the residual heat of kiln gases to raise the temperature of

feed water from 100 to 200 °C. The output of the boilers, i.e., the high pressure steam,

will be used to generate electricity through Steam Turbo Generator Set. The flue gases

leave the convection zone and then pass through an ESP where dust is removed. The

clean gas from the ESP will be finally discharged to atmosphere through stack.

AFBC (Air Fluidized Bed combustion) Technique

In this system, char, blast furnace gases and low-grade coal (washer reject) will be

used as fuel for generation of steam. The boiler consists of a grate as fluidized air is

supplied to the bed, the bed material (particular type of sand) remains in fluidized

state. This bed material is heated through separate combustion chamber with diesel

burner. The hot air passes through first chamber raising the temperature to 450 °C

then coal is charged which burns raising the temperature further to 950 °C. In this

manner the temperature of four chambers are raised so is the rise in pressure. The

steam thus produced fed to turbine to produce electricity. Major technical parameters

of the captive power plant are as follows:

Power generation 36 MW

Fuel Char, Washery rejects and BF gases

No and type of boiler 2 No. AFBC boilers

Boiler capacity 2 x lOO TPH

Condensate recycles better than 95%

Ash handling Wet ash handling type

Flue gas cleaning Electrostatic precipitator

Particulates in flue gas 100 mg/ Nm3, Maximum

Stack height 69 meters


15

3.6 Availability of Water Its Source, Energy/ Power Requirement and Source

3.6.1 Water Requirement

The details of water requirement for different purposes are presented below:

Water Requirement

Input Quantity (KLD) Output Quantity (KLD)

Makeup Water for

cooling

969 Cooling tower blow down 235

Losses 734

Boiler Feed Makeup 681 Blow down 158

Losses 523

Total 1650 1650

3.7 Quantity Of Wastes to be Generated (Liquid And Solid) And Scheme For Their

Management/ Disposal

3.7.1 Solid Waste Generation& its Disposal

Slag will be sold to construction industry and mill waste will be sold to cement

industry. The details of solid waste are given in below table:

Particular Quantity (TPD) Remark

Solid waste from Pelletization Plant 100

Filling of low laying area/road

construction

Char from Sponge Iron 150 Used in AFBC boiler

ESP & Bag filter 42 Sold to Cement Manufactures

Kiln Accretion and Mis. 4 Road Construction

Slag From MBF 481 Sold to Cement Manufactures

MBF Flue dust 48 Sold to Cement Manufactures

Slag from IF 160 Used for road construction

Solid waste from mill scales 40 Sold to Cement Manufactures

Fly ash 67 Sold to Cement Manufactures

Used Batteries 10 nos./year Sent to authorized recyclers

Waste oil 2000 l/year Sent to authorized recyclers


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3.7.2 Liquid Effluent

No liquid effluent will be generated at the plant site. The domestic wastewater

generated will be treated in STP and treated water will be reuse for green belt

development.

4.0 SITE ANALYSIS

4.1 Connectivity

4.1.1 Nearest Railway Station

Mantralyam Raod – 7.5 Km

4.1.2 Nearest Airport

Hyderabad airport is 180 km from the plant site.

4.2 Land form, Land use and Land Ownership

The Land use conversion already done.

4.3 Topography

The topography of the region is mostly plain dry industrial land and the climatic

conditions are semi-arid. The average annual rainfall is 700 mm, and the maximum

and minimum temperatures are 45 oC & 16

oC respectively.

There are no Ecological and Sensitive areas like Religious and Historic places,

Archeological Monuments, Scenic Areas, Hill Resorts, Biosphere reserves, National

Parks and Sanctuaries, Seismic Zones and Defense installations within the circular

area of 10 km radius from plant site.

5.0 PLANNING BRIEF

5.1 Planning Concept

The proposed project involves additional in Induction Furnace and rolling mill

production.

5.2 Population projection

The man power of plants includes manager, Engineer, skilled and unskilled Labours

and medical officers etc. As for the socio-economic is concerned from the plant

activity nearby villagers shall get in employment for about 900 persons. The proposed

plant activities also shall bring the positive change in the villages as the plant shall

provide direct employment to more than 450 people directly.


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5.3 Land use planning

The project is located in 60.7 ha land. There will not be change in land use as the land

already has converted in Industrial Area.

5.4 Assessment of Infrastructure Demand (Physical & Social)

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

was assessed on the basis of need and priority. The assessment will be made in the

socio economic survey &will be submitted at the time of final presentation regarding

Environment Clearance.

5.5 Amenities/Facilities

Rest shed, first-aid centre, ambulance service, drinking water facilities, will be

provided.

6.0 PROPOSED INFRASTRUCTURE

6.1 Plant Area (Processing Area)

The main plant area comprises of Induction furnace area and rolling mill area, raw

material handling area, storage area and greenbelt area etc.

6.2 Residential Area (Non Processing Area)

As the local persons will be given employment, no residential area/ housing is

proposed within the mining lease area.

6.3 Green Belt

More than 1/3rd

(20 ha) of total land availability is reserved for plantation i.e.

greenery. Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

and wind firm, deep rooted. A three tier plantation is proposed comprising of an

outer most belt of taller trees which will act as barrier, middle core acting as air

cleaner and the innermost core which may be termed as absorptive layer consisting

of trees which are known to be particularly tolerant to pollutants.

6.4 Water Management

About 1650 KLD will be required for steel project. This water will be supplied from


18

ground water.

6.5 Sewerage System

The domestic wastewater generated will be sent to septic tanks followed by soak

pits.

6.6 Industrial Waste Management

No industrial waste will be generated at the plant site. The domestic wastewater

generated will Treated in STP.

6.7 Solid Waste management

Slag will be sold to construction industry and mill waste will be sold to cement

industry.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

There will be no displacement of houses. Hence rehabilitation and resettlement is not

envisaged.

8.0 PROJECT COST ESTIMATES

The total project will be around Rs. 700 Crores.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local

People Including Tribal Population, If Any, In the Area.

The proposed Expansion plant will provide employment to about 100 local people

and helping them earn livelihood. The infrastructure facilities also will be improved in

the surrounding area.

***********


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Annexure 1: Project Configuration

S.no Unit Plant

Configuration

Production

Capacity

Status of

Implementation

as per old EC

1 Palletization Plant (Pellets) 1 x 3000 TPD 9,00,000 TPA Not Started

2 Sintering Plant (Sinter) 1 x 2000 TPD 6,00,000 TPA Not Started

3 Sponge Iron Kilns (Sponge

Iron)

6 x 100 TPD 1,80,000 TPA 2 x 100 TPD – is

in Operation

Remaining 4 x

100 TPD to be

Implementation

4 Mini Blast Furnace

(Hot Metal/Pig Iron)

1 x 380 m3 2,40,000 TPA Not Started

5 Induction Furnace (Billets

from CCM)

2 x 40 TPH 2,40,000 TPA Not Started

6 Billets Casting Machine/

Continuous Casting Machine

1 x 1000 TPD 3,00,000 TPA Not Started

7 Rolling Mill 1 x 1000 TPD 3,00,000 TPA Not Started

8 Power

Generation

Through

WHRB

6 x 10 TPH 20 MW 8 MW WHRB –

Civil Work

Started

Through FBC 2 x 100 TPH 2 x 18 MW Not Started

9 Ladle Furnace 1 x 40 TPH --- Not Started

10 Oxygen Plant --- 97,92,000

SM3/Annum

Not Started

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