Avinash Energy Private Limited

AVINASH ENERGY PRIVATE LIMITED

Located at: Mohra & Hirmi Villages, Simga Tehsil, Baloda Bazar -Bhatapara District, Chhattisgarh

PRE-FEASIBILITY REPORT [For installation of DRI Kilns to Manufacture 3,63,000 TPA of Sponge Iron, installation of Induction Furnaces to manufacture 3,30,000 TPA of M.S. Ingots / Billets, installation of Rolling Mill to manufacture 3,30,000 TPA of TMT bars / Structural Steel / Rolled Products, installation of Submerged Arc Furnaces to manufacture Ferro alloys (Ferro – Silicon – 12,600 TPA or Silico–Manganese- 28,400 TPA or Ferro–Manganese – 37,000 TPA) & Power plant - 42 MW (WHRB – 30 MW & FBC – 12 MW)]

Prepared by:

ISO 9001: 2008 Certified Accredited by NABET - QCI

TABLE OF CONTENTS

Chapter - 1 4 EXECUTIVE SUMMARY 4

Chapter – 2 5 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 5

2.1 Identification of project and project proponent 5 2.2 Brief description of nature of the project 5

2.3 Need for the project and its importance to the country and or region. 6

2.4 Demand And Supply Gap 6 2.5 Export Possibility 6

2.6 Domestic/Export Markets 7 2.7 Employment Generation (Direct and Indirect) due to the project. 7

Chapter – 3 8 PROJECT DESCRIPTION 8

3.1 Type of project including interlinked and interdependent projects: 8 3.1.1. Type of Project: 8 3.1.2. Interlinked Project: 8

3.2 General Location: 8 3.3 Details of alternate sites considered: Error! Bookmark not defined.

3.4 Size or magnitude of operation: 16 3.5 Manufacturing Process 17

3.5.1 Manufacturing Process Sponge Iron 17 3.5.2 Manufacturing Process MS Billets 18

3.5.3 Manufacturing Process TMT bars / Structural steels / Wire rod 19 3.5.4 Power Generation 24

3.5.4.1 Power Generation through WHRB 24

3.5.4.2 Power Generation through FBC 24 3.6 Raw material requirement, Transport etc.: 29

3.6.1 Raw Material Requirement and its sources (after proposed expansion) 29 3.6.2 Mode of Transport for Raw materials and finished products: 30

3.6.3 Market of Final Products: 30

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3.7 Availability of water its source, Energy / power requirement and source: 27 3.7.1 Water Requirement and its sources: 27 3.7.2 Sources of Energy/ Power and its sources: 28 3.8 Generation and disposal of Wastes [Waste Water and Solid Wastes]: 29 3.8.1 Waste Water Generation: 31 3.8.2 Solid Waste Generation and its disposal 29 Chapter – 4 33 SITE ANALYSIS 33 4.1 Connectivity 33 4.2 Land Form, Land use and Land ownership 33 4.2.1 Land Form: 33 4.2.2 Land Use of the Project Site 33 4.3 Topography 33 4.4 Existing land use pattern: 33 4.4.1 Land use pattern of the Project site 33

4.4.2 Environmental Setting of tHE PROJECT SITE: 33 4.5 Existing Infrastructure 34 4.6 Soil classification 34 4.7 Climatic data from secondary sources 34 Chapter – 5 35 PLANNING BRIEF 35 5.1 Planning Concept: 35 5.2 Population Projection: 35 5.3 Land use planning: 35 5.4 Amenities/Facilities. 35 Chapter – 6 34 PROPOSED INFRASTRUCTURE 34 6.0 Proposed Infrastructure 36 6.1 Industrial Area (Processing Area) 34 6.2 Residential Area (Non Processing Area) 34 6.3 Green Belt. 34 6.4 Social Infrastructure. 35

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6.5 Connectivity: 35 6.6 Drinking Water Management: 35 6.7 Sewerage System. 35 6.8 Industrial Waste Management. 35 6.9 Solid Waste Management 36 6.10 Power requirement & its source 36 Chapter – 7 36 Rehabilitation and Resettlement Scheme 36 Chapter – 8 37 Project Schedule & Cost Estimates 37 8.1 Likely date of start of construction: 37 8.2 Estimated project cost: 37 Chapter – 9 38 Analysis of proposal 38 9.1 Financial and social benefits: 38 9.2 Socio-Economic Developmental Activities 38

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Chapter - 1 EXECUTIVE SUMMARY

1.1. SALIENT FEATURES OF THE PROJECT Avinash Energy Private Limited, have proposed to setup the Integrated steel plant at Mohra & Hirmi Villages, Simga Tehsil, Baloda Bazar-Bhatapara District, Chhattisgarh. Following is the plant configuration and production capacity details: S.No. Name of the Unit & Product PROJECT PRODUCTION CAPACITY CONFIGURATION 1. DRI plant 4x100 TPD 3,63,000 TPA (Sponge Iron) 2x350 TPD 2. Induction Furnace 4x15 MT 3,30,000 TPA (M.S. Billets / M.s. Ingots) 2x20MT 3. Rolling Mill 2x500 TPD 3,30,000 TPA (TMT Bars / Structural Steels / Rolled Products) 4. Submerged Arc Furnaces Ferro – Silicon – 12,600 TPA ( Ferro Alloys) or 2x9 MVA Silico–Manganese- 28,400 TPA or Ferro–Manganese – 37,000 TPA 5. Captive Power plant 4x2.5 MW WHRB – 30 MW 2x10 MW FBC – 12 MW 1x12 MW

1.2. PROJECT PROPONENT Avinash Group - Profile Avinash Group has been incorporated in the year 1996 at Raipur. The company has been promoted by the young and energetic Civil Engineers in the family viz., Mr. Anand Singhania and Mr. Mukesh Singhania. Mr. Anand Singhania is the President of CREDAI, Chhattisgarh and is committed of spreading the activities of association beyond the frontiers of Chhattisgarh State. Avinash Group is consortium of Avinash Developers Pvt. Ltd., Avinash Builders, Mukesh Carriers AND Kaizen Motoventures Pvt. Ltd. Avinash Group is pioneer and exalt group of newly established Chhattisgarh State. It is founded on the strength of strong foundation and commitment beyond business. The group leads with vision, creativity and eligibility but ultimately thrives on integrity.

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Avinash Group invest their talent , energy and resources in the highest quality of planning design and construction that will last for generations and assure an unparalleled quality of life for those who live, work and shop here. Singhania family is one among the most reputed business families of Raipur. Originally the family had been in the food grains Export business since the time immemorial. The main pillar of the family Late Sri Birdichand Singhania who was not only seasoned businessman but also a prominent social activist and religious devotee who ensured diversification of the business in his lifetime venturing into various profitable avenues. To enumerate a few, the family is involved in Automobiles Dealership, Transportation, and Builders & Colonizers etc.

Organisation Structure - Overview ADPL is the brain child of two young entrepreneurs viz Anand Singhania and Mukesh Singhania. After graduating in Civil Engineering, Singhania brothers opted for diversification of family business and ventured in to the most competitive line of business i.e. Real Estate and construction. Singhania family enjoys high reputation and exemplary Goodwill in business and social circle and guidance of elders was always available to them in plenty. However, the young duo with their foresightedness and long vision as well as adopting modern business techniques harnessed all the resources available and established Avinash Builders at the helm of all the competitors which are plenty in numbers.

Without entering any B-School, they have shown remarkable business acumen conforming to the contemporary business style matching high standards. Their activities do not merely confine to the running of Builders Company but they are also active and indispensable part of social parties and gatherings as also office bearers of eminent International Clubs which are engaged in mass charitable activities. From its inception the focus of the company is to provide affordable & innovative house designs, with due credence to the ambiance & environment. Quality construction, timely completion & ensuring customer satisfaction at all times has played a large role in converting a small beginning to one of the pioneering construction companies of Chhattisgarh. ADPL have in their credit hundreds of artistic & lovable houses with more than 10 Million sqft. of quality construction completed. Efficient team of engineers & Architects are the driving force in the mega success of series of multistoried residential apartments, commercial complex, Shopping Malls and Office Towers etc. Most important factor which put ADPL ahead of the lot is it's absolute transparency of dealings & timely execution. They collaborate with the best architects and consultants and all their projects are meticulously planned and designed to offer living spaces that are creative and yet functional.

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DIRECTORS PROFILE: SHRI ANAND SINGHANIA: After graduating in Civil Engineering in the year 1995 Shri Anand Singhania diversified the family business in construction line. The innovative ideas and superb business acumen inherited from the family brought his construction company at the helm. The quality consciousness, trustworthiness and transparency earned loyalty of a large number of customers and in whose estimation he is the “ Construction Baron” of this region. He always remained Numero Uno among construction czars of the town without compromising his other areas of function in social circle. Shri Anand Singhania occupies covet post of the President of Rotary club of Cosmopolitan, Raipur. Presently he is the Vice President of CRIDAI National. He is actively involved in charitable works undertaken by the Rotary Club as well as a choices guest in every social and cultural programs organized in the local clubs. As the Managing Director of ADPL, he has shown great ability and quality of leadership. Name Shri Anand Singhania Fathers Name Shri Santosh singhania Date Of Birth 29-06-1972 PAN AJKPS7492K DIN 00017193 Qualification B.E. Civil Experience 22yrs Directorship Avinash Builders Avinash Developers Private Limited. Kaizen Motoventures Pvt. Ltd. Avinash Infra Projects Pvt. Ltd. Avinash Realtors Pvt. Ltd.

SHRI MUKESH SINGHANIA: Shri Mukesh Singhania is another Civil Engineer in the family who has passed out in the year 2000 and stepped in to the family’s construction business to assist his young cousin, Anand Singhania in promoting company’s activities. Blessed with unique business style and Management capabilities, his participation in the construction business and his keen interest in Finance proved boon for the family.

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Name Shri Mukesh Singhania Fathers Name Shri Naresh Kumar Singhania Date Of Birth 13-01-1978 PAN AKHPS6507M DIN 00017163 Qualification B.E. Civil Experience 18Years Partner/Directorship Avinash Builders Avinash Developers Private Limited. Kaizen Motoventures Pvt. Ltd. Avinash Infra Projects Pvt. Ltd. Avinash Realtors Pvt. Ltd.

The company is now proposing to set up a new unit as Avinash Energy Private Limited. This proposed unit is for a state-of-art Integrated Steel Plant with Captive Power Plant. The proposed unit will be setup on a land admeasuring 67 acers (27.129 Ha.) which is taken on lease for the proposed project for setting up a steel plant.

To meet the ever increasing demand of Steel, Avinash Energy Private Limited has decided to set up an Integrated Steel making facility consisting of a DRI Unit (Sponge Iron), Captive Power Plant to utilize the heat from the waste hot gases and Char/Coal, Steel Melt Shop of matching capacity having melting, refining and billet casting & Rolling Mill to manufacture TMT Bars and Structural Steel and SEAF for manufacture of Ferro Alloys.

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Chapter – 2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

Avinash Energy Private Limited, have proposed to setup the Integrated steel plant at Mohra & Hirmi Villages, Simga Tehsil, Baloda Bazar-Bhatapara District, Chhattisgarh. In view of the tremendous market potential of iron & steel products promoters have decided to setup an Integrated Steel Plant with Captive Power Plant. This project shall consist of production of Sponge Iron (DRI), Steel Billets, Re-rolled products (TMT Bars and structural steel) with Captive Power Plant and ferro alloys. Integration and Captive power will make the project profitable and make it financially more viable. The in-house consumption of sponge iron for manufacturing of billets, which would further be rolled into TMT bars and captive power plant utilizing the waste heat rejects from the sponge iron would improve the overall profitability of the project. Avinash Energy Private Limited proposed for installation of steel plant, envisage to produce the following product through different routes: Unit : Description DRI Kiln : Manufacturing of Sponge Iron using Iron ore, Limestone and dolomite as raw materials & Coal as fuel. Induction Furnace : Manufacturing of MS Billets/ M.S. Ingots using Sponge Iron, Scrap, Ferro Alloys as raw materials. Rolling Mill : Manufacturing of TMT bars / Structural steels using MS Billets / Ingots as raw material. Submerged Arc : Manufacturing of Ferro Alloys by smelting Manganese ore with LAM Furnace coke, quartz and Mn Slag. Power generation : Power generation through WHRB by utilizing hot waste flue gases from DRI kilns. Power generation through FBC boiler using coal, Dolochar as fuel.

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION. Indian Steel Industry Looking at the present world and India Steel scenario, decision by the Company to set up the unit is timely. Indian Steel industry is poised for a massive growth in next 10-12 years.

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International Steel Scenario Global Steel demand is rising on the back of accelerated infrastructure activity in China, CIS countries & India; housing and industrial boom in Middle East and the African Countries. During the last almost decade-long recession, the industry has consolidated in terms of ownership as well as mothballing of inefficient capacities. Internationally steel prices are expected to continue firming up.

National Steel Scenario Indian government has announced National Steel Policy (NSP) in early November, 2005. The policy envisages a compound annual growth rate (CAGR) of 7.3% per annum in steel sector up to 2019-20. To achieve this, the NSP aims to increase indigenous production from 44Mt level to about 110 Mt by 2019-20, through multi-pronged strategy. The focus of NSP is on to achieving global competitiveness, not only in terms of cost, quality and product- mix but also in terms of global benchmarks of efficiency and productivity. The government proposes to create incremental demand for domestic consumption of steel through promotional efforts, awareness drives and strengthen the delivery chain, particularly in rural areas. According to available estimates, the NSP mentions that domestic consumption of steel in India stood at 31Mt in 2003-04. Bringing production up to 110 Mt would, therefore, mean an increase in domestic consumption of about 80Mt. The urban per capita consumption is expected to go up from the present level of 77 kg to 165 kg in 2019-20 at CAGR of 5%, while in rural areas the consumption is slated to double from 2 kg to 4 kg at CAGR of 4.4 %. To boost production to a level of 110 Mt by 2019-20, the domestic producers of steel have announced massive expansion of capacities. In addition, many Greenfield projects have been planned. Two big global players from abroad, MITTAL ARCELOR, the world’s biggest steel producer and POSCO of South Korea, globally the fifth largest producer of steel, have also joined the Indian steel industry’s venture to meet the growth targets. Looking at the world average per capita steel consumption of 150 kg and the average of 328 kg in developed countries, the projections of NSP seem to be quite realistic.

2.3 DEMAND AND SUPPLY GAP Demand for steel is high and as soon as they are processed they will be supplied on PAN India absis to various type of consumers & users.

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2.4 EXPORT POSSIBILITY

As the Indian steel industry has entered into a new development stage from 2007-08, riding high on the resurgent economy and rising demand for steel. Rapid rise in production has resulted in India becoming the 4th largest producer of crude steel and the largest producer of sponge iron or DRI in the world. As the demand is more the export possibility of Sponge Iron will also be more. As the demand is more the export possibility will also be more.

2.5 DOMESTIC/EXPORT MARKETS

While the demand for steel will continue to grow in traditional sectors such as infrastructure, construction, housing automotive, steel tubes and pipes, consumer durables, packaging, and ground transportation, specialized steel will be increasingly used in hi-tech engineering industries such as power generation, petrochemicals, fertilizers, etc. The new airports and railway metro projects will require a large amount of steel. Hence the domestic and export markets for steel sector will rise.

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

The local areas will be benefited by way of generation of employment opportunities, increased demand for local products and services. There will be an overall improvement in the income level of the local people.

The project creates employment to about 500 persons directly once the whole plant comes to the operational stage and about 300 persons during construction stage. Top priority will be given to locals for Semi-Skilled and Unskilled jobs. With the development of this Plant there will be lot of scope for more ancillary development, which in turn will benefit the nation.

There will be a certain enhancement of educational and medical standards of people in the study area. There will be generally positive and beneficial impacts by way of economic improvements, transportation, aesthetic environment and business generation. There will be an overall upliftment of socio-economic status of people in the area with the implementation of the project.

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Chapter – 3 PROJECT DESCRIPTION 3 (i) TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY:

3.1.1. Type of Project:

Avinash Energy Private Limited proposed for installation of steel plant, envisage to produce the following product through different routes: Unit : Description DRI Kiln : Manufacturing of Sponge Iron using Iron ore, Limestone and dolomite as raw materials & Coal as fuel. Induction Furnace : Manufacturing of MS Billets/ M.S. Ingots using Sponge Iron, Scrap, Ferro Alloys as raw materials. Rolling Mill : Manufacturing of TMT bars / Structural steels using MS Billets / Ingots as raw material. Submerged Arc : Manufacturing of Ferro Alloys by smelting Manganese ore with LAM Furnace coke, quartz and Mn Slag. Power generation : Power generation through WHRB by utilizing hot waste flue gases from DRI kilns. Power generation through FBC boiler using coal, Dolochar as fuel.

3.1.2. Interlinked Project: As per the Ministry of Environment & Forests, New Delhi notification, dated 14thSeptember, 2006 and amendment thereof, All the Primary metallurgical plants were listed at S.N. 3(a) under Metallurgical industries (ferrous &nonferrous) under Category ‘A’ in EIA Notification, 2006. The proposal is appraised at the Central level as is comes under Category ‘A’. There are interlinked projects in the proposed expansion project.

3 (ii) LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH COORDINATES:  Plant is located at Mohra & Hirmi Villages, Simga (T), Baloda Bazar-Bhatapara (D), C.G..  Total land earmarked for the project is 27.129 Ha. (67 Acres). Total land taken on lease for the proposed project.

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 The Khasra Nos. of the total land are 146, 147, 148, 149, 150, 168/1,2,3&4, 169, 170/1,2,3,4&5, 171, 172/1,2,3,4,5,6,7,8,9&10, 173, 174/1&2, 175, 176, 177/1 & 3, 178, 179/1&2, 180, 181/1,2 & 3, 182/1 & 6, 183, 184 of Mohra Village & 872/2, 856, 855/3 of Hirmi village.  The coordinates of the Project site area S.No. Latitude Longitude 1. 21° 30' 59.76" N 81° 56' 23.15" E 2. 21° 31' 02.03" N 81° 56' 32.46" E 3. 21° 31' 05.63" N 81° 56' 46.99" E 4. 21° 31' 02.19" N 81° 56' 51.64" E 5. 21° 30' 54.12" N 81° 56' 49.65" E 6. 21° 30' 53.82" N 81° 56' 41.72" E 7. 21° 30' 53.65" N 81° 56' 35.07" E 8. 21° 30' 49.35" N 81° 56' 33.69" E 9. 21° 30' 48.19" N 81° 56' 21.39" E

 The entire project area will fall in the Survey of India topo sheet no. 64 G/14.  Google earth map, General Location map, Topographical map showing 10 KM. radius of the proposed project site of is shown as Figure No. 1, 2 &.3.  Plant layout show in Figure No. 4. Fig. No. 1 GOOGLE EARTH MAP SHOWING BOUNDARY OF THE PROPOSED PROJECT

Proposed project site

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Fig. No. 2 GENERAL LOCATION MAP SHOWING PROPOSED PROJECT SITE

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Fig. No. 3

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FIGURE – 4: PLANT LAYOUT

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3.3. DETAILS OF ALTERNATE SITES CONSIDERED The following three alternative sites have been considered for the proposed project: S.No. Particulars Site #1 Site # 2 Site # 3 (Mohra & (Kathiya) (Manpur) Hirmi) 1. Location (Village) Mohra & Hirmi Kathiya Manpur 2. Geographical Coordinates 21°30'57.27"N 21°28'11.64"N 21°33'27.62"N 81°56'35.55"E 81°55'21.37"E 81°53'7.52"E 3. Areas falling under the critically Nil Nil Nil polluted areas (within 10 Kms. Radius) 4. National Parks / Wild life Nil Nil Nil Sanctuaries / Bird Sanctuaries / Tiger reserve / Elephant corridors / Migratory routes for Birds / Reserve Forest (within 10 Kms. of the project site) 5. Sensitive Areas with 10 Kms. Nil Nil Nil radius of the site 6. Type of Land Double Crop 25% Single Crop 100% Double Crop 90% (As per records) Single Crop 75 % Single Crop 10 % 7. Distance of nearest Habitation Mohra – 1.2 Kathiya Village Manpur Village Kms (0.3 Kms.) (0.2 Kms.) 8. Nearest Water body Water body Kumahari tank Tank (0.27 Kms.) (0.5 Kms.) (0.12 Kms.) 9. Road Connectivity Exist Exist Exist 10. Rail Connectivity Available Available Available Based on the above criteria, Site # 1 at Mohra & Hirmi villages has been selected for the proposed coal washery.

3.4 Size or magnitude of operation: The plant configuration, production capacity of the proposed project is as follows. S.No. Name of the Unit & Product PROJECT PRODUCTION CAPACITY CONFIGURATION 1 DRI plant 4x100 TPD 3,63,000 TPA (Sponge Iron) 2x350 TPD 2 Induction Furnace 4x15 MT 3,30,000 TPA (M.S. Billets / M.s. Ingots) 2x20MT 3 Rolling Mill 2x500 TPD 3,30,000 TPA (TMT Bars / Structural Steels / Rolled Products) 4 Submerged Arc Furnaces Ferro – Silicon – 12,600 TPA ( Ferro Alloys) 2x9 MVA or Silico–Manganese- 28,400 TPA

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or Ferro–Manganese – 37,000 TPA 5 Captive Power plant 4x2.5 MW WHRB – 30 MW 2x10 MW 1x12 MW FBC – 12 MW

3.5 Manufacturing Process 3.5.1 Manufacturing Process Sponge Iron through DRI Kiln Major plant facilities The major plant facilities for the sponge iron plant envisaged are as follows:  Day bins  Rotary kiln and cooler  Off gas system  Product processing and product storage.

Day bins There shall be a day bin building to cater to raw material requirement of the kiln. The day bin building will comprise of six bins, one for iron ore, two for feed coal, one for limestone/dolomite and two bins for injection coal. These bins will generally have storage of about one day's requirement of screened iron ore feed (5-20 mm), feed coal (6-12 mm, 12 – 25 mm), limestone/dolomite (1-4 mm) and injection coal (3-6 mm. 6-12mm). Weigh feeders will be provided to draw the required quantity of various materials in proportion from the bins and the same will be conveyed to the kiln feed end and discharge end.

Rotary kiln and cooler The rotary kiln of 3.0 m dia. And 42 m length will be provided for reduction of iron ore into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion resistant refractory castable’s throughout its length with damps at feed end and discharge end.

The rotary kiln will be supported on four piers. A slope of about 2.5% shall be maintained. Then main drive of the kiln will be by two DC motors with thyristor control. The speed of the kiln can be varied depending upon the operating conditions. The speed of the kiln will be in the range of 0.25-0.75 rpm. The auxiliary drive of the kiln will be by two AC motors.

The other main components of the kiln will be as given below:

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 Feed end and discharge end transition housing of welded steel construction with refractory lining including feed chute.  Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end.  On board equipment like fans, manifolds, ports, slip ring, instrumentation etc.  Cooling fans at feed end and discharge end.  Feed end double pendulum valve & dust valves.

The kiln feed from the charging end will consist of sized iron ore (5-20mm), non-coking coal (6-25 mm) and limestone/dolomite (1-4mm). Air will be supplied to the kiln through shell mounted air fans. A part of the required coal (3-6mm, 6-12mm) shall be thrown from kiln discharge end. The slinger coal will be withdrawn from the respective bins in suitable proportion and pneumatically injected into the kiln. Necessary rotary feeder, compressor, piping and valves will be provided.

0 In the kiln, the iron ore will be dried and heated to the reduction temperature of 1000 - 1050 C. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide generated in the kiln from coal. The heat required for the reduction process will also be supplied by the combustion of coal.

Thermocouples will be installed along the length of the kiln shell for measurement of thermal profile of the kiln. The temperature will be controlled by regulating the amount of combustion air admitted into the kiln through no. of ports with the help of fans mounted on the kiln shell and by controlled coal slinging. The DC main drives provided to rotate the kiln will have variable speed. Auxiliary drive is provided for slow rotation.

The reduced material from the kiln will be cooled indirectly in a rotary cooler by an external water spray. The kiln will be provided with one rotary cooler. The rotary cooler will be of 2.3 m dia. And 22 m length and will be supported on two piers with a slope of about 2.5 %. The main drive and the auxiliary drive of the cooler will be by one no. separate AC motor. The speed of the drive will be about 1 rpm. The cooler will be provided with one plain riding ring and one thrust riding ring and will be provided with two sets of support rollers at two piers and one set of hydraulic thrust rollers with antifriction bearings. About 1 m end portion of the cooler acts as a screening section, which separates all the accretions larger than 50 mm from the reduced

18 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) material. These lumps will be discharged separately via. Lump gate. Rest of the material will be discharged on to the conveyor via double pendulum valve.

The other main components of the cooler will be the following.  Feed end housing (part of reactor to cooler transition) of welded steel construction with refractory lining.  Cooler discharge end housing of welded steel construction.  Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system at feed end and discharge end.

The cooler will be lined with refractory castable for about 4.0m length from the feed end. Bypass arrangement will be provided at the discharge end of the cooler for emergency discharge of materials. The cooled product will be conveyed to the product processing building by a system of belt conveyors. The cooling water will be collected in the trough below the cooler and sent to the cooling tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system will be followed in the plant.

The rotating parts of the kiln and cooler will be sealed suitably against the stationary parts at the connecting points to avoid leakage of dust laden gases.

Off gas system The kiln shall have its separate off gas circuit. Hot waste gases leave the rotary kiln at about 950 – 1000oC through kiln feed end housing, dust settling chamber and come to an After Burning Chamber (ABC), where combustibles are burnt completely by supplying excess air. The gases at about 900 - 950oC will then be led to a air cooled heat exchanger and then through an Electro- static precipitator (ESP) before letting them out into the atmosphere through ID fan and a stack of adequate height.

Product processing and storage There shall be one product processing unit for handling the cooler discharge. The product containing sponge iron, char and spent lime, from the cooler discharge end will be discharged to a set of conveyors and sent to the product processing building. The kiln-cooler system shall have a separate surge bin of approx. 200 T capacity. Product from surge bin can be withdrawn through

19 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) vibrating feeder and fed to the product processing building by conveyor. In the product processing building, the product will first be screened in a double deck screen having 3mm and 20mm screens. +20mm material shall be dumped as rejects. The screened product i.e., +3-20 mm and -3 mm fraction shall separately be sent to the product storage separation. Sponge iron lump (3-20 mm) shall be sent to the product storage building for storing in two no. of bunkers where three days storage has been proposed. The sponge iron fines (-3 mm) will be stored in the fines bunker in the product processing building itself where one day storage capacity will be provided. The sponge iron lump & sponge iron fines will be further conveyed from the respective bunkers by truck. The char/non-magnetics shall be stored in separate bins. Char will be utilized for power generation in the FBC Boiler.

3.5.2 Manufacturing Process MS Billets Steel Melt Shop (SMS) is crated to melt the Sponge Iron along with melting scrap and fluxes to make pure liquid steel and then to mould it in required size billets. The shop consists of following equipment and subassemblies:

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Induction Furnaces: Induction Furnace is a device to melt the charge material using electrical power. It consists of Crucible lined with water cooled induction coils, Electrical system to give controlled power to induction coil, Hydraulic tilting system, Heat exchanger to cool the circulating water, water softener for generating soft water, furnace transformer, Power Factor improvement system and surge suppressor.

Ladles: Ladles are pots with refractory lining inside to withstand 1600 degC temperature. It has side arms so that can be lifted with the help of crane. Ladles are used to stores the liquid steel from Induction Furnace and take it for further processing. Ladles are with bottom nozzle and pneumatically operated gate for discharge of liquid.

Ladle Refining Furnace (LRF): Ladle furnace is a mini electric arc furnace. It has three carbon electrodes, roof to cover the ladle, and furnace transformer of suitable capacity. The operation of electrodes, roof etc are controlled by hydraulic system. Ladle furnace is used either to keep the liquid steel for sequence casting or for further refining of the liquid steel to make better quality steel.

Cranes: Electric Over-head (EOT) cranes of various capacities are used to carry the ladles/materials at different places. Cranes are used in Melting hall to charge melting scrap, remove the ladles to the LRF, further to place it over the Tundish of the Continuous Caster, to remove billets from the cooling bed and store at designated places, and also for other petty use. Accordingly the sizes, capacity and numbers of cranes are decided.

Continuous Casting Machine (CCM) : CCM is used to continuously cast the liquid steel in required cross section and in length. It consists of Tundish, Mould, Bow with Withdrawal mechanism, straightening mechanism and cooling bed, hydraulic system for withdrawal mechanism, water pumps and cooling towers for water spray on the withdrawn section as well as on the cooling bed. Dummy bar is provided to start the casting. Tundish is a rectangular vessel, lined with refractory and having discharge nozzle with pneumatically operated gate. A stand is erected over it where the ladle is stationed for discharging the liquid in it. Mould is of copper with water cooled jacked. Its cross-section in the bottom is of the size of which billet is to be drawn. Initially the dummy for of the same size is kept inserted. When the liquid steel is poured in the mould the dummy bar is drawn slowly, so that the liquid steel in partially frozen state comes out of the mould. Water spray nozzles are installed to spray water over the just drawn billet to cool it

21 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) further and to harden the skin of the drawn billet.MS Billets will be produced in Continuous Casting Machine. The following is the Process flow diagram. The process flow diagram is shown below.

3.5.3 Manufacturing Process TMT bars / Structural steels / Rolled products A) With Re-heating furnace A pusher type furnace has been envisaged for the heating of billets. The furnace will be end charging and side discharging. It will have single row as well as double row charging facility. The following size of billet will be fed to Billet Re-Heating Furnace.

 100 mm x 100mm and 150 mm - 200 mm

The furnace will be heated with FO / Pulverized coal. The furnace combustion system will comprise of air blowers, FO storage, supply and preheating system and other associated facilities. The product of combustion will leave the furnace at charging end and exhausted through underground flue tunnel and passed through a metallic tubular recuperator before finally let off to a chimney of sufficient height after passing through Bag filter. A set of instrument will be used for smooth operation of the furnace.

Bar and round mill A cross country type mill has been envisaged for the plant. The stands have been grouped into roughing, intermediate and finishing groups. Roughing group will have 4 (four) stands, intermediate group will have 8 (eight) stands and finishing mill will have 8 (eight) stands. Roughing group of stands will be driven by one motor. 4 nos. of intermediate stands will be driven by two motors and balance 4 nos. will be driven by a separate motor. Each stand of finishing group will be driven by single motor. Necessary guides and troughs will be provided at entry and exit of mill stands. 22 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant)

One wire rod out let has been provided in the mill. The wire rod line will have 4 stand block driven by a single motor through gear box. Coil forming and handling of coil is provided.

Automated tilting, drop type tilter and feeding arrangement will be provided in roughing group of stands. Repeaters have been provided in roughing / intermediate stands as necessary.

Design provision has been made for introduction of slit rolling facility in future to roll 8 mm, 10 mm & 12 mm rebars in two strands. The rebars discharged from the mill will pass through a water cooling system comprising cooling pipes with high pressure water nozzles for rapid water quenching. At the cooling pipes the bar skin temperature will be reduced to about 600oC. The core of the bar still remains hot. This entrapped heat tempers the bar. This thermo-mechanical treatment of the bars increases tensile strength without adversely effecting weldability and elongation properties. This process eliminates requirement of cold twisting of bars for production of rebars.

A dividing shear, to cut the products to cooling bed length, will be located immediately after the water cooling system. This shear will divide all products to cooling bed lengths. Rake type cooling bed has been envisaged to receive the rolled product. Cooling bed will be provided with incoming and outgoing roller tables. One cold shear has been provided to cut the bars coming out of cooling bed into commercial length of 6 to 12 m. The bar products will be formed into bundles and will be strapped by strapping machine manually.

The finished products will be removed by overhead EOT crane and stored in the storage area or dispatched through road vehicles. Process flow chart is given below.

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3.5.4. Power plant 3.5.4.1 WHRB Power Plant Production of sponge iron in DRI kiln generates huge quantities of hot flue gases carrying considerable sensible heat. The energy content of these gases can effectively be used to generate electric power as well as steam for meeting various process requirements. Thus a WHRB (Waste Heat Recovery Boiler) power plant would be an ideally suited proposition to effectively make use of this waste gas. This WHRB Power plant would not only make the plant independent of external source of electric power to some extent but would also result in energy conservation and environment protection.

Steam Turbo-generators (STGs) envisaged for the Power plant will be single cylinder, multistage, extraction – cum – condensing type complete with condenser, air evacuation system, 2 x 100% condensate extraction pumps, electronic governing system, lubricating oil system, regenerative feed heating system etc. The turbine will be fed with steam generated from HRSG in DR kiln. The STGs will be located in the machine hall of the power plant.

4 x 10 TPH capacity of Waste Heat Recovery Boilers will be installed for 4 x 100 TPD kilns & 2 x 40 TPH Boilers will be installed for 2 x 350 TPD DRI Kilns to generate 30 MW Power.

3.5.4.2 AFBC Power Plant The unit will have One AFBC boiler (1 x 48 TPH Capacity) to generate 1 x 12 MW Power. The boiler will be designed for continuous operation at Turbine Maximum Continuous Rating (TMCR). A margin of 10% over TMCR will be taken into account to arrive at Boiler rated capacity. The

24 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) boiler will be natural circulation, circulating fluidized bed combustion, two pass, non reheat, single drum, balanced draft, semi-outdoor type. The boiler will have continuous evaporation rating of approx. 24 tons/hr. (BMCR will not be less than 110% of TMCR) with steam parameters at super heater outlet as 98 Kg/cm2 and 5400C (± 50oC). The feed water temperature at MCR at inlet to economizer is expected to be around 2300C. Steam parameter are to be fine tuned at Boiler outlet based on actual plant layout and piping arrangement. The boiler will be complete with ash /solid separator, economizer, air heater, ducting, FD fans, ID fans and PA fans. Air cooled condensers envisaged for Power plant to conserve water.

3.5.5 FERRO ALLOYS PLANT Ferro Alloys will be smelted at about 1350 – 15000C. This will be achieved by a conventional, Open Submerged Electric Arc Furnace. The three carbon Electrodes, partially submerged in the charge, are supported on hydraulic cylinders for upward and down ward movements to maintain the desired electrical conditions.

The body of the furnace is cylindrical in shape, and is lined with firebricks, silicon carbide bricks and carbon tamping paste. Three tap – holes are provided at 120 degree apart for drawing out both the molten alloy and Slag. During the repair works one of the tap – holes the other will function as stand by.

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The weighed raw materials will be thoroughly mixed in the proper proportion before charging into the furnace, through Skip, Telfer hoist and charging chutes. The charge will be pushed near to electrodes on Furnace top by a Charging Stoker.

As the charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the reductants, will be heavy, gradually settles at the bottom. At regular intervals the furnace will be tapped. The tap hole will be opened by Oxygen lacing pipe and after tapping is completed, it will be closed by clay plugs.

The liquid Silico manganese and Slag will be collected in a Ladle and Slag will be over flowed to sand beds. The metal being retained in the ladle having a Nozzle at bottom which allows metal flows on to C.I. Pans. After solidification the cakes will be broken manually to required lump size. a) SILICO MANGANESE & FERRO MANGANESE PROCESS

Manganese ore is in the form of MnO, SiO2, FeO, Al2O3, MgO and other Oxides. MnO is reduced to Mn and FeO is reduced to Fe taking Carbon from Coke / Coal and the product is produced as Si Mn/Fe Mn. The other oxides are simultaneously removed as Slag along with metal. The Slag and Metal are separated by virtue of its self-differential gravities after collecting in the ladle. The ladle will have a nozzle in the bottom portion through which the metal flows in to C.I. Pans.

Chemical Composition of Si Mn S.No. Constituent Percentage 1. Mn 60 – 65% 2. Si + 15% 3. C 2% 4. S & P 0.03% Max

Chemical Composition of Fe Mn S.No. Constituent Percentage 1. Mn 70 - 75% 2. Si + 1.5% 3. C 7 - 8 % 4. S 0.05% Max 5. P 0.4 % b) FERRO SILICON PROCESS

Ferro Silicon is a Slagless process. Quartz is the main raw material which contains 99%of SiO2. Charcoal and a small percentage of Coal is used as reductants. Mill Scale / Iron Ore is added to

26 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) obtain Ferro Silicon. FeO is reduced to Fe and SiO2 is reduced to Si Combining with Carbon and produced as Fe Si.

Chemical Composition of Fe Si S.No. Constituent Percentage 1. Si 70 - 75% 2. C 7 – 8 % 3. S 0.05 % 4. P 0.4% Max

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Process flow diagram – MANUFACTURING OF FERRO ALLOYS

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3.6 Raw material requirement, Transport etc.: 3.6.1 Raw Material Requirement and its sources Raw Material Quantity Sources Mode of Transport (TPA) For DRI Kilns (Sponge Iron – 363000 TPA) Iron ore 580800 NMDC and Other By rail & road Supplies from (through covered trucks) Chhattisgarh and Odisha Limestone 47190 Supplies from By road Chhattisgarh (through covered trucks) Coal Indian 471900 SECL and Other By rail & road Supplies from (through covered trucks) Chhattisgarh and Odisha Imported 302016 South African and Through sea route, rail Australian route & by road For Induction Furnace (MS Billets / Ingots) – 330000 TPA Sponge Iron 356400 In-house generation By Conveyor

Scrap 46200 Supplies from By road Chhattisgarh and Odisha (through covered trucks) Ferro Alloys 4950 Supplies from By road Chhattisgarh (through covered trucks) For Rolling Mill (TMT bars & Structural Steel/Rolled products) – 330000 TPA M.S. Ingots / Steel billets 379500 In-house generation & through conveyors & purchase trucks Furnace oil 10890 Supplies from Tankers (11200 Chhattisgarh KL) Pulverized coal Indian 66000 SECL and Other By road Supplies from (through covered trucks) Chhattisgarh and Odisha Imported 42240 South African and Through sea route / rail Australian route / by road For FBC Boiler [Power Generation 12 MW] Dolochar 108900 In-house generation through covered conveyors Coal Indian (100 %) 71280 SECL and Other By rail & road Supplies from (through covered trucks) Chhattisgarh and Odisha Imported (100 %) 45651 South African and Through sea route / rail Australian route / by road

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Raw Material Quantity (TPD) Sources Mode of Transport For Ferro Silicon unit (For 2 x 9 mVA) Chhattisgarh / By Rail & Road (covered trucks) Quartz 24450 Andhra Pradesh Mill scales 5000 In-house generation Through conveyor LAM Coke 3800 Raipur By Road (covered trucks) Maharashtra / By Road (covered trucks) EC Paste 1000 West Bengal Bag filter dust 750 In-house generation Through conveyor For Ferro Manganese unit (For 2 x 9 mVA) Manganese Ore 29750 MOIL / OMC By Rail & Road (covered trucks) Chhattisgarh / By Road (covered trucks) Dolomite 5050 Andhra Pradesh LAM Coke 5000 Raipur, Chhattisgarh By Road (covered trucks) Maharashtra / By Road (covered trucks) EC Paste 230 West Bengal Bag filter dust 500 In-house generation Through conveyor For Silico Manganese unit (For2 x 9 mVA) Manganese Ore 22175 MOIL / OMC By Rail & Road (covered trucks) LAM Coke 5300 Raipur By Road (covered trucks) Chhattisgarh / By Road (covered trucks) Dolomite 5050 Andhra Pradesh Chhattisgarh / By Road (covered trucks) Quartz 5700 Andhra Pradesh Maharashtra / By Road (covered trucks) EC Paste 315 West Bengal Ferro Manganese Slag 5000 In-house generation Through conveyor Bag Filter dust 440 In-house generation Through conveyor

3.6.2 Mode of Transport for Raw materials and finished products: The aforesaid few raw materials will be transported through rail up to the nearest available rail head and thereafter the same will be transported to the site through tarpaulin covered trucks.

3.6.3 Market of Final Products: It is proposed to install steel plant with rolled products facility. As the steel/ power sector had huge demand and supply gap. Hence marketing of the product has no problem.

3.7 Availability of water its source, Energy / power requirement and source: 3.7.1 Water Requirement and its sources: Water required for the proposed project will be 735 KLD and will be sourced through Ground water resources. Air cooled condensers will be provided for power plant to reduce the water

30 PRE-FEASIBILITY REPORT AVINASH ENERGY PRIVATE LIMITED (Steel Plant) requirement. Water permission from Central Ground Water Authority will be obtained before the commencement of the project. Following is the breakup of water requirement: WATER REQUIREMENT WATER REQUIREMENT S.No. Item (in KLD) 1. Sponge Iron 220 2. Induction Furnace 65 3. Rolling Mill 55 4. Power Plant (WHRB : 30 MW + FBC : 12 MW) a) Boiler makeup water 290 b) DM Plant regeneration 40 5 Ferro alloys plant 50 6 Domestic requirement 15 Total 735

3.7.2 Sources of Energy/ Power and its sources: Power required for the proposed project during construction will be taken from State Electricity Board. Power required for the proposed project during operation will be met partly from captive power plant (42 MW) and remaining from State Electricity Board. The following will be the power consumption break-up for each unit S.No. Plant Power Requirement (MWH) 1. DRI 5.3 2. SMS 29.2 3. Rolling Mill 6.3 4. Ferro alloys 42.0 5. Power Plant – WHRB 3.0 6. Power plant – AFBC 1.2 Total 86.9

3.8 Generation and disposal of Wastes [Waste Water and Solid Wastes]: 3.8.1 Waste Water Generation: The wastewater generated from the DRI plant, SMS & Rolling Mill will be sent to settling tank and will be recycled back to the process through closed-circuit cooling system. Effluent from power plant will be treated and after ensuring compliance with SPCB norms, it will be utilized for dust suppression, ash conditioning and for greenbelt development. Sanitary waste water will be treated in septic tank followed by sub-surface dispersion trench. Hence there will not be any chance of contamination of water bodies due to proposed project.

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3.8.2 Solid Waste Generation and its disposal The following will be the solid waste generation and disposal from the proposed project. S.No Waste Method of disposal

1. Ash from DRI Will be given to Brick manufacturers. 2. Dolochar Will be used as fuel in AFBC based power plant. 3. Kiln Accretion Slag Will be utilized in road construction. 4. Wet Scraper Sludge Will be given to brick manufacturer. 5. SMS Slag Slag from SMS will be crushed and iron will be recovered & remaining non –magnetic material being inert nature, will be used as sub base material in road construction / used for brick manufacturing / civil construction works like PCC and wall construction 6. Dust from APCS Will be being given brick manufacturers 7. Mill scales from Rolling Mill Will be given to Ferro alloy manufacturing units. 8. End Cuttings Will be recycled to SMS unit 9. Ash from Power Plant Will be given to Brick manufacturers 10. Ferro alloys Slag Slag produced from Ferro Manganese production will be utilized in Silico Manganese production. Slag produced from Silico Manganese production is utilized in road construction/landfill.

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Chapter – 4 SITE ANALYSIS

4.1 Connectivity The Project site is well connected with Rail and Road connectivity. The following table gives brief regarding connectivity of the proposed project site: Component Description Road : The proposed site is connected close to Village Road. However NH # 130 (Bilaspur – Simga road) is situated at a distance of 40.0 Kms. (By Road) from proposed site. Rail : Tilda R.S – 15.5 Kms . Air port : Raipur Airport – 41.8 Kms.

4.2 Land Form, Land use and Land ownership 4.2.1 Land Form: Present land is private agriculture land.

4.2.2 Land Use of the Project Site Present land use is agriculture.

4.3 Topography Topography of land is more or less flat terrain without much undulation.

4.4 Existing land use pattern: 4.4.1 Land use pattern of the Project site Total project area is 27.129 Ha. (67 Acres).

4.4.2 Environmental Setting of the Project Site: The Salient Features / Environmental features with in 10 km of the Project Site are given below. Salient Features / Environmental features Aeral Distance w.r.t. site / Remarks National Park/ Wild life sanctuary / None Biosphere reserve / Tiger Reserve / Elephant Corridor / migratory routes for Birds Historical places / Places of Tourist None importance / Archeological sites Industrial areas / cluster (MoEF office None memorandum dated 13th January 2010)

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Defence Installations None Village Nearest Village is Mohra (1.2 Kms.) Reserved forests None Water bodies Mahanadi canal – 1.5 Kms. Kumhari Tank -3.5 Kms. Banjari nala – 3.2 Kms. Few tanks & ponds exists within 10 Km radius Crops in the Study Area Paddy is the main crop followed by pulses. Highway Nil Railway station Nil Port facility Nil Airport Nil Interstate Boundary Nil Seismic zone as per IS-1893 Seismic zone – II R & R Not applicable as there are no habitations in the additional land proposed for expansion.

4.5 Existing Infrastructure There are no existing infrastructures in the proposed project site.

4.6 Soil classification In general it can be said that the district is covered by red gravely soils, red sandy soils, lateritic soils, red and yellow soils and black soils.

4.7 Climatic data from secondary sources It is too Hot in summer. Simga summer highest day temperature is in between 28 °C to 45 °C . Average temperatures of January is 22 °C , February is 24 °C , March is 29 °C , April is 32 °C , May is 36 °C .

Simga has a tropical wet and dry climate. Temperatures remain moderate for most of the year, apart from the summer from March to June, which can be extremely hot. Monsoon season starts from late June and ends in early October. Winters last from November to January and are mild, although lows can fall to 5 °C (42 °F). The average rainfall in the district is around 1400 mm.

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Chapter – 5 PLANNING BRIEF

5.1 Planning Concept:

Avinash Energy Private Limited is proposed for establishment of Sponge Iron production capacity from 3,63,000 TPA, Induction Furnaces to manufacture 3,30,000 TPA of M.S. Ingots / Billets, Rolling Mill to manufacture 3,30,000 TPA of TMT bars / Structural Steel / Rolled Products, Power plant of 42 MW (WHRB – 30 MW & FBC – 12 MW) & Ferro alloys plant production capacity of Ferro – Silicon – 12,600 TPA (or) Silico–Manganese- 28,400 TPA (or) Ferro–Manganese – 37,000 TPA.

5.2 Population Projection: There are no major human settlements in the vicinity of the project site. The manpower requirement will be sourced from the local areas to the extent possible; hence not much of settlement of outside people in the area. However population concentration may increase around the project site due to increase in ancillary activities.

5.3 Land use planning: Proposed project site is located at Mohra & Hirmi Villages, Simga Tehsil, Baloda Bazar-Bhatapara District, Chhattisgarh. Total land earmarked for the project is 27.129 Ha. (67 Acres). The following is the land use statement S.No. Item Area in acres 1. Built-up area 20.0 2. Storage area 5.0 3. Internal roads 3.0 4. Parking area 3.0 5. Greenbelt area 22.0 6. Open area 12.0 Total 67.0

5.4 Amenities/Facilities. Facilities like canteen, rest room and indoor games facilities will be provided in the proposed site as basic facilities to workers.

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Chapter – 6 PROPOSED INFRASTRUCTURE

6.0 Proposed Infrastructure 6.1 Industrial Area (Processing Area) The main plant area comprises of Kiln sheds, Furnace sheds, Rolling mill area, SEAF shed, TG Building, raw material storage and product storage etc.

6.2 Residential Area (Non Processing Area) No colony is proposed; however facilities like canteen, rest room and indoor games facilities will be provided in the proposed project site.

6.3 Green Belt. About 1/3rd of total land availability will be developed with greenbelt i.e 22 Acres of land will be allocated. 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.  5 m to 20 m wide greenbelt is being maintained all around the plant.  The tree species to be selected for the plantation are pollutant tolerant, fast growing, 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 Social Infrastructure. Social infrastructure will be developed as per need based in the Villages of the vicinity of the project.

6.5 Connectivity: The Project site is well connected with Rail and Road connectivity. The following table gives brief regarding connectivity of the plant site:

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Component Description Road : The proposed site is connected close to Village Road. However NH # 130 (Bilaspur – Simga road) is situated at a distance of 40.0 Kms. (By Road) from proposed site. Rail : Tilda R.S – 15.5 Kms . Air port : Raipur Airport – 41.8 Kms.

6.6 Drinking Water Management: The workers at the plant during construction will be provided with water for their requirement and for the construction activities. The construction labour will be provided with sufficient and suitable toilet facilities to allow proper standards of hygiene. These facilities would preferably be connected to a septic tank and shall be maintained properly to have least environmental impact. Drinking water required for the workers will be met from ground water resources.

6.7 Sewerage System. Domestic effluent collected through toilet blocks will be collected through well designed sewer network and send to Septic tanks followed by sub surface dispersion trenchs.

6.8 Industrial Waste Management. The wastewater generated from DRI, SMS and Rolling mill, Ferro alloy units will be recycled through closed circuit cooling system. No discharge of wastewater from the proposed project.

Effluent from power plant such as boiler blowdown, DM Plant regeneration. Initially the acidic and alkaline effluent streams coming from cation and anion units of DM plant will be neutralized in a neutralization tank. Service water will then pass through an Oil Separator to remove the oil content in the effluent. The pH of Boiler blowdown will be between 9.5 and 10.5. Hence this effluent stream shall be neutralized in a neutralization tank before mixing with other effluent streams. All these effluent streams will be mixed in a Central Monitoring Basin. Treated effluent will be used for ash conditioning, dust suppression and for greenbelt development. The sanitary wastewater will be treated in septic tank followed by sub surface dispersion trench. Hence there will not be any chance of contamination of water bodies due to proposed project.

6.9 Solid Waste Management The following will be the solid waste generation and disposal from the proposed project.

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S.No Waste Method of disposal

1 Ash from DRI Will be given to Brick manufacturers. 2 Dolochar Will be used as fuel in AFBC based power plant. 3 Kiln Accretion Slag Will be utilized in road construction. 4 Wet Scraper Sludge Will be given to brick manufacturer. 5 SMS Slag Slag from SMS will be crushed and iron will be recovered & remaining non –magnetic material being inert nature, will be used as sub base material in road construction / used for brick manufacturing / civil construction works like PCC and wall construction 6 Dust from APCS Will be being given brick manufacturers 7 Mill scales from Rolling Mill Will be given to Ferro alloy manufacturing units. 8 End Cuttings Will be recycled to SMS unit 9 Ash from Power Plant Will be given to Brick manufacturers 10 Ferro alloys Slag Slag produced from Ferro Manganese production will be utilized in Silico Manganese production. Slag produced from Silico Manganese production is utilized in road construction/landfill.

6.10 Power requirement & its source Power required for proposed project will be sourced from proposed Captive Power plant and from State power grid.

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Chapter – 7 Rehabilitation and Resettlement Scheme

No rehabilitation and resettlement is required as there are no habitations in the proposed project site.

Chapter – 8 Project Schedule & Cost Estimates

8.1 Likely date of start of construction: Construction activity will be initiated after obtaining Environmental Clearance & Consent for Establishment. Proposed Project will be completed within 7 years after obtaining the aforementioned clearances.

8.2 Estimated project cost: The estimated project cost for the proposed is about Rs. 400 Crores. The following is the breakup. Unit / Details Estimated Cost S.No. (Rs. In Crores) 1. For DRI Kiln (2 x 350 TPD, 4x100 TPD) 115 2. For Induction Furnaces (4 x15 MT & 2 x 20 MT) 40 3. For Rolling Mill (2x500 TPD ) 45 4. For FBC based power plant (12 MW) & WHRB (30 MW) 160 5. Ferro alloy plant ( 2x9 MVA) 30 6. For Occupational Health & Risk Assessment PHC + Ambulance + PPE for workers + Preliminary Medical Checkup for workers + Fire & Safety 3.5 7. For Corporate Environment Responsibility (CER) (as per Ministry’s Office Memorandum vide F.No. 22- 65/2017-IA.III dated 1st May 2018) 6.5 Total 400

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Chapter – 9 Analysis of proposal

9.1 Financial and social benefits: With the implementation of the proposed project, the socio-economic status of the local people will improve substantially. The land rates in the area will improve in the nearby areas due to the proposed activity. This will help in upliftment of the social status of the people in the area. Primary health centre will also be developed by us and the medical facilities will certainly improve due to the proposed project.

9.2 Socio-Economic Developmental Activities The management is committed to uplift the standards of living of the villagers by undertaking following activities / responsibilities as the part of Corporate Social Responsibility.  Health & hygiene  Drinking water  Education for poor  Village roads  Lighting

HEALTH & HYGINE  Personal and domestic hygiene,  Maintaining clean neighborhood,  Weekly health camps offering free-check up & medicines  Ambulance services  Education & drug de-addiction, aids.

DRINKING WATER  Making drinking water available at centralized locations in the village.

SUPPORTING EDUCATION  Providing books to all poor children,  Conducting annual sports festival in the village schools,

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Baseline Data Collection (1st October 2018 to 31st December 2018) Baseline data will be commenced from 1st October 2018.

Wind rose considered for selection of monitoring stations as per nearest IMD data (Raipur region) for October, November & December months.

The wind rose shows that winds are predominantly blowing from North East to South west direction.

Ambient Air Quality Monitoring Stations S.No. STATION DIRECTION DISTANCE CRITERIA FOR SELECTION w.r.t. to w.r.t. to project project site site (in Kms.) 1 Project site ------Representing Project site 2 Mohra S 1.2 Representing Nearest Habitation 3 Hirmi N 2.0 Representing Habitation near to Cement Plant & Mining activity (crosswind). 4 Rawan NE 8.3 Representing Habitation near to Cement Plant & Mining activity in Upwind receptor. 5 Nakti Kumhari SW 3.1 Habitation Representing Down wind direction. 6 Bardih E 1.9 Representing Habitation in crosswind direction. 7 Chhachhanpahri W 2.0 Representing Habitation in crosswind direction. 8 Keotara SW 5.5 Habitation Representing Down wind direction.

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Topographical Map showing Ambient Air Quality Monitoring Stations