Pre-Feasibility Report for Shakambhari Ispat & Power Limited {Category “A” – Expansion Project} Expansion of Shakambhari Ispat & Power Limited plant for production of 0.7875 million tons per annum Crude Steel, 0.214272 million tons per annum Ferro- Alloys (maximum) along with allied facilities at Village: Parvatpur Madandih Radhamadabpur, P.O. Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal
Prepared by:
Environment Consultant Vardan Environet (QCI NABET Accredited EIA Consultant) 82-A, SECTOR-5, IMT MANESAR, GURUGRAM (HARYANA) Contact No. 0124-4343752, 09953147268 www.vardan.co.in
CONTENTS
Chapter Description Page no. 1. EXECUTIVE SUMMARY 4 2. INTRODUCTION OF PROJECT & BACKGROUND INFORMATION 2.1 Identification of Project & Project Proponent 14 2.2 Brief Description of Project 16 2.3 Project Proponent 21 2.4 Need for the project and importance to the region 21 2.5 Imported Vs. Indigenous Production 22 2.6 Demand Supply Gap 22 2.7 Domestic / Export Market 23 2.8 Employment Generation due to the Project 23 3. PROJECT DESCRIPTION 3.1 Type of Project including Interlinked and Independent 25 Project 3.2 Location 26 3.3 Details of Alternative Site Considerations 26 3.4 Size and Magnitude of Operations 27 3.5 Process Details 30 3.6 Raw Materials Requirement 65 3.7 Resource Optimization 67 3.8 Solid Waste Generation & Management 68 3.9 Plant Layout Drawing 70 4 SITE ANALYSIS 4.1 Connectivity 71 4.2 Land Form, Land Use and Land Ownership 71 4.3 Topography of the Land 71 4.4 Proposed Land Use Pattern 72 4.5 Existing Infrastructure 72 4.6 Soil Classification 72 4.7 Climate Data 73 5 PLANNING BRIEF 5.1 Planning Concept 74 5.2 Population Projection 74 5.3 Land Use Planning 74 5.4 Assessment of Infrastructure Demand 75 5.5 Amenities / Facilities 75
Chapter Description Page no. 6 PROPOSED INFRASTRUTURE 6.1 Industrial Area (Processing Area) 76 6.2 Residential Area (Non-processing Area) 76 6.3 Greenbelt 76 6.4 Connectivity 76 6.5 Drinking Water Management 76 6.6 Sewage System 76 6.7 Industrial Waste management 76 6.8 Power Requirement & Supply / Source 77 7. REHABILITATION & RESETTLEMENT (R&R) PLAN 78 8. PROJECT SCHEDULE & COST ESTIMATE 8.1 Project Schedule 79 8.2 Cost Estimate 79 9. ANALYSIS OF PROPOSAL 80
M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report CHAPTER 1 EXECUTIVE SUMMARY 1.0 PREFACE
M/s Shakambhari Ispat & Power Limited (SIPL) is an existing steel plant at village- Parvatpur, Radhamadhabpur, Madandih, PO: Bortoria, Tehsil: Raghunathpur, District: Purulia, in West Bengal.
Company was incorporated on 19th October, 2001 under the Companies Act, 1956 (No. 1 of 1956) and is having Company Incorporation Number U27109WB2001PLC093869 as Ma Chhinnamastika Steel & Power Private Limited. The company subsequently has changed its name from Ma Chhinnamastika Steel & Power Private Limited to Shakambhari Ispat & Power Ltd w.e.f 30.12.2010.
The company obtained Environmental Clearance (EC) from MoEFCC vide F. No. J- 11011/201/2013-IA.II(I) on 21st December, 2016 for expansion of the existing steel plant. The Environmental Clearance was subsequently amended by MoEF&CC on 29th April, 2020. The configuration and capacities of the plant as per the EC and subsequent amendment is as follows:
Table 1.1: Configuration and Production Capacity of the Plant as per EC and subsequent amendment Sl. Facilities Configuration and Final Configuration as per No. Production Capacity as per Amendment issued on EC dated 21.12.2016 29.04.2020 Configuration Production in Configuration Production in TPA TPA 1. Coal Washery -- 740,000 -- 740,000 2. Iron Ore -- 630,000 -- 630,000 Beneficiation Plant 3. Pellet Plant 1x1870 TPA 582,000 1x1870 TPA 582,000 4. Sponge Iron Plant 3x100 TPD 544,000 4x100 TPD 544,000 4x350 TPD 2x350 TPD 1x600 TPD 1700 TPD 1700 TPD 5. Sinter Plant 1x20 m2 198,000 1x20 m2 198,000 6. Mini Blast Furnace 1x350 m3 249,900 1x350 m3 249,900 7. Induction Furnace 1x8 Ton 523,950 9x25 Ton 523,950 with LRF / VOD 2x15 Ton
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Sl. Facilities Configuration and Final Configuration as per No. Production Capacity as per Amendment issued on EC dated 21.12.2016 29.04.2020 2x35 Ton 4x25 Ton 8 Rolling Mill 1000 TPD 300,000 1000 TPD 300,000 9 Lime Plant 250 TPD 80,000 250 TPD 80,000 10 Oxygen Plant -- 225 TPD -- 225 TPD 11 Ferro-alloys Plant 4x12 MVA Fe-Mn 36608 4x9 MVA 63,150 Fe-Mn Si-Mn 26542 / Si-Mn/ Fe- Cr., Fe-Si,/ Pig Iron 12 AFBC Boilers -- 65 MW -- 62 MW 13 WHRB Boilers -- 34 MW -- 37 MW
CTE for establishments of the above units was obtained from WBPCB on 16.03.2017 vide memo no. 101-2N-21/2012€ and CTE for the amendment of the EC was obtained from WBPCB vide memo no. 245-2N-21/2012€ dated 09.09.2020 and vide memo no. 246- 2N-21/2012€ dated on 14.09.2020.
The status of Implementation of the project under the existing EC is as follows:
Table 1.2: Status of Implementation of the Project under the Existing EC
Plant As per EC granted by MoEFCC Implementation Status on 21.12.2016 & ammended on 29.04.2020 Unit Capacity in Operating Under To be TPA implementation Implemented Coal Washery -- 740,000 No No Yes Iron Ore -- 630,000 Shall be Beneficiation implemented Plant under the No No proposed project with changed configuration Pellet Plant 1x1870 TPA 582,000 Shall be implemented under the No No proposed project with changed configuration Sponge Iron 4x100 TPD 544,000 Implemented
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Plant As per EC granted by MoEFCC Implementation Status on 21.12.2016 & ammended on 29.04.2020 Unit Capacity in Operating Under To be TPA implementation Implemented Plant 2x350 TPD 1x600 TPD 1700 TPD Sinter Plant 1x20 m2 198,000 Shall be implemented under the No No proposed project with changed configuration Mini Blast 1x350 m3 249,900 No No Yes Furnace Induction 9x25 Ton IF 7x25 Ton IF Furnace with LRF LRF 1x30 Ton 2x25T LRF:1x30T 523,950 & CCM / VOD & CCM 3x6/11m 3x6/11m Rolling Mill 1,000 TPD 300,000 Implemented Lime Plant 250 TPD 80,000 No No Yes Oxygen Plant -- 225 TPD No No Yes Ferro-alloys 63,150 Fe-Mn / Si-Mn/ Fe- 2x9 MVA 2x9 MVA Plant 4x9 MVA Nil Cr., Fe-Si,/ Pig 31,575 TPA 31,575 TPA Iron AFBC (36 TPH) – 8.5 - - MW AFBC / CFBC --- 62 MW CFBC (100 CFBC (120 TPH) – TPH) – 25 - 28.5 MW MW WHRB @4x100TPD - - DRI – 8 MW WHRB @2x WHRB --- 37 MW 350TPD DRI- - - 15 MW WHRB @1x 1 X 31 MW 600TPD DRI- Nil turbine 14 MW Company has obtained Consent to Operate (CTO) valid till 31.07.2023 from WBPCB for the operating Units.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report 2.0 THE PROJECT
M/s Shakambhari Ispat & Power Limited has proposed for expansion of its existing steel plant by installation of following facilities on total plant area of 81.103Ha (200.41Acres).
Table 1.3: Configuration and Production Capacities of the existing & Proposed Units
Sl. Units Existing as per present EC Configuration & Production Remark No after Expansion Configuration Production Configuration Production TPA TPA 1. Coal Washery -- 740,000 --- 740,000 No expansion 2. Iron Ore -- 630,000 -- 1,000,000 Change in configuration Beneficiation and production Plant 3. Pellet Plant 1x1870 TPD 582,000 1x2835TPD 850,000 Change in configuration and production 4. Sponge Iron 4x100 TPD 544,000 4x100 TPD 910,800 By installation of Plant 2x350 TPD 2x350 TPD additional 1x600 TPD 1x600 TPD 2x600 TPD DRI Kiln, increasing the productivity and increasing no. of operating days from 320 to 330 days 5. Sinter Plant 1x20 m2 198,000 1x90 m2 795,600 Change in configuration and production 6. Mini Blast 1x350 m3 249,900 1x350 m3 416,500 Increase in production Furnace for the existing MBF by increasing the productivity from 2.4 t/d m3 to 3.4 t/d m3 7. Induction 9x25 Ton IF 523,950 9x25 Ton IF 787,500 Increase in production Furnace with LRF 1x30 Ton LRF 1x30 Ton from the existing LRF / VOD & CCM & CCM facilities by increase in 3x6/11m 3x6/11m transformer rating, Charge mix leading to enhance Heats per Day per Furnace 8. Rolling Mill 1,000 TPD 300,000 2x1000 TPD 660,000 By installation of additional 1x1000 TPD RM#2 and increasing no. of operating days from 300 to 330 9. Lime Plant 250 TPD 80,000 250 TPD 80,000 No expansion 10. Reheating - - 1x25TPH - Under proposed
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Sl. Units Existing as per present EC Configuration & Production Remark No after Expansion Configuration Production Configuration Production TPA TPA Furnace expansion 11. Oxygen Plant -- 225 TPD -- 225 TPD No expansion 12. Ferro-alloys 4x9 MVA Fe-Mn / Si- 8x9 MVA Fe-Mn / Si- Installation of Plant Mn/ Fe- Mn/ Fe-Cr., additional 4x9 MVA Cr., Fe-Si,/ Fe-Si,/ Fe-Si- furnace. Pig Iron Cr/ Pig Iron (63,150 (214,272 max.) max.) 13. AFBC / CFBC --- 62 MW --- 62 MW No expansion 14. WHRB – DRI -- 37 MW --- 55 MW Additional 16 MW from new 1x600 TPD DRI Blast Furnace ------9 MW Kiln and 2 MW from Gas based the existing WHRB of 1x600 TPD Total WHRB --- 37 MW --- 64 MW Total CPP --- 99 MW -- 126 MW Producer Gas 6 x 4000 24,000 Proposed under 15. ------Plant Nm3/hr Nm3/hr expansion Briquette Plant Proposed under 16. --- -- 1x 50TPH 300,000 for Ferro-alloys expansion Sinter Plant for Proposed under 17. -- -- 1x600TPD 216,000 Ferro-alloys expansion
3.0 THE PROJECT PROPONENT Mr. Deepak Kumar Agarwal, Chairman cum Managing Director, aged about 51 years, son of Mr. Ramawtar Agarwal is a commerce graduate. He has about 28 years of experience in various industries including coal trading, manufacturing of various Iron and Steel products like Sponge Iron, Billets, Gases, TMT etc. and trading of iron and steel products and trading of petroleum products. 4.0 LOCATION & LAND The project will be located at village- Parvatpur, Madandih, Radhamadabpur, PO: Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal on total land area of 81.103Ha (200.41Acres). 5.0 MANPOWER Existing manpower is 1700. Additionally, approx. 1250 persons comprising Technical Managerial & Supervisory Staff shall be employed for operation of the proposed plant.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report 6.0 POLLUTION CONTROL EQUIPMENT Following pollution control measures has been taken up for the project of M/s SIPL.
SL LOCATION POLLUTION CONTROL FACILITIES 1. DRI Kiln 4x100TPD DRI 1&2 - WHRB followed ESP with common stack DRI 3&4 - WHRB followed by ESP with common stack For Cooler discharge: Pneumatic dust conveying to ABC from Cooler Discharge Bag Filter for Coal Feeding Circuits, Iron Feeding circuits, Day Bin Stock , Cooler Discharge, Intermediate Bin, Product Separation Building, Water sprinkling at dust prone areas. 2. DRI Kiln 2x350TPD WHRB - followed by separate ESP with Common Stack. For Cooler discharge: Pneumatic dust conveying to ABC from Cooler Discharge Bag Filter for Coal Feeding Circuits, Iron Feeding circuits, Day Bin Stock , Intermediate Bin, Product Separation Building, Water sprinkling at dust prone areas. 3. DRI Kiln 1x600TPD WHRB followed by ESP attached with Stack. For Cooler discharge: Pneumatic dust conveying to ABC from Cooler Discharge Bag Filter for Coal Feeding Circuits, Iron Feeding circuits, Day Bin Stock , Intermediate Bin, Product Separation Building, Water sprinkling at dust prone areas. 4. SMS (9x25T) Multicyclone with Spark Arrestor and Fume Extraction system Induction Furnace with Bag filter 5. Captive Power Plant AFBC Boiler (36TPH): ESP attached with Stack CFBC Boiler (100TPH): ESP attached with Stack Bag Filter for Coal Handling Plant (CHP)
6. Ferro Division 4x9MVA SEAF: Bag Filter with FDC & Stack for individual units 7. ETP Installed at Rolling Mills area consisting of settling tank, flocculation & coagulation chambers, sand filter, followed by Clarifier and filter press. For cooling/blow down water recirculation tanks are made to reuse for dust suppression, Bed ash cooling & Fly ash conditioning etc. 8. Neutralization Pit For treatment of waste water from Softening Plant and DM Plant 9. Water Tanker For water sprinkling on road and other needy areas to control fugitive dust emission.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report SL LOCATION POLLUTION CONTROL FACILITIES 10. Domestic waste Septic Tank followed by soak pit Water treatment
7.0 PROJECT COST AND COMPLETION SCHEDULE Cost of the existing facilities is Rs. 1001 Crs. The estimated cost of the proposed facilities is Rs.300 Crs. After getting EC from MOEF&CC and CTE from WBPCB, tenders will be floated for purchase, installation and commissioning of equipment and units and earth work will start parallelly. Estimated completion schedule of project is 60 months.
8.0 SALIENT FEATURES OF THE PROJECT
Sl. Particulars Details No. 1 The Project Expansion Shakambhari Ispat & Power Limited plant for production of 0.7875 million tons per annum Crude Steel, 0.214272 million tons per annum Ferro-Alloys (maximum) along with allied facilities at Village: Parvatpur, Madandih, Radhamadabpur, P.O.: Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal 2 Location of the Project Village: Parvatpur, Madandih, Radhamadabpur, P.O.: Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal 3 Topo-sheet Nos. 73I/10 & 73I/14 4 Latitude 23°36'52"N 5 Longitude 86°47'12"E
6 Area of the Plant Existing: 71.71Ha (177.19 Acres) After Expansion: 81.103 Ha. (200.41Acres) 7 Biosphere Reserve / National Park / Wildlife Sanctuary / Ecological Not within 10 km radius of the project site sensitive area 8 Reserve Forest / Protected Forest No forest land is involved Panchet Reserve Forest 9 Existing Units and capacities as per 1. Pellet Plant 1x1870TPD the exiting Environmental 2. Sinter Plant 1x20m2 Clearance 3. DRI Kiln 4x100TPD, 2x350TPD, 1x600TPD
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Sl. Particulars Details No. 4. Induction Furnace 9x25T with LRF 1x30T and 3x6/11 CCM 5. Rolling Mill 1000TPD 6. Captive Power Plant: 99MW (37WHRB+62MW AFBC/CFBC) 7. Mini Blast Furnace- 1x350m3 8. Iron ore Beneficiation 0.63MTPA 9. Oxygen Plant 225m3 10. Coal Washery- 0.74MTPA 11. Lime Plant- 250TPD 12. Submerged Arc Furnace- 4x9MVA 10 Production as per the existing 1. Pellets- 582,000 TPA capacity 2. Sinter- 198,000 TPA 3. Sponge Iron- 544,000 TPA 4. MS Billets– 523,950 TPA 5. Long Rolled Products- 300,000 TPA 6. Captive Power- 99MW 7. Pig Iron- 249,900 TPA 8. Beneficiated Iron ore- 0.394 MTPA 9. Clean Coal- 0.33MTPA, Middling- 0.28MTPA 10. Calcined Lime- 80,000TPA 11. Ferro Alloys: 63150 TPA Si-Mn or Fe-Mn or Fe-Si or High Carbon Fe-Cr or Pig Iron or Combination of any with maximum production of 63150TPA 11 Proposed Expansion 1. Change in Configuration of Iron Ore Beneficiation Plant –1000,000TPA throughput 2. Change in Configuration of Iron Pellet Plant – 850,000 TPA 3. Capacity enhancement of existing 4x100 TPD, 2x350TPD & 1x600TPD DRI and installation of new 1x600TPD DRI 4. Capacity enhancement of existing Mini Blast Furnace 1x350m3 5. Change in configuration of existing 1x20 m2
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Sl. Particulars Details No. Sinter Plant to - 1x90m2 6. Capacity enhancement of existing 9x25Ton Induction Furnace 7. Rolling Mill- 1000TPD 8. Reheating Furnace- 1x25TPH 9. Capacity enhancement of existing 4x9MVA and installation of new 4x9MVA SAFs 10. Briquetting Plant- 1x50 TPH 11. Sinter Plant for Ferro Division - 1x600TPD 12. Captive Power Plant: a. DRI based WHRB 18MW, b. Blast Furnace Gas based 9MW 12 Production Capacity after the 1. Beneficiated Iron Ore – 625,000 TPA expansion 2. Clean Coal- 333,000 TPA, Middling – 283,000 TPA, Coal fines – 74,000 TPA 3. Pellet Plant 850,000 TPA 4. Calcined Lime – 80,000 TPA 5. Sponge Iron- 910,800 TPA 6. Pig Iron- 416,500 TPA 7. Sinter Plant- 795,600 TPA 8. MS Billets – 787,500 TPA 9. Long Products- 660,000 TPA 10. Ferro Alloys: Si-Mn 142,848 TPA or Fe-Mn 194,058 TPA or Fe-Si 64,285 TPA or High Carbon Fe-Cr 135,330 TPA or Fe-Si-Cr 88,664 TPA or Pig Iron 214,272 TPA or Combination of any with maximum of 214,272 TPA 11. Briquetting Plant- 300,000TPA 12. Sinter Plant (Ferro Div.)- 216,000TPA 13. Captive Power Plant: DRI WHRB based - 55MW, Blast Furnace Gas based 9MW
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report Sl. Particulars Details No. AFBC/CFBC -62MW 13 Cost of the proposed expansion Existing: Rs.1001Crs. Proposed: Rs. 300Crs. Total: Rs. 1301Crs. 14 Manpower Requirement Existing: 1700, Proposed: 1250, Total: 2950
15 Requirement of Water Total 13,690 m3/day after Expansion (Existing – 13,416 m3/day, Additional - 274 m3/day 16 Requirement of Power and Fuel Total 187 MW after expansion (Existing: 148.5MW, Proposed: 38.5 MW). Captive Power Generation: Total 126 MW after expansion (Existing: 99MW, Proposed: 27MW). Balance power requirement of 61 MW will be met from DVC, Company has already had agreement with DVC for supply of 50 MVA Power
DG set 2x500KVA, 1x750KVA & 2x1010KVA has been installed. 1010 KVA capacity DG Set will be installed with each the proposed units. HSD: 69 kl/year & LDO/FO: 630kl/year
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
CHAPTER 2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT The Project Shakambhari Ispat & Power Ltd. was originally incorporated on 19th October, 2001 under the Companies Act, 1956 (No. 1 of 1956) as Ma Chhinnamastika Steel & Power Private Limited, having Company Incorporation Number U27109WB2001PLC093869. The company subsequently has changed its name from Ma Chhinnamastika Steel & Power Private Limited to Shakambhari Ispat & Power Ltd w.e.f 30.12.2010. The Company obtained Environmental Clearance (EC) from MoEFCC vide F.No. J- 11011/201/2013-IA.II(I) on 21st December, 2016. The Environment Clearance was subsequently amended on 29.04.2020. The plant configuration and production capacities as per the amended EC and for the proposed expansion is given below: Table 2.1: Configuration and Production Capacities of the existing & Proposed Units
Sl. Units Existing as per present EC Configuration & Production Remark No after Expansion Configuration Production Configuration Production TPA TPA 1 Coal Washery -- 740,000 --- 740,000 No expansion 2 Iron Ore -- 630,000 -- 1000,000 Change in configuration Beneficiation in production Plant 3 Pellet Plant 1x1870 TPD 582,000 1x2835 TPD 850,000 Change in configuration and production 4 Sponge Iron 4x100 TPD 544,000 4x100 TPD 910,800 By installation of Plant 2x350 TPD 2x350 TPD additional 1x600 TPD 1x600 TPD 2x600 TPD DRI Kiln, increasing the productivity and increasing no. of operating days from 320 to 330 days 5 Sinter Plant 1x20 m2 198,000 1x90 m2 795,600 Change in configuration and production 6 Mini Blast 1x350 m3 249,900 1x350 m3 416,500 Increase in production Furnace for the existing MBF by increasing the productivity from 2.4 t/d m3 to 3.4 t/d m3
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
Sl. Units Existing as per present EC Configuration & Production Remark No after Expansion Configuration Production Configuration Production TPA TPA 7 Induction 9x25 Ton IF 523,950 9x25 Ton IF 787,500 Increase in production Furnace with LRF LRF 1x30 Ton LRF 1x30 Ton from the existing facilities / VOD & CCM & CCM by increase in 3x6/11m 3x6/11m transformer rating, Charge mix leading to enhance Heats per Day per Furnace
8 Rolling Mill 1,000 TPD 30,000 2x1000 TPD 660,000 By installation of additional 1x1000 TPD RM#2 and increasing no. of operating days from 300 to 330
10. Reheating Fce. -- -- 1x25TPH -- Proposed Expansion 9 Lime Plant 250 TPD 80,000 250 TPD 80,000 No expansion 10 Oxygen Plant -- 225 TPD -- 225 TPD No expansion 11 Ferro-alloys Plant 4x9 MVA 63,150 Fe- 8x9 MVA Fe-Mn / Si- Installation of additional Mn / Si- Mn/ Fe-Cr., 4x9 MVA furnace as well Mn/ Fe- Fe-Si,/ Fe-Si- Increasing in production Cr., Fe-Si,/ Cr/ Pig Iron from the existing facilities Pig Iron (2,14,272 max.)
12 AFBC / CFBC --- 62 MW --- 62 MW No expansion 13 Additional 16 MW from WHRB – DRI -- 37 MW --- 55 MW 1x600 TPD DRI (proposed) WHRB – Blast ------9 MW Furnace Total WHRB --- 37 MW --- 64 MW Total CPP --- 99 MW 126 MW 14 Producer Gas 6 x 4000 24,000 Proposed under ------Plant Nm3/hr Nm3/hr expansion 15 Briquette Plant 1x50 TPH 300,000 for Ferro-alloys 16 Sinter Plant for 1x600 TPD 216,000 Ferro-alloys
Company has obtained Consent to Operate (CTO) valid till 31.07.2023 from WBPCB for the installed Units. The existing plant is installed in total area of 71.71Ha (177.19Acres).
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
2.2 BRIEF DESCRIPTION OF THE PROJECT The project is for expansion of M/s Shakambhari Ispat & Power Limited for: A. Enhancement of Crude Steel Production from 0.52395 to 0.7875 MTPA by; i. Increasing the production capacity of MS Billets from 523,950 TPA to 787,500 TPA through 9x25Ton Induction Furnace along with 1x30T LRF & 3x6/11 CCM by increasing transformer rating with revision in Charge mix leading to enhance Heats per Day per Furnace. ii. Installing additional 1000 TPD rolling mill (addition to already installed 1000 TPD rolling mill) to produce total of 660,000 TPA long products iii. Additional installation of 1x25TPH reheating furnace iv. Increasing the production capacity of Iron ore Beneficiation from 630,000 TPA to 1,000,000 TPA by changing the configuration v. Increasing the production capacity of pellet plant from 582,000 TPA to 850,000 TPA by changing the configuration vi. Installing producer gas plant of 24,000Nm3/hr. capacity vii. increase the production of Sponge Iron from 544,0 00 TPA to 910,800 TPA by installing additional 1x600TPD DRI Kiln and enhancing the productivity and number of operating days of already installed 4x100 TPD+2x350 TPD+1x600 TPD DRI Kilns viii. changing the configuration of Sinter plant to 1x90m2 for total production of 795,600 TPA sinter. ix. Increasing the production capacity of to be implemented 1x350m3 MBF from 249,900TPA to 416,500TPA by increasing the productivity from 2.4 t/d m3 to 3.4 t/d m3. x. No changes proposed in the capacities of to be implemented units of Oxygen Plant, Coal washery and Lime Plant B. Enhancement of Ferro Alloy Production from 63150 TPA to 214,272 TPA by; i. Installing additional 4x9MVA SAFs and Increasing capacity from existing 4x9MVA SAFs for enhancing the production of Ferro Alloys to Si-Mn 142,848 TPA or Fe-Mn 194,058 TPA or Fe-Si 64,285 TPA or High Carbon Fe-Cr 135,330 TPA or Fe-Si-Cr 88,664 TPA or Pig Iron 214.272 TPA or Combination of any with maximum of 214,272 TPA ii. Briquetting Plant (1x50TPH) and Sinter Plant (1x600TPD) will be installed additionally for the Ferro-alloys plant.
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
C. Increasing the capacity of Captive Power Plant from 99 MW to 126 MW (Based on DRI WHRB, AFBC, CBFC & BF based) The project will be installed at village: Parvatpur Madandih, P.O. Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal in the total area of 81.103Ha (200.41Acres). The project activity is listed at sl.no. 3(a), Metallurgical Industry (Ferrous & Non-ferrous), under Category „A‟, as per the EIA Notification, 2006. and shall be appraised by the Expert Appraisal Committee at Ministry of Environment, Forest & Climate Change (Industry-1) for prescribing TOR for undertaking detailed EIA Study for the expansion project.
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
Table 2.2: PROJECT PROPOSAL Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA Pellet Plant Capacity with Grinding 1x1870TPD 582,000 268,000 1x2835TPD 850,000 enhancement Facility Producer Gas - - 6 x 4000 Nm3/hr 24,000 Nm3/hr 6 x 4000 Nm3/hr 24,000 Nm3/hr Plant Capacity DRI Kiln enhancement of 30,400 4x100TPD+ Sponge Iron 4x100TPD + 4x100TPD+ 53,200 544,000 2x350TPD+ 910,800 Plant 2x350TPD + 2x350TPD+ 45,600 2x600TPD 1x600TPD 1x600TPD 1x600TPD DRI Kiln 237,600 Mini Blast Mini Blast Furnace: Capacity Furnace: Blast Furnace 1x350m3 enhancement of 1x350m3 249,900 166,600 416,500 with PCI Pig casting Mini Blast Furnace: Pig casting Machine: 1x350m3 Machine: 1x1500TPD 1x1500TPD Sinter Plant of changed 597,600 Sinter Plant 1x20m2 198,000 configuration 1x90m2 795,600 (additional) 1x90m2 will be installed 9x25T 9x25T SMS (IF-LRF- Capacity MS Billets MS Billets LRF: 1x30T & MS Billets 523,950 LRF: 1x30T & CCM) enhancement 263,550 787,500 CCM: 3x6/11 CCM: 3x6/11m
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA
Long Products Long Products Rolling Mill 1000TPD 1000TPD 2000TPD 660,000 300,000 360,000
Reheating Fce -- -- 1x25TPH -- 1x25TPH --
Oxygen Plant 225TPD - - - 225TPD -
AFBC - 36 TPH WHRB @1x AFBC - 36 TPH 600TPD DRI - CFBC - 100 TPH CFBC - 100 TPH 62 MW 64TPH CFBC - 120 TPH CFBC - 120 TPH WHRB WHRB @4x100TPD 8 MW @4x100TPD DRI DRI - 40 TPH - 40 TPH Captive Power WHRB @2x BF Gas Based 27MW WHRB @2x 126MW Plant 350TPD DRI- 71 15 MW 350TPD DRI- 71 TPH TPH WHRB @2x WHRB @1x 600TPD DRI 128 600TPD DRI - 14 MW TPH 64TPH CPP (BF based) AFBC/CFBC-62 MW Total WHRB-37 MW Change in Configuration from Iron Ore 0.37 MTPA -- 0.63 MTPA 0.63MTPA to 1.0 -- 1.0 MTPA Beneficiation (additional) MTPA
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA
Coal Washery 0.74 MTPA - - - 0.74 MTPA
Lime Plant 250TPD 80,000TPA - - 250TPD 80,000TPA Fe-Mn-142,848, Fe-Mn-142,848, or or Si. Mn-194,058, Si. Mn-194,058, Capacity or or 63,150TPA enhancement of Fe Si –64,282 Fe-Mn or Fe Si –64,282 or 4x9MVA SAF with or Si. Mn or Ferro-Alloy metal recovery High Carbon High Carbon 4x9MVA SAF Fe Si or 8x9MVA SAF Plant with Plant Ferro Chrome – Ferro Chrome – with metal High Carbon Ferro with metal metal recovery + 135,330, or 135,330, or recovery Plant Chrome , or recovery Plant Plant Additional Ferro Silico Ferro Silico Pig Iron, or installation of Chrome – Chrome – in combination of 4x9MVA SAF 88,664, or 88,664, or any Pig Iron-214,272, Pig Iron- or 214,272, or in combination in combination of any of any Briquette Plant -- -- 1x 50 TPH 300,000 1x 50 TPH 300,000 Sinter Plant -- -- 1x600 TPD 216,000 1x600 TPD 216,000
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M/s Shakambhari Ispat &Power Limited Pre-Feasibility Report
2.3 PROJECT PROPONENT Mr. Deepak Kumar Agarwal, Chairman cum Managing Director, aged about 51 years, son of Mr. Ramawtar Agarwal is a commerce graduate. He has about 28 years of experience in various industries including coal trading, manufacturing of Various Iron and Steel products like Sponge Iron, Billets, TMT etc. and trading of iron and steel products and trading of petroleum products. The promoters / Directors of the company are in the business of steel and its allied products for considerable period of the time. They have suitable association, experience and background to explore the commercial possibilities of manufacturing and marketing billets.
With this strength, background and the prospects, the promoters envisaged establishment of the steel plant and incorporated the company for running the same under corporate structure.
Address for Correspondence: Mr. Deepak Kumar Agarwal M/s Shakambhari Ispat & Power Limited Village- Parvatpur Madandih, P.O.-Bortoria, Tehsil: Raghunathpur, District- Purulia, West Bengal Ph. No.: 9233331111 Email Id: [email protected]
2.4 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION
All the products proposed to be manufactured have high market demand. Steel is crucial to the development of any modern economy and is considered to be the backbone of the human civilization. The Iron & steel industry has tremendous forward and backward linkages in terms of material flow, income and employment generation. The level of per capita consumption of steel is treated as one of the important indicators of socio- economic development and living standard of the people in any country. All major industrial economies are characterized by the existence of a strong steel industry and the growth of many of these economies has been largely shaped by the strength of their steel industries in their initial stages of development. The demand and production have been growing at a healthy rate for the last few years and the forecast for the next decade and a half is also very promising.
As reported by the Indian Brand Equity Foundation, India‟s finished steel consumption grew at a CAGR of 5.69 percent during FY08-FY18 to reach 90.68 million tonnes (MT).
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India‟s crude steel and finished steel production increased to 102.34 MT and 104.98 MT in 2017-18, respectively. In 2017-18, the country‟s finished steel exports increased 17 per cent year-on-year to 9.62 MTPA, as compared to 8.24 MTPA in 2016-17. Exports and imports of finished steel stood at 0.99 MTPA and 1.22 MTPA, during Apr-May 2018.
Also, the annual requirement of non-cocking coal for various industrial sectors like power, steel and cement is increasing day by day. The reserves of lower ash good coal are depleting and hence in order to fulfill industrial demand, huge reserve of inferior grade of coal is being mined. The average ash of coal now being supplied by ECL is around 40–44%.
2.5 IMPORT Vs INDIGENOUS PRODUCTION
Global Crude steel production has recorded an annual growth of 3.46% during last 10 years (2008 to 2018). Annual growth rate of crude steel production was above 8.5% in India, in last 10 years in compare to 3.46% world growth rate and this will continue. Annual growth rate of crude steel production was above 8.4% in India, compare to 2.6% world growth rate and this will continue. 2.6 DEMAND-SUPPLY GAP Though, India is 2nd largest producer of steel in the World, India‟s contribution is only 17% of the world steel production. On a conservative estimate, the steel demand in India is expected to touch around 150 MTPA by 2020. Steel supply is, however, expected to reach only around 145 MTPA by the same time. The per capita steel consumption in India continues to remain at a level 68 kg in comparison to World average of about 208 Kg and 350 kg in developed countries. Hence long term and short term strategies are necessary in planning the development of the steel industry in the country to improve the level of per capita steel consumption. Private sector is playing an important role in supplementing the requirement of steel in the country. Their contribution in finished steel production has increased to 58.9% in 2017-18 as compared to 45% in 1992-93. In order to meet the increasing steel demand, new steel plants shall be established. It has been observed that a combination of small, medium and large capacity steel plants can contribute in big way in achieving the national interest of self-reliance. Private sector is playing an important role in supplementing the requirement of steel in the country. Their contribution in finished steel production has increased to 58.9% in 2017-18 as compared to 45% in 1992-93. It is expected that private sector will continue to play a dominant role in the future.
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Considering the prospects for the development for Infrastructure, construction and Industrial activity in India in the years to come, large scope exists for increased consumption of long steel products. The projections made by the Ministry of Steel in its Vision-2020 document, there is a significant domestic demand for steel in the Country. Considering the demand for steel in these sectors M/s. Shakambhari Ispat & Power Limited has planned to expand the production capacity of its existing plant at Village – Parvatpur Madandih Radhamadhapbur, P.O. Bortoria, Tehsil: Raghunathpur, District - Purulia in West Bengal. The State can be benefited from the project as there will be direct employment of large people in the Steel plant. Preference will be given to the people of the state possessing requisite skill and qualification criteria. Also there will be lot of scope for indirect employment of the people of the state in and around the project site. 2.7 DOMESTIC / EXPORT MARKET A constant increase in steel export from India and likely to increase further in the coming years. The New Industrial policy opened up the Indian iron and steel industry for private investment by: (a) Removing it from the list of industries reserved for the public sector and (b) Exempting it from compulsory licensing. Imports of foreign technology, as well as foreign direct investment, are now freely permitted up to certain limits under an automatic route. Ministry of Steel plays the role of a facilitator, providing broad directions and assistance to new and existing steel plants, in the liberalized scenario. Instead of selling MS Billets to Rolling Mills of other Units, it is now proposed to set-up enhance the capacity of Rolling Mill to produce TMT Bars and other Long Products in a most energy efficient and cost-effective manner. These Rebars are always in high demand in the construction sector. The finished product will be sold in the Steel markets of Major states in India especially Bengal, Jharkhand, Bihar, Sikkim, Uttar Pradesh and North Eastern States. The products will be produced indigenously and will be consumed in the country and also outside the country as per the demand. Already the company is exporting the product to Nepal. 2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT Existing manpower of the plant is 1700. The estimated additional direct manpower required for the proposed expansion is 1250, comprising administrative, technical, non- technical, skilled and unskilled workforce.
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Since the proposed site is located in close proximity of the industrial sectors, like Durgapur, Bokaro, Jamshedpur, Dhanbad & Asansol etc, availability of skilled labour will not pose any problem. However, specialized training for operation and maintenance will have to be given to selected candidates well in advance before commissioning of the plant. In addition to this there shall be indirect requirement of manpower in transportation sector for transportation of raw material. ------
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CHAPTER 3 PROJECT DESCRIPTION
3.1. TYPE OF THE PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF ANY The project is Industrial project listed under activity 3(a) Metallurgical Industries (Ferrous & Non-ferrous) of EIA Notification, 2006 and falls under Category „A‟.
The project is an expansion of existing works and will be located in the adjacent land area to the existing plant. Project is standalone project for creating Steel Making with rolling facility and Ferro-alloy production along with Captive power generation at one location without dependence on other projects. There is no interlinked project or interdependent project.
Village – Parvatpur, Madandih, Radhamadhabpur, P.O.-Bortoria,
Tehsil: Raghunathpur, District – Purulia, West Bengal Longitude - 23°33'5.55"N
Latitude - 86°32'15.97"E
PROJECT SITE
Purulia District
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3.2. LOCATION
Project will be installed in village- Parvatpur Madandih, PO- Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal. There is no national park, wildlife sanctuary/reserve forest existing within a 10 km radius of the plant. Asansol & Purulia are the nearest city to the project site and can be seen as good opportunity for accessing resources whenever required. The transportation of raw material as well as finished can be easily done by SH-5 (Asansol Purulia Road) at 700meters from project site and SH-8 (Durgapur Purulia Raghunathpur Road) at 10.15kms in south direction and NH-2 (Delhi Kolkata Highway) at 16km in north direction from plant site and also Ramkanali Railway station which is at 4.23km from proposed project site.
The Expansion of SIPL plant required additional land of 9.393Ha (23.22 Acres) located adjacent to the existing plant setup in 71.71Ha. (177.19Acres). Additional Land required is in possession of SIPL, The expansion unit will set up in the existing land as well as additional land making premises of 81.103Ha (200.41 Acres).
3.3. DETAILS OF ALTERNATE SITE CONSIDERED
Alternate site has not been examined as the project is for expansion of existing plant in the adjacently available land.
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3.4. SIZE OR MAGNITUDE OF OPERATION Table 3.1: Project Size Details Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA Pellet Plant Capacity with Grinding 1x1870TPD 582,000 268,000 1x2835TPD 850,000 enhancement Facility Producer Gas - - 6 x 4000 Nm3/hr 24,000 Nm3/hr 6 x 4000 Nm3/hr 24,000 Nm3/hr Plant Capacity DRI Kiln enhancement of 30,400 4x100TPD+ Sponge Iron 4x100TPD + 4x100TPD+ 53,200 544,000 2x350TPD+ 910,800 Plant 2x350TPD + 2x350TPD+ 45,600 2x600TPD 1x600TPD 1x600TPD 1x600TPD DRI Kiln 237,600 Mini Blast Mini Blast Furnace: Capacity Furnace: Blast Furnace 1x350m3 enhancement of 1x350m3 249,900 166,600 416,500 with PCI Pig casting Mini Blast Furnace: Pig casting Machine: 1x350m3 Machine: 1x1500TPD 1x1500TPD Sinter Plant of changed 597,600 Sinter Plant 1x20m2 198,000 configuration 1x90m2 795,600 (additional) 1x90m2 will be installed 9x25T 9x25T SMS (IF-LRF- Capacity MS Billets MS Billets LRF: 1x30T & MS Billets 523,950 LRF: 1x30T & CCM) enhancement 263,550 787,500 CCM: 3x6/11 CCM: 3x6/11m
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Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA
Long Products Long Products Rolling Mill 1000TPD 1000TPD 2000TPD 660,000 300,000 360,000
Reheating Fce -- -- 1x25TPH -- 1x25TPH --
Oxygen Plant 225TPD - - - 225TPD -
AFBC - 36 TPH WHRB @ 1x AFBC - 36 TPH 600TPD DRI - CFBC - 100 TPH CFBC - 100 TPH 62 MW 64TPH CFBC - 120 TPH CFBC - 120 TPH WHRB WHRB @4x100TPD 8 MW @4x100TPD DRI DRI - 40 TPH - 40 TPH Captive Power WHRB @2x BF Gas Based 27MW WHRB @2x 126MW Plant 350TPD DRI- 71 15 MW 350TPD DRI- 71 TPH TPH WHRB @2x WHRB @1x 600TPD DRI - 600TPD DRI - 14 MW 128TPH 64TPH CPP (BF based) AFBC/CFBC-62 MW Total WHRB-37 MW Change in Configuration from Iron Ore 0.370MTPA -- 0.63 MTPA 0.63MTPA to 1.0 -- 1.0 MTPA Beneficiation (additional) MTPA
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Plant As per EC granted by MoEFCC on 21.12.2016 Proposed Units/Enhanced Capacities Total after Expansion & Amendment to it on 29.04.2020 Unit Capacity TPA Unit Capacity in TPA Unit Capacity in TPA
Coal Washery 0.74 MTPA - - - 0.74 MTPA
Lime Plant 250TPD 80,000TPA - - 250TPD 80,000TPA Fe-Mn-142,848, Fe-Mn-142,848, or or Si. Mn-194,058, Si. Mn-194,058, Capacity or or 63150TPA enhancement of Fe Si –64,282 Fe-Mn or Fe Si –64,282 or 4x9MVA SAF with or Si. Mn or Ferro-Alloy metal recovery High Carbon High Carbon 4x9MVA SAF Fe Si or 8x9MVA SAF Plant with Plant Ferro Chrome – Ferro Chrome – with metal High Carbon Ferro with metal metal recovery + 135,330, or 135,330, or recovery Plant Chrome , or recovery Plant Plant Additional Ferro Silico Ferro Silico Pig Iron, or installation of Chrome – Chrome – in combination of 4x9MVA SAF 88,664, or 88,664, or any Pig Iron-214,272, Pig Iron- or 214,272, or in combination in combination of any of any Briquette Plant -- -- 1x 50 TPH 300,000 1x 50 TPH 300,000 Sinter Plant -- -- 1x600 TPD 216,000 1x600 TPD 216,000
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3.5. PROCESS DETAILS 3.5.1 Coal Washery (Existing Unit) The Capacity of the Coal Washery is 0.74 million tons throughput. Out of which, 0.33 million tons per annum is washed coal having 27% ash, 0.28 MTPA is middling and 0.05 MTPA reject. The technical parameters of the Washery are provided in table below:
Plant Capacity : 144.6 TPH No. of operating days in a : 320 year No. of operating hours in a : 16 hours (Two shift operating excluding day daily short maintenance at start up) Annual throughput : 0.74 MTPA Clean coal produced : 0.33 MTPA Middling produced : 0.28 MTPA Reject produced : 0.05 MTPA The Raw Coal shall be of 90% Lump & 10 % fines. Again lumps can be separated into washed coal, fines, middling and rejects
Process: The proposed washery shall be a heavy media cyclone-based coal processing unit and be of latest designs. ROM coal will be delivered to the truck dump station via tippers and the capacity of the truck dump hopper will be 25tons. The truck dump will be an elevated bunker with access for trucks to unload the ROM into the hopper. ROM will be conveyed to the crushing and screening tower using 1200mm belt conveyor, and discharged over a single deck scalping screen having a heavy duty rod deck for screening the (-) 50mm coal. The under size from the screen will be conveyed and stored in storage stockpile. The over size from the screen will be discharged to a double roll crusher with toothed rolls where the 50mm-250mm coal will be crushed to a consistent (-) 50mm size. The crusher product will also report to the stockpiling. A concrete stacking tube is proposed for stocking the raw crushed coal. The stacking tube will have a capacity to store 12,000MT of coal. There will be 2 reclaim hoppers with vibrating feeders at their discharge which will feed coal to plant. This feed coal will be discharged on a raw coal sizing & desliming screen where (-)10/13 mm coal will be removed on the first section of the screen and this coal having a relatively lower ash will be stored in fine coal bunker for sale. The oversize will proceed to the second section of the screen where the coal will be subjected to jets of water by which the slime on the coal body will be washed off. The effluent from the desliming screen will be taken to the effluent treatment plant.
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The coal slurry consisting of coal, water and magnetite will be pumped using a special heavy media pump to the heavy media cyclone. The heavy media bath is the main coal washing device in the coal preparation plant. The deep flow bath already carrying media (water & magnetite powder) and the deslimed coal is received by the bath. In the bath the lighter (clean) is separated through the overflow and the heavier (rejects) is gathered and conveyed through the reject outlet of the bath to the reject screen. Thus the clean coal and reject are separated. Both clean and the reject are sent to a draining and rinsing screens with specially designed under pans to collect the drain water and the rinse water separately. In the first section of the screen (drain section) the water and magnetite slurry is drained partially. The drain water flows back to the heavy media sump. In the second section of the screen (rinse section) water jets are used to wash the coal of magnetite sticking to body of coal. The rinse water being of a lower specific gravity than the slurry in the sump has to be subjected to a wet drum magnetic separator, where magnetite from the rinse water is concentrated and sent back to the heavy media sump for recirculation.
Fig. 3.1: Process flow of Coal Washery
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The reject coal from the reject D & R screen is discharged over the reject coal belt for suitable stock piling. The clean coal is discharged over the clean coal conveyer where the clean coal is blended with raw bypass coal in the ratio to give final ash content as required by the end user. The product is carried to a clean coal load out bin which has clamshell gate at the discharge for loading coal onto trucks. The effluent treatment plant consists of one Hi-rate thickener and its associated flocculent dosing system, underflow sludge carrying pump and a multi roll belt press. The effluent from the plant which reports to the Hi-rate thickener is collected in the thickener tank. This tank is dosed with suitable amounts of flocculent which aids settlement of suspended solids and helps to give a clearer overflow. The settled solids are collected at the bottom cone of the thickener tank by rotating rake arms, the height of which can be adjusted if the amount of solids in the effluent increases. The solids which are collected in the bottom of the thickener is pumped using a special centrifugal pimp to the multi roll belt press for reclamation of water. The dried cakes are blended with rejects. The overflow of the thickener which is clear water is pumped back to the preparation plant for recirculation. The proposed plant is a zero effluent plant and the process selected ensures minimum generation of dust. Table 3.2: Configuration and Production Details of Existing -Coal Washery
Existing Proposed Units Final Configuration Capacity Capacity Capacity Products Unit Products (TPA) (TPA) (TPA) Clean Coal- 0.33 MTPA -- -- Clean Coal- 0.33 MTPA Middling- 0.28 MTPA -- -- 0.74 Middling- 0.283 MTPA 0.74 MTPA MTPA Coal Fines – 0.074 MTPA -- -- Coal Fines – 0.074 MTPA Rejects- 0.05 MTPA Rejects- 0.05 MTPA
Table 3.3: Raw Materials Details of Existing -Coal Washery
Raw Materials Existing (TPA) Proposed (TPA) Total (TPA) Lump Coal 740,000 -- 740,000
3.5.2 Lime Plant (Existing unit) Both lime stone and dolomite can be co-calcined in same kiln due to low requirement of calcined dolomite. Raw lime stone and Dolomite will be screened and sized stone will be fed to Shaft kiln through skip hoist. The kiln feed size 30-60mm. The limestone will be calcined at a temperature 1050-11500C to achieve soft burnt lime. Fuel oil will be used for heating purpose (Specific fuel consumption 850K cal/kg of burnt lime). The discharge from the kiln will be routed through a closed loop screening system to separate out under size
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report fraction and screened lime will be dispatched to SMS through a system of belt conveyors. The under sized fraction of lime will be dispatched in close container to sinter plant. The flow-sheet diagram is given in below:
Fig. 3.2: Process flow of Lime Plant Table 3.4: Configuration and Production Details of Existing -Lime Plant
Existing Proposed Units Final Configuration Capacity Capacity Capacity Unit Unit Unit (TPA) (TPA) (TPA) Lime Kiln Lime Kiln 80,000 -- -- 80,000 1x250 TPD 1x250TPD
Table 3.5: Raw Materials Details of Existing –Lime Plant
Item Existing (TPA) Proposed (TPA) Total (TPA) Limestone 108,000 -- 108,000
3.5.3 Iron Ore Beneficiation Plant (Proposed with changed configuration) In Iron ore beneficiation the Fe content in iron ore fines is increased from a level of 58% to 65%, the process involves scrubbing/washing, closed circuit grinding with hydro- cycloning, flotex gravity separation followed by high intensity magnetic separation. Scrubbing / Wet Screening & Primary Grinding The input iron ore for beneficiation has been taken as 58% Fe -10 mm size. The prime function of beneficiation is to improve the iron content and decrease the alumina / silica
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report ratio. In wet circuit, scrubbing and washing are essential for aluminous and sticky ores. It ensures separation of claying matter from fines. On screening fraction +1 mm is subjected to grinding in ball mill and -1 mm fraction goes to the hydro cyclone for recovery of iron values. Desliming by Hydro Cyclone and Gravity Concentration Hydro cyclones are used to recover iron values from slimes. It is often found that slimes rich in laterites / limonite do not respond well to hydro cyclone or conventional gravity separators in lowering alumina to 2% or below. In such cases hydro cycloning in tandem with flotex density separator has been found to remove alumina in slimes. Secondary Grinding The slurry is then fed to a closed circuit secondary grinding in tandem with hydro cycloning and followed by flotex gravity separator so that the size of feed to HGMS is 45 microns which is the liberation point for Indian hematite ore. Subsequently the slurry is fed to high intensity magnetic separator (HGMS), having a intensity of 7000-20000 gauss for recovery of weekly magnetic hematite particles Concentrate Thickener Concentrate from HGMS is sent to dewatering cyclone to recover concentrate while the water reclaimed is recycled to the plant. The concentrate slurry is fed to the thickener where high ferrous content of iron settles over a period of time. In order to allow elimination of any remaining foreign material in the iron ore slurry, during the process of settling, it is subjected to agitation so that any remaining foreign material is washed away. Since the process of balling requires the moisture content of maximum 8%, the output from thickening machine is passed through ceramic vacuum disc filter and water content is reduced from 50% to 11%. The over flow water is reused in the process and concentrated iron ore slurry is sent to silos. Tailing Dewatering The over flow from the flotex density separator is sent to tailing thickener for onward pumping to tailing dam. In India the iron ore is mainly mined in Odisha, Karnatka and Chattisgarh using conventional drilling and blasting technique. In this conventional mining process nearly 50% iron ore is generated as -10 mm particles which are termed fines. In addition to mining process the processing in steel plant also leads to generation of fines. The iron ore fines generated at mine site were being piled in the past due to their less demand than generation. The steel plant fines were mostly dumped as waste in the past. The dumping of waste fines is not acceptable at present. The utilisation of waste fines is now essential in view of: a. Mineral conservation policy
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b. Preventing mineral wealth loss c. Avoiding environmental issue due to long storage of fines on soil. The exploitation of fines has been less in past due to economic reasons and absence of tougher guide lines concerning environmental problems. This has been causing the poor use of mineral wealth. In the changed economic scenario, the iron fines are now being demanded by iron makers. Still the demand of fines is less than its generation which requires new avenues of its use. Chemical composition of Indian Iron ore fines is as follows. Percentage Fe SiO2 Al2O3 MgO Size % 55-60 6.5 2.3 0.6 100μm-10mm For the utilization of iron ore fines, company is installing sinter plant and pellet plant.
Fig. 3.3: Process flow of Iron Ore Beneficiation plant Table 3.6: Configuration and Production Details of Existing -Iron Ore Beneficiation Plant
Existing Proposed Units Final Configuration Capacity Capacity Capacity Products Products Products (TPA) (TPA) (TPA) Beneficiated Iron Beneficiated Iron Unit under the existing 630,000 Ore- 393,375 1,000,000 Ore- 625,000 EC will be installed with Throughput Through put Tailings – Tailings – 236,250 revised configuration 375,000
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Table 3.7: Raw Materials Details of Existing -Iron Ore Beneficiation Plant
Item Existing (TPA) Proposed (TPA) Total (TPA) Iron Ore Fines 630,000 370,000 (additional) 1,000,000
3.5.4 Producer Gas Plant (Proposed Unit) Coal Gas, produced in Producer Gas Plant (PGP) using coal gas technology, is used as fuel in the pellet plant. This is a clean fuel. The composition of Producer Gas is CH4: 1.5% H2: 13.0% CO: 25.0% CO2: 6.0% N2: 53.9% H2S: 0.20% O2: 0.60% having Net Calorific Value: 1350 Kcal/Nm3. There will be 6 coal gasifiers to produce 4000 Nm3/hour of producer gas. In a fixed bed gasifier, the coal passes downward in counter current direction to gas flow, through various phases (devolatisation, gasification and combustion zones). Mixture of air and steam is introduced in lower part of gasifier through rotating grate. The basic reaction, which takes place in a typical fixed bed gasifier is:
Coal + Air + Steam = CO2 + CO + H2 + CH4 + Tar + Ash The configuration of gasifiers is “cold-clean gas mode”, with “indirect cooling” and separation of tar. There is common coal feeding system consisting of a feeding conveyor from ground hopper conveying coal onto the horizontal conveyor on top of battery of 12X4.0m gasifiers. The said system of conveyors supply coal to “top storage bunkers” of individual gasifiers as per process demand. The coal feeding system of individual gasifiers, consisting of pneumatically operated twin feeding doors, feeds coal into the gasifier reactor from the top storage bunker. Coal is converted into hot producer gas in a water jacketed reactor through a series of thermo-chemical reactions. Water in the water jacket of the gasifiers is converted into steam and then used in the gasification process. Ash generated during the gasification process travels down into the ash pan placed below the reactor. The ash pan is slowly rotated to facilitate discharge of ash from pan onto the ash conveyor. This creates a rotating water seal joint for discharge of ash through the water seal. The ash conveyor carries ash from each of the gasifiers to the ash dump (ash bunker). Gas coming out of individual gasifier reactors will be hot and raw. The gas cooling & cleaning system consists of indirect cooling type centrifugal tar separators and electrostatic precipitators. Hot-raw gas, exiting from the gasifiers will first be cooled and about 80% tar is separated in centrifugal tar separators. Gas from these separators goes to a common header to be conveyed to electrostatic tar separators. Tar from centrifugal tar separators gets collected in individual collection pots and then is pumped to tar storage. Cooling water is continuously circulated to tar separators for external cooling of gas. The temperature of cooling water is maintained within limits with the help of cooling towers.
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Residual tar in gas is separated out in electrostatic tar precipitators. The tar, so separated, will be first collected in tar pits and then transferred to tar tanks for storage. Tar has a good market value and will be sold to authorized chemical manufacturers. Various water seals are used for isolation of gas within the gasifier block, along the gas pipeline and in the gas utilization area. Water used in the seals will be collected when the seals are emptied and the same water is reused for filling the seals. So, there is no regular disposal of seal water. But there could be occasional disposal of seal-water. Such water (which would contain traces of phenols) would be incinerated in the after burning chambers of sponge iron kilns. Coal Tar generated from PGP shall be collected using “Centrifugal Tar Separator” and used as Fuel in DRI Kiln / alternately sold to authorized reprocessors. No waste water will be generated from the process. Centrifugal Tar Separator: Indirect Type Centrifugal Tar Separator‟ consists of 2 stages of indirect cooling of gas and simultaneous centrifugal tar separation. Gas rises upwards from the water seal into the first stage of separator. At the top of first stage, high velocity centrifugal motion is imparted to gas to separate out droplets of tar. As the gas travels down in the outer annular path, it is cooled by external forced cooling. At the same time, condensed and separated tar travels down along the wall of the annular path. As the gas enters the second stage, it is cooled and therefore tar separation is more effective. Here, again, similar action of high velocity centrifugal separation and indirect forced cooling is repeated. However, wastewater generated during the stage of gas cooling shall be charged in the ABC of DRI plant. In Indirect Type Centrifugal Tar Separator, there is no direct contact of gas with water. The cooling is done by heat transfer through wall to circulating water. Tar is removed by centrifugal action without any washing with water. Therefore, phenolic water is not generated in this method of tar separation and the associated water pollution issues are completely eliminated. Generated Tar from the producer gas plant is only 1782 Tons per year and shall be temporarily stored at an isolated location inside the plant premises having storage capacities for around 30 Mt Tar. Finally, it will be sold to authorized re-processors approved by WBPCB / CPCB. Table 3.8: Configuration and Production Details of Proposed -Producer Gas Plant
Existing Proposed Units Final Configuration Capacity Unit Configuration Capacity (TPA) Configuration Capacity (TPA) (TPA) 24,000 6x4000 24,000 - - 6x4000 Nm3/hr. Nm3/hr. Nm3/hr. Nm3/hr.
Table 3.9: Raw Materials Details of Proposed -Producer Gas Plant
Item Existing (TPA) Proposed (TPA) Total (TPA) Coal - 59,400 59,400
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3.5.5 Pellet Plant (Proposed with changed configuration) The process of palletization enables converting Iron Ore Fines into “Uniformed Sized Iron Ore Pellets” that can be charged into the blast furnaces or for Production of Direct Reduced Iron (DRI). Pellets are of uniform size, with purity of 63%- 65% contributing to faster reduction and high metallization rates. One units of 0.85 MTPA capacity pellet plant will be set up. In pellet plant, the concentrated iron ore fines will be mixed with limestone, coke breeze and bentonite. Process of pellets making involves following steps: Slurry Receiving and Filtration: The iron ore will be received by pipe line in slurry form in slurry receiving tanks and filtered in high efficient pressure filters. The iron ore is dewatered (called concentrate). The filtrate is clarified and reused in the pellet making. Drying & mixing: Moist iron powder cake is further conveyed to the mixer through a drier. Temperature of the dryer is controlled to reduce & attain the desired level of moisture to 9-10% required for proper mixing of iron ore. Fluxes Grinding: To improve certain properties of green pellet, quartz and limestone is grinded in a separate grinding machine which is enclosed type having no opening/ vent for to cause emission except the feed end and discharge end. The flux grinding circuit has cyclone & bag filter connected to pneumatic conveying arrangement of material to mixer. Flux powder is conveyed to the drier and the oversize particles collected from cyclonic bag filter chute is re-fed to the grinding mill and this cycle is also repeated. There is neither any generation of wastes nor any possibility of emission. Finely ground moist iron ore is mixed with flux and coal and bentonite or similar binding material in definite proportion and is fed to a mixer to make a mixture of iron ore powder, coal & fluxes required for making green pellet. Such mixture is stored in several surge bins in the burdening building. Surge bins & pelletizer: The discharge from surge bin is achieved with the help of weigh feeder provided with a virbo feeder. The discharge system feeds the mix on to the pelletiser. Pelletiser is an inclined disc rotating at variable speed. Shape, size and quantity of balls is achieved by manipulating the angle and rpm of the disc, moisture and the points of input & output of the disc. Water is added to mix through sprays so as to achieve final levels of moisture required to be achieved the required output. The pelletiser discharges the green pellets on to a collecting conveyor, which takes the product to the screening section. Two roller screens have been provided, one to separate undersize (-8 mm) and the other to separate over size (+16 mm). Both the screens have collecting conveyor underneath to take undersize pellets to the pelletiser for recycling, take over-size pellets to the damp grinding for recycling and to Roller screen charge 8-16 fraction to the travelling grate oven. Travelling grate oven: Right size green pellets are conveyed through a wide belt conveyor, which spreads the pellets to a width matching with the size of the travelling grate oven. The wide belt conveyor has a drive control so as to ensure matching with the speed of the
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report travelling grate. The right size green pellets / balls are then fed to endless linear travelling grate machine which travels inside the oven. The main part of this oven is a travelling grate travelling on rollers. The pellets are dried, and preheated on this grate, which travels at a speed set for achieving the desired retention time for which pellets must be inside the furnace. The metallurgical length of the furnace is divided into following three zones: (A) Drying Zone I (B) Drying Zone II (C) Preheating Zone Pellets pass through the above zones one after the other in sequence. The zones are maintained at 400oC, 600oC & 950-1050oC temperatures respectively. Each zone heats the pellets so as to remove the moisture, impart strength so that pellets can withstand the thermal conditions in the subsequent zone. The process of oxidation and decomposition reactions takes place and pellets achieve sufficient strength to withstand the impact of discharging from grate oven to the rotary kiln where the pellets are fired for final induration. There is no fuel burned in the travelling grate oven. The heat source is the hot air from the annular cooler and the flue gases from the rotary kiln. The sensible heat of the hot air and flue gases is fully utilised in the induration cycle and eventually the flue gases + air mixture are let out in the atmosphere via multi-cyclone and induced draft fan at about 100oC. The multi-cyclone separators ensure that suspended particulate matter emission is within 50mg/Nm3. The spillage material from the grate oven and the material spilled from feed end of rotary kiln are transferred to a screen, where it is screened. The material on the screen is sent to the kiln by a bucket lifter and a chute and the undersize fraction is transferred to the damp mill. Rotary Kiln: The pre-heated pellets/balls are then transferred to a rotary kiln for heat hardening at 1350oC to attain comprehensive strength for handling. This is a rotating kiln furnace inclined towards the discharge end and is rotated to ensure that preheated pellets are uniformly heated to the firing temperature of generally 1250-1350oC. The pellets are fed at the higher end, and are discharged at the lower end. The firing of fuel takes place at the lower end and the exhaust gases go out of the kiln near the higher end. The kiln is designed to operate at temperatures up to 1350oC. The speed of rotation of the kiln and so the retention time of pellets inside the kiln is fixed based upon the results of detailed testing of the raw materials. The refractory lining inside the kiln is designed for the thermal regime appropriate for the quality of raw materials. Gases after useful work done in rotary drum and traveling grate are passed through multi cyclone where the fine particles are collected. Flue gas discharge from multi-cyclone further goes to electrostatic precipitator by induced draft fan to concrete chimney. Dust/ fines collected at multi cyclone and ESP is recycled to the circuit in closed loop. Fuel preparation plant: Fuel for rotary kiln is primarily Producer Gas. As an economic alternative a small captive pulverized coal injection (PCI) plant incorporating a grinding mill (ball mill) & bag filter. The ground coal is carried by hot air at 350–400oC from section II & III of annular cooler. The coarser particles are separated by making the exhaust gases laden with coal to pass through a separator. The coarser particles are fed back into
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report the ball mill & recycled. The rest material goes to the bag filters, where it is separated from exhaust gases. The fine coal discharges into a bunker and the exhaust gases are let out through a vent at the bag filter top. From the bunker the coal is carried to the burner by a root‟s blower for combustion in the rotary kiln. PCI system being Installed for making Anthracite coal lump size to Pulverize coal process Includes feeding and grinding to make the anthracites lump coal to Pulverize. Major equipment used for having grinding with bag filter and Hot Air Generator (HAG) system. Pulverize coal used for raw material coal mixing and optional fuel for kiln. Annular cooler: This is the last metallurgical unit of the palletisation process and aims at cooling the fired pellets in a controlled manner and utilisation of the sensible heat of the pellets through the cooling medium. The equipment in which this function is accomplished is called “annular cooler”. This is eventually a structure rotating in a horizontal plane and consists of wind boxes, blowers and the drive. The cooler is divided into 3 sections and each section is served by a dedicated blower. The blowers blow air through the hot pellets and the hot air so generated in used for: Drying the pellets in grate furnace Carry coal from grinding mill Provide oxidizing atmosphere in the rotary kiln. The pellets eventually cool down to an acceptable temperature of 100-120°C. Product Handling: The cooled pellets are discharged from the coolers into the discharge bin, mounted on load cells The Product belt conveyors is equipped with a water spray system, which is used to cool down hot pellets in case of emergency only. The vibrating product screen finally screens out undersize material from the product pellets. The cooled pellets are discharged from the annular cooler on a belt conveyor, which carries the final product to the silos or stock pile as the case may be, from where it is dispatched to the customers.
Fig.3.4: Process flow of Pellet plant
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Table 3.10: Configuration and Production Details of Exiting & Proposed –Pellet Plant
Existing Configuration Proposed Configuration Final Configuration Capacity Capacity Capacity Configuration Configuration Configuration (TPA) (TPA) (TPA) Unit under the existing EC will be 1x1870TPD 582,000 1x2835 TPD 850,000 installed with revised configuration
Table 3.11: Raw Material Requirement Details of Exiting & Proposed - Pellet Plant
Raw Materials Existing as per EC Additional Total Iron ore fines 206,625 18,625 225,250 Beneficiation 393,750 231,000 624,750 Iron ore Bentonite 6,000 2,500 8,500 Coal/coke 5,000 17,000 Breeze 12,000 Dolomite 12,600 5,250 17,850 Total 630975 2,62,375 893,350
3.5.6 Sponge Iron Plant (Existing unit & Proposed) Sponge Iron or Direct Reduced Iron, DRI as it is popularly known, is a high ferrous content charge material and is used as a substitute for steel scrap as the primary raw material in the Induction Furnace, during the process of manufacture of steel. SIPL is using the proven technology of Coal based Rotary Kiln for the production of Sponge iron. The raw materials required for sponge iron production are high grade ores, non-coking coal and dolomite. Following major facilities are present: Raw Material Handling System Raw Material Feed System Main Processing System – Kiln Cooling System Product Separation System Waste Gas Cleaning System Plant De dusting
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Fig.3.5: Process flow of Sponge Iron Plant The plant will be suitably designed for conveyor transportation as well as storing system for both iron oxide feed, DRI product as well as by product like product fines. The utilities system design will include distribution network for utilities like nitrogen, oxygen, water, electric power, etc. The iron oxide material i.e. lump iron ore (sized) will be collected and conveyed for screening in the oxide screening station and then sent to oxide day bins for storage. The iron ore will be directly sent to the oxide storage bins. Two bins will be earmarked for pellet storage while one bin will store the iron ore lump. About two shifts storage capacity has been planned. Sponge iron is presently being used in Steel melting Shop for production of Billets and rest sold. Table 3.12: Configuration and Production Details of Exiting & Proposed -Sponge Iron unit Sponge Iron Units as Per Proposed Units Final Configuration Existing EC 24.4.2020 Capacity Capacity Capacity Configuration Configuration Configuration (TPA) (TPA) (TPA) Enhancement of 4x100 TPD 128,000 production of 30,400 4x100 TPD 158,400 existing 4 x 100 TPD 2x350 TPD 224,000 Enhancement of 53,200 2x350 TPD 277,200
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Sponge Iron Units as Per Proposed Units Final Configuration Existing EC 24.4.2020 Capacity Capacity Capacity Configuration Configuration Configuration (TPA) (TPA) (TPA) production of existing 2 x 350 TPD Enhancement of 1x600 TPD 192,000 production of 45,600 1x600 TPD 237,600 existing 1 x 600 TPD Installation of new 237,600 - - 1x600 TPD 237,600 1x600 TPD Kiln Total 544,000 366,800 910,800
Table 3.13: Raw Material Requirement Details of Exiting & Proposed -Sponge Iron Plant
Raw Materials Existing in TPA Proposed in TPA Final in TPA 4x100 TPD DRI Kilns (Existing capacity enhancement) Iron Ore 192,000 44,333 236,333 Coal 120,960 28,570 149,530 Dolomite 4,480 906 5,386 Total 317,440 73,809 391,249 2x350 TPD DRI Kins (E) + 1x600 TPD DRI Kilns (E) + 1x600 TPD DRI Kiln (Proposed) Iron Ore / Pellet 624,000 451,932 1,075,932 Coal 393,120 284,040 677,160 Dolomite 14,560 30,584 45,144 Total 1,031,680 766,556 1,798,236 GRAND TOTAL 1,349,120 840,365 2,189,485
3.5.7 Sinter Plant (Proposed with changed configuration) SIPL obtained the EC dated 24.04.2020 for setting up of 1x20m2 Sinter plant in the plant. As the sinter plant has not been installed till date, company now wishes to increase the capacity to 1x90m2 for the production of 795,600TPA Sinter. The sinter plant complex will consist sinter machine along with associated services facilities. Different units will be interconnected by conveyor galleries and junction houses for conveying raw fix, finished sinter, and sinter return fines. All the iron bearing materials (iron ore fines, flue dust), 100% BF return fines, 80% of total requirement of limestone, 80% of total requirement of dolomite are blended in the base blending yard. Blended mix and corrective additions of limestone (20% of total requirement), dolomite (20% of total requirement) are received from the raw material blending yard to the sinter plant proportioning building. Burnt lime will be carried by lime tanker and fed to lime bin by
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report pneumatic lime transportation system. A brief description of major facilities proposed for the sinter plant complex is given below. Proportioning unit: Suitable capacity of storage and proportioning bins has been envisaged for the sinter plant. The bunkers for blended mix and return fines will have single outlet while bunkers for corrective additions of crushed limestone and crushed dolomite will have twin outlets. All the bins will be suitably lined except return fines bin, which will be self-lined. The blended mix, corrective additions and in-plant returns will be fed to the common collecting conveyor by electronic belt weigh feeders, whereas, lime will be fed to common collecting belt conveyor by loss in weigh feeder. Proportioned material from belt weigh feeders below respective proportioning bins shall be transported to a combined mixing and nodulizing drum by a common belt conveyor. Combined mixing and nodulizing unit: Material from belt weigh feeders below respective proportioning bins will be transported to a combined mixing and nodulizing drum by a belt conveyor where the various raw materials will be moistened and mixed in drum mixer. Lime from lime bins will be discharged onto common collecting conveyor through lime dosing equipment. A fixed quantity of water of about 60% of requirement will be added in the mixing part and the rest variable quantity will be added in the nodulizing part depending on requirement. The raw mix discharged from mixing and nodulizing drum will be transported to sinter plant main building by a belt conveyor. Sinter plant main building: The sinter plant main building will mainly consist of hearth layer and raw mix feeding units, ignition furnace, sinter machine, hot sinter breaker. The sintering machine will comprise charging and discharging sprockets, drive unit, sprin loaded pallet cars with high chrome cast steel grate bars, rails, curved guides at charging and discharge ends, grate bar cleaning device, automatic lubrication system, provision for thermal expansion, wind boxes, wind main with dust hoppers and double cone dust valves, machine Spillage hoppers, sinter machine support structures. The hearth layer (15 - 25mm) will be spread onto the sintering machine first, followed by sinter mix. The height of the sinter mix bed onto the machine will be 650mm including 50mm protective hearth layer height. The ignition furnace with post heat hood and pre-heating (before ignition furnace) will be installed just after the sinter mix drum feeder. The ignition furnace will have suitably located energy efficient type gas firing burner designed for 2000 kcal/Nm3 of mixed gas. Gas mixing station and gas boosting station will be located outside sinter plant battery limit approximately 2500C to 3500C hot air for the combustion is supplied from waste heat recovery system of sinter cooler. Multicyclone will be provided at inlet of combustion air fan to supply clean hot air from discharge of cooler. The hot air for combustion will have control by having intake in cold air. The ignition temperature will be 1200 – 1300oC RC Lot burners will be provided for start-up and safety. Hot air from waste heat recovery system of sinter cooler will also be used for
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report preheating of raw material before ignition furnace and post heat hood after ignition furnace. The recovered waste heat from cooler will be utilized for ignition, post ignition and preheating of raw-mix. For suction of air through sinter mix bed on the sintering machine two numbers of exhausters will be provided.
Fig 3.6: Process flow of Sinter Plant Sinter Cooling Unit: Circular sinter cooler will be used to cool the sinter to less than 1000C after it is discharged from hot sinter breaker at approximately 8000C up to (-) 150 mm size, so that it can be transported through conventional conveyor system. Forced draught fans will be provided to cool the sinter in sinter cooler. Deep bed dip rail circular cooler of adequate capacity will be provided to match the sinter machine production with all the associated facilities like cooler fans, heat recovery system etc. Retention time for the coolers will be of approx. 60 minutes. Cooling of sinter is achieved by up-drafting ambient air through the bed of hot sinter to be cooled. The sinter after being cooled in the sinter cooler is transported to the screening house. In the screening house, sinter screening will be carried out in single deck screens arranged vertically in series. The screen house in sinter plant is a separate building in which all the vibrating screens will be located. These screens are arranged one above the other in order to facilitate successive screening of the gross sinter. Table 3.14: Existing & Proposed Configuration and Production Details -Sinter Plant
Existing Proposed Units Final Configuration Capacity Capacity Unit Unit Capacity (TPA) Configuration (TPA) (TPA) 1x20Sq. Unit under the existing EC will be 1x90Sq. 198,000 795,600 meters installed with changed configuration meters
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Table 3.15: Exiting & Proposed Raw Materials Details -Sinter Plants Requirement as Raw Materials Additional Total per Existing EC Iron Ore Fines 180,180 5,22,520 702,700 Return Sinter 17,820 51,678 69,498 Coke Breeze 18,018 50,495 68,513 Limestone 27,928 85,012 112,940 Quick Lime 9,010 27,190 36,200 Dolomite 14,054 42,418 56,472 Total 267,010 7,79,313 1,046,323
3.5.8 Blast Furnace Plant (Proposed with changed configuration) The blast furnace complex will comprise of a mini blast furnace along with its auxiliaries for production of hot metal/Pig iron. The MBF is envisaged to operate with sinter, iron ore lump, coke, coal dust and fluxes. The liquid slag will be granulated at slag granulation unit. The MBF top gas will be cleaned in dust catcher and gas cleaning system, and distributed to the stoves, runner drying and other furnaces. a. Stock house and charging system: The transportation of raw material from storage yard to the stock house will be done by belt conveyors. The raw material transported from storage yard will be distributed into the respective bunkers through shuttle conveyors envisaged at the top of the stock house bunkers. All materials, stored in different weigh hoppers will be charged sequentially into collecting conveyors which will discharge material into common charging conveyor which in turn will feed the material to the MBF top charging equipment. b. Blast Furnace: MBF shall be of structural steel construction of free-standing design and provided with four-post tower structure. The furnace shall be provided with under hearth water cooling system in close circuit. c. Hot Blast Stoves: The hot blast stoves will be designed for a blast temperature of 1250°C with an operating level of 1200°C. The 3-stoves combination with cyclic operation is considered appropriate for start-up and operation. Combustion air and combustion gas will be pre-heated by a heat recovery system using the waste gas from the stoves. d. Cast House: MBF will be provided with two cast houses with two tap holes in each cast house. The cast houses will be connected to each other. In the MBF sinter, iron ore lumps are charged from top of the blast furnace along with coke, limestone and dolomite with the help of skip car moving up and down driven by electric hoist operated by an operator situated in skip house. Operator keeps the furnace continuously full to the required level by keeping a watch on stack gauge rod. The air is blown inside the furnace through tuyers. This air provides necessary Oxygen for
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report combustion of the coke. Finally, the coke burns to from Carbon dioxide and generates sufficient heat for melting the Iron and slag. This gas travels upwards, comes across more hot coke and is reduced to carbon monoxide, which helps in preheating and reducing Iron ore in successive stages to Fe. The ash of the coke is fluxed with limestone to from slag. The slag and the molten metal accumulate in the hearth of the furnace and slag and metal are separately tapped from time to time. The gas from the top of the MBF contains calorific value of approximately 750kcal/Nm3. The total volume of gas 90000Nm3/hr will be passed through dust catcher and the other cleaning equipment and then 43000Nm3/hr of cleaned gas will be used as a fuel for preheating the air required in Mini Blast Furnace. Out of the balance gas, 4600Nm3/hr will be used in sinter plant and 42400Nm3/hr. will be used in power generation through WHRB. The liquid hot metal tapped out and used in SMS Furnace/alternately poured in mould to make Pig Iron to be used in steel making unit to manufacture Steel. The slag is granulated and the same will be sold to nearby cement plant to be used as a raw material for cement.
Fig. 3.7: Process flow of Mini Blast Furnace
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Table 3.16: Existing & Proposed Configuration and Production -MBF
Existing Proposed Units Final Configuration Capacity Capacity Unit Unit Unit Capacity (TPA) (TPA) (TPA) Only capacity MBF Additional 249,900 enhancement of 1x350 m3 416,500 1x350 m3 166,600 existing 1x350m3 MBF Pig casting Pig casting 1x1500TPD -- -- 1x1500TPD machine machine
Table 3.17: Exiting & Proposed Raw Materials Details -MBF
Raw Materials Existing Additional Total Iron Ore 299,880 -209,083 90,797 Sinter 179,930 516,875 696,805 Coke 112,455 74,970 187,425 PCI Coal 32,485 21,660 54,145 Quartzite 2,500 1,665 4,165 Total 627,250 406,087 1,033,337
Table 3.18: Mini Blast Furnace Gas Balance
BF Gas Balance
Gas generation Unit Qnty from 1 x 350 cum Blast Furnace Nm3/hr 90,000 Consumption Consumption of BF Gas in BF Nm3/hr Consumption in Hot Blast stove of 350 cum BF Nm3/hr 43,000 Consumption in Sinter Plant Nm3/hr 4,600
Balance BF gas for Power Generation Nm3/hr 42,400 BF Gas calorific value considered (Kcal/kg) Kcal/kg 750 Total Calorific Value given to CPP Kcal 318,00,000 Power Generation based on BF gas MW 9
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3.6.9 Steel Melting Shop (Proposed with changed configuration) SMS (IF-LRF-CCM Route) It proposed to enhance the production capacity to 787,500 TPA from 523,950 TPA MS Billets through 9x25T Induction Furnaces along with LRF of 1x30T capacity and 3x6/11m CCM. The process for manufacturing steel may be broadly divided into the following stages: a) Melting the charge mixed of steel & Iron scrap in Induction Furnaces b) Ladle teeming practice in LRF c) Billet casting in Continuous Casting Machine. Induction Furnace: Induction Furnace is basically furnaces meant for use of Sponge Iron as major raw material to produce mild steel. These furnaces work on the principal of electromagnetic induction. After the furnace is switched on, current start flowing at a high rate and comparatively low voltage through the induction coil of the furnace, producing an induced magnetic field inside the central space of the coils where the crucible is located. The induced magnetic field thus generated cut through the packed charge in the crucible. As the magnetic flux cut through the scrap/pig iron and complete the circuit, they generate an induced current in the scrap. The induced current as it flows the highly resistive path of scrap mix, generate tremendous amount of heat and melting the scrap. When these additives have melted completely, the power input may be increased to bring the temperature of metal up to the point most desirable for pouring. The current is then turned off and the furnace is tilted for pouring into the ladle. As soon as pouring has ceased, the crucible is cleaned completely from any slag or metal droplets adhering to the wall of the crucible and the furnace is now ready for charging again. An induction crucible furnace differs from arc furnace in the ways, which are important metallurgically, though both types of furnaces are used for making steel from scrap and alloys. Induction furnace do possess the following characteristics: High relatively, narrow melting vessel Low Crucible wall thickness Relatively small area of metal in contact with slag Low slag temperature No carburizing during melting down Powerful bath motion
Ladle Refining Furnace (LRF): A Ladle Refining Furnace (LRF) is used to relieve the primary melter of most secondary refining operations, and its primary functions are: Reheating of liquid steel through electric power conducted by graphite electrodes Homogenization of steel temperature and chemistry through inert gas stirring
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Formation of a slag layer that protects refractory from arc damage, concentrates and transfers heat to the liquid steel, trap inclusions and metal oxides, and provide the means for desulphurization.
Secondary functions that can be included with a ladle furnace are: Alloy additions to provide bulk or trim chemical control Cored wire addition for trimming or morphology control Provide a means for deep desulphurization Provide a means for dephosphorization Act as a buffer for down-stream steelmaking equipment
The function of the porous plug is to provide gas stirring of the molten metal to promote homogenization. Normal stirring operations are performed by percolating argon gas through a purge plug arrangement in the bottom of the ladle. A top lance mechanism serves as a back-up means for bath stirring in the event the plug circuit in the ladle is temporarily inoperable. The gas supply connection to the ladle is automatically made when the ladle is placed on the transfer car. Fumes and particulates generated during heating and alloying operations at the LRF will exit the water-cooled ladle roof through the various openings in the roof. These emissions will be captured (i.e. entrained) in ambient air drawn into a lateral draft type fume collection hood mounted on supporting structures above the ladle roof. The ladle roof is typically a water-cooled design with a refractory center or delta section and is configured to coordinate with existing ladles such that the roof will completely cover the top portion of the ladle when in the operating (i.e. fully lowered) position. Metal Recovery from Induction Furnace Slag: The processing of the steelmaking slag is normally carried out by, (i) solidifying and cooling of the hot liquid slag, (ii) crushing and magnetic separation treatment of the slag to recover the scrap, As steel making slag is formed, it is in a molten or red-hot state. This slag is immediately subjected to the cooling process upon removal. Usually, this is performed in a cooling yard by air cooling and moderate water sprinkling. Steel making slag contains metal which comes from the refining process or from some of the processing vessel (e.g. steel teeming ladle, or tundish). It is advantageous to separate this metal from the slag for the purpose of recycling the recovered metal in the primary steelmaking process. Hence, after cooling, the slag is crushed and the metal is recovered by magnetic separation. Further in order to increase the metal recovery ratio and to improve the quality of metal recovered, the crushing and magnetic separation process is repeated.
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Continuous Casting Machine: The ladle containing liquid steel is placed on the turret and brought over the tundish. The tundish act as a buffer and enable the liquid steel to move homogeneously down through nozzles, provided at the bottom of the tundish into moulds. The automatic mould level controller controls the steel level in the mould. The subsequent primary and secondary cooling transform the liquid steel into billets of the required dimensions and is drawn out with the help of a withdrawal and straightener unit and cut into required length by the shear provided in each strand. Once a ladle is emptied another ladle is brought into the casting position and the casting continues. The billets are gradually shifted to the cooling beds and then stacked orderly at the dispatch end for outside dispatch. The details about the cast number and quality of billets are marked on the billet stack.
Fig. 3.8: Billet Production (IF-LRF-CCM Route) process flow Table 3.19: Existing & Proposed Configuration and Production -SMS (IF-LRF-CCM Route)
Existing Proposed Units Final Configuration Capacity Additional Capacity Unit Unit Configuration (TPA) (TPA) (TPA) 9x25T Induction Capacity IF:9x25T Furnace 523,950 263,550 enhancement of LRF: 1x30T 787,500 LRF: 1x30T Billets Billets existing 9x25T CCM: 3x6/11 CCM:3x6/11
Table 3.20: Exiting & Proposed Raw Materials Details -SMS (IF-LRF-CCM)
Raw Materials Existing Additional Total after Expansion Sponge Iron 565,072 284,261 849,333 Pig Iron 60,866 30,618 91,484 Purchased + Return Scrap 60,213 30,308 90,521 Ferro-alloy 6,866 3,453 10,319 Total 693,017 348,640 1,041,657
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3.6.10 Rolling Mill (Existing & Proposed Unit) 300,000TPA of long products will be produced through already implementation 1000 TPD Rolling Mill as per the existing EC. Company has proposed to produce additional of 360,000TPA Long Products by installing 1x1000TPD Rolling Mills. Rolling mill consists of set of equipment together will produce the said quantity. Rolling mill will primarily comprise of one tunnel type temperature equalizing-cum-holding furnace with roughing and finishing strand, one pendulum type bar and cobble shear, one high pressure de-scaling station, run out roller table equipped with turnover cooling bed along with auxiliary facilities and roll shop equipment. TMT Process: By adopting thermo mechanically treatment process higher strength of TMT bars is obtained. In this process, steel bars get intensive cooling immediately after rolling. When the temperature is suddenly reduced to make surface layer hard, the internal core is hot at the same time. Due to further cooling in atmosphere and heat from the core, the tempering takes place. This process is expected to improve properties such as yield strength, ductility and toughness of TMT bars. With above properties, TMT steel is highly economical and safe for use. TMT steel bars are more corrosion resistant than other steel. Operating parameters The net operating hours of the mill are affected by various factors considering integrated direct linked operation with furnaces, ladle furnace and bloom caster unit, such as relining of furnaces, breakdown and mismatching of operational requirements between the units. Product weighing station: A product weighing station will be included to provide weight output to computer tracking and logging systems and print out a tag for attachment to the finished coil. Product marking machine: A marking machine will be provided to print bar data on outer wrap of the coil. The machine will comprise of the frame, print head, ink system, etc. The signals for marking data will be fed through PC and received through PLC / microprocessor system. Roll grinding and bearing inspection facilities: The roll grinding and bearing inspection facilities will be installed in a separate roll shop which will be located adjacent to the main mill bay. Shop layout: The proposed mill equipment and other associated facilities will be housed in multibay building consisting parallel bays for mill and roll grinding and bearing inspection facilities. The main equipment of the mill and storage area will be located in a bay of 25 m width having about 300 m length. This bay will be served by EOT cranes. All technological basements like oil cellars, hydraulic pump accumulator stations, strip cooling pump house, etc. will be located in the mill bay. The water circulation system including scale pit will be located outside the main mill building.
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Table 3.21: Existing & Proposed Configuration and Production - Rolling Mill
Existing Proposed Units Final Configuration Capacity Capacity Capacity Unit Unit Unit (TPA) (TPA) (TPA) 1000 TPD 300,000 1000 TPD 660,000 1000TPD Rolling Mill#1 + Long Rolling 360,000 Long Rolling Mill#1 1000 TPD Mill#2 Products Products Rolling Mill#2
Table 3.22: Exiting & Proposed Raw Materials Details- Rolling Mill
Raw Materials Existing Proposed Total Billets 315,000 378,000 693,000
3.6.11 Reheating Furnace (Proposed) Reheating furnace is used for heating of billets before hot rolling in Rolling Mill. A Pusher Type Reheating Furnace of capacity 1x25TPH will be installed. Reheating Furnaces will be provided with duel type burners using LDO/FO. Billets will be heated to temperature up to 1020°C. Billets will be directly fed from CCM to the Rolling Mill bypassing the Reheating Furnace. Reheating Furnace shall only be used when billets are not directly rolled due to any reason like shutdown of Rolling Mill for maintenance etc. 3.6.12 Air Separation Plant (Existing Unit) As per existing EC 1x225TPD Air separation plant shall be installed to supply oxygen, Nitrogen and Argon to various manufacturing units. Oxygen will be required for oxygen enrichment in the blast furnace, blowing in the electric arc furnace, secondary refining, cutting of slabs in continuous casting plant, and for general purpose use in various units of the steel plant. Nitrogen will be mainly required as carrier gas in coal dust injection system, bell less top equipment for blast furnace, DRI unit and also for occasional purging of fuel gas pipelines and equipment. Argon will be required for shrouding in the tundish and mould in the continuous casting plant, stirring in ladle. Air separation: An air separation plant separates atmospheric air into its primary components, typically nitrogen and oxygen, and also argon and other rare inert gases. The most common method for air separation is fractional distillation. Cryogenic air separation units (ASUs) are built to provide nitrogen, oxygen and argon. Cryogenic Oxygen Plant: A cryogenic oxygen plant is an industrial facility that creates molecular oxygen at relatively high purity. Oxygen is the most common element in the earth's crust and the second largest industrial gas. In steelmaking oxygen is required for the basic oxygen steelmaking. Today, modern basic oxygen steelmaking uses almost two tons
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report of oxygen per ton of steel. The cryogenic air separation achieves high purity oxygen of more than 99.5%. The resulting high purity product can be stored as a liquid and/or filled into cylinders. 3.6.13 Ferro Alloy Plant (Existing & Proposed) Proposal is to have production of Si-Mn 142,848 TPA or Fe-Mn 194,058 TPA or Fe-Si 64,285 TPA or High Carbon Fe-Cr 135,330 TPA or Fe-Si-Cr 88,664 TPA or Pig Iron 214.272 TPA or Combination of any with maximum of 214,272 TPA by installing 4x9MVA SAFs in addition to the existing 4x9MVA SAFs along with Metal Recovery Plant of 1x25TPH. Proposal also involves installation of 1x50TPH Briquetting Plant and 1x600TPD Sinter plant for Ferro Alloys division. Submerged Arc Furnaces: Conveyor system will be envisaged to feed the day bins for different ferro alloy production. Vibrating feeders will be located below each ground hopper, which will transport the material on a vibratory screen through conveyor. In order to store the materials in individual bunker a reversible shuttle conveyor will be provided on top of bunker. A conveyor shall be provided to collect the sized mixture of material from surge hopper on ground level and dump the same in to a feed hopper. The material from this hopper shall be collected by a conveyor and transported to a rotating unidirectional conveyor mounted on the rails. By way of rotation this conveyor will get aligned with charging bins and correction bins, which are located around the circumference of this rotation. The charging bins will extend further in the form F.A. chute, up to the furnace. Pneumatically operated slide gates will be provided in each chute. These gates will be operated from the central control desk. The furnaces will be tapped at an interval of about two and half hours considering eight numbers of heats per day. The tap hole will be opened by tap hole drilling machine. Oxygen lancing will be resorted for piercing the solidified metal/slag in the tap hole for proper flow of metal and slag from the furnace. Tap hole closing device has been envisaged for closing the tap hole after tapping. Skimmer/ladle tapping arrangement will be provided. The liquid metal will be cast in moulds or in sand bed. The slag from the furnace will be collected, cooled and disposed at suitable area allocated for slag disposal. The furnaces will be equipped with charge feeding hoppers, chutes, transformer, electrodes and gas cleaning plant. Entire facilities of Ferro Alloy Plant are already in operation and there is only proposal to add Pig iron production with available facilities. Production of Pig Iron: M/s SIPL is also considering production of Pig iron from SAFs. Maximum 214,272 TPA Pig iron can be produced from 8x9MVA SAF. The process of manufacturing of Pig Iron in SAF includes smelting of various raw materials in SAF. Mill scale, iron ore / sinter with reducing agents and fluxing materials are charged into the furnace from the top. High current at low voltage is passed through the raw
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materials charged with the help of electrodes. Raw material mix charged into the furnace gets heated up due to I2R effect of high current passing through the charge through the electrodes. When temperature of charge reaches to chemical reaction temperature, carbon present in reductants gets reacted with oxides of iron ore, mill scale and quartz. Thus, metallic iron and Silicon are extracted as metal from the ores. Unreacted materials, impurities and residual oxides formed as slag. Metal and slag in molten form gets collected at the bottom of the Furnace after each interval of 3-4 hours. Tapped molten mass consists of mixture of metal and slag. Metal is separated from slag by gravity separation method. Production process is continuous. Load of Furnace during smelting and tapping process remains same. Following chemical reactions take place;
Fe2O3 + 3C 2Fe + 3CO FeO + C Fe + CO Oxides in the iron present in the ore get reduced to metallic iron with the help of carbon from reducing agents and Carbon Monoxide is liberated.
Silicon is present in the raw materials in the form of SiO2. SiO2 present in iron ore,
reducing agents, quartz, etc., Silicon is smelted from SiO2 as per the following equation: SiO2 + 2C Si + 2CO Thus, in smelted molten metal, Fe and Si are present in molten form. Metal, so smelted is called Pig Iron. Thus, metal contains some carbon in dissolved state as carbides of metal. Certain amount of phosphorous is also present in the metal. This is smelted from the phosphates present in iron ore and reducing agents. It may be noted that entire oxides of iron do not get reduced to metallic iron. Certain amount of iron in FeO from remains unreacted and forms a part of slag. Similarly, certain amount of SiO2 remains unreacted and forms a part of slag. Dolomite and Limestone is added to provide proper fluidity of slag. Thus, CaO and MgO of these fluxing materials are also part of slag. Table 3.23: Details of Exiting & Proposed Configuration and Production- Ferro Alloys Plant After Existing Proposed Units Expansion 4x9MVA 4x9MVA 8x9MVA
As per From capacity From New Capacity Products approved EC enhancement of proposed Total
from 4 x 9SAF existing 4x9 SAF 4x9 SAF (TPA) Si. Mn-, or 42,100 29,324 71,424 1,00,748 1,42,848 Fe-Mn-, or 57,192 39,837 97,029 1,36,866 1,94,058
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After Units Existing Proposed Expansion Fe Si – , or 18,945 13,196 32,141 45,337 64,282 High Carbon Ferro 39,884 27,781 67,665 95,446 1,35,330 Chrome , or Ferro Silico Chrome, - 44,332 44,332 88,664 88,664 or Pig Iron or 63,150 43,986 1,07,136 1,51,122 2,14,272 Combination of any 63,150 43,986 1,07,136 1,51,122 2,14,272 with maximum of
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Table 3.24: Exiting & Proposed Raw Materials Details– Ferro-Alloys Plant Existing Production in TPA Proposed Production after Expansion in TPA) (from Existing 4 x 9 SAF) (from 8 x 9 SAF) HC Fe- Pig HC Fe- Fe-Si- Fe-Mn Si-Mn Fe-Si Fe-Mn Si-Mn Fe-Si Pig Iron Cr. Iron Cr. Cr.
57192 42100 18945 39884 63150 194058 142848 64282 135330 88664 214272 (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) (prod.) Raw Materials Maximum production of any product or in Maximum production of any product or in combination of combination of any any Mn Ore 137262 75780 - - - 465,738 257126 - - - - Coke 25737 23155 4812 21537 22103 87326 78566 16328 73078 37,682 74,995 Charcoal -- -- 18945 ------64282 -- 17,733 -- Steam Coal 13893 47,140 Dolomite 5719 4210 ------19406 14285 ------Limestone ------5557 ------18,856 Quartz -- 6315 33343 6780 -- -- 21427 113136 23006 9,531 -- Briquettes ------75780 ------257126 -- -- Chrome Ore (Friable) ------13162 ------49,659 -- -- Magnesite ------1994 ------6,766 -- -- Ferro-chrome chips ------49,652 -- Sinter ------83358 ------2,82,839 Fe-Mn Slag -- 25260 ------85,709 ------Mill Scale -- -- 7200 -- 17682 -- -- 24427 -- 8,866 59,996 Electrode Paste 972 926 890 559 947 3299 3142 3021 1895 4,433 3,214 Total 169690 135646 65190 119812 143540 575769 460255 221194 406530 127897 487040
Slag 51473 35785 947 35896 31575 174662 121421 3214 121797 4433 107136
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3.6.14 Briquette Plant (Proposed-Ferro-Alloys Plant) 1x50TPH Briquetting plant has been envisaged for production of 300,000TPA Ferro chrome briquettes only through chrome ore fines. Additionally, lime and molasses will be needed as binder. The green briquette formed from briquetting press will be cured naturally, in briquetting shed at the raw materials storage area for ferro chrome inside the ferro alloy plant. 1. Blending: The Briquette quantity, grade and ratio are received from Operation head of Ferro- chrome Plant. Requirement of desired grade is designed with available grade and ratio of virgin chrome ore fines. Respective quantity of various grade of Chrome ore fines are issued from R/M storage yard to blend yard through Weigh Bridge. Blending is prepared in open yard using heavy earth movers (Proclaine, Payloader, JCB etc.). 2. Feeding to Under Ground Bunker: The bended fines are loaded to tippers and sent to underground bunker (hopper) feed after weighment at Weigh Bridge. Over size chrome ore lumpy (Boulders) are handpicked at Grizzly of the Feed Hopper. The hoppers discharge onto a common belt leading to +15mm screen house. Then (- 15mm) size feed in and conveyed to a rotary dryer. 3. Drying: The drying process is a solid-state physical preparatory process for the removal of superficial water from the solid ore fines/concentrates by thermally induced evaporation. This is achieved by passing a forced draught of hot air from burning fossil fuels through a cylindrical 9meter long vessel of double shell construction and rotating about its longitudinal axis. Fines are turned over continually by the rotation of the dryer. Meantime appropriately sized fossil fuel is burnt over slow-moving stoker gratings and the hot combustion gases pass through the dryer in a co-current draught. 4. Screening: The dry ore fines are feed to a closed screen of +6mm size and the – 6 mm size is conveyed to a Pan-mixer through weigh hopper. 5. Mixing: The chrome ore fines discharged from the weigh hopper are mixed with lime and Molasses, in order to provide binding effect to ore, to facilitate the briquetting process. The mixture material is feed to a Hydraulic Briquetting Press. 6. Briquetting: Chrome ore is briquetted under pressure by passing the mixture over a set of rolls equipped with segment pockets. The resulting briquette (70mm long, 45wide and 22-28mm thick) is screened; the undersize is recycled in a closed circuit while the oversize is warehoused in a shed. 7. Curing: Curing of briquettes occurs in a shed over a 96-hour period during which lime sets in to confer long-term strength on the briquette. The briquette stockpiles ought not to exceed 1-2m in height as this may allow for high heat retention with the consequent loss of molasses' binding ability. The compressive strength of the
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briquette is tested at the point of manufacture and thereafter at 24 hourly intervals for four days. The briquettes take between 72-96 hours to attain complete strength that exceeds the levels necessary for transportation and feeding into a submerged electric arc furnace. After curing the briquettes retain their strength, and feed to furnace for production of High carbon Ferro Chrome. During furnace feeding the lower size particles are separated through a vibrating screen. The under-size material (usually called Return Fines) is again subjected to go through the Briquetting Process. Table 3.25: Proposed Configuration– Briquette Plant
Existing Proposed Units After Expansion Capacity Capacity Capacity Unit Unit Configuration (TPA) (TPA) (TPA) -- -- 50 TPH 300,000 50 TPH 300,000 Table 3.26: Raw Material Details of Proposed -Briquette Plant
Raw Materials Existing Proposed Total Chrome Ore Fines --- 324,720 324,720 Hydrated Lime --- 9,900 9,900 Molasses --- 15,840 15,840 Total --- 350,460 350,460
3.6.15 Sinter Plant (Proposed-Ferro Alloys Plant) Considering availability of iron ore fines in the region, SIPL is planning to install 1x600TPD Sinter Plant. Sinter will be used in Submerged Arc Furnace to produce Pig. Abstract the maximum utilization/consumption of sinter in SAF depend on commercial benefits and technical suitability for SAF operations. As on today, sinter has become widely accepted and preferred burden material in SAF. The sintering technology was developed for the treatment of the waste fines of Mn Ore & coke. Metallurgical wastes Flue dust and GCP dusts (from Bag Filter) are being used at present by collecting from proportionate bunkers. Brief description about process The process is to mix manganese dust and coke fines, sometimes GCP dust as per production and metallurgical requirement, in a muller mixer machine, then ignition of mixture in a bed with bottom suction. After completion of the sintering process, sinter cake will be crushed and manually it will go to SAF.
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Table 3.27: Proposed Configuration & Production Details – Sinter Plant
Existing Proposed Units After Expansion Capacity Capacity Capacity Unit Unit Configuration (TPA) (TPA) (TPA) -- -- 600 TPD 216,000 600 TPD 216,000
3.6.16 Metal Recovery Plant (Existing Ferro-Alloys Plant) Ferro-alloy slag consists some portion of valuable ferro-alloys which can be obtained in directly saleable condition and can be sold at reasonably good market rates as compared to the main ferro-alloys products. Metal Recovery Plant of 1x25 TPH is being used to recover this valuable portion of metal. Ferro-chrome slag will be sent to the Metal Recovery Plant wherein it is crushed as to extract good quality of ferro-chrome from the slag waste. This process involves following 3 steps: Crushing & Screening of metal containing slag Separation of metal from slag Re-crushing of middling to realize additional metal Crushing & Screening: This circuit produces a crushed slag which would aid the metal liberation in further stages. Cone crushers are used to maximize shear at metal-slag interphases. Wherever, possible, the multiple cycles of crushing and maintaining in a close circuit so that minimum crushed size is achieved. To minimize fines, the reduction ratio are kept as low as possible. Separation of Metal from Slag: This involves two – stage recovery jigging process; known as the „Coarse Jigging‟ and „Fine Jigging‟. During the course jigging stage, the cut density is set with an aim to recover clean metal and not with a focus on recovery. The coarse fraction is crushed to have an output in the form of saleable coarse alloy. An under-bed air pulsated jig with a float control system is on the discharge gates. A hydro-dynamically stable float is positioned in the jigging bed. Later during the Fine Jigging, the cut density is lowered to focus on recovery. Since the material is fine, a strongly pulsed Jig is not required here. Only a single stage is required to utilize „through the bed‟ Jigging as the material quantity reaching this stage is only about 5% of the total feed. The output of this stage is in form of fine tailings and slimes. The final disposed middling from coarse jigging and very fine metal from fine jigging are used for furnace feed. Re-crushing of Middling: The re-crushed middlings are returned for re-jigging to recover additional material. The throughput material (slag) requirement in an MRP (Metal Recovery Plant) is 3 times of its output. i.e 3MT of slag needs to be fed to achieve 1MT
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report of saleable ferrochrome. The feed size specifications shall be provided by the technology supplier based on the final equipment design parameters. The standard composition of High Carbon Ferro chrome (HCFC) is as given below: Chromium - 57% to 63% Carbon - 6-8% Silicon - 4% Phosphorus - 0.0025-0.03% Sulphur - 0.03% Max
3.6.17 Captive Power Plant a) Waste Heat Recovery Boiler (WHRB) based on DRI: As per existing EC company has permission for generation of 37MW power by utilizing the sensible heat of waste gases coming from installed 4x100TPD, 2x350TPD and 1x600TPD. Now company proposes to have 16MW of captive power generation through the WHRB of proposed 1x600TPD DRI Kiln and 2MW will be generated through surplus steam of already installed 1x600TPD DRI Kiln. Existing Proposed Final Facilities (MW) (MW) (MW) CPP WHRB @4x100TPD DRI - 40 TPH 8 - 8 CPP WHRB @2x 350TPD DRI- 71 TPH 15 - 15 CPP WHRB @1x 600TPD DRI - 64TPH 14 2 16 CPP WHRB based on 2nd 600TPD DRI- - 16 16 64TPH Total 37 18 55 About Process: After burning chamber (ABC) and Dust settling chamber (DSC) will be located at the exit of DRI Plant Kiln. Part of the dust carried by the waste gases will settle down at DSC. The DSC and ABC assembly will be connected to the DRI Plant Kiln through refractory lined duct. The combustibles in the waste gases are burnt in the After Burning Chamber which will raise the waste gas temperature thus making the waste gases free from carbon mono-oxide. Provision for spraying water will be made to control the temperature if required. From ABC outlet the WHRB will be connected through a refractory lined duct. An emergency stack cap on top of ABC will be provided for diverting the waste gases to atmosphere when WHRB is under shutdown or break down. Each Kiln has a Waste Gas Volume discharged at 900 to 9500C (9500C maximum). This heat contains significant calorific value (GCV of mixed fuel - about 2300 kcal/Nm3.The well tried out configuration for WHRB is comprised of an Evaporator, Super-heater in two (2) sections and an Economizer which will bring down the temperature of gases.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report
Gas Cleaning System: The gases passing out of WHRB will be passed through one multi- field Electrostatic Precipitator before releasing the gas, having huge quantity of dust particles, into the atmosphere. The ESP will be installed between the WHRB and the stack. The dust content in the gas, downstream of ESP shall be limited to 30mg/Nm3. The ESP Unit will be provided with transformers, rectifier and controls. The dust particles will be collected below ESP in hoppers and conveyed by means of conveyors or pneumatically and stored in silos. This will be subsequently disposed off by trucks.
Fig 3.9: Process Flow of Power Generation through WHRB b) Atmospheric Bubbling Fluidized Bed Combustion (AFBC) Boiler As per existing EC company is having permission for power generation of 8.5MW through the installed 36TPH capacity AFBC Boiler suitable for coal and char firing. No change or increment is proposed for power generation through AFBC in present proposal. About Process: AFBC boiler is suitable for combustion of low-quality fuel. In AFBC boiler, fluidization bed combustion method is used in which the solid fuel is continuous fed for burning into hot fluidized bed made of inert bed material. Inert fluidized bed is heated to the ignition temperature of fuel and fuel is supplied continuously into the bed. The fuel burn rapidly and the bed attain a uniform temperature. In AFBC boiler combustion is taking place at about 850- 950 degree Celsius. The boiler uses the following solid fuels: a. Char (2,446 GCV) is generated as solid waste in the existing Kilns. The annual generation of Char is 163,944 Tons.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report b. Coal with an average calorific value of 3,500Kcal/Kg. The Boiler is lighted up using Diesel Oil. The complete furnace section is made of water-cooled membrane wall construction arranged as a gas & pressure tight envelope. Refractory is provided inside the furnace on the water wall for a suitable height. The steam drum is designed and provided simple and efficient drum internals, resulting in high steam purity at all load condition of boiler output. Gas Cleaning System: Electrostatic precipitators are envisaged for dust collection. The ESP is designed to limit the outlet emission to 30mg/Nm3. The blow down system for the boiler includes one of CBD and one IBD tank with all associated drains and vents, level gauges, temperature and pressure gauges etc. The boiler is provided 2 nos. of feed pump along with motor drive. One spray-cum-tray deaerator with storage tank is provided. c) Circulating Fluidized Bed Combustion Boiler (CFBC): As per the existing EC company is having permission for power generation of 53.5MW. This shall be achieved through the installed 100TPH and installation of another approved 120TPH capacity CFBC Boilers. No change or increment in the power generation through CFBC is proposed. About Process: The CFBC is a type of Fluidized bed combustion that utilizes a recirculating loop for even greater efficiency of combustion. Up to 95% of pollutants can be absorbed before being emitted into the atmosphere therefore achieving lower emission of pollutants. The coal is burnt in a bed of hot particles maintained in flowing air. A chamber is provided with an air supply system through the wind box chamber at the bottom of furnace, an air distributor which promotes even distribute of air flow through the bed, and a chamber filled with sand which is called bed of the boiler which contains alumina 45-35% and silica 55-65 or other granular material. Air is made to flow through the air distributor into the sand; it will pass through the voids of a stationary mass of sand. The flow rate is maintained such that the drag force exerted on the particle by air flow exceeds the contact forces between the sand particles caused by gravity. This brings the sand particles in suspension in the upward stream. The fluidised action promotes complete coal combustion at relatively low temperatures and provides a means to transfer combustion heat efficiently from the bed to the steam tubes. The exhaust gases will be discharged from boiler to ESP and then into the atmosphere through induced Draft fan and chimney. The pressure drop in the boiler ducts and ESP will be kept to match with the requirement of existing ID fan. The boiler will be of semi-outdoor type with a weather canopy and side covering of trapeze corrugated steel sheets or other suitable materials, as available. d) Based on Blast Furnace Gas: It has been proposed to produce 9MW captive power based on utilizing 42400 Nm3/hr of Blast furnace gas out of total 90000 Nm3/hr coming out from Blast Furnace.
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The gas coming out from Blast furnace is assumed to have calorific value of 750 kcal/kg. Steam Turbine generator: The board description of the steam turbine generator envisaged is indicated below: The Steam turbine will be single, Horizontal, Single blade condensing type. The set shall be complete with gear box, barring gear box, condenser, air evacuation system condensate extract pumps, generator cooling systems, gland sealing with gland vent condenser and lube oil system. Conversion of Heat Energy in Steam to Mechanical work will be done by expanding the same in Steam Turbine which shall provide mechanical energy in the form of rotational torque. Steam while passing through various stages of Turbine will release both pressure and temperature and will be ultimately dumped to Condenser at near vacuum condition. Low pressure steam will be condensed by air in Air Cooled Condenser. Condensed Water from the Air-Cooled Condenser will be fed back to Boiler through Air Ejector, Gland Steam Condenser and Deaerator for re-generative heating and air removal. Boiler Feed Pump shall take suction from Deaerator and feed deaerated water to Boiler Economiser Table 3.28: Details of Exiting & Proposed Configuration and Power Generation
Existing Proposed Final Facilities (MW) (MW) (MW) Based on Waste Heat Recovery Boiler (WHRB) CPP WHRB @4x100TPD DRI - 40 TPH 8 - 8 CPP WHRB @2x 350TPD DRI- 71 TPH 15 - 15 CPP WHRB @1x 600TPD DRI - 64TPH 14 2 16 CPP WHRB based on 2nd 600TPD DRI- - 16 16 64TPH Total 37 18 55 Based on AFBC Boiler CPP AFBC - 36 TPH 8.5 - 8.5 Total 8.5 - 8.5 Based on CFBC Boiler CPP CFBC - 100 TPH 25 - 25 CPP CFBC - 120 TPH 28.5 - 28.5 Total 53.5 - 53.5 Based on Blast Furnace Gas BF Gas Based - 9 9 Total Power Generation 99 27 126
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Table 3.29: Details of Raw Requirement for Exiting & Proposed Power Generation
Raw Materials Existing Proposed Total Coal (3500 Kcal/Kg) 343,603 TPA - 343,603 TPA Char (2446 GCV) 233,196 TPA - 233,196 TPA Blast Furnace Gas (750 kcal/Kg) - 42,400 Nm3/hr 42,400 Nm3/hr
3.6. RAW MATERIAL REQUIREMENT
The proposed site is located near the State Highway and Eastern Railway line. The Raw materials and products can easily be transported to the site. The project site is well connected by road and rail. SH-5 (Asansol Purulia Road) is at 700 meters from project site and SH-8 (Durgapur Purulia Raghunathpur Road) is at 10.15kms in south direction and NH-2 (Delhi Kolkata Highway) is at 16km in north direction from plant site. The nearest railway station is Ramkanali at 4.23km from proposed project site. Asansol & Purulia are the nearest cities where market facilities are available.
3.6.1. Annual Requirement of Raw Materials
Table 3.30: Annual Raw Materials Requirement
Total after Source Mode of Sl. Existing Raw Material expansion Transport No. (TPA) (TPA) A Steel Making Division A-01 Iron Ore 533,880 553,062 Odisha/ Jharkhand Rail A-02 Iron Ore fines 1,016,805 1,927,950 Odisha/ Jharkhand Rail A-03 PCI Coal 32,485 54,145 West Bengal Rail A-04 Non-Coking Coal 1,609,683 1,986,693 West Bengal Rail A-04 Limestone 135,928 220,940 Birmitrapur, Odisha Rail A-05 Quick Lime 9,010 36,200 Local Market Road A-06 Coke Breeze 18,018 68,513 Local Market Road A-07 Coke 112,455 187,425 Local Market Road A-08 Purchased + Return Local Market Road 60,213 90,521 Scrap A-09 Dolomite 45,694 124,852 Imported Ship/Rail A-10 Ferro-alloys 6,866 10,319 - In-House A-11 Bentonite 6,000 8,500 Kutch, Gujarat Road B Ferro Alloys Division B-01 Mn Ore 137,262 465,738 Imported/Domestic Rail
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Total after Source Mode of Sl. Existing Raw Material expansion Transport No. (TPA) (TPA) B-02 Coke 25,737 87,326 Imported/Domestic Rail B-03 Charcoal 18,945 64,282 Local Market Road B-04 Steam Coal 13,893 47,140 Local Market Road B-05 Dolomite 5,719 19,406 Imported Ship/Rail B-06 Limestone 5,557 18,856 Birmitrapur, Odisha Rail B-07 Quartz 33,343 113,136 Local Market Road B-08 Briquettes 75,780 257,126 Internal In-House B-09 Chrome Ore Odisha Rail (Friable) 13,162 44,659 B-10 Magnesite 1,994 6,766 Imported Ship/Rail B-11 Ferro-chrome chips 0 49,652 Odisha Rail B-12 Sinter 83,358 282,839 Internal In-House B-13 Fe-Mn Slag 25,260 85,709 Internal In-House B-14 Mill Scale 17,682 59,996 Internal In-House B-15 Electrode Paste 972 4,433 Local Market Ro• B-16 Iron ore Fines -- 140,400 Odisha/ Jharkhand Rail B-17 Hydrated Lime -- 9,900 Local Market Road B-18 Molasses -- 15,840 Local Market Road
*Maximum raw material quantity for maximum production of any Ferro-alloys
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3.7. RESOURCE OPTIMISATION
The requirement of makeup water for industrial and domestic purposes after the proposed expansion will be 13,690 m³/day including domestic use. Company is already having permission from DVRCC for drawing 1.69 MGD (7,683m3/day). Water shall be provided by DVRCC as when required by the project upon implementation. A dedicated 12 km pipe line from Lakhanpur point near Panchet Dam of Damodar River to plant premises has been laid. Floated type of pump is installed to draw the water from river. Table 3.31: Water Requirement of the Project (m3/day) Unit As per existing EC Total after Expansion Iron Ore Beneficiation Plant 335 392 Coal washery 540 540 Lime Plant 26 26 Pellet Plant 635 842 Sponge Iron Plant 1352 2,625 Sinter plant` 216 1,080 Blast Furnace 1,128 2,142 Induction Furnace with CCM 780 888 Air Separation Plant 220 220 Rolling Mill 420 1,090 Ferro Alloy Plant 460 570 Captive Power plant 7,128 2,897 Briquetting Plant for FA Div - 10 Sinter Plant for FA Div. - 2 Producer Gas Plant -- 150 Domestic 176 216 Total Water Requirement 13,416 13,690
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3.8. SOLID WASTE GENERATION AND MANAGEMENT
Type of Waste Quantity in Tons (TPA) Mode of Disposal Existing Total after the proposed Expansion Induction Furnace 76,015 114,251 Total Slag generation shall be 126945 TPA, Slag (After (After metal however after recovery of 12695TPA of metal recovery) metal, remaining slag of approx. 114251 recovery) TPA will be used as aggregates after crushing IF Bag Filter Dust 16,347 24,570 Will be recycled in Sinter Plant Scale - CCM 6,290 9,828 Shall be used for production of Fe-Si or Fe- Si-Cr. Or will be used in Sinter Plant Mill Scale - RM 4,950 9,900 Will be recycled in Sinter Plant Dolochar from DRIs 136,000 233,196 Will be used in AFBC/CFBC Boiler for power generation Wet Scrapper 13,600 23,354 Will be used in CPP for power generation Sludge DRI ESP Dust 65,280 107,428 Will be bricks & cement manufacturing units Coal Washery 50,000 50,000 Will be used in Briquetting Plant Rejects Tailings from 236,250 375,000 Will be sold to tile manufacturing company Beneficiation Plant Pellet Plant Dust 29,680 43,350 Will be Reused in Pellet Plant or Sinter Plant Tar from Producer -- Will be given to nearby coke oven plant 1,782 Gas Plant Ash (Cinder) from -- Will be given to the brick manufacturing 16,038 Producer Gas Plant plants BF Granulated Slag 107,450 179,095 Will be used in the nearby Cement Plant BF Flue Dust 2,750 10413 Will be used in the Sinter Plant Sinter Plant ESP Dust 10,890 43,758 Recycled in Sinter Plant Return Sinter 17,820 69,500 Recycled in Sinter Plant Fly-ash from CFBC 272,450 272,450 Will be given to nearby Cement plant or & AFBC Brick manufacturing Unit Bottom ash from 68,110 68,110 Will be given to the brick plants CFBC & AFBC Ferro-alloys Fe-Mn Slag 51,475 174,662 Will be used for production of Si-Mn
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Type of Waste Quantity in Tons (TPA) Mode of Disposal Existing Total after the proposed Expansion Fe-Mn Bag Filter 1,315 4,463 Will be used in Ferro-alloys Sinter Plant Dust Si-Mn Slag 35,785 121,421 Slag is non-hazardous and will be used for construction of roads or filling of low-lying area Si-Mn Bag Filter 380 820 Will be used in Ferro-alloys Sinter Plant Dust Fe-Cr. Slag 35,896 121,797 Slag shall be further processed in grinding and Metal Recovery Plant and shall be used for construction purpose after TCLP test Fe-Cr. Dust 800 2,710 Will be used in Briquette Plant Fe-Si. Slag 947 3,214 Ferro Silicon Slag will be used for cement manufacturing/ industries as a raw material & used for medium carbon silico manganese production purpose Fe-Cr.-Si Slag -- 4,433 Slag is non-hazardous and will be used in cement manufacturing industries as a raw material as well as for construction and Road filling material after undergoing TCLP Test. Pig Iron Slag 31,575 107,136 Pig Iron Slag will be used for cement manufacturing as a raw material Briquette Plant Dust --- 15,300 Recycled in the plant
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3.9. Plant Layout
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CHAPTER 4 SITE ANALYSIS 4.1 CONNECTIVITY Site Location Village: Parvatpur Madandih Radhamadhabpur, P.O. Bortoria, Tehsil: Raghunathpur, District: Purulia, West Bengal Height above MSL 152 meters Road Connectivity SH-5 (Asansol Purulia Road) at 700m from project site and SH-8 (Durgapur Purulia Raghunathpur Road) at 10.15kms in south direction and NH-2 (Delhi Kolkata Highway)at 16km in north direction from plant site Rail Connectivity Ramkanali Station is at 4.23km in south direction from proposed site Nearest Airport Netaji Subhash Chandra Bose International Airport, Kolkata (205 kms). South East Nearest Port Haldia Port 220 kms. In South East direction Nearest River Damodar River at 6.0 km in North direction Near Reservoir Panchet Reservoir at 5.8km in West direction Ramchandrapur Reservoir at 5.5km in SE Direction National Park, Wildlife Sanctuary, Gar Panchkot Reserve Forest Reserve Forest within 10 kms.
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP The Expansion of SIPL plant required additional land of 9.393Ha (23.22 Acres) located adjacent to the existing plant setup in 71.71Ha. (177.19Acres). Additional Land required is in possession of SIPL, The expansion unit will set up in the existing land as well as additional land making premises of 81.103Ha (200.41 Acres).
4.3 TOPOGRAPHY OF THE LAND The soil of the Purulia district is an undulating tract of high ridges and low valleys. The major part of the district is plain. The alluvial areas are found in very narrow strips along the rivers. The valleys are steep along the rivers. Alluvial fans are found in the fringe areas of Ajodhya hills. The soils of the district are mostly sedentary in nature. Colluvial soil is found only in the valley bottom. Soils of undulated uplands are shallow, gravelly, the course having low water holding capacity. These lands are either severely eroded or very susceptible to erosion. The whole district is a network
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of a number of rivers. The principal rivers of the district are Damodar, Kangsabati, Kumari, Darakeswar and Subarnarekha. All the rivers have an easterly and southeasterly course, only the Subarnarekha flows south and receives west and south west-flowing tributaries. All the tributaries of these rivers are non-perennial and subject to flash floods. The Kangsabati is the master stream of the district. 4.4 PROPOSED LAND USE PATTERN Land Use after the expansion shall be as follows: Table 4.1: Land Use Pattern of Plant Area Existing Plant Land Total Plant Area After Sl. Plant Area Expansion No In Acres In Ha. In Acres In Ha. 1. Plant & Machineries 77.49 31.360 97.95 39.638 2. Raw material Storage 8 3.240 8.31 3.363 3. Water Handling Area 1 0.405 1.23 0.498 Waste Material Storage 4. 3 1.214 5.63 2.278 Yard 5. Rain water storage Area 4.1 1.66 4.77 1.931 6. Truck Parking 0 0 1.73 0.700 Drainage and Internal 7. 5 2.023 12.54 5.075 Road Office, Store, Temple, 8. 0.1 0.041 2.11 0.854 Misc. Building 9. Railway Siding 20 8.093 0 0 Green Belt Development 10. 58.5 23.674 66.14 26.766 (33% of Total Area) Total Land Area Required 177.19 71.710 200.41 81.103
4.5 EXISTING INFRASTRUCTURE Infrastructure available for water supply, power (including back-up power), Lab, weigh Bridge, Drinking Water, Rest Room, Toilets and Medical Unit. No additional facilities required. 4.6 SOIL CLASSIFICATION The soil in the district is in general of the residual type derived from the weathering of the Archean granites, gneisses, and schists. Laterite soil prevails in the uplands whereas in the valleys reddish clay loam or white to reddish clay are common. Many textural classes are seen such as sandy loam, reddish loam, white or reddish stiff clay, etc because of the undulating nature of the topography the soil cover is thin and the
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soil is generally gravelly. Almost in the entire district the soil is acidic and the fertility is low. 4.7 CLIMATE DATA Climate of the district is tropical type. Winter in the area lasts from November to February. Temperature of the atmosphere ranges between 60C to 200C. Atmospheric temperature during summer ranges 260C to 480C. Summer lasts from March to June. Humidity in the areas varies between 70 to 85%. Dry hot wind in summer blows across the district with the velocity ranging between 5-6km/hr. The normal rainfall in the district is about 1322mm. the main source of rainfall is the south west monsoon, which accounts for 80% of the total rainfall. Western and South western part of the district are affected by draught because of high run-off factor.
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report
CHAPTER 5 PLANNING BRIEF 5.1 PLANNING CONCEPT The project is for expansion of M/s Shakambhari Ispat & Power Limited for enhancement of 0.7875 Million Tons Per Annum Crude Steel, 0.214272 Million Tons Per Annum Ferro-Alloys (maximum) along with allied facilities at the Village – Parvatpur, Madandih, Radhamadhapbur, P.O. Bortoria, Tehsil: Raghunathpur, District - Purulia in West Bengal. in the total area of 81.103Ha. (200.41Acres). Number of Coal Mines of Eastern Coal Fields (subsidiary of Coal India Limited) are located in the northern part. Other industries like IISCO Steel Plant of Steel Authority of India Limited, Chittaranjan Locomotive Works, Hindustan Cables Ltd., Disergarh Power supply, Damodar Valley Corporation, Burn standards, couples of Cement plant, such as Burnpur Cement and quite a few Refractory units such as Kabita Refractory are located in this area. The project shall be implemented within 60 months after grant of Environmental Clearance from Ministry of Environment, Forest & Climate Change and Consent to Establish from West Bengal State Pollution Control Board. Material will be transported by Rail & Road. Plant is having nearest railway station Ramkanali at 4.23km from project site and there exists a railway siding adjacent to plant boundary connected to Ramakanli station. Also, SH-5 (Asansol Purulia Road) is at 700 meters from project site and SH-8 (Durgapur Purulia Raghunathpur Road) is at 10.15kms in south direction and NH-2 (Delhi Kolkata Highway) is at 16km in north direction from plant site. 5.2 POPULATION PROJECTION Manpower requirement for the proposed expansion shall be 1250 and will be sourced from local population. Hence there will not be increase in population due to direct employment in the area due to the proposed expansion. 5.3 LAND USE PLANNING The Expansion of SIPL plant required additional land of 9.393Ha (23.22 Acres) located adjacent to the existing plant setup in 71.71Ha. (177.19Acres). Additional Land required is in possession of SIPL, The expansion unit will set up in the existing land as well as additional land making premises of 81.103Ha. (200.41 Acres).
Existing Plant Land Total Plant Area After Sl. Plant Area Expansion No In Acres In Ha. In Acres In Ha. 1. Plant & Machineries 77.49 31.360 97.95 39.638
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Sl. Existing Plant Land Total Plant Area After Plant No Area Expansion 2. Raw material Storage 8 3.240 8.31 3.363 3. Water Handling Area 1 0.405 1.23 0.498 Waste Material Storage 4. 3 1.214 5.63 2.278 Yard 5. Rain water storage Area 4.1 1.66 4.77 1.931 6. Truck Parking 0 0 1.73 0.700 Drainage and Internal 7. 5 2.023 12.54 5.075 Road Office, Store, Temple, 8. 0.1 0.041 2.11 0.854 Misc. Building 9. Railway Siding 20 8.093 0 0 Green Belt Development 10. 58.5 23.674 66.14 26.766 (33% of Total Area) Total Land Area Required 177.19 71.710 200.41 81.103
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
Project is located in area with already available infrastructure. The plant has well connected National Highway as mentioned in the above chapters. Plant has also well- developed connecting roads inside plants for movement of raw material, storage areas for raw materials and finished products since the plant is under operation. Also, a railway siding is present adjacent to the project site for the transportation of raw material and finished product. 5.5 AMENITIES / FACILITIES The following facilities are already available at the project site as it is an operational plant: Administration Building Stores Time and security offices First aid and fire-fighting station Canteen and welfare center Toilets and Rest rooms Car parks and cycle / scooter stands No other additional facilities are proposed.
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CHAPTER 6 PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREA (PROCESSING AREA) Within the premises of M/s SIPL there will be industrial area of 45.777 Ha. (113.12 Acres) comprising of Plant & Machinery area, Raw Material storage Area, Water Handling Area and Waste material storage yard. 6.2 RESIDENTIAL AREA (NON-PROCESSING AREA) There is no proposal of any residential colony as the required manpower will be sourced from local population. Facilities like Canteen, Rest room, Toilets already exists in the plant. There will be Non-processing area of 35.326Ha. (87.29 Acres) comprising of facilities such as – Store & administrative block, Truck Parking, Drainage area, Rain water storage, Internal Roads and greenbelt area. 6.3 GREEN BELT Green Belt will be developed over 33% of the plant area. Indigenous trees will be planted in 26.766Ha (66.14 Acres) out of the total area of 81.103Ha (200.41 Acres). Tree density of 1500 trees per hectare with indigenous species will be planted. 6.4 CONNECTIVITY Project site is well connected by road and rail. Road Connectivity: SH-5 (Asansol Purulia Road) is at 700 meters from project site and SH-8 (Durgapur Purulia Raghunathpur Road) is at 10.15kms in south direction and NH-2 (Delhi Kolkata Highway) is at 16km in north direction from plant site. Rail connectivity is through Ramkanali Railway Station which is at 4.23km from the project site in South direction. Also, there exists a railway siding adjacent to plant boundary connected to Ramkanali station. 6.5 DRINKING WATER MANAGEMENT Raw water from DVVRC will be treated in Water Treatment Plant and is being supplied for drinking purpose in Offices, Canteen and Work place. Employees are being provided potable water for drinking. 6.6 SEWAGE SYSTEM Sufficient and suitable toilet facilities of proper standard and hygiene have been provided. Septic tanks followed by soak pit facilities are provided for all the toilet points made at different location in the plant premises for the treatment of sewage effluent. 6.7 INDUSTRIAL WASTE MANAGEMENT There is no waste water discharge from the plant. Cooling water is being recycled after cooling in the Cooling Towers. Blow down water from Cooling Towers are being used
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for slag cooling and dust suppression. Zero discharge shall be maintained after the proposed expansion. Solid Waste Management discussed in para 3.9, above. 6.8 POWER REQUIREMENT & SUPPLY / SOURCE Power Requirement Hourly power requirement for operation of the existing plant is 148.9MW. Power is being provide by DVC from 33KV Sub-station for operation of the plant. Company has already had agreement with DVC to supply 50 MVA Power. After commissioning of all the units under existing EC, company shall obtain the permission for total 61 MVA. Table: Power Requirement Details
Existing Proposed Total (MW) (MW) (MW) Power Requirement 148.9 38.50 187 Captive Power Generation 99 27 126 Balance Power required from Grid 49.5 11.5 61
After adjusting the captive power generation, additional Power requirement will be fulfilled by drawing electricity from 132KV line from Damodar Valley Corporation. Accordingly, 132KV substations shall be installed at plant premise to distribute the electricity to different consumption units. For emergency power requirement 2x500KVA, 1x750KVA & 2x1010KVA DG Set has been installed. Additionally, 1010KVA DG set shall be installed with each unit under the proposed expansion. ------
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CHAPTER 7 REHIBILITATION AND RESETTLEMENT (R&R) PLAN
Additional Land required for the proposed expansion is 9.393Ha (23.22Acres) which is in possession of SIPL. Resettlement & Rehabilitation is not required as there is no displacement of any houses, habitation or livestock.
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CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATE
8.1 PROJECT SCHEDULE
M/s Shakambhari Ispat & Power Limited has initiated actions to get statutory clearances to start the project. Clearances required are Environmental Clearance from Ministry of Environment, Forest & Climate Change and Consent to Establish from West Bengal Pollution Control Board. Completion schedule of the project is 60 months. “Zero date” for a project is reckoned as the date on which the all-statutory clearance to start the project are received. 8.2 COST ESTIMATE Estimated cost for the proposed expansion is Rs.300 Crores. Total Project Cost is estimated as Rs. 1301 Crs. including cost of existing plant as Rs. 1001 Crores. ------
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CHAPTER 9 ANALYSIS OF PROPOSAL
Over the last few years, there has been a great change in the Indian Economic Scenario due to Global slowdown which affected the whole world including India. The major sector which took the toll was Steel & Power Sector. The Company has been taken up by the experienced promoters engaged in the same activities. They possess sound network for marketing of the steel products having good existing customer base. The company does not feel any problem from marketing point of view. They have direct connection with the Customers, Users and with the entire network required for marketing of the products. To make end product economically viable in present fluctuating market, M/s Shakambhari Ispat & Power Limited has proposed for enhancement of Crude Steel production to 0.7875 Million Tons Per Annum, Ferro Alloys production to 0.214272 Million Tons Per Annum (maximum) along with allied facilities. Capacity expansion will essentially meet the increasing steel demand of Long steel products and ferro alloys in India. Long steel Product is the primary output of the company which would be sold in the open market. India is the fifth-largest consumer of steel in the world. The main areas of consumption of steel are infrastructure, construction, mechanical and automotive industries. The consumption of steel in airports, hotels and retail stores, railway coaches, wagons, etc is growing immensely. Ferro Alloys are important additives for Steel for enhancement of its properties of Steel. Alloying elements such as Manganese (Mn), Silicon (Si), Chromium (Cr), Molybdenum (Mo), Tungsten (W) etc. are required to be added to Steel while it is still in molten state to improve various physio-mechanical characteristics. These elements are normally added to steel in the form of Ferro Alloys. Besides alloying functions, Ferro Alloys are very essential for Steelmaking as it is used for deoxidizing and degassing. Steels are mainly classified according to its alloying elements such as low alloy, medium alloy and high alloy Steels. The demand for Steel is increasing vis-a-vis production in India. Hence, the demand for Ferro Alloys, which is a necessary addition, is bound to increase. Each ton of Mild Steel produced requires a minimum of 10- 15 kg of Ferro Alloys. The Company under flagship of Shakambhari Group is in the business of steel for period of more than one decade. Presently the company produces a chain of value-added products such as Long steel Products and Ferro Alloys.
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The Directors of SIPL are experienced Industrialist, dynamic, practical, hardworking & self-made entrepreneur. They have excellent reputation in & around Bengal, Jharkhand, Bihar, Sikkim, Uttar Pradesh and North Eastern States. The products will be produced indigenously and will be consumed in the country and also outside the country as per the demand. The management team consists of experienced and matured professionals. The team is quite capable of managing the business. Therefore, no financial problem is envisaged. The technology involved in expansion project is well proven and reliable. Many plants are operating all over the country in this pattern are successful. All equipment purchased shall be brand new & latest in model and will be purchased from reputed suppliers. For O&M of the plant, experienced Engineers /Technicians are available in the region.
So far, the marketing channel and network is concerned the company will use its existing network which will be looked after by the different levels of sales management team ranging from marketing manager to field assistant. Further, being an existing company with a good track record and experienced team of professionals, it has established its own distribution network over the years for the sale of its products. The company will thus, capitalize on its existing network and expand on the same for the sale of its output. The company has an established market in hand for the proposed product. As the promoters are having good experience of marketing as well as manufacturing same products, ready market in their hand and promoters themselves are closely involved in all the affairs of the company resulting better marketing network, efficient production planning, timely and economical raw material procurement and utilization of the resources at optimum level, will definitely do better from their competitors. Thus, the company does not foresee any problem in selling its output in view of the burgeoning economy combined with the boom in the infrastructure sector will help the company. Profitability of project is quite attractive. Project is technically and financially viable with positive impact on the local infrastructure. The region shall also be benefited from the project as there will be direct employment of people in the Steel plant. Preference will be given to the people of the state possessing requisite skill and qualification criteria. Also, there will be lot of scope for indirect employment of the people of the state in and around the project site like in transportation sector. In view of the above the Expansion Project of M/s Shakambhari Ispat and Power Limited is technically feasible and financially viable hence recommended for implementation. We
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M/s Shakambhari Ispat & Power Limited Pre-Feasibility Report request EAC to recommend TOR for conducting the EIA Study for obtaining Environmental Clearance from Ministry of Environment, Forest & Climate Change.
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