M/s Lal Ferro Alloys co.(P) Ltd PFR
1: INTRODUCTION OF THE PROJECT
1.1 About the Project
In view of the demand for steel in the country M/s LAL FERRO ALLOYS CO. (P) LTD has established Pig Iron Plant (1 X 23 M3) 12,000TPA, and Hard Coke Plant (24 Ovens) 15000 TPA . NOC for Pig Iron Plant and Hard Coke Plant was issued on 25.07.2007 at, Biswasdih, P.O. Gadi Srirampur, Dist. Giridih Jharkhand State. However the unit could not be operated for want of Environment Clearance. The unit applied to MoEF & CC, New Delhi for Environmental clearance for all the installed as well for the proposed induction furnace unit of (1 x 6 T) 18000 TPA ingots/billets.
The present proposal is to obtain the same as above.
The proposed project is listed in the new EIA Notification S.O. 1533, dated 14.09.06 as category A at Serial No. 3(a) under heading No. 3 and 4(b) under heading No. 4 of Materials Production. It requires prior environmental clearance from Ministry of Environment and Forest, Government of India, New Delhi.
1.2 History of the Project
Application for Consent to Establish (CTE) for Pig Iron & Hard Coke unit submitted to Jharkhand State Pollution Control Board, Ranchi on 05.10.2005. NOC for Pig Iron (40 TPD) & Hard Coke (50 TPD) issued vide No225 dated 25.07.2007. After setting up the plant applied for Consent to Operate on 30.12.2008. During the processing of CTO, it came into knowledge that EC is required for the Pig Iron Unit just before final consideration for grant of CTO. Before this it was not known about any process of EC. No condition of EC was mentioned in the NOC granted. Even various correspondences from JSPCB during the process of consideration of CTO, EC was not asked for. However, as required, application was filed to MOEF for Environment Clearance on 19.08.2009.As per circular no F.No.J-l-10L3147/ZOO6-lA-ll (l) dated 21.11.2006, setting up the plant was within the purview of the notification, application was filed as existing units - MBF and Hard coke and proposed addition of Induction Furnace. The draft EIA was submitted to JSPCB on 02.11.2012 for conduct of public hearing. During the process of consideration, it was suggested by Member secretary, JSPCB that since setting up the plant was not violation but the plant has not come into operation as CTO was not granted, the word existing be replaced by "Already installed . Accordingly the word ‘existing’ was replaced by ‘already installed’ and public hearing conducted on 22.01.2013. Final EIA submitted to MOEF on 27.06.2013. Proposal was considered in the 25th EAC (Industry) meeting held on 13.10.2014 at serial no. 25.3.3 & detailed presentation was done and minutes issued accordingly. Subsequent to the above meeting we received 2 letters from ministry being dated 09.12.2014 & 16.12.2016 requiring certain compliances. These compliances were submitted to MOEF on 04.08.2016 as follows: 1 Prepared by : Vardan Environet, Gurugram
M/s Lal Ferro Alloys co.(P) Ltd PFR
1. Copy of credible action initiated by Jharkhand State Pollution Control Board. 2. Resolution of the Board of Directors stating that no violation of Environment Protection Act will not be violated in future 3. Resolution is also taken to the effect that Status quo shall be maintained. Reminder submitted to MoEF & CC, New Delhi on 22.11.2016 for grant of Environment Clearance.
1.3 Company Profile and Proponent Detail
M/S LAL FERRO ALOYS Co. (P) LTD. is proposed project is an expansion to an installed Pig Iron Plant (1 x 23 M3 MBF) with capacity 12000 TPA and Hard Coke Plant (24 Ovens) of 15000 TPA with addition of Induction Furnace (1x 6 Ton) with manufacturing capacity 18000 TPA of MS Ingots/billets. The organization intends to expand its plant in the coalfield belt of the state of Jharkand at village – Biswasdih, in the district of Giridih. It plans to diversify itself into two dissimilar projects in order to diversify its risk and create a healthy working environment. The total cost of the expansion project is estimated to be Rs 2.45 Crores. 1.4 Address of Project Proponent
M/s Lal Ferro Alloys Pvt Ltd at Vill: Biswasdih, P.O. Gadi Srirampur, District Giridih, Jharkhand Phone no: 9931573899 Fax: 06532-223003 Mail id: [email protected], [email protected]
Company Details Name LAL FERRO ALLOYS Co. (P) LTD. Plant Location and Registered Vill : Biswasdih, P.O. Gadi Srirampur Office Dist. Giridih, Jharkhand. Installed units Pig Iron & Hard Coke Proposed units Induction Furnace Sector Iron & Steel Constitution Private Limited Co. The company has been promoted by a group of experienced businessmen who are presently engaged in manufacturing and trading business of various products. They are:
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1.5 Project Proponent Detail SL. No Name & Designation Age Qualification Experience
He has more than 10 years of experience in trade and business of Coal and Hard Coke. He is considered one of the biggest 1 Sri Chetu Saw 38 Inter supplier of Coal and coke products in Giridih and clearly understands the demand and supply scenario of Coal and Coke products. He has over 5 years of experience in the line trade and business since his involvement in the family business of export house 2 Sri Sumeet Bagaria 28 Graduate of Mica in Giridih since more than 30 years in the name and style of M/s Mohan International, Promoted by Sri Kamal Pd. Bagaria.
1.6 Importance of the Project
Pig Iron is one of the basic raw materials required by the foundry and casting industry for manufacture of various types of castings for the engineering sector. There exists a growing demand for pig iron in the international market, which has resulted in the international price of pig iron to soar up. Brazil, currently one of the major suppliers of pig iron in the world market has started to tighten the supply because of high inflation rate and severe shortage of coal. Even other suppliers like Japan and China have become buyers. This coupled with the government’s desire to export more value-added pig iron than iron ore has bettered the prospects of pig iron export.
India was the most economic producer of steel in the world during 1960s, but during 1970s the regular maintenance and technology up gradation aspects of steel plants were neglected which resulted in the decline of steel production. During the same period the steel industry in other parts
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of the world was moving up technologically, aiming at energy saving and efficient utilization of all grade of raw materials. Under such circumstances Indian steel prices went up with regard to international prices, which in turn affected the rate of consumption. The growth of the steel sector is intricately linked with the growth of the Indian economy and especially the growth of the steel consuming sectors. India has become self-sufficient in iron and steel materials in the last 3 - 4 years. Exports are rising and imports are falling. Production and production capacities are increasing. At the same time, productivity of our steel plants must be maintained at levels close to international standards. The role of secondary steel sector is very significant in meeting the demand supply gap, in view of the fact that the existing integrated steel plants have its limitations to push up output in short term. Also on other hand, setting up of a new integrated steel plant will take its own course. 1.7 Details of the site:
No. Features Details 1 Village, District and State Vill : Biswasdih, P.O. Gadi Srirampur
2 Survey of India Topo. sheet covering 72 L / 8 3 Latitudeth l t d di 240 08’ 34” N. 4 Longitude 860 19’ 51” E. 5 Land use at the proposed project site Industrial 6 Nearest Highway State Highway 1.25 KM (SW) 7 Nearest Railway Station Giridih - 4.5 km 8 Nearest major habitation Giridih - 4.5 km 9 Nearest River Ushri – 4.1 KM, Barakar River – 8 KM 10 Forest Reserve Forest – NIL,
11 National Park NIL within 10 KM
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2: PROJECT DESCRIPTION 2.1 Site Location
The proposed site is located at Vill: Biswasdih, P.O. Gadi Srirampur, District Giridih, of Jharkhand State and is about 1.25 KM from State Highway.
Latitude : 240 08’ 34” N.
Longitude: 860 19’ 51” E.
2.2 Type of Land: Fallow and Plain land with Gentle slope and 281 M above MSL. Since the entire movement of incoming and outgoing materials will be by road, no rail head or rail connection is required. However a railway line (North Railway Giridih line) passes at a distance of 4.5 Km from the site
2.3 Site details :
Selection of suitable site for a project is as important as selecting a technology and suppliers. Factor which are taken into account for selection of site are proximity to raw materials or market and availability of manpower, water, infrastructure and ease of transportation. However a new dimension has also raised concerns in selection of site and that is environment. Factors taken into consideration while selecting the site:
• Availability of land. 5 Prepared by : Vardan Environet, Gurugram
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• Flat terrain and soil strength. • Connectivity. • Overall impact on environment • Availability of water and power • Other infrastructure
The proposed project is an expansion at the site, which is well connected to state highway and nearby railway station. Hence, sufficient infrastructure exists and lesser resources are required to be deployed for modernization as infrastructure. Since, construction for infrastructure does not require and hence does not affect the environment in any way. As the proposed site has all the above facilities and is adjacent to an industrial belt housing similar and other types of industries, no other site was considered.
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Fig 1 : Google Image of the Project site
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Fig 2: Key Plan
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PLANT SITE
Fig 3: Location map
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Fig 4 : Layout Plan of the project site
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3: SIZE OR MAGNITUDE OF OPERATION
3.1 PRODUCTION CAPACITY
The proposal is for addition of one Induction Furnace unit (18000 TPA) to already installed Pig Iron Unit (12000 TPA) and Hard Coke Unit (15000 TPA) form various raw materials like iron ore, quartz, lime stone, coke, dolomite, Lime stone, Coal etc.
3.2 QUANTITY OF INCOMING MATERIALS
SPECIFIC REQUIREMENT REQUIREMENT SL No RAW MATERIAL CONSUMPTION PER DAY PER YEAR
PIG IRON UNIT (INSTALLED)
1 IRON ORE 1.6 64 19200
2 COKE 0.75 30 9000
3 DOLOMITE 0.1 4 1200
4 LIME STONE 0.12 5 1500
MANGANESE 5 0.04 1.6 480 ORE
HARD COKE (INSTALLED)
1 COAL 1.25 62.5 18750
INDUCTION FURNACE (PROPOSED)
1 PIG IRON 0.67 40 12000
2 SPONGE IRON 0.5 30 9000
3 SCRAP 0.12 7.20 2160
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3.3 SOURCE OF RAW MATERIALS
SL No ITEM SOURCE MODE OF TRANSPORTATION
1 IRON ORE Barajamda Road
2 COKE In House Road
3 DOLOMITE Bhutan Road
4 LIME STONE Patratu Road
5 MANGANESE ORE In House Road
6 COAL BCCL, Jharkhand Road
The operational efficiency and quality of product are mainly dependent upon the quality and size of raw material, hence utmost care will be taken in procuring and storage of the raw materials. 3.3 MASS BALANCE
Fig 5: Material balance for Induction Furnace
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3.4 TECHNOLOGY AND PROCESS DESCRIPTION
The project envisages manufacture of Pig Iron by Mini Blast Furnace technology
Selection of suitable production process and the capacity of the production units form the nucleus around which the basic concept of a plant is developed. While the selection of a process takes into account factors like type of product, availability of local raw material, process status, specific energy consumption, level of energy required, environment, and pollution etc., the capacity selection of major units would depend on the volume of production, available unit sizes, economies of scale etc. The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone. The coke is the reducing agent and is partly burnt as a fuel to heat the furnace; but to reduce consumption of this expensive commodity, additional fuels, such as natural gas, fuel oil, and pulverized coal are added to the air blast injected near the bottom of the furnace. By doing this, coke consumption has been halved since the 1980s to an average 500 kg (1,100 lb) per tonne of metal produced. The air reacts with the carbon in the coke to produce carbon monoxide, which combines with the iron oxides in the ore, reducing them to metallic iron. This is the basic chemical
reaction in the blast furnace; it has the equation Fe2O3 + 3CO = 3CO2 + 2Fe. The limestone in the furnace charge acts as a flux to combine with the infusible silica present in the ore to form fusible calcium silicate slag. Without the limestone, iron silicate would be formed, with a resulting loss of metallic iron. Calcium silicate and other impurities form a slag that floats on top of the molten metal at the bottom of the furnace. Ordinary pig iron as produced by blast furnaces has the composition: iron, about 92 per cent; carbon, 3 to 4 per cent; silicon, 0.5 to 3 per cent; manganese, 0.25 to 2.5 per cent; phosphorus, 0.04 to 2 per cent; with a trace of sulphur. A typical blast furnace consists of a cylindrical steel shell lined with a refractory, which is any non- metallic substance such as firebrick. The shell is tapered at the top and at the bottom and is widest at a point about one quarter of the distance from the bottom. The lower portion of the furnace, called the bosh, is equipped with several tubular openings or tuyeres through which the air blast is forced. Near the bottom of the bosh is a hole through which the molten pig iron flows when the furnace is tapped, and above this hole, but below the tuyères, is another hole for draining the slag. The top of the furnace, which is about 27 m (90 ft) in height, contains vents for the escaping gases, which are collected, de-dusted, and then blended with natural gas for use as a fuel within the plant. The blast furnace top is fitted with a charging device such as a pair of round hoppers closed with bell-shaped valves through which the charge is introduced into the furnace, or a movable chute that is continuously adjusted to direct the charge to the required spot in the top of the furnace. The materials are brought up to the top of the furnace by conveyor or in small dump cars or skips that are hauled up an inclined external skip hoist.
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Blast furnaces operate continuously. The raw material to be fed into the furnace is divided into a number of small charges that are introduced into the furnace at 10- to 15-minute intervals. Slag is drawn off from the top of the melt about once every 2 hours, and the iron itself is drawn off or tapped about five times a day. An important development in blast-furnace technology, the pressurizing of furnaces, was introduced after World War II. By “throttling” the flow of gas from the furnace vents, the pressure within the furnace may be built up to 1.7 atmosphere or more. The pressurizing technique makes possible better combustion of the coke and higher output of pig iron. The output of many blast furnaces can be increased by 25 per cent in this way. Experimental installations have also shown that the output of blast furnaces can be increased by enriching the air blast with oxygen, a level of 2.5 to 5 per cent being common. The process of tapping consists of knocking out a clay plug from the iron hole near the bottom of the bosh and allowing the molten metal to flow into a clay-lined runner and then into a large, brick- lined metal container, which may be either a ladle or a rail car capable of holding as much as 100 tonnes or more of metal. Any slag that may flow from the furnace with the metal is skimmed off before it reaches the container. The molten pig iron is then transported to the steel-making shop. Modern blast furnaces are operated in conjunction with basic oxygen furnaces and occasionally an electric arc furnace, or in a few countries the older open-hearth furnaces, as part of a single steel- producing plant. In such plants the molten pig iron is used to charge the steel furnaces. The molten metal from several blast furnaces may be mixed in a large mixer vessel before it is converted to steel, to minimize any irregularities in the composition of the individual melts. Selection of suitable production process and the capacity of the production units form the nucleus around which the basic concept of a plant is developed. While the selection of a process takes into account factors like type of product, availability of local raw material, process status, specific energy consumption, level of energy required, environment, and pollution etc., the capacity selection of major units would depend on the volume of production, available unit sizes, economies of scale etc. 3.5 TECHNOLOGY FOR MANUFACTURE OF HARD COKE
Coking coal contributes to approximately 50% of the cost of hot metal. Therefore, it is logical that coke quality and price needs to be kept under control in the iron and steel industry to be competitive. The two primary variables that influence the price and quality of BF coke are – coke making technology and raw materials used. Some of the technological developments that have improved performance of industry are:
• Stamp Charging of Coal • Partial Briquetting of Coal Charge (PBCC)
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• Selective Crushing of Coals • Dry Coke Quenching
3.5.1 Non-Recovery/ Heat Recovery Coke Production: Non-Recovery coke plants, originally referred to as beehive ovens, have large oven chambers. The carbonization process takes place from the top by radiant heat transfer and from the bottom by conduction. Primary air for combustion is introduced into the oven chamber through several ports located above the charge level in both pusher and coke side doors of the oven. Combusted gases exit through common tunnel via a stack which creates natural draft. Since by-products are not recovered, the process is called Non-Recovery Coke making. The waste gas is fed into a waste heat recovery boiler to convert excess heat into steam for power generation; hence, the process is also called Heat Recovery Coke making. Non-Recovery Coke Oven Technology
The Non-Recovery Coke Ovens are considered eco-friendly in comparison to recovery type. It is less capital intensive and has short construction periods of approximately 6 months. Main features are: • Energy of carbonisation is supplied by burning the gaseous volatile products released from the coal charge during carbonisation. • Heat generated by the combustion of the volatile matter, produces high temperature zone in the free space above the coal charge. This radiates back into the coal charge downwards. • The products of combustion are drawn through the various points in the oven arch and passed through side wall off-take flues into a series of sole flues located below the oven floor. • Application of heat takes place from above, sides and below the charge. Temperature at the point where burning gases are drawn into the side off take ports is of the order of 1200 oC.
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Fig 6: A typical flow-scheme of Non Recovery Type Coke Oven plant
3.5.2 Advantages of Non-Recovery Coke Oven
• Low Capital cost; low operating and maintenance cost; and hence low cost per ton of coke conversion. • High coke yield and flexibility of operation; No external heating required • Heat transfer is in vertical direction against horizontal as in case of by-product or recovery type oven design • Exhaust flue gas can be utilized for power generation. • No effluent discharge, all volatiles are fully burnt resulting in clean flue gas with minimal environmental impact. • Ovens of non-recovery type are being operated under suction to avoid any explosion during operation and to prevent pollution. • Extensive flue system ensuring complete combustion of all hydrocarbons leaving a clean stack gas with in permissible limit.
3.6 INDUCTION FURNACE (M.S. Ingots/billets) – TECHNOLOGY
Induction Furnace is an established process for production of liquid steel using 100% solid charge comprising appropriate proportion of Scrap / DRI / HBI / Pig Iron. India has witnessed an un- precedent growth in induction furnace steel making in just two decades.
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The technology for the proposed mini steel plant is selected as 6 TPH Induction Furnace (steel melting) with an installed capacity for production of 18000 TPA MS Ingots/billets.
3.6.1 Induction furnace (IF)
Major technological features of induction furnace envisaged are as follows.
Two crucible per furnace; one crucible will be powered and other crucible will be kept as standby and ready to take over when the first crucible goes under patching / lining, thus ensuring continuous productivity. Continuous charging of charge-mix. Quick release of worn out crucible
Fig 7: Flow Scheme of Induction furnace
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3.7 MANUFACTURING PROCESS - PIG IRON
The project under study has installed a Mini Blast Furnace of much smaller size. It is going to adopt only some of these techniques which are less capital oriented and provides relatively more benefits. It is going to have higher hot blast temperature, use of sinter and pellets, slag granulation system etc. With the introduction of Blast Furnace, it has become possible to manufacture iron in a continuous process. The features of the blast furnace are as below: • An arrangement for charging material in blast furnace. • An arrangement for taking out molten metal. • An arrangement to blow air into the furnace.
3.7.1 Important points of the Mini Blast Furnace manufacturing process are: • Hearth at the base which serves the purpose of crucible to store molten metal and slag. • A high shaft formed by joining two cones. The one on the lower side is known as “Bosh” and upper one as “Stack”. • A double cup and cone arrangement to close the throat of furnace. • Tapping out the molten metal from one outlet in the lower portion of the hearth. • Let out for lighter slag – another “Slag notch”. • Introducing Blast of air, tuyeres and • Out let for gases of the Furnace.
The other important equipment’s of Blast Stoves which contains high alumina bearing balls. The heat of the air is increased by passing through brick work generators, heated by burning the waste gases collected from the top of the furnace. The waste gases collected at the throat of the furnace is burnt in the stove and the products of the combustion passes through the brick work and then to the chimney. The heat is thus observed by the balls and by passing the blast through the stove balls in a direction opposite to that taken by products of combustion it attains the desired temperature. At least three stoves are required, two on gas and one on the blast in a sequence. Advantages of hot air blast: • The raw coal powder can be used through tuyeres replacing some coke. • Less fuel is now required in the furnace, owing to the heat already conveying the air. • The temperature in front of the tuyerers is increased and the fusion zone or the furnace brought lower down. • The furnace works with lesser irregularity and is more easily controlled. • Foundry grade pig iron can be easily produced. 18 Prepared by : Vardan Environet, Gurugram
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In the blast furnace sinter, the iron ore lumps and pellets are charged from top of the blast furnace along with the Coke, Limestone & Dolomite by the help of skip car moving up and down by the electric hoist. It keeps the furnace continuously full to the required level by keeping a watch on the stack gauge rod. The hot air is blown inside the furnace through the tuyeres. This air provides necessary oxygen for combustion of the coke inside the furnace which generates carbon dioxide. This gas travels upwards, comes across more hot coke and is reduced to the carbon monoxide which helps in preheating and reducing iron ore in successive stages to iron (Fe). The ash of the coke is fluxed with limestone to form slag. The slag and the molten metal accumulate in the hearth of the blast furnace which are subsequently tapped from time to time. It is proposed that the slag will be granulated and the same will be sold as a raw-material for the cement plants. The gas is released from the top of the blast furnace containing calorific value of approx 900 kilo calories/NM3. The gas is passed through dust catcher and the other Gas Cleaning Systems so that it is finally clear enough to be used as a fuel for preheating the air in the Blast Furnace. The liquid hot metal will be directed towards the pig casting machine and it will provide the pig iron shed to the molten metal. Finally the Pig Casting Machine will transport the finished product at the end of the machine. The cooling arrangement of Pig Casting Machine will convert the molten metal into solid pig iron. 3.7.2 Chemical reactions in the blast furnace
Considering the chemical change taking place in the blast furnace, the conditions under which it works must be borne in the mind. In the furnace the temperature varies continuously from throat to the hearth. Near the throat the temperature is 2000C max. Next is the stack where the reduction takes place and the temperature is up to 800 deg. cent. Next is the zone of slag formation with temperature from 8000C to 12000C and finally near the hearth is the zone of fusion with a temperature of 12000C to 15000C. After charging the materials, it takes a considerable time in descending to the lower part of the furnace. In its descent, the ore meets carbon-mono-oxide produced from the coke at the hearth and air blast.
2C + O2 = 2 CO
Above the boshes, at a dull red heat, the reaction takes place in two stages, as under:-
Between 4000C - 7000C:
Fe2O3 + CO = 2 FeO + CO2
Between 7000C - 9000C:
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FeO + CO = Fe + CO2
The ore is thus reduced to metallic iron.
Further, in the upper zone limestone charged as flux is reduced to lime.
CaCO3 = CaO + CO2
Carbon dioxide is expelled in the upper part of the furnace and calcium oxide combines with the gangue and produces slag consisting of calcium silicate:
CaO + SiO2 = Ca SiO3
Near the centre of the furnace where the temperature is of a bright red heat (10000 - 12000), the following reaction also takes place simultaneously:
2CO = CO2 + C
The liberated carbon is utilized for the completion of the reduction process. The norms of consumption of raw materials differs from plant to plant depending upon the health of the plant, technology followed, nature of important input raw materials, melting practice extent to which fuel injection is practiced, design of plant, resources used efficiency, type of steel manufacture etc. The requirement of raw materials differs from one plant to another depending upon technological route followed. For example raw material needed for integrated steel plants differs very much from those of Electric Arc Furnace (EAF) or Sponge Iron making units. The steel melting scrap in International market is depleting. Therefore, manufacturing of sponge iron, which is a partial substitute, is being encouraged. But all others units needs Iron ore as starting materials, irrespective of process and technology followed. Several units in private sector are engaged in Sponge Iron and merchant Pig Iron making which is eventually used for steel making. Therefore, it is difficult to summarize precisely the pattern of raw materials consumption in the country. Never the less the Iron ore, manganese ore, coal & coke, flux & refractory, etc are invariably used in Iron and Steel making. The growth in domestic demands (plus expected level of export demand) for Iron and Steel items leads to growth in investment in steel sector and eventually results in increased domestic production. This eventually leads to grow in demand for inputs including raw materials. The forecasting of demand helps industry to gear its activities for expansion of production capacities or locate new source of supply.
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Fig 8: BLAST FURNACE PROCESS FLOW CHART
Raw Material Yard
Feeding Conveyor
Stock
H
Charging Cold Blast
Conveyor From
Supplying Sending BF Gas for Gas BLAST FURNACE Cleaning Plant Hot Blast
Clean Gas to Metal from Runners From Slag Runner to SGP Stove or Flare
PIG CASTING
MACHINE
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Fig 9 :MATERIAL HANDLING FLOW CHART
RAW MATERIAL STOCK YARD
Feeding Conveyor
Shuttle Conveyor
Bunkers
Vibro Feeder
Vibrating Screens Fines Conveyor
Weigh Hoppers Fines Hoppers
Collecting Conveyor
Charging Conveyor
Blast Furnace Small Bell
Blast Furnace
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3.8 MANUFACTURING PROCESS – HARD COKE Coking is the process of heating coal in coke ovens to drive volatile matter from it. Ovens are heated by coke-oven gas, which burns in heating flues in an oven's side walls. Waste gases from this combustion pass out through a stack or chimney. At either 20- or 30-minute intervals, the flows of gas, air and waste gas are reversed to maintain uniform temperature distribution across the wall. The design of heating systems varies from battery to battery. Approximately 40 percent of the total coke oven gas produced from coking is returned to the heating flues for burning after having passed through various cleaning and co product recovery processes. The process of filling the oven with coal is called charging. The actual coking process begins with coal charging. 'Larry cars’ atop the batteries ‘take on’ coal from storage bins and carries it to the ovens. This process can also done manually. Currently it is planned to carry the coal manually to the oven. The coal is dropped through four charging holes in the top of an oven. Charging-hole lids, taken off before charging, are then replaced. After nearly all the coal has been dropped into an oven, a pusher machine extends a large steel ram to level the coal within the oven to a height that provides a space above the bed of coal to allow for the collection of gases emitted during the coking process. The gases driven from the coal during coking are carried away from the oven through refractory- lined standpipes or ascension pipes. Refractory is a special type of brick. Pipes from each oven are connected to a 'collecting main,' which runs the length of a battery, and which carries the gases and waste ammonia liquor to the coal chemical processing facilities. During a charge, steam aspirators located in gas off take pipes are turned on to maintain negative pressure in the oven chamber and thus contain charging emissions. After charging, a worker turns off the steam aspirators, replaces the charging lids and seals them. These designs plus careful work practices minimize emissions. Once charged, coal is allowed to 'coke' for from, for example, from 24 to 36 hours depending on the battery and the way it is operated. Times may vary even wider depending on the battery. The coking time can be changed depending on production requirements. When coking is finished, the oven is dampened from the collecting main and the oven doors are removed. A large ram, mounted on the pusher machine is used to push the coke out of the oven from the 'pusher-side' out through the 'coke side.' A coke guide on the coke side directs the coke across a bench and into a 'quench car.' A quench car is equipped with emission control devices that spray water over the hot coke to suppress release of particulate emissions.
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Preparing Coke for Use After quenching, the temperature of coke is about 300 degrees F to 400 degrees F. The quench car dumps the coke onto a coke wharf, which feeds the coke onto conveyer belts that transport it to a coke screening station. The screening station is a processing point that either diverts the coke to a truck 'load-out' bin or sends it to be separated according to size. The load-out bin holds the coke for dump trucks to transport it to storage piles. Coke is fed onto a single-deck scalping screen where large pieces of coke are separated for crushing before rejoining the smaller coke for screening.
3.9 MANUFACTURING PROCESS – INDUCTION FURNACE Sponge Iron, Pig Iron, Scrap etc are brought near Induction furnaces with the help of scrap bucket transfer cars and EOT cranes. DRI from the day bins is conveyed to operating platform of induction furnaces. Before starting the IF, the crucible is inspected. Initial quantity of scrap/ pig iron is charged into the IF with transformer at full load. After the scrap/ pig iron is fully melted and the temperature of the melt reaches above 16000C, DRI is continuously charged into the furnace. Initial charging of scrap is done with the help of scrap bucket and overhead crane. The subsequent feeding of charge materials is done by Goliath crane. Main activities of the operation such as charging of input materials, melting and de-slagging are done simultaneously. As soon as charge is melted, bath sample is taken and temperature measured. The steel at this stage is ready for tapping. Predetermined quantity of ferro-alloys is added in the ladle during tapping. The molten metal is finally poured in moulds to form M S Ingots/billets on cooling.
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M/s Lal Ferro Alloys co.(P) Ltd PFR
4: SITE ANALYSIS
S.No. Particulars Details 1. Latitude 240 08’ 34” N 2. Longitude 860 19’ 51” E 3. Altitude 281m above MSL 4. Toposheet 72 L/8 5. Seismicity Area falls under least affected earthquakes zone II 6. Present land use Industrial 7. Climatic condition Ambient Air temp 10o C to 37o C
8 Defense Installation Nil 9. Nearest Town Ranidh 1.5 Km E
10. Nearest Railway station Giridih - 4.83 KM ,N 11. Nearest airport Durgapur 100 KM, E 12. Water Source / Rivers Reservoir : 10 Km N Usri Nadi : 4.1 Km E Barakar River : 8 Km SW 13. Inland, coastal, marine There are no coastal or marine water near the site. 14. Topography Gently undulating and sloping 15. Highway/railway line State Highway : 1.25 Km SW Giridih Rly Line : 4.0 Km NW 16. Historical Places Nil
17 State, National boundaries Nil 18 Reserve Forest/Protected In a range of 3 to 10 Km
19 Areas already subjected to Mohanpur, Srirampur & Biswasdih (1Km-4 Km) pollution or environmental damage
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M/s Lal Ferro Alloys co.(P) Ltd PFR
4.1 Features of On- Site Data:
Site specific data for the period December 2011 to February 2012 were collected in the study area. 1. Temperature varies between 11.5 0C and 28.6 0C during this period with hottest month was being February. 2. Humidity varies between 44.5 % and 54.5 % with December being the most humid month. 3. Rainfall varies between 5.1 mm and 19.4 mm during these three months. 4. Predominant wind direction was from North-West. The wind speed and direction are important factors that control the movement of dust and gaseous pollutants across the atmosphere. Hence special emphasis was given to monitor the wind pattern in and around the study area
4.2 Hydrogeology
The state is underlain by variety of rock formations from Pre-Cambrian to recent age. A major part of the state is underlain by formations comprising of granites, granite gneisses, meta- sedimentaries and a variety of volcanic rocks. The volcanic formation represented by Rajmahal traps are exposed as patches in a linear fashion in the north-eastern part. The sediments belonging to Vindhayan system are seen exposed in the north- western part of the state. The lateritic capping is invariably seen in the south western part. Recent alluvial formations are mostly confined to the valleys along major rivers of the state. The ground water exploration has revealed presence of 3 to 4 potential fractured zones at variable levels within a depth of 200 m from the ground level. The discharge of the exploratory wells is highly variable ranging between 3.6 to 54 m3/hr. In some of the pockets higher discharge wells has also been constructed.
4.3 Topography and Drainage
The topography of the site is flat. Ursi River flows from north-west to south-east on the eastern part of the site. It is a perennial water source of the area and also the sink for industrial and domestic waste water from the area. A large number of ponds, reservoirs are present in the area. Number of dug-wells and tube wells are present in the 10 km study area. The study area is part of lower Gondwanas and consists of the general Stratigraphy sequence of Talchir, Da-muda and Panchet rocks of which Damuda series is the most important. The important rock types are sandstones, shales, traps and coal seams. The entire region is a plain area having a gentle slope from the south to the north. This needs to be changed as the details of study area in toposheet in presentation are not clear, original topo to be referred.
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M/s Lal Ferro Alloys co.(P) Ltd PFR
4.4 Seismic Hazard and earthquake
According to GSHAP data, the state of Jharkhand falls in a region of low to high seismic hazard. As per the 2002 Bureau of Indian Standards (BIS) map, this state also falls in Zones II, III & IV. Historically, parts of this state have experienced seismic activity in the M 5.0 range. Approximate locations of selected towns and basic political state boundaries are displayed
The primary goal of GSHAP was to create a global seismic hazard map in a harmonized and regionally coordinated fashion, based on advanced methods in probabilistic seismic hazard assessments. Available databases and information has been utilized by the ASC to generate the following maps using the freely available Generic Mapping Tools (GMT) software.
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M/s Lal Ferro Alloys co.(P) Ltd PFR
4.5 TRANSPORTATION SYSTEM
All the materials required for construction and operation of the plant will be transported through road. State Highway is at a distance of nearly 1.25 Km. from the site which connects Giridih to Dhanbad and NH 2. The site has also good connectivity with other major cities. Hence transportation of materials by road is feasible as the existing network of roads is adequate to accommodate increase of traffic due to the project. Buses will be provided for manpower communication. Most of the workers will be local and if required houses in the nearby villages and town will be taken on lease for accommodating outside manpower. Other major industrial towns like Asansol, Raniganj, Durgapur, Jamshedpur and Rourkela are within an approachable distance from the Plant site
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M/s Lal Ferro Alloys co.(P) Ltd PFR
5: PLANNING BRIEF
As the manufacturing products are very much dependent on raw materials, it is required to have proper infrastructure for connectivity. The proposed site is connected to through road and rail network. Availability of other utilities i.e. water, power, fuel in this area makes this site more suitable for proposed project.
5.1 Raw Material and there source
SL No ITEM SOURCE MODE OF TRANSPORTATION
1 IRON ORE Barajamda Road
2 COKE In House Road
3 DOLOMITE Bhutan Road
4 LIME STONE Patratu Road
5 MANGANESE ORE odisha Road
6 COAL Open auction Road
Quantity Of Incoming Materials
SL SPECIFIC REQUIREMENT REQUIREMENT RAW MATERIAL No CONSUMPTION PER DAY PER YEAR
PIG IRON UNIT (INSTALLED)
1 IRON ORE 1.6 64 19200
2 COKE 0.75 30 9000
3 DOLOMITE 0.1 4 1200
4 LIME STONE 0.12 5 1500
MANGANESE 5 0.04 1.6 480 ORE
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M/s Lal Ferro Alloys co.(P) Ltd PFR
HARD COKE (INSTALLED)
1 COAL 1.25 62.5 18750
INDUCTION FURNACE (PROPOSED)
1 PIG IRON 0.67 40 12000
2 SPONGE IRON 0.5 30 9000
3 SCRAP 0.12 7.20 2160
5. 2 Manpower Projection: The total man power required for the project has been estimated at 120, inclusive of managerial, supervisory, administrative, skilled /unskilled workers, and security staff. Training would also be provided by the consultant. Company does not envisage any difficulty in availability of adequate man power
5.3 Land use planning (breakup along with greenbelt etc).
Land Use Breakup
Area Area SL No Type of use (in acres) (in ha.)
1 Plant Area 2.80 1.13
2 Raw Material Storage 1.34 0.54
3 Road & Infrastructure 1.86 0.75
4 Green belt 3.86 1.56
5 Office & Stores 0.16 0.07
6 Vacant area 1.73 0.70
Total Land Area 11.75 4.75
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M/s Lal Ferro Alloys co.(P) Ltd PFR
5.4 PROJECT COST
The total cost of the expansion project is estimated at Rs. 2.45 Crores. It includes cost of land, building & sheds, plant & machinery, electrical and other fixed investment.
5.5 MANPOWER REQUIREMENT
The total man power required for the project has been estimated at 120, inclusive of managerial, supervisory, administrative, skilled /unskilled workers, and security staff. Training would also be provided by the consultant. Company does not envisage any difficulty in availability of adequate man power.
5.6 POWER REQUIREMENT
The power requirement for the proposed unit is 500 KVA. The power shall be sourced through DVC and DG sets 0f 500 KVA will be installed for emergency. Details of Electric Motor Installed:
SL No. DESCRIPTION KVA
1 Pollution Equipment 14.92
2 Pump House 85.79
3 Blast Furnace 294.67
4 Hard Coke 104.44
5 Miscellaneous 0.18
Total 500.00
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M/s Lal Ferro Alloys co.(P) Ltd PFR
5.7 FIRE FIGHTING FACILITIES
As blast furnace and Sinter plant involves lot of material handling and high temperature operations, so to protect the plant from fire hazards, adequate fire fighting measures have been planned. The following fire protection facilities have been provided.
Fire hydrant system Portable fire extinguishers Manual fire alarm system
5.8 WATER REQUIREMENT
Ground water source shall be used for which appropriate number of bore wells will be dug. Circulating water requirement for the plant is 23-25 m3 .Total make-up water estimated at 160 m3/day.
Plant Section Make up Water Quantity
Blast furnace 120 m3/day
Induction furnace 15 m3/day
Hard coke plant 20 m3/day
Domestic use 5 m3/day
total make up requirement 160 m3/day
Water will be sourced from underground through bore well. Permission for the same has been obtained.
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WATER FLOW DIAGRAM
Rain water harvesting Source of Water (Bore Well)
Rain Water Tank 3 (800 M )
/day
3 M
Water 160 up Make tank
3 Process Water Tank 155 M / day 3
3 3 5 M / day 5 M / day
15 M3 / day Domestic use Green belt & Water sprinkle Evaporation Loss Evaporation day / 3 M
Induction Furnace 140 Soak pit MBF &
Hard Coke Plant
Recycle
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6: PROPOSED INFRASTRUCTURE
6.1 Description of Proposed Mitigative Measures to be Incorporated In Project
Proposed Type of Pollutants production Process operation environmental Mitigation released facilities pollution
Raw Material Water Unloading, Stocking Dust Air Pollution Handling suppression
Feeding RM in stock Fugitive Raw Material Bin of MBF, Hard Emission Dust Air Pollution Feeding Coke Ovens and Control Induction Furnace system
Melting of Raw Air Pollution material, Chemical Production Process Fume & Dust Air Pollution Control Reaction in Furnace/ system ovens.
Molten Metal Solid Waste Disposal And Discharge, Slag Air Pollution Product Processing in form of Sale of Solid Discharge and Hard Slag Land pollution Waste Coke Discharge
Covering of Sizing, Storage, Trucks, Loading & Product handling Dust Air Pollution dumpers and Transporting of water Product Suppression
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6.2 MEASURES FOR ENVIRONMENT MANAGEMENT a) Ambient Air Quality Management: . Fume extraction system for suction of fugitive emissions from raw material charging area and then to bag filter . Water sprinkling and green belt development for maintenance of AAQ. . Fugitive emissions can also be kept low by making pucca haul roads within the premises and making arrangements for water spraying at all the dusty places in the premises and during loading, unloading process. . Control of Stack Emissions and Fugitive Emissions will have a direct impact on the ambient conditions. . Development of planned green belt in the industry will also control ambient conditions • All de-dusting units will be connected to a stack of height 30 m. • The fugitive emissions of suspended particulate matter (SPM) will be maintained below 2000 µg/M3 at a distance of 10 m from the source. • Appropriate disposal of solid waste.
For Pig Iron Division Bag filter system for control of emissions from Blast furnace and dust from charging section of mini blast furnace. It is the integral part of the system and the Blast Furnace cannot operate without the same.
For Hard Coke Division Hard Coke Manufacturing Units accounts for a significant amount of Particulate and Gaseous Emissions from the process. Coke oven is operated under negative pressure and adopt upper and lower oven door structure, which can avoid dispersion of fume and dust emission. The volatile matters produced during coal carbonization are completely burnt.
Induction Furnace The following measures for minimizing adverse impact on the environment will be incorporated
o Fume extraction system with bag filter. Particulate matter emission from de-dusting units will be maintained below 100 mg/NM3. o All de-dusting units will be connected to a stack of height 30 m.
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b) Waste Water Management Water requirement is only for cooling purpose. There would be no discharge of any effluent to the outside area. Hence at present there appears no requirement for any Effluent treatment plant. Domestic discharge from canteens and toilets must be channeled through proper sewage channels and soak pits. Should any situation arise for discharge for liquid effluents, necessary treatment will be undertaken.
c) Solid Waste Quantity of solid waste generation is estimated. Appropriate disposal program must be undertaken. The solid waste is not hazardous in nature.
NON HAZARDOUS WASTE: The main Solid waste generated as follows:
Solid Waste Waste Management From Process From PCD
Slag sold to cement unit. APC dust Installed BF Slag – 18.4 TPD 1.50 TPD reused
Non Hazardous, Sale to slag Proposed IF Slag – 2.0 TPD 0.525 TPD processing units
Total 20.4 TPD 2.025 TPD As above
Slag from Induction furnace was usually used for low land filling. However recently the Slag is being purchased by slag processing unit for use in village & other road making after grinding & removal of iron content from it
6.2 HAZARDOUS WASTE:
There is no hazardous waste from the plant except for used oil of equipment which is either used in-house for mould lubrication or saleable to the registered recyclers in the market. The hazardous waste generated will be collected, handled, stored and disposed as per Hazardous Waste (Management, Handling & Transboundary Movement) Rules 2009 amended till date.
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6.3 SOLID WASTE MANAGEMENT
Solid waste generated as above will be disposed off or used as follows:
• Dust from bag filters will be used for land filling. • Slag from process will be sold to slag processing units for village and other road making after recovery & removal of iron content from it
6.4 STACK HEIGHT
Minimum stack height requirement for other units is 30 meters from ground level. However, for this plant it is recommended that stack height be 35 meters for better performance and minimize fugitive emissions.
6.5 GREEN BELT DEVELOPMENT PLAN
As per MOEF guidelines, for siting of industry, a 5m wide green belt around the limits and road side of the industry is suggested. Total Green belt area should be 33% or more of plant area. Species of tree to be used for plantation should be such that they are fast growing, strong, and pollutant resistant. The plantation should be a mix of different varieties.
6.6 OCCUPATIONAL SAFETY AND HEALTH
Occupational safety and health is very closely related to productivity and employee – employer relationship. The main factors of occupational health in such plants are dust and noise. To avoid any adverse effect on the health of workers due to dust, noise and vibration etc., sufficient measures have already been addressed. Other measures mainly relating to health and safety measures are:
i. Provision of canteen cum rest shelters for workers with amenities like drinking water, fans etc. ii. Training of employees for use of safety appliances and first aid. iii. Extensive publicity and propaganda related to safety. iv. Regular maintenance and testing of all equipment and machineries as per manufacture’s guidelines. v. Periodical health check-up of all employees. vi. Provision of dispensary/first aid in the premises.
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6.7 Rain Water Harvesting Plan
Storm water drains will be laid out according to the contour of the site. Part of the storm water will get collected in water bodies and strategically placed dug wells which will act as water reservoirs during emergencies and also recharge the aquifer. Some of these problems being reduced well yields, land subsidence, intrusion of salty water especially in coastal areas, leakage into the aquifer of highly mineralized water. In order to overcome these serious environmental implications the recharge potential of groundwater resource has to be equally or in some cases more important aspect than the abstraction potential.
6.8 DESIGN TARGETS OF POLLUTION CONTROL SYSTEMS
The proposed pollution control measures would be designed on the basis of the following criteria:
STACK EMISSION:
Particulate matter : 100 mg/Nm3.
SO2 would be permitted within the
NOx carrying capacity of the environment
De-dusting units:
Particulate matter (PM) : 50 mg/Nm3
Noise level : 75 dB(A) maximum at plant boundary during
Day and 70 dB(A) during night
WORK ZONE ENVIRONMENT:
Fugitive dust emission : 2000 ug/m3 (max) at a distance of 10 m (approx.) from the sources aerial coverage
Noise level : less than 85 dB(A) for a maximum period
of 8 hrs exposure
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M/s Lal Ferro Alloys co.(P) Ltd PFR
7. Rehabilitation and Resettlement (R&R) Plan:
As there is no displacement of any human settlement, rehabilitation and resettlement plan does not arise.
8. Project Schedule, & Cost Estimates Financial and social benefits with special emphasis on the benefit to the local people including tribal population if any, in the area:
The project as mentioned above will generate direct and indirect employment to local people. More than 120 people will be directly benefitted due to the project which is expected to be completely developed by 2018-2019. Under the Corporate Social Responsibility, Lal Ferro Alloys Co (P) Ltd. will develop a policy of either developing the villages in the vicinity by identifying the requirements or will adopt the villages for their development. The social requirements will be identified such as Drinking water requirement, Promotion of Educational institutions, Medical facilities to the villagers (especially Senior Citizens and infants or pregnant ladies). Community centres, recreation facilities etc will also be developed as part of social responsibility.
The basic target would be the development of the local villages in the vicinity of the project. Hence, tremendous scope for development of the local population economically is envisaged. As there is no tribal population in the vicinity, there may not be much contribution towards the development of the tribal population.
Employment Potential Attempt is made to estimate the indirect employment effect of the project. The expected “Direct: Indirect employment ratio” has been projected as 1: 3.5 with the distribution in Ancillary (1 : 1), Transport (1 : 1) and Manufacturing (1 : 1.5). It is observed that about 450 - 500 people may get indirect employment only in these sectors due to the project.
CSR
The company is committed to develop the surrounding area in a well-coordinated and balanced manner while safe guarding the environment and social aspects. Proposed project is expected to contribute towards upliftment of local people’s quality of life & it will generate inputs for industrial/economic development in the region. Following guidelines are given to proponents for protection of workmen likely to be engaged from the nearby villages, as also a discussion towards the end covering community benefits. The company will take adequate steps to get local people
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into confidence so as to avoid any misconceptions amongst the local people in future
Company has done following social work in village Biswasdih (2008-09):
Construction of 1 nos of Bore well - Rs. 43,000/-
Supply of Education Materials - Rs. 25,000/-
Financial help to villagers (medical & others) - Rs. 65,000/-
Total Expenses - Rs. 1,33,000/-
Budget for Peripheral Development (Next 10 Years)
AMOUNT SL NO PROPOSED PROGRAMME - ADDITIONAL VILLAGES (RS. IN LACS)
Supply of Study Materials & Financial Aid to 1 3 2.50 Village Schools
2 Health Camp, Free Supply of Medicine etc. 3 4.25
Promotion of Cultural and social welfare 3 3 4.75 activities
Training to villagers through self help group for 4 3 2.00 self employment, education & family planning
Sub - Total 12.50
Buffer for activities as recommended by locals 43.00
TOTAL 55.50
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Estimated Capital Investment & Recurring Cost for Implementation of EMP
For Installed For Proposed SL No Recurring Capital Recurring ITEM DESCRIPTION Capital Investment cost/year Investment cost/year (Rs.Lacs) (Rs. Lacs) (Rs. Lacs) (Rs.Lacs) Air Pollution Control Integral part of 1 8.50 System for MBF MBF + 5.25 12.00 4.50 Water Sprinkling 0.85 0.20 2 1.70 0.85 System Disposal of Solid - 4.25 3 - 2.50 wastes Green Belt 1.00 0.30 4 2.50 0.75 Development Rain Water 1.05 0.50 5 4.75 0.60 Harvesting 14.90 9.75 TOTAL 14.20 13.20
ESTIMATED COST OF ENVIRONMENT MONITORING SL Environment Monitoring Parameter Frequency Annual Cost No
1 Stack Monitoring Half Yearly 10,000.00
2 Fugitive Monitoring Quarterly 30,000.00
3 Ambient Air Quality Monitoring Half Yearly 30,000.00
4 Water Quality monitoring Yearly 5,000.00
5 Noise Quality Monitoring Yearly 3,000.00
6 Soil Quality Monitoring Yearly 5,000.00
Total Rs. 83,000,00
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M/s Lal Ferro Alloys co.(P) Ltd PFR
Conclusion
On the basis of the overall results of the present impact assessment the following conclusions are drawn:
The project is not going to cause any damage to the existing agricultural situation. Instead, it is likely to provide the farmers with on-farm income. The project has strong positive effect on average consumption in the study area, and is likely to increase average income through multiplier effect. The project has very strong positive employment and income effects, both direct as well as indirect. There is a possibility of increase in industrial development in the vicinity. This is likely to bring more skill diversification among local people. The project is going to have positive impact on health care and occupational safety. The project will have positive impact on educational status of people of the study area. Overall community development is envisaged due to this project.
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