PRE-FEASIBILITY REPORT

Of Proposal For 2.4 MTPA Pellet Plant Over an Area of 42.040 Acres

At Village- Tanto, Tehsil- Barbil, Dist.- Keonjhar, Odisha By

Project Proponent: M/s Narbheram Power and Steel limited

Avani Signature, 6th floor, 91A/1, Park Street, Kolkata , West Bengal, India

Prepared by: -

VISIONTEK CONSULTANCY SERVICES PVT. LTD (An Enviro Engineering Consulting Cell) Bhubaneswar, Odisha NABET Certificate No. -NABET/EIA/2023/RA 0209

TABLE OF CONTENTS

Chapter Topic Page No. No. 1 Executive Summary 1 1.1 Executive summary 1 1.2 Details of Products Proposed 1 1.3 Salient Features of the Proposed Project 2 1.4 Land Use Planning 4 2 Introduction 6 2.1 Identification of the Project and Project proponent 6 2.2 Brief Description of Nature of the Project 6 Need for the Project and its Importance to the 2.3 6 Country 2.4 Demand Supply Gap 7 2.5 Imports vs. Indigenous Production 7 2.6 Export Possibility 7 2.7 Domestic/ Export Markets 8 2.8 Employment Generation 8 3 Project Description 9 Type of Project Including Interlinked and 3.1 9 Interdependent Projects 3.2 Location with Co-ordinates 9 Details of Alternate Sites Considered and the Basis 3.3 15 of Selecting the Proposed Site. 3.4 Size or Magnitude of Operation 17 3.5 Project Description 17 3.5.1 Process Description- Iron Ore Pellet Plant 17 3.6 Resource Optimization/ Recycling and Reuse 30 Envisaged in the Project Availability of Water Its Source, Energy Power 3.7 31 Requirement 3.7.1 Water Requirement 31 3.7.2 Power Requirement 31 3.8 Fuel Requirement 32 Quantity of Wastes to be Generated and Scheme 3.9 33 for their Management/Disposal 3.9.1 Treatment for Recycle and Reuse 33 3.9.2 Solid Waste & Hazardous Waste 33 Details of Air Pollution Control Devices Proposed in 3.9.3 34 Different Units Schematic Representation of the Feasibility 3.10 35 Drawing 4 Site Analysis 36 4.1 Connectivity 36 4.2 Landform, Land use and Land Ownership 36 4.3 Topography & Drainage 38 4.4 Existing Land Use Pattern 39 4.5 Existing Infrastructure 41 4.6 Soil Classification 41 4.7 Climatic Data from Secondary Sources 41 4.8 Social Infrastructure Available 43 5 Planning Brief 45 5.1 Planning Concept 45 5.2 Population Projection 45 5.3 Land Use Planning 46 5.4 Amenities/ Facilities 46 6 Proposed Infrastructure 47 6.1 Industrial Area (Processing Area) 47 6.2 Residential Area (Non-Processing Area) 48 6.3 Green Belt 48 6.4 Social Infrastructure 49 6.5 Connectivity 49 6.6 Drinking Water Management 50 6.7 Sewage System 50 6.8 Water Treatment Plant 51 6.9 Industrial Waste management 52 6.10 Solid Waste Management 52 7 Rehabilitation and Resettlement (R&R Plan) 53 7.1 Policy to be Adopted 53 8 Project Schedule & Cost Estimates 54 8.1 Planning of Activities 54 Estimated Project cost Along with Analysis in 8.2 55 Terms of Economic Viability Of the Project

8.3 Cost Breakup for Environmental Management plan 56 9 Analysis of Proposal 51 Financial and Social Benefits with Special 9.1 57 Emphasis on the Benefit to the Local People

List of Table

Table No. Name Page No. Table 1.4 Land Use Breakup 4 Table 2.8 Manpower Breakup 8 Table 3.1 Project Configuration 9 Table 3.2 Latitude & longitude of Project Site 14 Table 3.3 Site Suitability Analysis 15 Table 3.5.1 Zone Details 23 Table 3.6 Raw Material Quantity & Source 30 Table 3.7.1 Breakup of Water Requirement 31 Table 3.7.2 Power Requirements 31 Table 3.9.1 Treatment for Recycle and Reuse 33 Table 3.9.2 Solid Waste & Hazardous Waste 33 Table 3.9.3 Details of Air Pollution Control Devices Proposed 34 Table 4.2 Land Use Breakup 36 Table 4.4 Distance of various landmarks 39 Table 4.7.1 Annual Average Rainfall 42 Table 4.7.2 Month-wise Predominant Wind Directions 43 Table 4.8 Nearby Facilities / Social Infrastructure 43 Table 5.2 Manpower Requirement 45 Table 6.1 Total Land Breakup 47 Table 6.3.1 Tree Species Name 48 Table 8.1 Project Implementation Schedule 54 Table 8.2.1 Summary of the Estimated capital Cost of the Projects 55 Table 8.2.2 Operating Expenses 55

List of Figures Figure Name Page No. Figure 3.2.1 Location of the Plant on the Map 9 Figure 3.2.2 Toposheet Map of the Proposed Plant Area 10 Figure 3.2.3 Google Earth Image of the Plant Site 10 Figure 3.2.4 Site Photographs of the Plant Area 12 Figure 3.2.5 Layout of Project Site 13 Figure 3.3 Google Earth Images of Alternate Sites 16 Figure 3.5.1 Pellet Plant Process Flow Diagram 18 Fig. No 3.5.2 Pellet Plant Material Flow Diagram 29 Figure 3.7.1 Water Flow Diagram 32 Figure 3.9 Schematic Diagram of Environmental Component 35 Figure 4.3 Drainage Map 38 Figure 4.4 Land Use Map 41 Figure 6.5 Google earth Image of the Connecting Road 50 Figure 6.7 STP Flow Diagram 50

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. Chapter 1

Executive Summary 1.1 Executive Summary

The Project Proponent, M/S Narbheram Power And Steel Private Limited is one of the Group Companies of Atha Group, a diversified conglomerate actively involved in the businesses of Steel, Mining, and Renewable Energy sectors. Atha Group has become one of the leading companies in the Mining Industry in India. Narbheram Power And Steel Pvt Ltd (NPSPL) is the steel manufacturing SBU of Atha Group, established in the year 2003, having its integrated steel manufacturing unit in the district of Dhenkanal, Odisha State. This company now intends to set up of 2.4 MTPA (1.2 MTPA X 2 Units) capacity iron ore Pelletization plant at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha.

Iron Ore Fines generated in the company’s iron ore mines and nearby mines in Joda- Barbil area will be used to make iron ore pellets by agglomerating them. This product will be used for captive consumption in the company’s sponge iron plants as well as will be sold in the open market.

1.2 Details of Products Proposed 2.4 MTPA Pellet Plant - Input and Output % Per hour Per Day Per year Raw Material Iron ore fines (t) 95.91 340.00 8,160 26,92,800 Bentonite (t) 0.71 2.50 60 19,800 Anthracite Coal (t) 1.69 6.00 144 47,520 Limestone (t) / Dolomite(t) 1.69 6.00 144 47,520 Total Inputs 100.00 390.50 9372 28,07,640 Product Pellets, Net (t) 85.48 303.00 7273 24,00,000 Pellet Fines 5.68 20.14 483 1,59,480 Process Loss 7.99 28.36 680 2,24,400 ESP dust 0.85 3 72 23,760 Total outputs 100.00 390.5 9372 28,07,640

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 1

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

1.3 Salient Features of the Proposed Project Proposed 2.4 MTPA Pellet Plant over an area of 42.040 acre A. Name of the project (17.013 ha.) at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited

Sl. No. in the As per EIA Notification 2006 and amendments, thereof the B. schedule project falls under Sl. No. 3 (Material Production), Project Activity ‘3 (a)’ Metallurgical Industries; Category – A C. Project Proponent Detail Name of the M/S Narbheram Power And Steel Private Limited Company Registered Office Avani Signature, 6th Floor, 91A/1, Park Street, Kolkata D. Area of Plant 42.040 Acres (17.013 ha.)

Total land: 42.040 Acres (17.013 ha.) Classification of Land Forest land: 24.00 Acres (9.712 ha.) Non Forest land: 9.950 Acres (4.027 ha.) Records Not Available: 8.09 Acres (3.274 ha.) E. Location Details Village Tanto Tahasil Barbil District Keonjhar State Odisha Topo Sheet No. F45H8 & F45N5 Latitude 22° 2'38.18"N Longitude 85°22'5.87"E

F. Environmental Setting Details (approximate aerial distance and direction from the project site)

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 2

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Possible Vulnerable Habitation Groups in Nearby Area Tanto Village – 0.12 Km, N Jhadagaon- 1.39 km NE Bhusugaon- 2.89 Kms ENE School SSVM Bhadrasahi- 1.86km NE St, Teresa School, Joda – 4.6km SE Hospital E.S.I. Hospital Corporation – 5.4km E TATA Steel Hospital, Joda – 5.7km SE Place of Worship Shiva Temple, Bhadrasahi – 2.12 km NE Nearest City/Town Town- Bhadrasahi- 1.9km (NE) City-Barbil- 6.3km (NNE) Nearest National NH-215 – Approx. 0.250 km (North) Highway/ State Highway Nearest Railway Barbil Railway – 6.46km (North) station Nearest Airport Tanto-Barbil Airstrip – 0.242 km (East) Rourkela Airport- 61.3km (North-west) Biju Patnaik International Airport – 204km (SSE) Name of the RF, PRF, PF, Distance in km. National Parks, Wildlife etc. Sanctuaries, Biosphere Sidhamatha RF 1.5km SSW Reserves, Reserve Thakurani Reserve Forest 3.75km NE forest, and Protected Lakrahaghat RF 4.8km SW forest within 10 km Uliburu RF 7.3km N radius Karo RF 7.8km NWW Baitarani RF 7.83km SSE Name Distance & Direction

Kundra Nala 4.4km – SE Water Body (within 10 km radius)(Aerial) Karo River 6km – NNW Sona Nadi 6.97km E Bolani Reservoir 7.35 – NNE Jhikra Waterfall 7.67km – NW Baitarani River 9.95 km – SE Seismic Zone II (Low Damage Risk Zone)

G. Cost Detail

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 3

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Total Cost of Project Rs 350.0 Crores Cost for Environment Capital Cost : Rs.30 Crores Protection Measures Recurring Cost: Rs.12 Crores per Annum H. Basic requirement for the project

Manpower 258 Requirement Source Local people will be given preference in employment as per eligibility. Power Requirement 18 MW Source State grid- OPTCL Make-up Water 4800 KLD Requirement

Source Baitarani River

1.4 Land Use Planning The total land required for this pellet plant project is 42.040 Acres. The proposed project land is near the Roida mines in Barbil Tehsil, of Keonjhar district, Odisha. The coordinates of the site are 22° 2'38.18"N and 85°22'5.87"E. Land use break up is predicted to be as below: Table No. 1.4: Land Use Break Up

Forest Plot data Non Forest Sl. Total area Area not Name of Unit Area No. (In Acre) (In available (In Acre) Acre) (In Ac)

1 Iron Ore Day Bins Building 0.148 0.148 0.000 2 Iron Ore Grinding Plant Building 1.035 0.550 0.485 3 Concentrate Thickener 0.103 0.103 0.000 4 Slurry Tanks 0.150 0.000 0.150 0.000 5 Filtration Plant Building 1.150 0.150 1.000 0.000 6 Mixing & Balling Building 1.050 1.050 0.000 7 Induration Furnaces 2 nos 4.193 2.890 1.303 8 Process Fans & ESPs 0.652 0.652 0.000 8A Chimneys 2 Nos (45m height each) 0.250 0.250 0.000 9 Hearth Layer Separation Building 0.093 0.093 0.000 Additive Storage Shed + Additive 10 0.560 0.560 0.000 Grinding Plant 11 Coke Storage & Dosing Building 0.198 0.100 0.098

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 4

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Induration furnace feed end Dedusting 12 0.200 0.200 0.000 Buiulding 13 Control Room & MCC 0.250 0.250 0.000 Induration furnace Discharge end 14 0.297 0.297 0.000 Dedusting 15 Recirculating Water Pump Station 0.198 0.198 0.000 16 Fuel Pump House (FO & LDO) 0.525 0.000 0.525 0.000 17 Laboratory Building 0.127 0.127 0.000 18 Raw Water Pump Station 0.215 0.200 0.015 19 Compressor Station 0.109 0.000 0.109 0.000 20 Cake Drying Air Station 0.100 0.100 0.000 21 Diesel Generator 0.100 0.100 0.000 22 Water Reservoir 2.500 1.000 1.000 0.500 23 Pellets Storage Area+ Dedusting 2.000 0.399 0.555 1.046 24 Administration Building 0.077 0.000 0.077 Pellets Fines Storage Area 25 0.550 0.000 0.350 0.200 +Dedusting RM storage(Iron Ore) & Handling 26 1.005 0.450 0.555 System 27 Machinery Maintenance Workshop 0.200 0.100 0.100 28 Producer Gas Plant 7.355 1.000 3.400 2.955 29 132KV Switchyard 0.200 0.000 0.200 0.000 30 Effluent Treatment Plant 0.250 0.100 0.150 31 Diesel Storage Area 0.100 0.000 0.050 0.050 32 Sewage Treatment Plant 0.100 0.000 0.100 0.000 33 Drains 0.450 0.000 0.400 0.050 34 Roads 0.617 0.100 0.251 0.266 35 Truck Parking Bays 1.000 0.200 0.800 36 Procuct Entry Gate 0.007 0.007 0.000 37 Product Exit Gate 0.007 0.007 0.000 38 Raw material Entry Gate 0.007 0.007 0.000 39 Raw material Exit Gate 0.007 0.007 0.000 40 Light Vehicle , Staff & Exit Gate 0.005 0.005 0.000 Total Plant facilities 28.140 11.400 8.090 8.650 41 Green Belt 13.900 12.600 1.300 Total 42.040 24.000 8.090 9.950 Note: Since there are no records for 7 plots covering total area of 8.090 Acres, the same have been considered as Forest Land in the FC application. Thus, in the FC application total forest area is shown as 32.29 Acre (24.00 + 8.090).

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 5

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. Chapter – 2

Introduction

2.1 Identification of the Project and Project Proponent

ATHA Group has become one of the leading business houses in the Indian Mining and Minerals Industry. The Group has M/s. Narbheram Power and Steel Private Limited as its steel manufacturing subsidiary. ATHA group has a diversified project sector which consists of Iron Ore Mining, Coal Mining, manufacture of Sponge Iron & Billets and Captive Power Plant, generation of renewable energy through Solar Power Plants, etc. The M/s. Narbheram Power And Steel Private Limited was established in 2003 in Dhenkanal, Odisha, having its integrated steel manufacturing unit. The company has a current capacity of producing 1 MT crude steel.

2.2 Brief Description of Nature of the Project It is a proposed Greenfield project of 2.4 MTPA Iron ore Pellet Plant based on Travelling/Straight Grate technology and total cost of the project envisaged is Rs 350.0 Crores. The required technological machinery and other necessary facilities will be established/installed for the production of iron ore pellets with quality suitable for use in a blast furnace or direct reduction process of iron making. It is an independent project and falls under category A as per the EIA Notification 2006 and amendments thereof. The details of the project and the process are addressed in the subsequent chapters.

2.3 Need for the Project and its importance to the Country and/or Region The development of industrial projects plays a key role in the economic growth of any country. Iron is the most important metal to mankind and its principal alloy, steel, is widely used for domestic, agricultural, industrial, and defense purposes. Per capita, steel consumption is a major indicator of the economic status of any country. ✓ World crude steel production for the 64 countries reporting to the World Steel Association (world steel) was 161.9 million tons (Mt) in October 2020, a 7.0% increase compared to October 2019. (Source- worldsteel.org). ✓ Per capita finished steel consumption in 2018 was 224.5 kg for the world and 590.1 kg for China (Source: World Steel Association). The same for India was 73.3 kg in 2018 (Source: JPC) and 75.7 kg (Prov.) in 2019. The per capita

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 6

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Consumption of India in 2018-19 was 74.1 kg and that in 2019-20 was 74.6 kg (Prov.) (Source: JPC). ✓ The Indian steel industry has entered into a new development stage, post - deregulation, riding high on the resurgent economy and rising demand for steel. The rapid rise in production has resulted in India becoming the 2nd largest producer of crude steel during 2018 and 2019, from its 3rd largest status in 2017. ✓ The country was also the largest producer of Sponge Iron or DRI in the world and the 3rd largest finished steel consumer in the world after China & t h e USA in 2019 (Prov.) (Source: Ministry of Steel, GOI) 2.4 Demand Supply Gap The total recoverable reserves of iron ore in India are about 9,602 million tons of hematite and 3,408 million tons of magnetite. However, the country has the inadequate infrastructure for catering to the iron ore demands of all the DRI / Steel plants. The excessive fines generated from iron ore crushing units are mostly going to waste. To meet the ever-increasing demand for steel and demand for pellets by a large no of sponge iron units in the country, it is envisaged to set-up a 2.4MTPA capacity iron ore pellet plant. The Pellet plant at Tanto, Keonjhar is slated to produce pellets utilizing iron ore fines & the additives like Bentonite, Limestone, Anthracite Coal & Coke, etc.

2.5 Imports vs. Indigenous production Indian steel plants mainly cater to domestic demand. Special steels that are not manufactured in the country are imported like CRGO, HSS, and Steels for defense, space, nuclear sectors, etc. where special steels in various grades and smaller quantities are required. However, due to the dumping of steel at very cheap prices by some foreign countries, low-quality steel also gets imported at prices not remunerative to domestic steel producers. The export normally consists of semi-finished steels and ordinary grades of HRC, Rebar’s, etc.

2.6 Export Possibility Production will be done to meet the growing demand for Steel in the country. The pellets, produced will be used mainly for the company’s sponge iron plants and then will be available to sell in the open market. However, in future export possibility is also envisaged.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 7

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

2.7 Domestic/ Export Markets As mentioned above, the pellets produced shall be used for indigenous steel production. However, exporting the same in the future is not ruled out.

2.8 Employment Generation Due to the establishment of the plant, various employment scopes will be generated and for the semi/unskilled laborers importance will be given to the locals. As the operation and maintenance of such plant requires human resources in different categories like managers, engineers, highly skilled, skilled, and semi-skilled workforce in a different discipline, commercial, accountants and financial managers, unskilled labor force, clerical, medical security personal, etc. The estimated manpower requirement is 258. The detailed Breakup of the employees is given in the table below: Table 2.8: Manpower Breakup

Middle & Sr. Skilled & Junior Managerial Services semiskilled Unskilled Managerial Pellet plant 2 2 8 45 86 Laboratory 1 2 6 9 Power distribution 1 2 4 38

Purchase & Stores 2 2 5 12 Finance & Accounts 1 1 2 10 1 Human Resources 1 2 3 2 Administration 2 2 2 2 Total 3 10 20 75 150

The above manpower requirement is as per the planning purpose and it may change in the future while the plant will be operational and all the machinery will be installed.

Local people will be given preference in employment for all the skilled, semi-skilled and unskilled section and the rest will be recruited from outside.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 8

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Chapter – 3 Project Description 3.1 Type of Project including interlinked and interdependent projects, if any: Following production is envisaged for the proposed project: Table No 3.1: Project Configuration

Sl No. Product Proposed Total Configuration (Final Production) 1 Iron Ore Pellet Plant 2x 1.2 MTPA 2.4MTPA

2 Producer Gas Plant 5x 6,500 Nm3/hr 32,500 Nm3/hr

This is a proposed stand-alone Project. There are no interlinked or inter-dependent projects. 3.2 Location (map showing the general location, specific location, and project boundary & project site layout) with coordinates

Fig. 3.2.1 Location of the plant on the map

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 9

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig 3.2.2 Toposheet map of the Proposed Plant Area

Fig 3.2.3 Google Earth Image of the Plant site

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 10

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

NE side of the Project Site – Tanto village in the back drop

ENE side of the Project Site

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 11

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

SW side of the Project Site

Fig. No. 3.2.4: Site Photographs of the Plant Area

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 12

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig 3.2.5 Layout of Project Site

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 12

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Table No 3.2: Latitude & Longitude of Project Site SL_No Longitude Latitude 1 85°22'05.74716" 22°02'46.52556" 2 85°22'08.80428" 22°02'46.12884" 3 85°22'08.45328" 22°02'45.18672" 4 85°22'09.99516" 22°02'44.90412" 5 85°22'09.16392" 22°02'43.64484" 6 85°22'08.90724" 22°02'42.63396" 7 85°22'09.03576" 22°02'42.09432" 8 85°22'09.41268" 22°02'41.42616" 9 85°22'09.74640" 22°02'41.06652" 10 85°22'08.06772" 22°02'41.32320" 11 85°22'07.93056" 22°02'36.32064" 12 85°22'07.82760" 22°02'35.84976" 13 85°22'07.73040" 22°02'33.60732" 14 85°22'07.44636" 22°02'33.08244" 15 85°22'07.70232" 22°02'32.96220" 16 85°22'07.54176" 22°02'32.33904" 17 85°22'07.67388" 22°02'32.30088" 18 85°22'07.62024" 22°02'31.06860" 19 85°22'07.52700" 22°02'30.91056" 20 85°22'08.30640" 22°02'30.82236" 21 85°22'08.02848" 22°02'30.09084" 22 85°22'07.90140" 22°02'30.04692" 23 85°22'07.33584" 22°02'29.00976" 24 85°22'06.63132" 22°02'28.14036" 25 85°22'02.13600" 22°02'29.72508" 26 85°21'58.43952" 22°02'30.94224" 27 85°21'56.97216" 22°02'29.34420" 28 85°21'53.18568" 22°02'31.56432" 29 85°21'47.75976" 22°02'34.74528" 30 85°21'53.70264" 22°02'34.78164" 31 85°21'53.74080" 22°02'35.63988" 32 85°21'55.30428" 22°02'37.75992" 33 85°21'54.96156" 22°02'38.16672" 34 85°21'56.58912" 22°02'39.73020" 35 85°21'57.18888" 22°02'39.64452" 36 85°21'57.63852" 22°02'40.11540" 37 85°21'59.13756" 22°02'40.95060" 38 85°22'00.93648" 22°02'43.24200" 39 85°22'01.84800" 22°02'42.97992" 40 85°22'04.08432" 22°02'44.03436" 41 85°22'05.30508" 22°02'45.46932" 42 85°22'05.25396" 22°02'45.48444"

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 14

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. 3.3 Details of Alternate Sites Considered and the basis of Selecting the Proposed site, Particularly the Environmental Considerations gone into should be highlighted. Three sites were considered for the construction of the proposed Pellet Plant project. An assessment to identify the most suitable site out of the three alternate sites was carried out. The Site Suitability Analysis was undertaken for the three sites: For identification of the most suitable Site for the development of the Pelletisation Facility, the assessment was carried considering the following aspects: ➢ Physical settings ➢ Environmental Considerations and ➢ Social Considerations

Table No. 3.3: Site Suitability Analysis

Sl Parameter Option 1 Option 2 Option-3 No (Tanto) (Bhusugaon) (Kolha Roida)

1 Total Land area 42.04 Acres 41.983Acres 42.390 Acres Forest Area 24.00 Acres 29.771 Acres 36.231 Acres Non Forest Area 09.95 Acres 12.212 Acres 6.159 Acres Records not available 8.09 Acres - (taken NIL NIL as forest land) Additional land Additional land required for required for Approach Road (1.8 Approach Road (8.9 Kms x 30 Mtrs) Kms x 30 Mtrs) = 13.340 Acers may = 65.96 Acers may involve Forest land involve Forest land

2 Tree Felling 168 186 1712 (Trees would not be felled; they would be transplanted) 3 Distance from NPSPL Iron Adjacent to the 5.40 Kms. 11.40 Kms Ore Mines Mining Lease.

4 Project Affected Families 14 32 12 (PAF) Project Displaced Families NIL NIL NIL (PDF) 5 Water connectivity Baitarani River- 18.4 Baitarani River- Baitarani River- 20.9 Km, 17.95 Kms, Kms, Kundra Nalla- 8.8 Kundra nallah-8.2 Kundra nalla- Km, Kms, 4.2Kms, Karo River- 7.5 Km Karo river- 9.2 Kms Karo River-12Kms

6 Power connectivity Barbil Grid -8 Kms Barbil Grid -7 Kms Barbil Grid - 9.5Kms

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 15

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. 7 Road Connectivity to N H 0.25 Km 1.8 Kms 8.9 Kms 215 8 Railway Connectivity Barbil Rly Siding- Barbil- 9.0 Kms Barbil- 18.35Kms 10.5 Kms, Banspani- 13 Kms Banspani- 21.5 Kms Banspani Rly Sdg- 13.5 Km

9 Distance from nearby Kasia Mines – 2.95 Kasia Mines-6.35 Kasia Mines- 12.50 Merchant Iron Ore Mines Kms Kms Kms Roida-I Mines Roida-I Mines- Roida-I Mines (MESCO) – 3.39 (MESCO) -7.44 Kms (MESCO)- Kms GUALI (RPS)- 15.50 13.57Kms GUALI (RPS)- 11.25 Kms GUALI (RPS)- 21.68 Kms Kms 10 Ecology There is no National There is no National There is no National National Parks, Wildlife Parks, Wildlife Parks, Wildlife Parks, Wildlife sanctuaries and Bio sanctuaries and Bio sanctuaries and Bio sanctuaries and Bio sphere Reserves sphere Reserves sphere Reserves sphere Reserves within 10 Km from within 10 Km from within 10 Km from the proposed site the proposed site the proposed site

Fig 3.3 Google Earth Images of alternate sites

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 16

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

3.4 Size or Magnitude of Operation This project is proposed for setting up of green-field 2.4 MTPA (2 x 1.2MTPA) capacity Iron Ore pellet plant with 5x6500 Nm3/hr Producer Gas Plant over an area of 42.040 Acres. As per EIA Notification 2006 and amendment thereof, this project falls under S. No. 3 (Material Production), Project Activity ‘3 (a)’ Metallurgical Industries. The estimated investment cost of the proposed project is estimated to be Rs 350.0 Crore.

3.5 Project description

3.5.1 Process Description- Iron Ore fines Pellet Plant

Pelletisation plant- operating regime

The Pellet plant shall be designed to operate for 330 working days per year, 24hours per day on the basis of 3 shifts working.

Pellet plant process flow Pellets are heat hardened balls produced from concentrates and natural iron ores of different mineralogical & chemical compositions to produce charge materials with improved properties for iron making. The pelletization process involved various steps viz, feed preparation, green ball formation, pellet induration, and product dispatch. Steps involved in the pelletization process are given in the figure below:-

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 17

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig. No 3.5.1: Pellet Plant Process Flow Diagram

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 18

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

a) Induration of green balls The qualified green balls produced in Pelletising discs are subjected to thermal treatment viz. drying, preheating, firing, and cooling during which the pellets attain adequate strength to withstand handling, transportation and charging into furnace besides increased porosity, reducibility, reduction strength, etc. Majority of the pellet plants worldwide, use either straight grate process or the Grate-kiln process. Traveling grate process is to be adopted here and the justification behind opting for this technology is mentioned below: 1. Being more Technologically Advanced, Travelling Grate Technology is widely used across the globe. Approximately eighty percent (80%) of the total pellets production in the country use Travelling Grate technology. 2. Heat input required through the fuel is 2,40,000 Kcal / Ton of pellet in Traveling Grate and 2,90,000 Kcal for Grate-Kiln (GK) Technology. 3. Due to stable and almost unmoving bed of pallets, combustion is uniform and dust emissions are low as compared to Grate Kilns. Thus it is a more environment friendly process. 4. As the movement is not rotary in nature, there is no generation of kiln dust in Travelling Grate as compared to Grate Kiln. 5. The downtime in case of Travelling Grate is less as there is no requirement of removal of large ash particles (accretion). On an average, the availability of Travelling Grate Furnaces is 330-350 days as compared to 300-320 days in case of Grate Kiln. 6. Unlike the Grate Kiln technology, where the pellets come in direct contact with the refractory lining and has a higher refractory consumption, Travelling Grate has a lower refractory consumption. 7. Since Induration time is dependent on raw material and the quality requirement, it is usually lower in Travelling Grate. 8. One great advantage of the straight grate is that the configuration of wind-boxes can be easily be changed to define off gas conditions, ideal for recirculation or gas cleaning equipment 9. All process gases from straight grate under any circumstances and time will be released to the atmosphere always via the gas treatment ESP system. In case of Grate Kiln, during an emergency stoppage, the process off gases of the rotary

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 19

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

kiln burner have to be released to the atmosphere via an emergency stack without any gas cleaning treatment. 10. Thus it can be seen that Travelling grate process enjoys very distinct advantages with less fines generation, more flexibility in heating pattern with varied ore quality particularly to take care of the LOI (Loss of Ignition) and lower maintenance & less refractory failure.

b) Travelling grate process

In the traveling grate technology, all thermal process steps are done in one piece of equipment, the traveling straight grate. It consists of a stationary furnace with an endless, revolving chain of pallet cars, carrying the pellets through the furnace, where they are dried, indurated, and cooled. Green pellets are subject to different thermal zones during the process of induration like drying, preheating, firing, after firing, and cooling zone. The cooling zone of the Indurating machine is designed to cool down the fired pellets to an average temperature of ≤150°C. 5 number of process gas fans will be provided to re-circulate process gas through different zones. ESPs will also be provided to clean the wind box and hood exhaust gases. The induration system consists of a single indurating machine completely covered with a lined hood for gas recirculation. The machine is an endless metallic conveyor with 162 pellets. The endless chain is enclosed by a stationary refractory lined hood above the moving pallets. The underside of the moving pallets is also enclosed by steel chambers, with or without refractory lining. Circulation of process gases through the hood and wind boxes of these zones facilitates heat exchange between the gases and the pellets, eventually accomplishing the process of induration. c) Pellet plant process description

Additive Grinding Unit Wet grinding of Binder (Bentonite) and Additives (Limestone/Dolomite + Coke Breeze) is envisaged. Different raw materials received in this unit shall be distributed to respective bins by the reversible conveyor. For storing raw additives in this building there are total three(3) numbers of steel bins in this building , one each for Limestone/Dolomite, Anthracite Coal/Coke breeze & Bentonite.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 20

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

All the bins shall be designed to ensure mass flow of the material and will be equipped with manual isolation gate and belt weigh feeders at the outlet of bins. Two vertical roller mills are envisaged for grinding of additives. One for the grinding of Coke & Limestone and the other for Bentonite. The ground products are collected in the respective intermediate storage bin located inside the Additive grinding building. The Ground products from the intermediate storage bins are pneumatically conveyed by pipeline to the respective Bins (2 numbers) in Mixing area.

d) Ground Material Storage and Mixing unit Filter cake either from the filtration building directly or from the emergency filter cake storage held shall be transported by a series of belt conveyors or fed to one filter cake storage bin. In additional to filter cake bin, there are two (2) other additive bins provided in this unit. Bins shall be used for storage of ground coke +limestone (1 no.), ground Bentonite. Ground additives shall be fed separately to these bins by pneumatic conveying systems. Cassette type Bag filter (With side opening for removal of cassettes) system with fan shall be provided above each bin for de-dusting of pneumatic conveyed material. Loss- in-weigh feeders shall be provided at each of ground additives bin outlet for drawing pre-set quantity of material and dosing it to belt conveyor, carrying filter cake to mixer. Manual gate valve at discharge of each bin shall be provided for isolation in case of maintenance on downstream equipment. Pre-set quantity of filter cake & additives dosed on the collecting belt conveyor, shall feed the material to a High Intensity Mixer, for thorough mixing of material. A good & homogenous mixture improves the green ball stability and helps to reduce the additive consumption. Through controlled addition of process water, the moisture content of the mixed material will be properly adjusted to 8.5 –9.5%. Moistened mix discharged from mixer shall be transported by a series of belt conveyors to mix material bins.

e) Balling Unit

The mixed material from the mixing unit shall be transported by a series of belt conveyors and delivered to a horizontal belt conveyor, located above mix material bins. Balling discs with VVVF drive is provided with a diameter of 7.5 m. Inclination of discs

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 21

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

can be adjusted between 44 and 53 deg. with a motorized inclination control. RPM of discs shall be finalized during engineering so that green pellets with a target size between 9 and 16 mm are to be produced. Green balls from the balling disc are collected on a conveyor and transferred to Induration building and distributed on a Reciprocating belt conveyor with oil hydraulic drive .From here the green pellets are fed to indurating machine via wide belt conveyor & roller screen, for final separation prior to feeding the indurating machine. The reject oversize and undersize green pellets from roller screen(+16mm & -9mm) are collected by the separate belt conveyors and re-circulated in the process through several belt conveyors of main route after shredding f) Induration Furnace Unit Green pellets are subject to different thermal zones during the process of induration like drying, preheating, firing, after firing and cooling zone. The cooling zone of the Indurating machine is designed to cool down the fired pellets to average temperature of ≤100 deg. C. The Induration machine is considered as 2x189 sq m reaction area. A number of process gas fans will be provided to re-circulate process gas through different zones. ESPs will also be provided to clean the wind box and hood exhaust gases. Induration system consists of a single indurating machine completely covered with a lined hood for gases recirculation. The machine is an endless metallic conveyor with pallet cars. The machine is divided into five heat zones namely:- • Up draught & Down draught drying, • Preheating • Firing • After firing • Cooling zone with circular cooler Measurement of temperature shall be through radiation pyrometer. Emergency water spraying arrangement on finished pellets on belt conveyor at indurating machine discharge end shall be provided in case temperature rises above set point. ESP shall be envisaged for process De-dusting facility at the Hood exhaust and wind box exhaust of indurating machine. For plant de-dusting at the discharge end of indurating machine and hearth layer separation/ product screening system – Dust-Extraction system (DE system) comprising of wet scrubber is envisaged. Slurry collected below the scrubber is pumped to the High Rate Thickener. A steel bin for storage of hearth and side layer is provided above the feeding station of Indurating machine. Hearth and side layer storage bin, has separate chutes for feeding hearth & side layers to the indurating machine

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 22

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. as per process requirement. The height of the hearth layer on the pallets can be adjusted by a motor driven discharge gate. The hearth & side layers bin shall be load cell mounted. g) Hearth Layer Separation / Product Screening Building (HLSB) HLSB has two functions. Two separate pellets are required as hearth and side layer on the Indurating machine and also to screen out undersize fines pellets. Heat hardened pellets from the Induration building discharged along with dribbles below the induration machine and are transported to the hearth layer separation building by a conveyor. The head end pulley of this conveyor is located in Hearth Layer Separation Building HLSB. Indurated pellets are used as a hearth and side layer to protect the grate bars in the pallet car. The product bin will be emptied either continuously by the set of conveyors going to the product pellet storage yard or the set of conveyors going to the Induration building for the supply of hearth and side layer. One chute is provided from the bin to feed to the Vibro feeder to convey Hearth and side layer pellets to the Induration building with a set of conveyors. Also, there is a provision of feeding these sets of conveyors through the ground hopper. In case of emergency when the bin is full the pellets shall be discharged through the emergency cut provided from the chute of the incoming conveyor, onto the ground. The pellets from the ground shall be fed to the ground hopper vide pay loader. The pellets from the bin are discharged via a rod gate onto a Vibrating screen and after screening pellets are conveyed to the product conveyor located on the ground and further transport pellets to pellet stockyard / Storage silos by a set of conveyors. The under size pellets (- 5 mm) from below the screen are discharged on to a fines conveyor which will then be conveyed to a fines bin.

The machine will be equipped with latest state-of-the-art automation and control system for uniform heating and firing of green pellets and speed control of the grate, etc. for production of superior uniform quality of products. The indicative length and reaction area of each zone is indicated in the table below.

Table No. 3.5.1: Zone Details

No. of Zone distribution Wind boxes Length(m) Area(m2) Updraft drying 3 9 27 Downdraft drying 2 6 18 Preheating 4 12 36 Firing 4 12 36

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 23

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

After firing 1 3 9 Cooling 1 5.5 16. 49.5 5 Cooling 2 1.5 4.5 13.5 Total 21 63 235.5

h) Producer Gas Plant Two Stage Coal Gasification Process Theory: Bituminous coal is lifted to the coal storage bin by lifting system; the coal is added in the carbonation stage of two-stage coal gasifier by a programmable control feeding system. Air is blown in the bottom of furnace by air blower, at the same time, low pressure steam goes through the blending bin and blends with air, becomes the gasification agent, which will carry on the gasification reaction with 1200 Celsius degree semi coke in the gasification stage. Producer gas is made by the gasification agent, which is mixture of steam and air, which goes through red-hot fixed burning bed. The oxygen content in the air and steam react with the carbon in the fuel; generating the producer gas with has ingredients like CO, CO2, H2, CH4, C2H4, N2 etc. Reaction of steam and carbon is endothermic reaction: C + H2O= CO + H2. When steam here reacts with carbon monoxide: CO + H2O = CO2 + H2. In the reducing zone, quick reaction is occurred when the temperature is below 1200 Celsius degree CO2 + C = 2CO and H2O + C=H2 + CO. When the coal gas goes through the reducing zone, flammable gas content raises rapidly, carbon dioxide and steam content decrease. Across the reducing zone, a part of coal gas is withdrawn through a series of vent in the gasifier walls and is called “DOWN STAGE GAS”. Its temperature is around 300-400 Celsius degree and container dust and ash particles. This down stage gas is treated in the cyclone to remove the dust particles, and is then cooled through a heat exchanger. In this heat exchanger the heat is given to the water in the steam drum. The gas is further cooled in a wind cooler, where natural air cools the gas to a lower temperature. In the carbonation stage, the coals added in the gasifier are dried, preheated and carbonated, generate steam, tar and coal gas, exported from the top of gasifier together, this part of gas is called “up-stage coal gas”, its temperature is around 100-120 Celsius degree. The temperature of upstage coal gas is about 100- 150 Celsius degree, goes into electric detarrer to remove tar. Water and tar come from the bottom of electric detarrer is sent to the tar tank. The Upstage and downstage coal gas are mixed in the entrance of indirect cooler, the temperature after mixing and cooling in the indirect cooler is 35-40 Celsius degree. Then the mixed gas goes through electric de-oilier to remove dust and light oil. The coal gas pressure adder increases the

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 24

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. pressure of the coal gas to the desired value and then connects to the transmitting coal gas pipelines which take the gas to the equipment. Mixture from the indirect cooler are separated, light tar is sent to light tar tank, water is sent to phenolic water tank.ygen and carbon react, and then heat output: 2C + O2 =2CO, C + O2 = CO2. a. Phenolic water generation: Reasons and Quantity The coal gasification system generated coal gas of 2 types, upstage at 100 degree C and downstage at 400 degree C. We cool the coal gas to ambient 40 degree C with indirect cooling at 3 stages and without any direct washing of gas. There is NIL fresh water conversion or contact with coal gas and therefore ZERO generation of phenolic water. b. Condensate Phenolic Water Generation: Reasons and Quantity The coal gas carries the moisture when generated from coal with inherent and other additional moisture. On cooling, the maximum vapour carrying capacity of the coal gas decreases as per the dew point. The resultant extra water vapour condenses to form water droplets. These droplets carry the organic matter in them. This is called Condensate phenolic water. The quantity depends on the moisture level of coal and is normally around 3 % of the coal fed into the Gasifier system. For the proposed gasification system at your pellet plant, the maximum coal consumption is 380 Tons / day and therefore the average quantity of condensate phenolic water generated will be around 11.5 KL / day. The quantity of the condensate phenolic water will vary due to: 1. Weather 2. Relative humidity 3. Coal moisture 4. Coal volatile matter 5. Coal gas temperature 6. Coal gas demand from the system 7. Operational condition of the system. The system is designed to reuse the phenolic water in the Heat Exchanger and the generated steam and phenolic vapour. The generated steam and vapour are used in the process of coal gas generation. The excess can be disposed by Incineration. c. Phenol water analysis Phenol water contains various organic compounds to the average of 5 % by weight which are condensate of the coal gas volatile matter like phenol, general oil, tar and impurities in the water d. Disposal The condensate phenolic water is pumped and then burned with the help of coal gas at temperature > 1100 degree C in a specially designed online Incinerator e. Exhaust of incinerator analysis: The incinerator chamber is maintained at temperature > 1100◦ C. All the organic matter is converted to carbon dioxide and water to steam f. Detail specification of the incinerator (FSL 2200 Incinerator)

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 25

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

The coal gasification process would involve fuel feeding into the 5 nos of Gasifiers, gas filtration, and finally piping of the gas to the application. The project equipment would comprise of continuous fuel feeding equipment, reactor shell with skirt, ash bowl, moving pyramidal shape grate, gas outlet and cleaning assembly, first stage gas cleaning system (spray towers), ultra gas cleaning system comprises of gas filter device (Electrostatic Precipitator), structures and platforms for all equipment, and instrumentation.

In the proposed producer gas plant, the producer gas generated from heating of coal in the gasifiers would be passed through a series of spray towers where the impurities will be separated out by direct scrubbing with water. The cleaned gas would be pumped through duct to the final application.

Features & Advantages

• The Coal Gasifier system is capable of gasifying several types of solid fuel such as

Indian Steam coal, Imported coal, Briquettes at high efficiency.

• Low NOx formation due to low flame temperature.

• Low SOx formation due to negligible sulphur content in fuel.

• Extremely Low Particulates and smoke emission due to the complete direct firing of

Producer Gas compare to solid fuels / liquid fuels firing.

• Clean Gas and environmentally friendly system. Due to technology superiority

producer gas is clean and free from phenolic and other impurities.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 26

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. Important perspectives of environment pollution mitigation from the proposed producer gas plant

Type of Incinerator and its Advantages The proposed incinerator is “Independent System” Incinerator and not “After Process” Incinerator and thus there is no chance of any contamination of the process system as the system has separate combustion air source and low operation / design ratio. Moisture of the coal condenses and is collected as phenolic water i.e. reused in the system. As there is no water scrubbing, no Fresh Water is converted to Phenolic Water.1881 KLPA or 5.7 KLD Phenolic Water shall be incinerated. Capacity of incinerator has been designed accordingly.

Additional Measures for Control of Dioxin and Furan Emissions The generation of dioxins and furans is mainly attributed to low temperature (200° C – 800° C) and incomplete combustion. As soon as the temperatures rise above 800° C, Dioxins are completely destroyed. The same will not happen in this system as it has high operation temperature (designed for operations at temperatures > 1000° C). However, the following measures shall be undertaken for the control of dioxin emission:

• Good combustion chamber design to optimize the supply of air for achieving more complete destruction of waste. • The flue gas resulting from the combustion process is raised to a temperature of 1100°C for at least 2 seconds for destruction of dioxin/furan in the flue gas. • Regular cleaning of boiler tubes to prevent build-up of fly ash, which can serve as a catalyst for dioxin/furan reformation. • Facilities for injection of activated carbon by powered injection system, which is operated in parallel with the alarm warning system to capture any dioxin/furan, if reformed, for treatment. • Regular monitoring of combustion products including dioxin/furan emissions. • Suspension of waste feeding operation to allow urgent trouble shooting and problem-fixing, when abnormal monitoring readings of air emissions or incinerator temperature is detected.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 27

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig. No 3.5.2: Pellet Plant Material Flow Diagram

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 28

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

3.6 Resources optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined Raw material requirement: Table 3.6: Raw Material Quantity & Source

Per year Approximate Mode of Material (Tonnes / Source Distance Transport Year) (Kms) Roida II Mines and other Iron Ore Iron ore fines 26,92,800 03-15 Closed mines in the Joda / Barbil area Conveyor/ Road Local traders of Bhuj, Gujarat Bentonite 19,800 1900 Rail/Road Product Limestone/ Local Market / Sundargarh, 47,520 185 Road Dolomite Odisha Coke / Coal 47,520 Open Market 280 Rail/Road Fines Fuel for Gasifier – 1,25,400 Open Market 280 Rail/Road Coal

The raw materials will be transported through rail and by road in covered vehicles. The nearby railway siding are Barbil siding at 10.5 kms, Banspani siding at 13.5 kms and Bolani siding at 17 km from the site.

The Raw Material Handling Section would be provided with dust suppression (DS) by water sprinkling at the stockyard and multiple dust extraction (DE) systems for the dust generation points at the screen, conveyor transfer point, and gas sealing devices to arrest the dust emissions to the atmosphere. The DE system shall consist of bag filter units complete with ducts, extraction fans, and a stack of appropriate height. The exhausted gases sucked through the Pellet plant will be cleaned in an Electro Static Precipitator (ESP). The dust collected will be discharged into a water-sealed scraper and sent to the primary mixing unit for recirculation. Waste gases will be discharged into the atmosphere through a chimney. STP and ETP will be installed for the treatment of domestic waste and industrial water for circulation respectively and will be reused in the process.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 29

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

3.7 Availability of Water Its Source, Energy/Power Requirement, and Source 3.7.1 Water requirement The total water required is 200 m3/hr i.e. 4800 KLD. The source of water will be Baitarani river. The pickup point is estimated to be approximately 9.95 km aerial distance from the plant boundary. The length of the water pipeline will be approximately 15 km. Table No: 3.7.1 Break up of water requirement Water consumption Utility m3/h m3/d Water lost with filter cake 45 1080 Evaporation losses at thickener 9 216 Producer Gas Plant 6.25 150 Process water for dust suppression and 34 816 emergency cooling of pellets Losses in cooling water 50 1200 Miscellaneous 19 456 Potable water 1 24 Water for storage for the lean period 35.75 858

Total 200 4800

3.7.2 Power Requirement For the pelletizing complex total power requirement will be nearly 18MW. Power required for the plant operation shall be sourced from the State grid. The main power consumption in the pelletizing process is by the combination circuit consisting of ball mills and the Induration process air fans. For emergency backup 2 DG sets of capacity 1000 KVA each will be installed. Table No 3.7.2 Power Requirements

Item Unit Requirement Maximum demand MW 18 Average demand with all units working. MW 16.2

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 30

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig. No 3.7.1: Water Flow Diagram

3.8 Fuel Requirement: FO shall be used in the Induration Furnace for Pellet Heat Treatment and Firing and LDO shall be used in the Furnace Start Up and drying of additives. Their requirements would be 12000 KLPA and 2.5KLPA respectively. Coal will be used as fuel in Producer gas plant and the quantity is 1,25,400 Tonnes/yr.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 31

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. 3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their management/disposal

3.9.1 Treatment for recycle and reuse: Process water, etc.

Sl. Process Final use of Quantity Measures envisaged No. water the water From the total phenolic water 1881 TPA water will be incinerated. The additional The rest 1881 TPA Phenolic water 2 Total: 3762 TPA measures for control of will be reused in the from PGP Dioxin and Furan emission process. is mentioned in section 3.5 (h). Water and From floor wash Water will be circulated recovered ore will 3. & cleaning 72 KLD through the clarifier to be re-used in separate the iron ore fines. process Water will be reused in the plant From drinking & STP of capacity 20KLD will 4. 16.8 KLD activities and sanitation be installed greenbelt development.

3.9.2 Solid waste/by products & Hazardous waste

Facility Waste Quantity(TPA) Management Solid Waste ESP Dust 23,760 TPA Recycle in Pellet Plant (used in house) Pellet Plant Recycle in Pellet Plant (used in house) Pellet Fines 1,59,480 TPA or sold to outside parties Sold to Authorized Coal tar processing PGP Plant Tarry Waste 5,115 TPA units.

Hazardous Waste

Used oil/Waste Oil 3 KLPA Stored and disposed to Authorized Residue of Oil & Tar recyclers/CHWTSDF as per norms 2 KLPA storage From the total phenolic water 1881 TPA Phenol from PGP 3762 TPA water will be incinerated and the rest 1881 TPA will be reused in the process.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 32

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

3.9.3 Details of Air Pollution Control Devices proposed in different units Probable pollution sources Mitigation measures Grinding Wet grinding process will be followed to reduce the dust emission. Loading/unloading of raw Water sprinkling/dry fog system will be installed. materials and dispatch of Materials will be transported in covered conveyer. materials. Mixing area Bag filters and/or wet scrubbers will be used to de-dust the transfer points for powdery material.

Induration area Electrostatic precipitators will be used for cleaning the furnace exhaust gases before releasing them to the environment through the process stacks. Also dedusting will be done through Electro Static Precipitator (ESP) or wet scrubber for feed end, discharge end, and HLSB areas

Additive Grinding Bag filters will be used at all fine material transfer points for efficient de-dusting

All the stack heights for the dedusting units will be around 30mtrs height. ESP stack 2 nos. chimneys will be of 45 mtrs height each. All the APCDs will be designed for PM emission below < 30 mg/Nm3.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 33

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

3.10 Schematic representations of the feasibility drawing which give information about EIA purpose

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 34

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Chapter 4

Site Analysis 4.1 Connectivity

The proposed plant area is well connected by NH-215 which is around 0.250 km in the North. The nearest Railway Station is Barbil which is about 6.1km in the North direction. Rourkela Airport at 61.3 Km NW and Biju Patnaik International Airport, Bhubaneswar is about 204 Km in SSE direction from the project site. 4.2 Landform, land use and land ownership The Plant will need main Plant Facilities, Raw Material & Product Storage yard, Water Storage Reservoir & Treatment plant, Auxiliary facilities, viz. Administrative Building, Technical Building, etc. The detailed land use break up for the existing and proposed plant has been given in the table below: Table No 4.2: Land use Breakup

Sl. Name of Unit Total Forest Plot data Non Forest No. area Area not Area (In Acre) (In available (In Acre) Acre) (In Ac) 1 Iron Ore Day Bins Building 0.148 0.148 0.000 2 Iron Ore Grinding Plant Building 1.035 0.550 0.485 3 Concentrate Thickener 0.103 0.103 0.000 4 Slurry Tanks 0.150 0.000 0.150 0.000 5 Filtration Plant Building 1.150 0.150 1.000 0.000 6 Mixing & Balling Building 1.050 1.050 0.000 7 Induration Furnaces 2 nos 4.193 2.890 1.303 8 Process Fans & ESPs 0.652 0.652 0.000 8A Chimneys 2 Nos (45m height each) 0.250 0.250 0.000 9 Hearth Layer Separation Building 0.093 0.093 0.000 10 Additive Storage Shed + Additive 0.560 0.560 0.000 Grinding Plant 11 Coke Storage & Dosing Building 0.198 0.100 0.098 12 Induration furnace feed end Dedusting 0.200 0.200 0.000 Buiulding 13 Control Room & MCC 0.250 0.250 0.000 14 Induration furnace Discharge end 0.297 0.297 0.000 Dedusting 15 Recirculating Water Pump Station 0.198 0.198 0.000 16 Fuel Pump House (FO & LDO) 0.525 0.000 0.525 0.000 17 Laboratory Building 0.127 0.127 0.000 18 Raw Water Pump Station 0.215 0.200 0.015 19 Compressor Station 0.109 0.000 0.109 0.000

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 35

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

20 Cake Drying Air Station 0.100 0.100 0.000 21 Diesel Generator 0.100 0.100 0.000 22 Water Reservoir 2.500 1.000 1.000 0.500 23 Pellets Storage Area+ Dedusting 2.000 0.399 0.555 1.046 24 Administration Building 0.077 0.000 0.077 25 Pellets Fines Storage Area +Dedusting 0.550 0.000 0.350 0.200 26 RM storage(Iron Ore) & Handling 1.005 0.450 0.555 System 27 Machinery Maintenance Workshop 0.200 0.100 0.100 28 Producer Gas Plant 7.355 1.000 3.400 2.955 29 132KV Switchyard 0.200 0.000 0.200 0.000 30 Effluent Treatment Plant 0.250 0.100 0.150 31 Diesel Storage Area 0.100 0.000 0.050 0.050 32 Sewage Treatment Plant 0.100 0.000 0.100 0.000 33 Drains 0.450 0.000 0.400 0.050 34 Roads 0.617 0.100 0.251 0.266 35 Truck Parking Bays 1.000 0.200 0.800 36 Procuct Entry Gate 0.007 0.007 0.000 37 Product Exit Gate 0.007 0.007 0.000 38 Raw material Entry Gate 0.007 0.007 0.000 39 Raw material Exit Gate 0.007 0.007 0.000 40 Light Vehicle , Staff & Exit Gate 0.005 0.005 0.000 Total Plant facilities 28.140 11.400 8.090 8.650 41 Green Belt 13.900 12.600 1.300 Total 42.040 24.000 8.090 9.950

Note: Since there are no records for 7 plots covering total area of 8.090 Acres, the same have been considered as Forest Land in the FC application. Thus, in the FC application total forest area is shown as 32.29 Acres (24.00 + 8.090).

Broad Land use Break-up for Project Site: Sl. Name of Unit Forest Area Non-Forest Total Area No. (Acres Area (Acres (Acres)

1 Production & Plant Facilities 8.800 5.284 14.084 2 Raw Material yard and Finished 3.100 2.100 5.200 Products storage 3 Office and other Permanent 1.200 0.000 1.200 Structures 4 Internal Road & Paved Area 1.200 0.100 1.300 5 Water Reservoir and water 3.000 0.500 3.500 complex, STP, ETP & RWH 6 Pellet Fines storage and 2.190 0.666 2.856 handling

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 36

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

7 Green Belt & Plantation 12.600 1.300 13.900 TOTAL AREA 32.090 9.950 42.040

4.3 Topography & Drainage The coordinates of the plant area are 22° 2'38.18"N and 85°22'5.87"E. It is situated at Tanto, Tehsil- Barbil, Keonjhar, Odisha. The topography of the plant area is flat and the slope is downward towards the North-East direction.

Fig. No. 4.3: Drainage Map

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 37

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

The elevation of the buffer zone in 10 Km radius varies from 443 m AMSL in N near Champuasahi village to 844 m AMSL in NE in the Thakurani Reserve Forest. The average elevation of site varies from 492 to 514 meters AMSL. The perennial river Karo and Kundra Nala flows about 6 km in the NNW direction and 4.4 km in the SE direction of the lease area respectively and forms the main drainage system of the area. River Baitarani flows at a distance of 9.95 Km in the SE direction of the proposed site.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ)), shortest distances from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from the HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.

Total Land- 42.04 Acre (17.013 Ha.)

Forest land: 24.00 Acres (9.712 Ha.), Records Not Available (considered as Forest Land) : 8.09 Acres (3.274 ha.) and Non-Forest land: 9.95 Acres (4.027 Ha.),

The land pattern is of mixed type. The connectivity & distance to nearest sensitive areas are mentioned below.

Table No. 4.4: Distance of various landmarks

Details S. Particulars (with approx. aerial distance & direction from No. the project site) 1. Nearest City Barbil- 6.6km (NNE) Nearest National 2. NH-215 – Approx. 0.250 km (North) Highway / State Highway 3. Nearest Railway station Barbil Railway – 6.46 km (North)

4. Nearest Airport Tanto-Barbil Airstrip – 0.242 km(East) Rourkela Airport- 61.3km (North-west) National Parks, Wildlife Sidhamatha RF – 1.5km SSW Sanctuaries, Biosphere Thakurani RF- 3.75km NE Reserves, Reserve Lakrahaghat RF- 4.8km SW 5. forest and Protected Uliburu RF- 7.3km N forest within 10 km Karo RF- 7.8km WWN radius Baitarani RF – 7.83km SSE

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 38

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited. 1. Roida II Iron Ore Mines of M/s. NPSPL- Adjacent (S) 2. Brahmani River Pellet Limited- 0.3km (W) 3. Arya Steel plant- 5.6km (NNW) 6. Nearby Industries/Mines 4. Guali Iron ore mines – 7.28km (SW) Kundra Nala- 4.4km (SE) Karo River- 6km (NNW) Sona Nadi- 6.97km E 7. Water Body Bolani reservoir- 7.35km (NNE) Jhikra Waterfall- 7.6km (NW) Baitarani River – 9.95km (SE)

8. Defense installations BOM Bolani CISF Camp area, Balagoda- 6.9km NW 9. Seismic Zone II (Low Damage Risk Zone)

*Aerial Distance is considered for distance calculation.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 39

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Fig. No. 4.4: Land Use Map 4.5 Existing Infrastructure As the pellet plant is a proposed project there is no existing infrastructure within the premise.

4.6 Soil Classification Part of the area inside the lease is covered with lateritic soil & alluvium. The "soil is fully infertile with brown to red color on the uppermost 0.0 to 0.5 m.

4.7 Climatic Data from Secondary Sources The climate of the region is tropical wet and dry. The south-west monsoon normally sets in the study area by the first week of July. There are four major seasons in the study area namely: Summer season March to May monsoon season June to September Post monsoon Season October-November Winter Season December to February

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 40

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Annual mean maximum temperature The annual mean maximum temperature in the region varies from 27.60C (December) to 41.80C (May) while annual mean minimum temperature varies from 12.0 0C (December & January) to 27.10C (May). Annual average rainfall The rainfall does not show any cyclic occurrences but shows erratic variations. The monsoon season spreads over the months from June to September. The annual total rainfall as recorded in the area by the lessee is given in the following table. Table No. 4.7.1: Annual Average Rainfall

Years Total rainfall (mm) 2009 750 2010 627 2011 1877 2012 1571 2013 1928 2014 1156 2015 969 2016 1129 2017 1573 2018 1215 2019 1116

Annual average Relative Humidity The area is humid during the monsoon; the mean monthly morning RH in the district varies from 63% in April- May to 84% in August. The afternoon means monthly RH varies from 54% in January to 81% in August. The RH reaches as high as 93% and often above 80% in the monsoon period. Annual average Wind Speed and Direction Generally, light to moderate winds prevails throughout the year. Winds are light and moderate particularly during the morning hours while during the afternoon hours, the winds are stronger. Predominating Wind Direction is South West. Avg. month-wise predominant wind directions are as below.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 41

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Table No. 4.7.2: Month-wise predominant wind directions

Sl No Month Direction Prominent wind Direction 1 January North-East > South –West 2 February South South-West > North North-East

3 March South South-West > North-East 4 April South > North 5 May South South-West > North North-East Predominant Wind 6 June South South-West > North North-East Direction is SW in most of 7 July South-West South > North-East North the year except winter 8 August South-West South > East North where it is NNE. 9 September South-West South > North East 10 October North North-East > South 11 November North North-East > North North-West 12 December North North-East > North North-West Source: India Meteorological Department

4.8 Social Infrastructure Available Barbil city is 6.6km from the plant site. All amenities including schools, colleges, Hospital, Temples are available within 10 km from the plant site. Almost all the villages in the buffer zone are electrified. Under the Corporate Social Responsibilities, development of the nearby villages is being undertaken. Table No. 4.8: Nearby Facilities/Social Infrastructure

Facilities/Social Description Infrastructure Details of nearby Villages Name of Distance & Population VillageTanto Direction0.12 km- N (Population180 Kasia 1,15 km-WN 1,040 Census 2011) Fulabadi 1.25 km NE 108 Jhadagaon 1.39 Kms NE 962 Bhusagaon 2.89 Kms ENE 2,207 Educational Facilities SSVM, Bhadrasahi - 1.86km NE

St. Teresa School, Joda- 4.6km SE

Medical Facilities: E.S.I. Hospital Corporation- 5.4km East

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 42

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.040 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

TATA Steel Hospital- 5.7km SE Central Hospital – 6.7km East Road & Other Infrastructure NH-215 – 0.250 km North SH- 10B- 2.3 km North East Specific Measures for Safe • Green Belt development in the north east and east guard of nearby habitation direction will be of 25 mtrs to reduce the dust emission and noise pollution effect on the nearby human settlement. • Boundary wall and 15m high wind shield will be constructed along the project boundary near the habitation area. • Water reservoir is proposed to be built in that section rather than any other plant facilities. • Wet grinding process and Conveyor for transportation of materials will be used to reduce the dust emission. • Half-Yearly random health checkup of the people living adjacent to the plant boundary will be done.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 43

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.04 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

Chapter 5 Planning Brief

5.1 Planning Concept (type of industries, facilities, transportation, etc.) Town and Country Planning/ Development authority classification. The proposed capacity of the iron ore pellet plant is 2.4 MTPA. The plant site will be comprised of a Grinding & Filtration, Mixing & Balling and Pelletizing building, water reservoir, Storage of raw materials & Finished Products, Green belt along with other service facilities.

5.2 Population Projection The estimated manpower requirement is 258. The break-up of the estimate is given in the table below.

Table No 5.2: Manpower requirement

Sr. Middle & Services Skilled & Unskilled Managerial Junior Managerial semiskilled Pellet plant 2 2 8 45 86 Laboratory 1 2 6 9 Power distribution 1 2 4 38 Purchase & Stores 2 2 5 12 Finance & 1 1 2 10 1 Accounts Human 1 2 3 2 Resources Administration 2 2 2 2 Total 3 10 20 75 150

This is the predicted manpower requirement considering the technology and machinery to be adopted. Final review and recruitment will be done after the finalization and installation of all the necessary facilities.

The estimate considers 3 shift operation per day and continuous operation round the year except for planned shutdowns and breakdowns. This manpower requirement planning includes all the activities to be carried out inside the plant-like production, transportation, managerial supervision, etc., and other dependent activities outside the plant area.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 44

Pre-Feasibility Report for Proposed 2.4MTPA Pellet Plant over an area of 42.04 acre at Village-Tanto, Tehsil-Barbil, District–Keonjhar, Odisha by M/s Narbheram Power And Steel Private Limited.

5.3 Land use planning In total, 42.04 Acres of land will be adequate to accommodate the entire planned facilities. The plant is located in village Tanto in the Keonjhar district of Odisha, India. The total green belt area will be 13.90 acres. The breakup of land has been provided in Chapter 4. 5.4 Amenities/Facilities The following site services shall be provided within the pellet plant area to facilitate Pelletization: ✓ All statutory services; like a first aid center, drinking water station, rest shelters, sheds; shall be provided close to the plant being developed. ✓ Electricity/ DG shall be provided in the plant. ✓ There shall be an ambulance in the area which, during an emergency can take the patient to the nearest hospital. ✓ There will be provision for water supply systems for drinking purpose from the Baitarani River and will be distributed throughout the project area and nearby villages for domestic consumption shall be maintained. ✓ Temporary office facilities for official works shall be maintained.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 45

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

Chapter – 6 Proposed Infrastructure 6.1 Industrial Area (Processing Area)

All the machines and buildings for the proposed installation of the 2.4 MTPA pellet plant will be within the site boundary of the 42.04 Acre area. The total land breakup of the plant area in detail is mentioned below.

Table No 6.1 Total Land Break Up SL. No Unit Eqpt / Building Area Area in Foundation Size (in Sq. m) Acre (in meter) PLANT FACILITIES 1 Iron Ore Day Bins Building 30 20 600 0.148 2 Iron Ore Grinding Plant Building 70 60 4200 1.038 3 Concentrate Thickener 23 18 414 0.102 4 Slurry Tanks 30 20 600 0.148 5 Filtration Plant Building 85 55 4675 1.155 6 Mixing & Balling Building 91 47 4277 1.057 7 Induration Furnaces 2 nos 154 109 16786 4.148 8 Process Fans & ESPs 77 35 2695 0.666 8A Chimneys 2 Nos (45m height each) 41 26 1066 0.263 9 Hearth Layer Separation Building 21 17 357 0.088 10 Additive Storage Shed + Additive Grinding Plant 72 31 2232 0.552 11 Coke Storage & Dosing Building 35 23 805 0.199 12 Induration furnace feed end Dedusting Buiulding 35 23 805 0.199 13 Control Room & MCC 52 21 1092 0.270 14 Induration furnace Discharge end Dedusting 58 21 1218 0.301 15 Recirculating Water Pump Station 40 20 800 0.198 16 Fuel Pump House (FO & LDO) 59 36 2124 0.525 17 Laboratory Building 35 14.5 507.5 0.125 18 Raw Water Pump Station 40 22 880 0.217 19 Compressor Station 30 15 450 0.111 20 Cake Drying Air Station 25 16 400 0.099 21 Diesel Generator 32 13 416 0.103 22 Water Reservoir 110 92 10120 2.501 23 Pellets Storage Area+ Dedusting 180 45 8100 2.002 24 Administration Building 20 15 300 0.074 25 Pellets Fines Storage Area +Dedusting 55 40 2200 0.544 26 RM storage(Iron Ore) & Handling System 117 35 4094 1.012 27 Machinery Maintenance Workshop 45 19.5 877.5 0.217 28 Producer Gas Plant 200 148 29600 7.314 29 132KV Switchyard 40 21 840 0.208

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 46

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

30 Effluent Treatment Plant 43 23.8 1023.4 0.253 31 Diesel Storage Area 23 18 414 0.102 32 Sewage Treatment Plant 23 18 414 0.102 33 Drains 610 3 1830 0.452 34 Roads 624 4 2496 0.617 35 Truck Parking Bays 95 42.5 4037.5 0.998 36 Procuct Entry Gate 14 2 28 0.007 37 Product Exit Gate 14 2 28 0.007 38 Raw material Entry Gate 14 2 28 0.007 39 Raw material Exit Gate 14 2 28 0.007 40 Light Vehicle , Staff & Exit Gate 10 2 20 0.005 Total Plant facilities 28.140 11.400 8.090 8.650 41 Green Belt 13.900 12.600 1.300 Total 42.040 24.000 8.090 9.950

6.2 Residential Area (Non-Processing Area) As local workers from nearby areas shall be engaged in the Plant activities, no residential area/housing is proposed. Additionally, the infrastructure in nearby localities is well developed, where they can have their accommodation. Barbil town is approx. 6 Kms from the Project Site, where accommodation is available.

6.3 Green Belt The 33% of total plant area (42.04 Acre) i.e. 13.90 Acre will be available for the green belt. The proposed green belt plan will include plantation along the roads and around various facilities like shops and offices. There are 168 trees present in the acquired area (as given in Table 6.3.1). Out of these, 71 trees shall be retained (44 in Greenbelt and 27 in various locations inside the plant area). Remaining 97 trees shall be transplanted. Break up of these 71 and 97 trees are enclosed as Annexure II and III respectively. Table No. 6.3.1: Tree Species Name

Sl. No. Species Name Number 1 Sala 17 2 Mahula 43 3 Tentuli 3 4 Kanchan 3 5 Kendu 5 6 Miss 18 7 Mango 8

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 47

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

8 Panas 3 9 Kusum 6 10 Baro 7 11 Simili 5 12 Chocharia 17 13 Ambeda 3 14 Krishna Chuda 3 15 Kashi 3 16 Saguan 11 17 Jamun 1 18 Ato 2 19 Bhalia 2 20 Charo 2 21 Acacia 1 22 Chakunda 2 23 Bahara 3 Total 168

6.4 Social Infrastructure Details of social infrastructure available and demand have been discussed in Chapter – 4 and Chapter – 5 respectively.

6.5 Connectivity 6.5.I The site is well connected with road, NH- 215 (at a distance of nearly 0.250 km in the North direction). 6.5.II Barbil Railway Station is at a distance of 6.1km in the North direction. 6.5.III Tanto-Barbil Airstrip is at a distance of approx. 0.272 km East direction. 6.5.IV Biju Patnaik International Airport is at a distance of 204km in the SSE direction.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 48

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

Fig No 6.5: Google Earth Image of the Connecting Road 6.6 Drinking Water Management Water to be used for drinking and domestic purposes are likely to be 24 KLD. There shall be a purified water supply system for drinking water and distributed to the project area and surrounding villages. Drinking water from the overhead storage tank will be supplied to the various units of the plant through the G.I. piping network.

6.7 Sewage System The sewage generated due to domestic usages will be treated in STP. The capacity of the STP will be 20KLD and the Sewage Treatment Plant (STP) will be based on the MBBR technology.

Fig. No 6.7: STP Flow Diagram

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 49

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres Bar Screen and O&G Trap Bar screen traps the floating, non bio degradable solids. O&G Traps restricts the floating Oil and Grease from reaching the reactors. Equalization Tanks With the help of diffusers the sewage is thoroughly mixed in the Equalization tank. It also ensures uniform flow to the Biological system. Anoxic Tank De-nitrification and luxury uptake of phosphorus take place by mixing a food source of raw sewage with microorganisms by returning suspended sludge. Aerobic Reactors In the reactors, microbiological growth takes place over specially designed carrier elements which digests the Organic load and generates sludge. Oxygen is diffused through fine bubble diffusers. Flocculation Zone A flocculation zone with agitation arrangement is introduced with dosing system before the clarification to enhance the settling process which helps in removal of TSS. Subsequently it facilitates phosphate removal. Clarification Settling media is specially oriented inside the clarifiers for efficient removal of sludge from the water. Disinfection The water coming out from the Clarifiers has limited organic load and can be discharged to drains/ water bodies after suitable disinfection by chlorine. Tertiary Treatment To reuse, the grey water is passed through a filtration media to further reduce the suspended organic load. Sludge Conditioning and Handling The sludge generated is fully digested, i.e. no odour, and is dewatered for subsequent handling with the help of filter press or centrifuge.

6.8 Water Treatment Plant The water treatment for the plant is mostly for cooling purposes with a small part of the requirement being for drinking and other direct process needs. To minimize the fresh water drawn from the source, recirculation system has been adopted. The

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 50

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres surface runoff generated will be fully neutralized before discharging into natural resources or being used within the plant for various activities like water sprinkling, plantation etc. Surface Runoff is expected to be around 12 CuM/hr. Runoff collected through garland drains will get settled in a settling pond of 180 CuM. Pump capacity will be 12 CuM/hr and from the settling tank it will go to the flocculator and then clarifier by adding coagulants to it before discharging it to the process water reservoir or natural drainage source.

The process water will be treated in the treatment plant. At first it will be collected to a collection/settling tank then it will be go to the clariflocculator where all the heavy particles will settle down. The treated water will be stored in reservoir to be reused in the plant activities.

6.9 Industrial Waste Management Hazardous wastes are wastes with properties that make them dangerous or potentially harmful to human health or the environment. Hazardous wastes can be liquids, solids, contained gases, or sludge. The hazardous waste generated from the plant will be treated as per the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016 and amendments thereof. The quantity with waste utilization is mentioned in section 3.9.

6.10 Solid Waste Management • Generation, handling and management of solid waste is given at Chapter 3, sec. 3.9.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 51

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres Chapter 7 Rehabilitation and Resettlement (R&R Plan) 7.1 Policy to be Adopted (Central/State) in Respect of the Project Affected Persons Including Home Oustees, Land Oustees, and Landless Laborers (Brief outline to be given)

No habitation or houses exist within the proposed plant boundary over an area of 42.04 acres. Also, the land is not under agriculture. The proposed land is under process of lease and acquisition through IDCO, Odisha.

Hence no Rehabilitation and Resettlement is envisaged for this project. However, the 14 PAFs shall be compensated as per R&R policy of Government of Odisha.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 52

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres Chapter- 8 Project Schedule & Cost Estimates

8.1 Likely date of start of construction and likely date of completion (schedule for the project to be given) Planning of Activities Proper time allotment and planning of all associated activities have to be done for the smooth running of the plant. The different types of activities are mentioned below: ✓ Material handling ✓ Compressed air facilities ✓ Water reservoir ✓ Power transmission and distribution ✓ Human Resource Management ✓ Telecommunication ✓ Waste treatment etc. The factors which are responsible for the timely implementation of the project are:- ✓ Arrangement of proper finance for the project. ✓ Finalization of the layout of the proposed plant. ✓ Design of utilities and services. ✓ Placement of orders for plant and machinery. ✓ Arrangements for Govt. sanctions and supply of power. ✓ Recruitment of personnel. Project Implementation Schedule The installation of the above-mentioned facilities is envisaged to be completed within 15 months from the zero date. All statutory approvals required for the project, the possession of land necessary for installation of the units envisaged, and the financial closure of the project are expected to be completed before the Zero date. Table No 8.1: Project Implementation Schedule

Project Module Start Date End Date Land Acquisition & Statutory Zero Date Clearances Basic engineering and tender Zero Date 2nd month documents Order of Equipment Zero Date 3rd month Civil Works & Structural fabrication 5th month 10th month

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 53

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

Structural Erection 7th month 10th month Delivery of Equipment 8th month 11th month Erection of Equipment 11th month 14th month Commissioning of installed equipment 14th month 15th month Commercial Production 15th month

8.2 Estimated Project Cost Along with Analysis In Terms of Economic Viability of the Project The cost estimation of this project is mentioned in the table given below in which all the costs are estimated as per current cost and may vary in the future. Similar projects are referred for the preparation of this data. Table No. 8.2.1: Summary of the estimated Capital Cost of the project Sl. No Item Unit: Rs Crores 1 Land 5.0 2 Civil and Structural works 50.0 3 Plant & Machinery 170.0 4 Producer Gas Plant 46.6 Subtotal 271.6 5 Engineering, consultancy, project management, 10.0 etc. 6 Preliminary expenses 3.0 7 Pre-operative expenses 2.0 8 Provision for contingencies 23.0 Fixed capital cost excluding IDC (1 to 7) 309.7 9 Interest during construction (IDC) 24.8 Fixed capital cost including IDC (1 to 8) 334.4 10 Margin Money for working capital 15.5 11 Total capital cost (1 to 10) 349.9 Say 350 Crores

Expenses for the operation of a 2.4 MTPA capacity Pelletization plant are mentioned below. Table No 8.2.2: Operating Expenses

Specific Cost per ton Items UOM Rate Consumption (Rs/DMT) Iron Ore fines t 2058.00 1.12 2,305 Fuel Oil ltr 30.00 5 150

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 54

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres

Anthracite coal / coke breeze kg 10.50 19.8 208 Power kWh 6.50 52.00 338 Bentonite kg 4.00 8.25 33 Lime stone/Dolomite kg 3.00 19.8 59 Fuel for Gassifier (Coal) kg 10.5 52.25 549 Water cost m3 10.00 0.65 7 Grinding media kg 75.00 0.25 19 Subtotal 3,668 Spares & Consumables Rs 1 176 176 Labour Rs 1 35 35 Salary Rs 1 123 123 Admin OH Rs 1 18 18 Utility Cost Rs 1 18 18 Total Opex 4,038

8.3 Cost Breakup for Environmental Management plan

Sl No Items Rs. In Crores 1 Power 8.0 2 Spares & Maintenance Bag Filter 3.0 Water sprinkling for dust suppression 1.0 Total 12.0

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 55

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres Chapter 9 Analysis of proposal 9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal, population, if any in the area The proposed configuration will have the following benefits: ✓ The manpower required for this project is 258 out of which preference will be given for employment of local people as per eligibility. ✓ High probability of Indirect employment generation from shops, hiring of vehicles/drivers and other temporary works will be there. ✓ The project will improve the socio-economic condition and living standard of the local population. ✓ Special emphasis on financial and social benefits like priority in employment, and awareness related to educational, and health will be given to the local people including the minority people in the area. ✓ Proper mitigation measures will be taken up for the impacts of the project on environment. ✓ It will add to the revenue generation of the District /State. M/s. Narbheram Power And Steel Private Limited will take into account measures for the socio-economic upliftment & welfare of nearby villages: ✓ Local infrastructure development ✓ Social Afforestation ✓ Extending support to games, sports, and culture to the local community ✓ Health and medical facilities ✓ Social awareness programs will further improve the quality of life and standard of living such as sanitation and hygiene, etc.

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 56

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres ANNEXURE – I

Optimization of Previous Proposal vis-à-vis Current Proposal for Same site: Tanto Sl. Parameter Previous Current No. 1 Total Area (Acres) 57.005 42.04 2 Forest Area (Acres) 47.315 24 3 Non Forest Area (Acres) 9.69 9.95 Land Records Not Available 4 - 8.09 (Acres) Height of the Chimneys 5 75 45 (Metres) Distance of Chimney from 6 680 815 airstrip boundary (Metres) Shortest Aerial Distance of 7 plant boundary from National 50 140 Highway (Metres) 8 Water Reservoir Area (Acres) 7.166 2.501 Road distance of Tanto from 9 0.04 0.12 plant site (Kilometres) Road distance of Fulabadi 10 1.08 1.25 from plant site (Kilometres) Road distance of Kasia from 11 1.12 1.15 plant site (Kilometres) Road distance of Jhadgaon 12 0.44 1.39 from plant site (Kilometres) Road distance of Swapneswar 13 Mahadev Temple from plant 1.6 2.26 site (Kilometres) 14 Number of trees involved 196 168 Untarred Approach Road to Passing through the plant 15 Outside the plant boundary Bhusagaon area Closed Conveyor System from 16 Not envisaged Envisaged Mine to Plant

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 57

Pre Feasibility Report for Proposed 2.4MTPA Pellet Plant at Village-Tanto, Barbil, Odisha by M/S Narbheram Power & Steel Private Limited over an area of 42.04 Acres Annexure II Trees To Be Retained

To be To be Sl. Species Number retained in retained No. Name Green Belt in Plant 1 Mahula 21 10 11 2 Kanchan 3 3 0 3 Kendu 5 5 0 4 Miss 14 11 3 5 Kusum 5 5 0 6 Baro 5 5 0 7 Simili 5 5 0 8 Chocharia 6 - 6 9 Sal 4 - 4 10 Saguan 3 - 3 Total 71 44 27

Annexure III Trees To Be Transplanted Sl. No. Species Name Number 1 Sala 13 2 Mahula 22 3 Tentuli 3 4 Kanchan 0 5 Kendu 0 6 Miss 4 7 Mango 8 8 Panas 3 9 Kusum 1 10 Baro 2 11 Simili 0 12 Chocharia 11 13 Ambeda 3 14 Krishna Chuda 3 15 Kashi 3 16 Saguan 8 17 Jamun 1 18 Ato 2 19 Bhalia 2 20 Charo 2 21 Acacia 1 22 Chakunda 2 23 Bahara 3 Total 97

Visiontek Consultancy Services Pvt. Limited, Bhubaneswar 58