for Proposed Expansion of the Steel Plant by installation of Pellet Plant with Grinding Facility (2x0.85 MTPA), Sponge Iron Plant (1x350 TPD Kiln), Induction Furnaces (3x25T), Capacity revision from approved 600 TPD to 1000 TPD Rolling Mill along with 7 MW capacity Captive Power Plant and Producer Gas Plant (12x 4000 Nm3/hr)
At
Village Mahuda, P.O. Rukni, P.S: Para, District: Purulia, West Bengal
Project Proponent
M/s Bravo Sponge Iron Pvt. Ltd. 41A, A.J.C. Bose Road, Diamond Prestige Building, 8th Floor, Room No. 801, Kolkata - 700017, West Bengal
Bravo Sponge Iron Pvt. Ltd. CONTENTS Project Feasibility Report for Expansion project
CONTENTS Chapter no Description Pages 01 Introduction 02 02 Industry Scenario 03 03 Site Location 05 Major Plant Facilities 1.7 MTPA Iron Ore Pellet Plant with grinding Unit 48000 Nm3/hr Producer Gas Plant 04 350 TPD Sponge Iron Plant 13 7 MW of Power Plant on WHRB of 350 TPD Kiln Revision from 600TPD to 1000 TPD Rolling Mill. Material Balance 05 Raw materials Requirement and its source 01 Infrastructure and Resources Availability of Land 06 Availability of Power 05 Availability of Water Transport Link Environmental Aspects Air Pollution Control Water Pollution Control Solid Waste Management 07 04 Noise Pollution Control Fire Protection System Green Belt Development Rain water Harvesting 08 Manpower Requirement 01 09 Project Period 01 10 Project Cost and Commercial Evaluations 01 11 Conclusion 01
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 01
Introduction Bravo Sponge Iron Private Limited (BSIPL), a private limited company was originally incorporated on 14th February 1997 vide Company Incorporation Number U27106WB1997PTC082921 with the Registrar of Companies, West Bengal. BSIPL started manufacturing sponge iron in the year of 2003 under the management of Bhalotia Group, Jamshedpur. In June 2015, it has been taken over by Shakambhari Ispat Group who is having a vast experience in the line of steel manufacturing.
The Admin and Correspondence office is at “Diamond Prestige”, 41A, AJC Bose Road, 8th Floor, Room no – 801, Kolkatta-700017. Whereas site is located at vill- Mahuda, PO- Rukuni, PS- Para, Raghunathpur of Purulia district in West Bengal- 723145, having Latitude: 230 32‘ 52” N & Longitude: 860 32‘ 49” E.
The present plant configuration of BSIPL is as follows
As per EC letter from MoEF&CC dated 18.04.2017 SL Particulars of Plant under operations Balance to be Final facilities implemented Configuration 1 Sponge Iron Plant 395 TPD 395 TPD (1x95 + 1x100 + 2x100 TPD) 2 SMS 2 x 15 T 2 x 15 T 600 TPD (Induction Furnace) 3 Rolling Mill - 600 TPD 600 TPD 3 Power Plant 10 MW 8 MW 18 MW (4x10TPH WHRB + (1X20 TPH 1 x 20TPH AFBC) AFBC + *Balance 12 TPH Steam from existing AFBC)
Bravo Sponge Iron Pvt. Ltd. is planning for expansion project in their existing unit with following proposed unit. The Plant configuration for proposed unit is given as below:
SL Particulars of facilities Capacity 1 Pellet Plant (2 X 0.85 MTPA) with grinding Facilities 5600 TPD 2 Producer Gas Plant(12X 4000 Nm3 /hr) Coal Base 48000 Nm3/hr 3 Sponge Iron Division (1 X 350 TPD) 350 TPD 4 SMS through Induction Furnace with CCM (3 x 25 T) 750 TPD 5 Rolling Mill (Revision from 600 TPD to 1000 TPD) 1000 TPD 6 Power Plant (WHRB based, utilizing waste heat from 350TPD DRI) 7 MW
1 | of P a g e 2
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 01
Salient Features of the project
The company has acquired 78.37 acres of land, out of which the existing plant is installed on around 40 acres of land and the proposed expansion project shall be implemented on balance land which is sufficient for installation of proposed project along with 33% Green Belt.
The project cost is estimated to be ₹ 475 Crores.
The project site is well connected by road and rail. The National Highway NH-2 is about 32 Km away from the existing site. The nearest railway station is Rukni which is less than 1 km away from the site. Asansol & Purulia are the nearest cities where market facilities are available
Existing set up engages approx. 670 manpower and further additional 1000 manpower shall be sufficient for proposed expansion project. Since the proposed site is located in close proximity of the industrial sectors, like Durgapur, Bokaro, Jamshedpur, Dhanbad & Asansol etc, availability of skilled labour will not pose any problem. Apart from the above direct employment, Indirect Labourers will be required which is easily available in Purulia and Asansol area
The project will require 1416 m3/ day which will be drawn from Kargoli point which is 13 Km away from the plant site. Apart from proposed project, existing units, units under implementation and unit to be implemented requires 868 m3/ day. Necessary arrangement has been made for 0.55 MGD of water (2500 m3/ day ) with DVRRC.
Proposed Project along with existing running unit and units which are under implementation and units to be implemented required approx. 67.5 MW power. Taking captive power generation of 25 MW, only 42.5 MW will be purchased from DVC.
2 | of P a g e 2
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 02
2.0 INDUSTRY SCEANARIO
2.1 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION:
All the products proposed to be manufactured have high market demand. Iron & Steel is a basic commodity for all industrial activity and its consumption marks industrial prosperity. The Iron & steel industry has tremendous forward and backward linkages in terms of material flow, income and employment generation. Iron & Steel is a core industry and thus its demand is strongly linked to the overall economic activity of the nation. Given the inherent long-term potential of the Indian economy and its cyclical nature, the long- term prospects of the steel industry are fairly comfortable. The demand and production has been growing at a healthy rate for the last few years and the forecast for the next decade and half is also very promising.
As reported by Indian Brand Equity Foundation, India’s finished steel consumption grew at a CAGR of 5.69 percent during FY08-FY18 to reach 90.68 million tonnes (MT). India’s crude steel and finished steel production increased to 102.34 MT and 104.98 MT in 2017- 18, respectively. In 2017-18, the country’s finished steel exports increased 17 per cent year-on-year to 9.62 MT, as compared to 8.24 MT in 2016-17. Exports and imports of finished steel stood at 0.99 MT and 1.22 MT, during Apr-May 2018.
DEMAND SUPPLY GAP:
On a conservative estimate, the steel demand in India is expected to touch around 150 MTPA by 2020. Steel supply is, however, expected to reach only around 145 MTPA by same time.
World Steel Association has projected Indian steel demand to grow by 5.7% in 2017 while globally steel demand has been projected to grow by 0.5% in 2017
The National Steel Policy 2017 has been formulated keeping in mind the rapid developments in the domestic steel industry (both on the supply and demand sides) as well as the stable growth of the Indian economy. The National Steel Policy 2017 aims to achieve 300 million tonne of steel-making capacity which will require an additional investment of Rs 10 lakh crore by 2030-31 setting a target of 160 kilograms per capita steel consumption by 2030. In comparison, per capita finished steel consumption in 2015 is placed at 208 kg for world, 489 kg for China and only 61 kg for India.
As a facilitator, the Government monitors the steel market conditions and adopts fiscal and other policy measures based on its assessment. In view of rising imports, the Government had earlier raised import duty on most steel items twice, each time by 2.5% and imposed a gamut of measures including anti-dumping and safeguard duties on a host
1 | of P a g e 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 02
of applicable iron and steel items.
The liberalization of industrial policy and other initiatives taken by the Government have given a definite impetus for entry, participation and growth of the private sector in the steel industry. This had led to expansion, forward integration, diversification and modernization of existing units.
The Cabinet also cleared another policy which will mandate giving preference to iron and steel products that are manufactured in India for all government tenders. At least 15 percent value has to be added to the notified steel product in India to qualify as domestic steel.
There is a distinct relation between steel consumption and the GDP growth rate world over. In India, GDP is expected to remain a figure of above 7% in Current and Next Financial Years while it is expected to touch thereafter Double Digit Figures of 11-12%. This will be possible with National Focus on Large Infrastructure Development with huge Investment and India is bound to witness sustained growth in the steel requirement in the years to come. India will emerge as the Second Largest Producer of Crude Steel in near future.
It is foreseen that there will be sufficient demand in local/Indian Market of Steel, TMT Bars and Rods and cement for constructional needs, Silico Manganese for Steel Making and others.
M/s BISPL has drawn up a growth plan with the objective of increasing its market share in Indian steel industry. Keeping all these in mind, the Company has planned expansion, forward integration and diversification of the existing facilities in an effective environment friendly way.
2.2 IMPORT VS. INDIGENOUS PRODUCTION:
On liberalization of the Indian steel sector with effect from 24.05.1992, iron and steel industry was included in the list of High priority industries for automatic approval for foreign equity investment up to 51%. This limit has since been increased to 100%. The import regime for iron and steel has undergone major liberalization moving gradually from a controlled import by way of import licensing, foreign exchange release, canalization and high import tariffs to total freeing of iron and steel imports from licensing, canalization and lowering of import duty levels. Export of iron and steel items has also been freely allowed. Import duty on capital goods was reduced from 55% to 25%. Duties on raw materials for steel production were reduced. These measures reduced the capital costs and production costs of steel plants.
2 | of P a g e 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 02
Imports: Iron & steel are freely importable as per the extant policy. Data on import of total finished steel (alloy + non alloy) is given below for last five years:
Exports: Iron & steel are freely exportable. Data on export of total finished steel (alloy + non alloy) is given below for last five years:
2.3 EXPORT POSSIBILITY: Above figures are indicative of constant increase of steel export from India and likely to increase further in coming years. The New Industrial policy opened up the Indian iron and steel industry for private investment by (a) removing it from the list of industries reserved for public sector and (b) exempting it from compulsory licensing. Imports of foreign technology as well as foreign direct investment are now freely permitted up to certain limits under an automatic route. Ministry of Steel plays the role of a facilitator, providing broad directions and assistance to new and existing steel plants, in the liberalized scenario.
The Company is already exporting to Nepal
3 | of P a g e 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 03
3.1 Connectivity.
The connectivity of the site to the key logistic/raw material/utility centres has been tabulated below:
Connectivity Details Rail The nearest railway station to the site is Rukni (1.0 km). Other railway station in close proximity are Adra Railway Junction (14 kms). Road The plant is also closely connected with Sate highway-5 (12 kms). The unit is located about 32 kms from NH2 which provides easy and good transport connectivity. Airport The nearest airport is Kazi Nazrul Islam Airport, Durgapur (71 Kms), Netaji Subhash Chandra Bose International Airport, Kolkata (218 kms). Town/ Cities The nearest Town/ Cities to the site are: Purulia – 30 kms Asansol – 44 kms
3.2 Land form, Land use and Land ownership.
The proposed units would be placed within 31.73 Hectares (78.37 acres) of land in the existing plant boundary. The required land is already in possession by the Company. As per existing land used pattern, land is generally flat and no major earth filling is required for the proposed project.
3.3 Topology The soil of Purulia district is undulating tract of high ridges and low valleys. The major part of the district is plain. The alluvial areas are found in very narrow strips along the rivers. The valleys are steep along the rivers. Alluvial fans are found in the fringe areas of Ajodhya hills. The soils of the district are mostly sedentary in nature. Colluvial soil is found only in valley bottom. Soils of undulated uplands are shallow, gravelly, course having low water holding capacity. These lands are either severely eroded or very susceptible to erosion. The whole district is a network of number of rivers. The principal rivers of the district are Damodar, Kangsabati, Kumari, Darakeswar and Subarnarekha. All the rivers have an easterly
3 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 03
and south easterly courses, only the Subarnarekha flows south and receives west and south west flowing tributaries. All the tributaries of these rivers are non- perennial and subject to flash floods. The Kangsabati is the master stream of the district.
3.4 Geomorphology of the Area Geomorphology broadly refers to the information on landforms. The aspects of morphology, morphogenesis, morpho-chronology and morphometry are vital inputs in preparation of geomorphological maps. The various geomorphic units in the buffer zone of the project site were interpreted, delineated and mapped from the satellite images followed by ground verification. The oldest rock formations were found in Purulia district of west Bengal. The major rock types of Purulia district are Phyllites, mica schist, and carbon phyllite, calcitic and dolomitic marbles which are followed by the rock formations belonging to the iron-ore series, viz. mica-schist, and phyllite and quartztic rocks. A thin bed of laterite gonditic rocks carrying manganese ore occur amidst these along a narrow zone between kinjirma and Bargaon at the western part and Pandrisila in the central part of the division. Gneiss and granites, pegmatites occupy the area around Purulia. The primary ones are Coal, Limestone, Rock Phosphate, China Clay and Quartz. Beside, a few other minerals like mica, bauxite lead, copper and zinc are also found. Limestone and dolomite are available in Purulia district. The economic mineral of lesser importance found in this division are coal, Phosphate and Quartz, pyrite building materials and kaolin etc
3.5 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distance from the periphery of the project to periphery of the forests, national park, wild life sanctuary, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. In case of notified industrial area, a copy of the Gazette notification should be given.
All the units shall be accommodated within 31.73 Hectares (78.37 acres) of land in the existing plant boundary. There is no national park, wildlife sanctuary/reserve forest exist within 10 km radius of plant.
4 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 03
3.6 Existing Infrastructure The proposed units would be placed within 31.73 Hectares (78.37 acres) of land in the existing plant boundary. Most of the facilities are available for setting up of the proposed steel plant such as Electricity, Water, Transportation of raw materials and finished goods etc. skilled and unskilled workers are also easily available within the industrial area. The project site already has proper road linkage for transport of materials and equipment. Rukni Railway Station is about 1.0 km from the project site. The NH-2 road is passing about 32.0 kms away in the North direction and the nearest distance of SH-5 in the East direction is about 12 kms with respect to the project site. The nearest Airport is Kazi Nazrul Islam Airport, Andal, around 71 km from the project site. Netaji Subhas Chandra Bose International (NSCBI) Airport, Kolkata, which is about 218 kms from the project site. Kolkata city is located at a distance of about 216 kms from the project site. Kolkata Port is around 211 kms away and Haldia Port is 230 kms away from the Project Site.
3.7 Soil classification The soil of Purulia district is undulating tract of high ridges and low valleys. The alluvial areas are found in very narrow strips along the rivers. Alluvial fans are found in the fringe areas of Ajodhya hills. The soils of the district are mostly sedentary in nature. Colluvial soil is found only in valley bottom. Soils of undulated uplands are shallow, gravelly, course having low water holding capacity. These lands are either severely eroded or very susceptible to erosion. The soils of the surrounding area of the project site are predominantly grayish in colour and sandy loamy in structure.
3.8 Climate data from secondary sources The meteorological data described from the IMD Station located at Purulia, which is around 30 km. from the Project Site and deemed to be representative of the project area. The station is observed to be well manned and equipped. The climate here is tropical. Purulia in summers are hot and dry with temperatures ranging from lows of 23°C to highs above 48°C. Winters are dry and cool with daily temperatures ranging from 5 °C to 20 °C. The total annual mean rainfall of Purulia district received is about 1230 mm.
3.9 Social Infrastructure available. All infrastructure facilities such as Education, Health facilities and other Social facilities are adequate at Purulia (30 kms), Asansol town (44 kms). Entire area is enjoying the modern facilities.
5 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
MAJOR PLANT FACITIES:-
The major production facilities which are under various stage along with the proposed expansion project at Village Mahuda PO- Rukini, District Purulia, West Bengal, Pin code- Pin code- 723145 is presented in below table.
UNITS AS TOTAL UNITS BALANCE UNITS AS PER EC PER EC UNITS AS UNITS FINAL FROM (STATE + PROPOSED SL UNIT PER STATE UNDER UNDER TO BE CONFIGUR MoEF&CC MoEF&CC UNITS CLEARANCE OPERATION IMPLEMENTION IMPLEMENTED ATION DATED CLEARANCE) 18.04.2017 Pellet Plant with 2 X 0.85 1 ------1.7 MTPA Grinding MTPA Facility 1X100 TPD (as per NOC 745 TPD dated 1X100 TPD (1X100 TPD 1X100 TPD + Sponge 5.12.2002) + + 1x95 TPD + 1x95 TPD 2 2X100 TPD 1x95 TPD + - - 1 X 350 TPD Iron Plant 1x95 TPD (as + 2X100 + 2X100 2X100 TPD per State EC TPD TPD + dated 1X350 TPD) 24.03.2008) SMS 1350 TPD (Induction 600 TPD 600 TPD 300 TPD 150 TPD 150 TPD 750 TPD 3 - (4 x 15 T + Furnace (4 x 15 T) (4 x 15 T) (2 x 15 T) (1 x 15 T) (1 X 15T) (3 x 25T) 3 x 25T) with CCM)
Capacity revision from Rolling 4 - 600 TPD 600 TPD - - 600 TPD* approved 600 1000 TPD Mill TPD* to 1000 TPD
8 MW 10 MW (1X20 TPH 18 MW 18 MW 25 MW Captive (4x10 TPH Proposed AFBC (8 MW (8 MW WHRB (15 MW 5 Power - WHRB + - + *Balance 12 7 MW WHRB WHRB + 10 + 10 MW WHRB + 10 Plant 1X20 TPH TPH Steam MW AFBC) AFBC) MW AFBC) AFBC*) from existing AFBC)
Producer 12 x 4000 48,000 6 ------Gas Plant Nm3/hr Nm3/hr
4. PROCESS OF MANUFACTURING FOR PROPOSED UNITS • 2 x 0.85 MTPA Iron Ore Pellet Plant with grinding facilities. • 12 x 4000 Nm3/hr Producer Gas Plant • 1 x 350 TPD Sponge Iron Plant. • 3 x 25 T SMS through Induction Furnace route with matching Caster • 1000 TPD Rolling Mill(*Capacity revision from approved 600 TPD* to 1000 TPD) • 7 MW of Power Plant based on WHRB, utilizing waste heat from 350 TPD Kiln
1 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
4.1 PROCESS OF MANUFACTURING FOR PROPOSED PELLET PLANT
Two units of 0.85 MTPA capacity pellet plant will be set up. In pellet plant, the concentrated iron ore fines will be mixed with limestone, coke breeze and bentonite and grounded in a Grinding Unit. The grounded material is transported pneumatically to mixer. The material balance for proposed pellet plant is given in below table
MATERIAL BALANCE FOR 2 X 0.85 MTPA OF PELLET PLANT Input Material Qnty (TPA) Output Material Qnty (TPA) Iron Fines 1764000 Pellet Plant Pellet 170800 Bentonite 11760 1.7 MTPA Limestone 16800 considering 305 days Coal 67200
The mixed material is conveyed to balling disc for making green balls, where water is added. The green balls are called pellets, which are screened to 9 -16 mm size in a double deck roller screen. Oversize and undersize material are returned to mixed material bins for reuse. The pellets are fed by conveyor to the travelling grate of indurating furnace for heat hardening. Mixed gas (blast furnace / coke oven gas) or producer gas is used as fuel to achieve temperature of 1300oC. Producer gas plant is also considered to supply the gaseous fuel requirement of pellet plant. Heat provides recrystallisation, bonding and imparts strength to the pellets. The indurated pellets are air-cooled using a fan. The cooled pellets are taken to stockpile by belt conveyors after separation of hearth and side layers in the hearth layer separation bin. The hearth and side layers are reused in the furnace.
Slurry receiving and filtration: The iron ore will be received by pipe line in slurry form in slurry receiving tanks and filtered in high efficient pressure filters. The iron ore is dewatered (called concentrate). The filtrate is clarified and reused in the pellet making.
Mixing: The iron ore concentrate is mixed with additives like coke fines, limestone powder, and bentonite in high intensity mixer and with required quantity of water for ideal moisture for next stage of process called balling.
Balling: The homogeneous feed is fed to balling discs. Green balls are formed in an inclined pan, driven by variable frequency drives.
2 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
Figure- 5.0 : Schematic Process Flow of Pellet Plant
Indurations: The green balls are converted to pellets by fired in the indurating furnace. In this process, the wet pellets are dried, preheated, indurated, and cooled on a continuous moving grate without intermediate transfers. The indurating burners will be fired with coal gas. The process air introduced for pellet cooling will be circulated from the cooling zone of the grate in a multipass manner to the other process zones. The heat transferred to the air in the cooling zone will be transferred to the zones for drying and preheating of the green pellets. The indurating furnace divided in to five zones. The zones are up draft drying, down draft drying, preheating, firing, cooling zones. The indurating temperature is around 1300 deg C.
Product Handling: Pellet is discharged from end of the machine and screened to remove materials that are recycled to the hearth layer. The pellets are stored in sheds.
3 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
4.2 PROCESS OF MANUFACTURING FOR PROPOSED PRODUCER GAS PLANT
Coal Gas, produced in Producer Gas Plant using coal gas technology, will be used as fuel in the pellet plant. This is a clean fuel. The composition of Producer Gas is given below
CH4: 1.5 %
H2: 13.0 % CO: 25.0 %
CO2: 6.0 %
N2: 53.9 %
H2S: 0.20 %
O2: 0.60 % Net Calorific Value: 1350 Kcal/ Nm3
There will be 12 coal gasifiers to produce 48000 Nm3/hour of producer gas. In a fixed bed gasifier, the coal passes downward in counter current direction to gas flow, through various phases (de- volatisation, gasification and combustion zones) Mixture of air and steam is introduced in lower part of gasifier through rotating grate. The basic reaction takes place in a typical fixed bed gasifier is: Coal + Air + Steam = CO2 + CO + H2 + CH4 + Tar + Ash
The resulting gas is tapped at the top of the gasifier. It is taken to cyclone for dust separation. The gas is cooled using air in a recuperator. Thereafter the gas is taken to Electrostatic Tar Separator where tarry waste is separated from the gas. Tar is collected in underground storage tanks and sold. Water is used only to cool the gasifier sheel (non-contact cooling). No wastewater is generated from the gasifier. Ash is extracted by rotation of a grate and disposed as per MOEF&CC Rules.
The material Balance for proposed Producer Gas Plant is given in below table
MATERIAL BALANCE FOR 12 X 4000 Nm3/hr MTPA OF PRODUCER GAS PLANT Input Material Qnty (TPA) Output Material Qnty (TPA) Producer Gas Plant Coal (4500 GCV) 118800 PG Gas 48000 12 x 4000 Nm3/hr working days 330 Tar 3564 Ash 23760
4 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
4.3 PROCESS OF MANUFACTURING FOR PROPOSED SPONGE IRON PLANT
The direct reduction iron plant will be of conventional Rotary Kiln technology. The rated capacity of the kilns will be 1x350 TPD to produce sponge iron. The plant will be suitably designed for conveyor transportation as well as storing system for both iron oxide feed, DRI product as well as by product like product fines. The utilities system design will include distribution network for utilities like nitrogen, oxygen, water, electric power, etc.
Figure – 4.0 : Process flow of DRI Plant
The process converts lump iron ore into highly metallised, passivated iron product. The product is in the form of pellets/lumps and contains a variable and controlled percentage of carbon. This is an ideal feed material for quality steel making. The presence of Fe3C assures that the product is passivated i.e. non-pyrophoric even without briquetting and allows easy, safe handling and transport.
The material Balance for proposed 1 X 350 TPD DRI is given in below table
MATERIAL BALANCE FOR 1 X 350 TPD OF DRI PLANT Qnty Input Material Qnty (MT) 1 x 350 TPD DRI Plant Output Material (MT) Pellet 198198 considering 330 days Sponge Iron 138600 Coal 124740 and with 1.2 Dolochar 24948 Dolomite 67914 Productivity Flue dust 53361
5 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
When the temperature reaches a value of about 500-600 deg C, the hematite (Fe2O3), in presence of CO, changes to magnetite (Fe3O4). When the burden reaches the lower zone of the furnace and comes in contact with hotter and richer gas, the magnetite is reduced to wurstite (FeO). The reduction of wurstite to metallic iron is the slowest stage of the whole reduction process. It requires high temperatures and gas with high reduction potential and these conditions are reached in the reducing gas injection zone. The overall reduction process is represented by the following reactions:
Fe2O3 + 3CO 2Fe + 3CO2
Oxide material handling: The iron oxide material i.e. lump iron ore (sized) will be collected and conveyed for screening in the oxide screening station and then sent to oxide day bins for storage.
The iron ore will be directly sent to the oxide storage bins. Two bins will be earmarked for pellet storage while one bin will store the iron ore lump. About two shifts storage capacity has been planned.
4.4 PROCESS OF MANUFACTURING FOR PROPOSED POWER PLANT
Waste gases generated from DRI (Sponge Iron) plant contain carbon monoxide and other volatile matter which after combustion releases significant heat. This heat contains significant calorific value (GCV of mixed fuel - about 2300 kcal/Nm3). This heat will be used to produce steam through Waste Heat Recovery Boiler. The high pressure steam will be used to run turbines and generate 7 MW electricity.
Waste Heat Recovery Boiler will be installed behind the ABC of proposed DRI kiln in bypass configuration. The flue gases after ABC will be taken to uni-fired furnace chamber and then flow over banks of super heater, convective evaporator and economizer before being discharged to atmosphere through ESP, ID fan and stack.
Waste Heat Recovery Boiler: After burning chamber (ABC) and Dust settling chamber (DSC) will be located at the exit of DRI Plant Kiln. Part of the dust carried by the waste gases will settle down at DSC. The DSC and ABC assembly will be connected to the DRI Plant Kiln through refractory lined duct.
The combustibles in the waste gases are burnt in the After Burning Chamber which will raise the waste gas temperature thus making the waste gases free from carbon mono-oxide. Provision for spraying water will be made to control the temperature if required. From ABC outlet the WHRB will be connected through a refractory lined duct. An emergency stack cap on top of ABC will be provided for diverting the waste gases to atmosphere when WHRB is under shutdown or break down.
6 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
The boiler will be complete with evaporator steam drum, mud drum, bank of super heaters, economizer, attemperator, air fans, ESP, internal piping etc. Soot blowing and super heater attemperation system will also be provided. Boiler will be provided with blow down tanks (IBD, CBD etc), sample cooler.
Flue gas cleaning system: The exhaust gases will be discharged from boiler to ESP and then into the atmosphere through induced Draft fan and chimney. The pressure drop in the boiler ducts and ESP will be kept to match with the requirement of existing ID fan. The boiler will be of semi- outdoor type with a weather canopy and side covering of trapeze corrugated steel sheets or other suitable materials, as available.
The gases passing out of WHRB will be passed through one multi-field Electrostatic Precipitator before releasing the gas, having huge quantity of dust particles, into the atmosphere. The ESP will be installed between the WHRB and the stack. The dust content in the gas, downstream of ESP shall be limited to 30 mg/Nm3. The ESP Unit will be provided with transformers, rectifier and controls. The dust particles will be collected below ESP in hoppers and conveyed by means of conveyors or pneumatically and stored in silos. This will be subsequently disposed off by trucks.
PROCESS FLOW DIAGRAM – 7 MW WASTE HEAT RECOVERY BASED POWER PLANT
7 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
Steam Turbine generator: There shall be one TG of 15 MW capacity. The board description of the steam turbine generator envisaged is indicated below:
The Steam turbine will be single, Horizontal, Single blade condensing type. The set shall be complete with gear box, barring gear box, condenser, air evacuation system condensate extract pumps, generator cooling systems, gland sealing with gland vent condenser and lube oil system. Condensing steam turbine generator with inlet steam parameter of 66 ata and 465 5°C at emergency steam valve inlet is provided.
Conversion of Heat Energy in Steam to Mechanical work will be done by expanding the same in Steam Turbine which shall provide mechanical energy in the form of rotational torque. Steam while passing through various stages of Turbine will release both pressure and temperature and will be ultimately dumped to Condenser at near vacuum condition. Low pressure steam will be condensed by air in Air Cooled Condenser. Condensed Water from the Air Cooled Condenser will be fed back to Boiler through Air Ejector, Gland Steam Condenser and Deaerator for re-generative heating and air removal. Boiler Feed Pump shall take suction from Deaerator and feed deaerated water to Boiler Economiser.
Deaerator and feed water system: There will be a deaerator with feed tank. 2 boiler feed water pumps with motors (1 working + 1 stand by) shall be provided along with common suction header, auto recirculation valve, suction/discharge valve, non return valve, pressure gauge, temperature gauge etc.
Electrics: The electrics include generators, transformers, switchgear – main and auxiliary, battery room etc.
Instrumentation & Control: Effective control and measurement of process parameters along with data acquisition system in the control room has been envisaged.
Auxiliary Services: Auxiliary service systems such as EOT crane, telecommunication, air conditioning and ventilation shall be adequately envisaged.
8 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
4.5 PROCESS OF MANUFACTURING FOR PROPOSED INDUCTION FURNACE
It is also proposed to install 3x25 T numbers of Induction furnaces.
The plant will produce steel in the form of billets, TMT Bars and Strips & Structural products through IF-CCM-RM route. Steel making will be done using induction furnaces. A brief description of the processes is dealt in subsequent paragraphs and the process flow sheet is given below.
Steel Making by Induction Furnace
The greatest advantage of the Induction Furnace is its low capital cost compared with other types of Melting Units. Its installation is relatively easier and its operation simpler. Among other advantages, there is very little heat loss from the furnace as the bath is constantly covered and there is practically no loss during its operation. The molten metal in an Induction Furnace is circulated automatically by electromagnetic action so that when alloy additions are made, a homogeneous product is ensured in minimum time. The time between tap and charge, the charging time, power delays etc. are items of utmost importance is meeting the objective of maximum output in tones/hours at a low operational cost. The disadvantage of the induction furnace is that the melting process requires usually selected scrap because major refining is not possible.
The process for manufacturing steel may be broadly divided into the following stages:
i) Melting the charge mixed of steel & Iron scrap 9 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
ii) Ladle teeming practice for Casting (OR) iii) Direct teeming practice for billet Casting unladdable teeming machine
The material Balance for proposed 3 X 25 MT SMS (IF) is given in below table
MATERIAL BALANCE FOR 1 X 350 TPD OF DRI PLANT Input Material Qnty (TPA) Output Material Qnty (TPA) Pig Iron 47394 3 x 25 SMS with IF Billets 247500 Sponge Iron 216563 Considering 10 heats per Slag + Scrap 37125 Ferro Alloys 484 day for 330days Reverted Scrap 4950 Scrap 31263 Scrap from Slag 4455
The furnace is switched on, current starts flowing at a high rate and a comparatively low voltage through the induction coils of the furnace, producing an induced magnetic field inside the central space of the coils where the crucible is located. The induced magnetic fluxes thus generated out through the packed charge in the crucible, which is placed centrally inside the induction coil.
As the magnetic fluxes generated out through the scraps and complete the circuit, they generate and induce eddy current in the scrap. This induced eddy current, as it flows through the highly resistive bath of scrap, generates tremendous heat and melting starts. It is thus apparent that the melting rate depends primarily on two things (1) the density of magnetic fluxes and (2) compactness of the charge. The charge mixed arrangement has already been described. The magnetic fluxes can be controlled by varying input of power to the furnace, especially the current and frequency.
In a medium frequency furnace, the frequency range normally varies between 150-10K cycles/second. This heat is developed mainly in the outer rim of the metal in the charge but is carried quickly to the center by conduction. Soon a pool of molten metal forms in the bottom causing the charging to sink. At this point any remaining charge mixed is added gradually. The eddy current, which is generated in the charge, has other uses. It imparts a molten effect on the liquid steel, which is thereby stirred and mixed and heated more homogeneously. This stirring effect is inversely proportional to the frequency of the furnace and so that furnace frequency is selected in accordance with the purpose for which the furnace will be utilized.
The melting continues will all the charge is melted and the bath develops a convex surface. However, as the convex surface is not favorable to slag treatment, the power input is then naturally decreased to flatten the convexity and to reduce the circulation rate when refining under a reducing slag. The reduced flow of the liquid metal accelerates the purification reactions by constantly bringing new metal into close contact with the slag. Before the actual reduction of steel is done, the liquid steel which might contain some trapped oxygen is first treated with some suitable deoxidizer. When no purification is attempted, the chief metallurgical advantages of the process attributable to the
10 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
stirring action are uniformity of the product, control over the super heat temperature and the opportunity afforded by the conditions of the melt to control de-oxidation through proper addition.
As soon as the charge has melted clear and de-oxidising ions have ceased, any objectionable slag is skimmed off, and the necessary alloying elements are added. When these additives have melted and diffused through the bath of the power input may be increased to bring the temperature of metal up to the point most desirable for pouring. The current is then turned off and the furnace is tilted for pouring into a ladle. As soon as pouring has ceased, any slag adhering to the wall of the crucible is crapped out and the furnace is readied for charging again.
As the furnace is equipped with a higher cover over the crucible very little oxidation occurs during melting. Such a cover also serves to prevent cooling by radiation from the surface heat loss and protecting the metal is unnecessary, though slags are used in special cases. Another advantage of the induction furnace is that there is hardly any melting loss compared with the arc furnace.
CONTINUOUS CASTING MACHINE
The molten steel from the IF is cast in a continuous casting machine to produce billets. In some processes, the cast shape is torch cut to length and transported hot to the hot rolling mill for further processing. Other steel mills have reheat furnaces. Steel billets are allowed to cool, and then be reheated in a furnace prior to rolling the billets into bars or other shapes.
The process is continuous because liquid steel is continuously poured into a ‘bottomless’ mould at the same rate as a continuous steel casting is extracted.
1) Before casting begins a dummy bar is used to close the bottom of the mould. 2) A ladle of molten steel is lifted above the casting machine and a hole in the bottom of the ladle is opened, allowing the liquid steel to pour into the mould to form the required shape. 3) As the steel’s outer surface solidifies in the mould, the dummy bar is slowly withdrawn through the machine, pulling the steel with it. 4) Water sprays along the machine to cool/ solidify the steel. 5) At the end of the machine, the steel is cut to the required length by gas torches.
11 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
4.6 PROCESS OF MANUFACTURING FOR PROPOSED ROLLING MILL
The company is planned to set up Rolling Mill for Long products as a finished product. The proposed capacity of Rolling Mill is as follows,
Rolling mill consists of set of equipment together will produce the said quantity. Rolling mill will primarily comprise of one tunnel type temperature equalizing-cum-holding furnace with roughing and finishing strand, one pendulum type bar and cobble shear, one high pressure de-scaling station, run out roller table equipped with turnover cooling bed along with auxiliary facilities and roll shop equipment.
Operating parameters
The net operating hours of the mill are affected by various factors considering integrated direct linked operation with furnaces, ladle furnace and bloom caster unit, such as relining of furnaces, breakdown and mismatching of operational requirements between the units. Considering the effect of the external factors enumerated above and the operation and maintenance requirements of the mill itself, the net annual operating hours of the mill will be about 7200.
Product weighing station : A product weighing station will be included to provide weight output to computer tracking and logging systems and print out a tag for attachment to the finished coil.
Product marking machine: A marking machine will be provided to print bar data on outer wrap of the coil. The machine will comprise of the frame, print head, ink system, etc. The signals for marking data will be fed through PC and received through PLC / microprocessor system.
Roll grinding and bearing inspection facilities: The roll grinding and bearing inspection facilities will be installed in a separate roll shop which will be located adjacent to the main mill bay.
Shop layout : The proposed mill equipment and other associated facilities will be housed in multibay building consisting two parallel bays for mill and roll grinding and bearing inspection facilities. The main equipment of the mill and storage area will be located in a bay of 30 m width having about 200 m length. This bay will be served by EOT cranes. The motor room for the mills will be located in a bay of 21 m width and 63 m length, and will be served by one 45 t capacity EOT crane. All technological basements like oil cellars, hydraulic pump accumulator stations, strip cooling pump house, etc. will be located in the mill bay. The water circulation system including scale pit will be located outside the main mill building.
TMT Process: By adopting thermo mechanically treatment process higher strength of TMT bars is obtained. In this process, steel bars get intensive cooling immediately after rolling. When the temperature is suddenly reduced to make surface layer hard, the internal core is hot at the same time. Due to further cooling in atmosphere and heat from the core, the tempering takes place. This process is expected to improve properties such as yield strength, ductility and toughness of TMT bars. With above properties, TMT steel is highly economical and safe for use. TMT steel bars are more corrosion resistant than Tor steel. 12 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 04
The overall material balance for entire facilities’, i.e running unit, units under implementation, units to be implemented and proposed new plant is given in below table
Input Material Qnty (TPA) Output Material Qnty (TPA) Iron Fines 1793400 Pellet Plant Pellet 1708000 Bentonite 11956 1.7 MTPA Limestone 17080 considering 305 days Coal 68320
Input Material Qnty (TPA) Output Material Qnty (TPA) Producer Gas Plant Coal (4500 GCV) 118800 PG Gas 48000 12 x 4000 Nm3/hr Tar 3564 working days 330
Input Material Qnty (TPA) 745 TPD DRI Plant Output Material Qnty (TPA) Pellet 421878.6 (1 X 95 + 1 X 100+ 2 X200 Sponge Iron 295020 Coal 265518 + 1 X 350) Dolochar 5310 Dolomite 144560 considering 330 days and with 1.2 Productivity
Input Material Qnty (TPA) Output Material Qnty (TPA) Pig Iron 85309 SMS with IF Billets 445500 Sponge Iron 389813 4x15T + 3 X 25T Slag 66825 Ferro Alloys 872 Considering 10 heats per Scrap from CCM 8910 day for 330days Scrap from Slag 8019 Scrap 56274
Input Material Qnty (TPA) Output Material Qnty (TPA) 1000 TPD - (Structural Billet from IF Route 346500 Long Product #1 330000 and Long Product) Scrap 16500 considering 330 days
Input Material Qnty (TPA) Output Material Qnty (TPA) Power Plant- AFBC Coal (3500 Kcal/Kg) 44355 Power 10 10 MW Dolochar(2500GCV) 53104 Ash 58475
13 | of P a g e 1 3
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 05
RAW MTERIALS REQUIREMENT The annual requirement of major raw materials and their probable sources of procurement are given below. Estimated Annual Requirement of Raw Material Raw Material Existing Proposed Total Mode of Source Plant Plant transport Sponge Iron Plant Pellet 223680 198198 421879 Internal Coal 140778 124740 265518 Rail/road Imported/ West Bengal & through e-auction. Dolomite 76646 67914 144560 Rail/Road
SMS (IF route) Pig Iron 37915 47394 85309 Rail/Road Sponge Iron 173250 216563 389813 Internal/Road Ferro Alloys 387 484 872 Road Scrap 25011 31263 56274 Internal/Road
Rolling Mill Billets 207900 138600 346500 Internal
Power Plant-AFBC Coal - - 44355 Rail West Bengal & through e-auction. Dolochar - - 53104 Internal
Pellet Plant Iron Ore Fines - 1764000 1764000 Rail Orissa/jharkhand Bentonite - 11760 11760 Rail/Road Kutch,Gujarat Limestone - 16800 16800 Rail/Road Birmitrapur, Orissa. Coal - 67200 67200 Rail/Road West Bengal & through e-auction.
Producer Plant Coal - 118800 118800 Rail/Road West Bengal & through e-auction.
Note: The Raw Material requirement is based on assumption.
The raw materials will include some moisture and undergo some losses during transportation, handling and screening. Considering all such losses, the estimated gross annual requirement of raw materials is to be procured annually.
1 | of P a g e 1
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 06
Infrastructure and Resources
6.1 Availability of Land The layout of the plant has been developed considering the plant and facilities coming under the proposed project only, total 78.37 acres of land is required for the proposed project along with existing units.
The company has acquired 78.37 acres of land, out of which the existing plant is installed on around 40 acres of land and the proposed expansion project shall be implemented on balance land which is sufficient for installation of proposed project along with 33% Green Belt. The proposed expansion project will be installed within the existing plant premises.
SL Units Land Utilization
1 Existing - Sponge Iron Plant 4.5 Acres
2 Proposed - Sponge Iron Plant 7.8 Acres
3 Existing & Proposed - SMS ( IF) 3.87 Acres
4 Existing & Proposed - Power Plant 2.33 Acres
5 Proposed - Rolling Mill 6 Acres
6 Proposed- -Pellet Plant with Producer Gas Plant 20 Acres
7 Existing & Proposed - Raw material Yard 5 Acres
8 Proposed - 132 KV Substation 2 Acres
9 Water Reservoir 0.5 Acres
10 Admin Building, Stores, time office etc 0.5 Acres
11 Existing & Proposed - Green Belt 25.8 Acres
Total 78.30Acres
The plant layout of the proposed project is presented in below Figure
1 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 06
2 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 06
6.2 Availability of Power
The total power requirement is mentioned in detailed in below table. After adjusting the captive power generation, additional Power requirement will be fulfilled by drawing electricity from 132 KV line from Damodar Valley Corporation.
Accordingly 132 KV substations is being installed at plant premise to distribute the electricity to different consumption units.
SL Units Existing Under / to be Proposed Total implemented
1 Sponge Iron Plant 1 - 1 2
2 SMS ( Induction Furnace) 10 10 25 47
3 Power Plant 1 0.8 0.7 2.5
4 Rolling Mill - - 4 4
5 Pellet Plant - - 6 6
6 Producer Gas Plant - - 6 6
7 Misc 0.5 0.5 1 2
Total Consumption(in MW ) 12.5 13.8 41.2 67.5
Total Generation (in MW) 10 8 7 25
Power from Grid 2.5 5.8 34.2 42.5
3 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 06
6.3 Availability of Water
The nearest source of water will be Damodar River which is close to the proposed site. Company has already applied for 0.55 MGD of water and which has been also approved by WBIDC. Accordingly based on our requirement 0.15 MGD of water is sanctioned by DVRRC. And rest water shall be provided by DVRCC as when required by the project upon implementation..
A dedicated 12km pipe line from Kargoli point near Damodar River to plant premises has been laid. Floated type of pump is installed to suck the water.
SL Units Existing Under / to be Proposed Total implemented
1 Sponge Iron Plant 158 - 140 298
2 SMS ( Induction Furnace) 90 90 225 405
3 Power Plant 216 173 151 540
4 Rolling Mill - - 200 200
5 Pellet Plant - - 400 400
6 Producer Gas Plant - - 350 350
7 Domestic uses 27 14 50 91
Total (in m3/d ) 491 377 1416 2284
Total (in MGD ) 0.108 0.082 0.311 0.502
4 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 06
6.4 Transport Link
The site is well connected with road and rail. Purulia is well connected with the industrial Belt of Raniganj & Asansol. The NH-2 only at 19 Km away from the plant site is passing south of the project site. The SH-5 connects Towns such as Adra, Sataldih, and Neturia & Raghunathpur is 5 km away from the project site. The site is 190 km away from Kolkata city. A number of private & government buses connect Purulia district with the rest of West Bengal and Jharkhand.
The nearest railway station Rukni is on North direction at 1 km away from the plant site. Damodar River is flowing only 9 Km away from the project site and the company draws water from Mautore Dam near Cheliyama under the irrigation & waterways Directorate, Govt of west Bengal/ DVRRC from Damdore river to meet its water requirement.
The connectivity of the site to the key logistic/raw material/utility centres has been tabulated below:
Connectivity Details
Rail The nearest railway station to the site is Rukini Station which is less than 1000m. Other railway stations in close proximity are Adra Railway Station (14 Kms), Purulia Railway station(30 Kms) and Asansol Railway Station (44 Kms). The Company is in very close proximity to Rukini Railways siding, which is being used for transportation of Raw materials and finished goods.
Road The plant is also closely connected with highway which provides easy and good transport connectivity. The NH-2 only at 19 Km away from the plant site is passing south of the project site. The SH-5 connects Towns such as Adra, Sataldih, and Neturia & Raghunathpur is 5 km away from the project site
Airport The nearest airport is Kazi Nazrul Islam Airport, Durgapur (60 Kms), Netaji Subhash Chandra Bose International Airport, Kolkata (218 Kms)
Town/ Cities The nearest Town/ Cities to the site are: Purulia – 30 Kms Asansol – 44 Kms
5 | of P a g e 5
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 07
7.0 ENVIRONMENTAL ASPECTS This chapter covers the genesis of pollution, principal sources of pollution, nature of pollution and proposed measures required for meeting the prevailing statutory requirements of gaseous emissions, waste water characteristics, noise level etc. for environmental management purpose in connection with the proposed expansion project. Pollution prevention and control measures are enumerated as below:
Genesis of Pollution: The genesis of industrial pollution can be assessed from the project concept described in earlier paragraphs. The specific aspects, which need to be looked into for assessing the pollution potential, are: (i) Physical-chemical characteristics of raw materials, (ii) Manufacturing technology involving a set of physical and chemical conversions of raw materials and lastly, (iii) The generation of all types of wastes, namely, gaseous, liquid and solid having specific characteristics.
The pollutants in the form of solids, liquids and gases that are expected to be generated from various Units of the proposed Sponge Iron Plant, Steel Melting Shop, Rolling Mill, and Captive Power Plant. Release of such pollutants without proper care may affect the environment adversely. Pollution of the environment not only adversely affects the human beings, flora and fauna but also shortens the life of the machinery and equipment. This vital aspect, therefore, has been taken into account while planning the plant and equipment and adequate measures have been proposed to limit the emission of pollutants within the stipulations of statutory norms. However, the proposed units excepting the captive power plant by and large are less polluting in nature.
7.1 AIR POLLUTION CONTROL Sources of air pollution can be broadly divided into two groups – process and non-process. Process emissions would be those which would be emitted during production/operation of the plant, while non-process emissions would be due to different material handling facilities. The main air pollutants from process emissions would be SO2, NOx and to some extent PM while for non-process emission the main pollutant would be PM.
1 | of P a g e 4
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 07
A number of systems have been proposed for air pollution control which will provide safe environmental conditions in the working area and will ensure acceptable air quality in the surrounding area of the steel plant. Different air pollution control facilities / equipments that would be considered include dry fog dust suppression systems, dust extraction systems, bag filters, ESP etc. Cleaned waste gases would be discharged through tall stacks to ensure adequate dispersion and dilution of pollutants. Captive Power Plant Contribution to air pollution would be from -
a) Particulate emission from the stack as a result of the combustion of Dolochar & Imported coal b) Ash particles due to their storage/ disposal and handling c) Sulphur dioxide d) Oxides of Nitrogen Particulate emission from the stack would be governed according to the Central Pollution Control Board Emission Regulation. Electrostatic precipitators having efficiency of 99.89% or better will achieve the limit of particulate emission below 50 mg/Nm3. As far as coal dust suppression is concerned, water spraying arrangement will be provided at suitable locations.
7.2 WATER POLLUTION CONTROL Waste water generated from the different areas of the plant will be treated to the desired extent in suitable treatment facilities and recycled back to the process, as far as practicable, facilitating adequate reuse of water in the respective recirculating systems and economizing on the make-up water requirement. Sewage generated from toilet blocks etc. shall be treated in septic tank-soak pit system. The water thus collected shall be used for dust suppression at raw material handling system, ash handling, landscaping etc. Thus, Water system will be designed for “Zero Discharge” wherein all discharges will be treated and reused in the plant. The proposed captive power plant will employ air cooled condenser which will drastically bring down the water requirement. The Boiler blowdown will be controlled to maintain system solids loading within normal limits for proper water chemistry. The effluent will have less than 100 ppm suspended solids and will be led into the station sump mix with other station effluents to reduce temperature and utilized for disposal of ash in slurry form.
2 | of P a g e 4
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 07
Surface run-off will be settled in a settling basin prior to reuse/ disposal.
7.3 SOLID WASTE MANAGEMENT Solid wastes that will be generated from IF are slag and dust. The hot slag generated from IF will be transferred to slag yard after cooling. IF slag will be used for road construction and land filling purposes. Dolochar from the existing & proposed Sponge Iron Plans will be used in AFBC boiler. Solid wastes that will be generated from caster are the scales. The scales will be collected from the drain and transferred to IF for reuse. The solid wastes from the rolling mill like end cuts and miss rolls, will be used in induction furnace. The fly ash generated from Captive Power Plant will be sold as a raw material for cement plants and brick manufacturing. The bottom ash from CPP will be used as land filling. Fly ash and bottom ash from ESP and Boiler furnace will be transferred by close pipes to two closed silos. From silos that ash will be transferred in closed trucks and then brought to cement and brick manufacturing.
7.4 NOISE POLLUTION CONTROL Noise generation will be considered while selecting equipment. Equipment would not generate noise more than 85 dB (A) at 1 m distance. Wherever required noisy equipment will be placed on vibration isolators or housed in a separate enclosure or surrounded by baffles covered with noise absorbing material. As the operator would be stationed in the control room, there will be minimum chance of exposure to high noise levels. However personnel working in high noise zones will be provided with personal noise protection equipments (e.g. ear muffs, ear plugs) and their duty hours will be regulated to control noise exposure levels.
7.5 FIRE PROTECTION SYSTEM In addition to the yard fire hydrant system, the fire protection systems envisaged for the plant are as follows: - Internal fire hydrant for storied buildings to be tapped-off from the outdoor fire water header. - Fire detection and alarm system for electrical rooms, cable basements/cellars, cable tunnels, selected oil/hydraulic cellars.
3 | of P a g e 4
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 07
- Portable fire extinguishers such as CO2, foam and dry chemical powder in all areas of the plant with fire hazard.
7.6 GREEN BELT DEVELOPMENT OBJECTIVE
To capture the fugitive emission, if any, from the plant and to attenuate the noise generated from the plant machinery and to improve the aesthetics of the plant site, a green belt will be developed within the plant area.
The green belt is a set of rows of trees planted in such a way that they form an effective barrier between the plant and the surrounding areas. Prevalent wind directions shall be taken into consideration to ensure adequate capturing of the air pollutants around the plant.
Open spaces, where tree plantation is not possible shall be covered with shrubs and grass. The plantations shall match with the general landscape of the area and be aesthetically pleasant. Adequate attention will be paid to planting of trees and their maintenance and protection. Out of the total plant area of 9.42 hectares (23.28 acres), 3.1 hectares (33% of the total area) shall be covered under Green Belt.
7.7 RAIN WATER HARVESTING It is proposed to achieve proper utilization of rain water by harvesting through rain-water harvesting mechanism in the plant area. Rain water harvesting will be done following the guidelines of the concerned Authority.
4 | of P a g e 4
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 08
8.0 MANPOWER REQUIREMENT
Operation and maintenance of the proposed expansion project requires human resources in different categories like managers, engineers of different discipline like metallurgical, mechanical, electrical, electronics, computer, civil, structural, chemical, etc., highly skilled, skilled and semi-skilled work force in different disciplines, commercial, accountants and financial managers, unskilled labour force, clerical, security personal, etc.
Factory human resources In order to operate and maintain the plant facilities, including its technical and general administration needs, the manpower requirement for the proposed project has been estimated to be 490 persons.
The above estimate covers the top management, middle and junior level executives and other supporting staff. Further approx. 1100-1200 manpower shall be required which may be unskilled/semi skilled or contractual Labours
The tentative requirement of man power in different disciplines for the proposed project is given below.
Manpower with new Proposal
SL Grade Existing New Proposal Total 1 ITI Trained 32 60 92 2 Diploma Engineer 16 30 46 3 Graduate Engineer 12 20 32 4 B.Sc. / M.Sc. 12 20 32 5 Commerce Graduate 12 20 32 6 Graduate 15 30 45 7 Others 71 140 211 8 Unskilled/Contractual 500 680 1180 Total 670 1000 1670
Since the proposed site is located in close proximity of the industrial sectors, like Durgapur, Bokaro, Jamshedpur, Dhanbad & Asansol etc, availability of skilled labour will not pose any problem.
Apart from the above direct employment, Indirect Labourers will be required which is easily available in Purulia and Asansol area
1 | of P a g e 1
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 09
9.0 PROJECT PERIOD
The installation of several production units along with utilities and services require co-operation for procurement of equipment, equipment foundations, awarding of all contracts and supervision of all construction jobs at plant site. The factors which are responsible for timely implementation of the project are : i) Arrangement of proper finance for the project. ii) Finalization of layout of the proposed plant. iii) Designing of utilities and services. iv) Placement of orders for plant and machinery. v) Arrangements for Govt. sanctions and supply of power. vi) Recruitment of personnel.
As per an initial estimate around 36 months will be needed for implementation of the project.
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 10
10.1 ESTIMATED COST As per initial estimate, the cost of the project works out to around ₹ 475 Crores.
SL Particulars of facilities Capacity Project Cost
1 Pellet Plant with grinding 5600 TPD ₹ 320 Crores Facilities (2 X 0.85 MTPA)
2 Producer Gas Plant 48000 Nm3/hr ₹ 25 Crores (12X 4000 Nm3 /hr) Coal Base
3 Sponge Iron Division 350 TPD ₹ 60 Crores (1 X 350 TPD)
4 SMS through Induction Furnace 750 TPD ₹ 25 Crores with CCM (3 x 25 T)
5 Power Plant 7 MW ₹ 20 Crores (WHRB based from 350TPD)
6 Rolling Mill(from 600TPD to 400 TPD ₹ 25 Crores 1000TPD)
Total cost of proposed expansion project ₹ 475 Crores
10.2 COMMERCIAL & FINANCIAL FEASIBILITY EVALUATION The focus of proposed expansion project is cost reduction by producing quality material as per the required specification. There will be complete integration right from the beginning to finished products. . The estimated cost of the project is expected to be around ₹ 475 Crores. There will be substantial savings due to the said project as company will also be eligible for various incentives. The company has a good track record of implementing and commissioning capital for the proposed project as per schedules. The total project is expected to be commissioned over a period of 36 months in phased manner. The benefit from the project planned will begin to be acquired from year one only.
1 | of P a g e 1
Bravo Sponge Iron Pvt. Ltd. Chapter Project Feasibility Report for Expansion project 11
16.0 CONCLUSION
Here we have examined the feasibility of the expansion project from 3 angles, which is the backbone of any project to succeed -
Environmental feasibility Commercial and financial feasibility and Pre and post project scenario in which company will operate.
The outcome shows that results are positive which indicate a positive feasibility.