VIKKRAM PRIVATE LIMITED Badtumkela, Rajamunda, Banei, Lahunipara, Sundargarh, Odisha

TECHNO ECONOMIC FEASIBILITY REPORT for 72,000 TPA DRI, 0.85 MTPA Beneficiation Plant, 0.6 MTPPA Pellet Plant, 0.12 MTPA SMS, MTPA Rolling Mill and 10 MW Power Plant

of VIKKRAM PRIVATE LIMITED Badtumkela, Rajamunda, Banei, Lahunipara, Sundargarh, Odisha

Prepared by

GLOBAL TECH ENVIRO EXPERTS PVT. LTD. C-23, BJB NAGAR BHUBANESWAR-751014 PH. NO.-06742433487 Email:- [email protected] Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

TABLE OF CONTENTS

CHAPTER-1 ...... 2 EXECUTIVE SUMMARY ...... 2

1.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT ...... 2 1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...... 2 1.3 RAW MATERIAL ...... 3 1.4 PRODUCT ...... 3 1.5 WATER REQUIREMENT ...... 3 CHAPTER-2 ...... 6 INTRODUCTION OF THE PROJECT ...... 6

2.4 GLOBAL STEEL SCENARIO: ...... 8 2.5 DOMESTIC STEEL SCENARIO: ...... 9 2.6 EMPLOYMENT GENERATION DUE TO PROJECT ...... 10 CHAPTER-3 ...... 11 PROCESS DESCRIPTION ...... 11

3.1 LOCATION OF THE PROJECT ...... 11 3.2 DETAILS OF ALTERNATE SITES ...... 13 3.3 SIZE OR MAGNITUDE OF OPERATION ...... 13 3.4 PROCESS DESCRIPTION ...... 14 3.5 RAW MATERIAL INVENTORY ...... 24 3.6 RESOURCE OPTIMIZATION /PROCESS FLOW SHEET ...... 26 3.7 WATER REQUIREMENT ...... 27 CHAPTER-4 ...... 31 SITE ANALYSIS ...... 31 CHAPTER-5 ...... 34 PLANNING BRIEF ...... 34 CHAPTER-6 ...... 36 PROPOSED INFRASTUCTURE ...... 36

6.6 MAN POWER REQUIREMENT ...... 39 CHAPTER-7 ...... 40 REHABILITATION & RESETTLEMENT (R&R) ...... 40 CHAPTER-8 ...... 41 PROJECT SCHEDULE & COST ESTIMATES ...... 41 CHAPTER-9 ...... 42 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ...... 42

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-1 EXECUTIVE SUMMARY

1.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

M/s Vikram Pvt. Ltd. has existing Integrated Steel Plant at village- Badtumkela in the district of Sundergarh, Odisha. The project is located at latitude 210 50’ 17.66’’ N and longitude 840 55’ 38.61’’ E.

Vikram Private Limited was incorporated in the year 2000 under the name and style of M/s Masco Plexus Private Limited with the aim of manufacturing value added steel products. The company was renamed M/s Vikram Private Limited in the year 2002 & in the year 2006.The company undertook its first manufacturing activity by setting up a Direct Reduced Iron (DRI) plant with 2 numbers of 100 tons per day capacity kilns at Bad Tumkela in the district of Sundargarh, Odisha.The total plant is running under the coordination of Mr. Dibyaranjan Behera, Director addressed by House No. S3/H1-2, Kalinga Vihar, Chhend colony, Rourkela, 769015. The address of the correspondence is at 2A Ganesh Chandra Avenue, Commerce House, 5th Floor, Room No.10 B, Kolkata-700 013, India.

1.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The plant has existing only two nos. of 100 TPD DRI producing 66,000 TPA sponge iron. It has already obtained Environmental Clearance for the backward integration of Beneficiation plant & pelletization plant of 0.85 MTPA & 0.6 MTPA respectively with 10MW power plant.

Now, the company wants to get the Environmental Clearance for enhancing the DRI production to 72,000 TPA, 0.12 MTPA Induction Furnace with CCM & LRF and 0.1 MTPA Rolling mill to produce TMT bar for sale with 10 MW power plant in Phase-1, 0.25 MTPA Pellet plant in Phase-2 and 0.85 MTPA beneficiation with 0.35 MTPA pellet plant in Phase-3.

 This was a DRI unit going for an integrated Steel plant with backward integration of beneficiation and pelletization and forward integration of IFCCMLRF and Rolling mill.

 Due to the existing demand of steel product and pricing structure for raw material, at present the forward integration is given importance for sustainability of the project.

 On the next phase the backward integration will be implemented to make the integrated steel plant scalable.

 For the total project land requirement along with solid waste management & greenbelt development is 102 acres, all of which has been duly acquired & in possession of the company.

 Public appraisal has been completed for the total land earlier with beneficiationpelletizationDRI units with 10 MW power plant using DRI waste heat & dolo char with minimum washed coal.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

The proposed backward & forward integration plants to be set at the existing plant site. So, no alternate site is chosen.

1.3 RAW MATERIAL

Required Raw materials are Iron Ore Lumps, Iron Ore Fines, Dolomite/Lime, Bentonite, non-Cokng Coal, Coke, MS Scrap, Pig Iron, Lime, Gypsum & Sand. Most of raw materials are available locally, in the state of Orissa. Hence procurement of these raw materials for the proposed expansion does not seem to have any problem for setting up the expansion project. Iron Ore will be sourced from near by mines of Koira, Keonjhar, Joda and Barbil area. Coal will be purchased from MCL, Dolomite will be sourced from Rajgangpur/ Biramitrapur.

Most of the raw material shall be received by road. Separate store yard for the major raw materials such as iron ore and coal exists.Transports will be done by the environmentally compliant trucks. Some raw materials & products will be done by train also. Bharat-III/ Euro-III trucks will be used in the transportation system. The raw materials & products shall be covered fully during the transportation to avoid spillage & fugitive emissions on the road.

Separate store yard for the major raw materials such as iron ore and coal will be provided. The material shall be unloaded manually from the trucks in the stock yard. The yard shall have provision to store around one months’ stock of material.

1.4 PRODUCT

The product-mix shall be 72,000 TPA sponge iron, 6,00,000 TPA iron ore pellet, 1,25,000 TPA billet and 1,00,000 TPA long steel products.

1.5 WATER REQUIREMENT

The source of water for the present plant is underground water. The existing plant requirement is 205 cum/ day including domestic consumption. The total water requirement for the proposed project shall be around 2976 cum/ day.

1.6 ENERGY/POWER REQUIREMENT

Fuel

Major fuel required is about 18000 KL/ year of Furnace Oil. About 300 KL/year of LDO will be required for line flushing.

Power

The total load of the proposed project is about 30 MW which shall be met partly through own captive power plant 10 MW and balance 20 MW from the state grid.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

1.7 WASTE MANEGEMENT

Solid Waste Management

Total quantity of solid waste generation will be 1,46,525 TPA, from which some will be recycled in Induction Furnace & DRI and others are used as law land filling material.

Waste Water Management

There will not be any waste water from the process. The slime from washing screen will be sent to a settling pond and dewatered. The water will be recycled back. The product slurry from Ball Mill will be passed through the filter press and concentrate cakes will be sent to the Concentrate Bin. The filter water will be recycled back. The waste water from canteen and office toilets will be sent to a soak pit.

1.8 CONNECTIVITY

The site is located at village Bad-Tumkela under Lahunipara police station of Sundargarh district in the State of Orissa. The location is well connected with road and rail. The NH- 23 is passing only at 2 Km away from the proposed site. The site is 47 Km distance from the Rourkela town. The nearest railway station Barsuan Railway station is about 20 Km away from the plant site. Brahmani River is flowing only 1.2 Km away from the project site and the company will draw water from the river to meet its water requirement. The site is well connected to the basic raw material source like coal & iron ore. The company will meet the coal & the iron sourced from Koira & Joda in Odisha.

1.9 TOPOGRAPHY

Geographically, the district Sundergarh is not a compact unit and consists of widely, dissimilar tracts of expansive and fairly open country, inaccessible forests, river valley and mountainous terrain. Broadly it is an undulating table-land of different elevations broken up by rugged hill ranges and cut off by torrential hill streams and the river Brahmani. The study area requires data regarding topography, zoning, settlement, industry, forest, roads and traffic etc. the collection of this data was done from Survey of India Toposheet No is 73 C/13. The site is situated at an altitude of 240 m above MSL. The general slope of the district is from North to South. There is an open well-cultivated plain country land along the valley of the Brahmani River particularly in the south direction. The highly populated area is Boneigarh and Rajamunda and Parts of the South direction Dharanidhar Palli RF, East direction Amarurhi RF are coming within the 10 km buffer zone project area.

Secondary information on meteorological conditions has been collected from the nearest IMD station at Jharsuguda and IMD Book (1970-2000). Predominant wind direction is NE.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

1.10 LAND DETAILS & EXISTING INFRASTRUCTURE

The total land available for the proposed project is about 102 acres from which 94.5 Acres of land already been acquired & quantity of land to be acquired is 7.5 Acres.

The growth of industrial sectors in 2x100 TPA DRI Plant, Office Building, Machine shop, Canteen, Material Handling Facility of the existing infrastructure developments.

1.11 PERIPHERAL DEVELOPMENT PLAN

M/s Vikram Private Limited will make sincere efforts to improve the socio-economic status of the local habitants. A welfare scheme will be prepared by the company for the socio economic development of the area. The scheme will envisage promotion of education in the adjoining villages by giving aid to the local schools, providing drinking water facility and organizing health check up programmes. The progress of the scheme will be reviewed periodically and further action will be taken as deeming fit.

1.12 GREENBELT DEVELOPMENT

In order to contain the air emission and also to improve the plant aesthetic, the company proposes to develop greenbelt, landscaping and avenue plantation for which about 32 acres of land will be earmarked in the layout of the proposed expansion project which is about 31% of total land.

1.13 POLLUTION CONTROL MEASURES

For air pollution control: Water sprinkler, bag filter , ESP & Stacks will be used.

For waste water treatment: ETP, settling Tank etc.

1.14 MAN POWER REQUIREMENT

The total man power requirement for plant operation on completion of the proposed expansion will be around 954. The details are tabulated below.

1.15 PROJECT COST

The cost of the project is estimated to be around Rs. 450 Crores.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-2 INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

The company profile of M/s Vikram Pvt. Ltd. (VPL) is as follows:

 Vikram Private Limited was incorporated in the year 2000 under the name and style of M/s Masco Plexus Private Limited with the aim of manufacturing value added steel products.

 The company was renamed M/s Vikram Private Limited in the year 2002 & in the year 2006.

 The company undertook its first manufacturing activity by setting up a Direct Reduced Iron (DRI) plant with 2 numbers of 100 tons per day capacity kilns at Bad Tumkela in the district of Sundargarh, Odisha.

 The operation of the plant has been satisfactory over these years.

 The total plant is running under the coordination of Mr. Dibyaranjan Behera, Director addressed by House No. S3/H1-2, Kalinga Vihar, Chhend colony, Rourkela, 769015. The address of the correspondence is at 2A Ganesh Chandra Avenue, Commerce House, 5th Floor, Room No.10 B, Kolkata-700 013, India.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

 This was a DRI unit going for an integrated Steel plant with backward integration of beneficiation and pelletization and forward integration of IFCCMLRF and Rolling mill.

 Due to the existing demand of steel product and pricing structure for raw material, at present the forward integration is given importance for sustainability of the project.

 On the next phase the backward integration will be implemented to make the integrated steel plant scalable.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

 For the total project land requirement along with solid waste management & greenbelt development is 102 acres, all of which has been duly acquired & in possession of the company.

 Public appraisal has been completed for the total land earlier with beneficiationpelletizationDRI units with 10 MW power plant using DRI waste heat & dolo char with minimum washed coal.

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION

TMT rod and bar products are normally used in constructional/structural work and Rolled plates are used in manufacture of equipments and house hold uses and so products have demand for development of the country.

Steel is a basic commodity for all industrial activity and its consumption marks industrial prosperity. The steel industry has tremendous forward and backward linkages in terms of material flow, income and employment generation.

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.

It has been estimated by certain major investment houses such as Credit Suisse that India’s steel consumption will continue to grow at 16 % rate annually fuelled by demand for construction projects worth US $1 trillion. The scope for raising the total consumption for steel is huge, Per capita consumption of steel at current levels is about 65 kg. As a comparison per capita steel consumption in China is 430 kg and the world steel consumption per capita average is 180 kg.

By 2020-21 the demand at 7 % and 8 % GDP growth is estimated to be 123 million tons and 137.5 million tons respectively. Taking a mean figure of 130 million ton, there is a need of 65 million ton in 10 years time. This translates into an average growth requirement of about 10 million tons per year.

Ministry of steel has projected that steel capacity in the country is likely to be 124.06 million tons by 2011-12. Further based on the status of MOUs signed by private producers with various State Govt., it is expected that India’s steel capacity would be nearly 293 million tons by 2020.

The present investment plan of Vikram Pvt. Ltd. relates to backward as well as forward integration projects. Backward integration is expected to ensure easy availability of its main feed stock, namely iron ore in pelletalized form. It will be a substitute to scarce high grade iron ore lumps.

The company will be able to establish direct link with the ultimate consumer with the help of forward integration.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Undoubtedly the development of this industrial project will give rise to the production of finished products like construction material which is in demand. In the meanwhile generation of various wastes would also take place from the project and there by environmental degradation is anticipated. However the use of advanced technology and proper management, planning and application of meticulous Environment management plan, shall substantially reduce environmental problems and the project shall becomes acceptable as it leads to socio-economic development of the region.

2.4 GLOBAL STEEL SCENARIO:

Steel is a key driver of the world's economy. The industry directly employs more than two million people worldwide, with a further two million contractors and four million people in supporting industries. In 1950-India and China had same level of per capita consumption of steel. But then India remained mostly stagnant whereas China went about Industrialization and increased its production as well as consumption. However India improved between 1997 to 2003, but steel then per capita steel has remained very low in comparison to China.

In 2007 World steel output reached 1343.5 million metric tons and showed a growth of 7.5% over previous year.

China remained World’s largest crude steel producer in 2007 producing 489.00 million metric tons and USA 97.20. India occupied 5th position producing 53.10 million metric tons for the second consecutive year.

 In 2013 the world crude steel production reached 1606 million tons and showed a growth of 3% over 2012. (Source: World Steel Association or WSA)  China remained the world’s largest crude steel producer in 2013 (779 mt) followed by Japan (111 mt), the USA (87 mt) and India (81 mt) at the 4th position.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

 WSA has projected Indian steel demand to grow by 3.3% in 2014 as compared to global steel use growth of 3% and Chinese growth of 3.1%. For 2015, further recovery is projected for world (3.3%) and India (4.5%) and a slowing down for China (2.7%).  Per capita finished steel consumption in 2013 is estimated at 225 kg for world and 515 kg for China.

2.5 DOMESTIC STEEL SCENARIO:

 The Indian steel industry has entered into a new development stage from 2007-08, riding high on the resurgent economy and rising demand for steel.

 Rapid rise in production has resulted in India becoming the 4th largest producer of crude steel and the largest producer of sponge iron or DRI in the world.

 As per the report of the Working Group on Steel for the 12th Plan, there exist many factors which carry the potential of raising the per capita steel consumption in the country, currently at 59.2 kg. These include among others, an estimated infrastructure investment of nearly a trillion dollars, a projected growth of manufacturing from current 8% to 11-12%, increase in urban population to 600 million by 2030 from the current level of 400 million, emergence of the rural market for steel currently consuming around 10 kg per annum buoyed by projects like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas Yojana among others.

 At the time of its release, the National Steel Policy 2005 had envisaged steel production to reach 110 million tons by 2019-20. However, based on the assessment of the current ongoing projects, both in Greenfield and Brownfield, the Working Group on Steel for the 12th Plan has projected that the crude steel steel capacity in the county is likely to be 140 mt by 2016-17 and has the potential to reach 149 mt if all requirements are adequately met.

 The National Steel Policy 2005 is currently being reviewed 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 since the release of the Policy in 2005.

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. While the existing units are being modernized/expanded, a large number of new steel plants have also come up in different parts of the country based on modern, cost effective, state of-the-art technologies. In the last few years, the rapid and stable growth of the demand side has also prompted domestic entrepreneurs to set up fresh Greenfield projects in different states of the country.

Crude steel capacity was 102 mt in 2013-14 and India, the 4th largest producer of crude steel in the world, has to its credit, the capability to produce a variety of grades and that too, of international quality standards. The country is expected to become the 2nd largest

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha producer of crude steel in the world by 2015-16, provided all requirements for creation of fresh capacity are adequately met.

Further based on the status of MOUs signed by private producers with various State Govt., it is expected that India’s steel capacity would be nearly 293 million tons by 2020.

[Source: Ministry of Steel]

2.6 EMPLOYMENT GENERATION DUE TO PROJECT

The project will plan to give more employment opportunities to skilled & unskilled workers by Direct & Indirect Employment. The total man power requirement for plant operation on completion of the proposed expansion will be around 954. Rather than those some contractual workers are to be employed for the construction & operational phase.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-3 PROCESS DESCRIPTION

3.1 LOCATION OF THE PROJECT

The project site is located at Badtumkela, Banei, PS- Lahunipada, via- Rajamunda, Sundergarh, Odisha with coordinates of Latitude & longitude of 210 50’ 17.66’’ N 840 55’ 38.61’’ E respectively.

Fig 3.1: Site Location Map

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Fig 3.2: Satellite imagery of location-Vikram Iron & Steel Pvt. Ltd.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Fig 3.3: Project Site Layout

3.2 DETAILS OF ALTERNATE SITES

The proposed backward & forward integration plants to be set at the existing plant site. So, no alternate site is chosen.

3.3 SIZE OR MAGNITUDE OF OPERATION

The proposed modification cum expansion project will be recommended at the existing plant premises of 102 acres of land with450 crore of total project cost.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

3.4 PROCESS DESCRIPTION

M/s Vikram Private Limited has an existing running unit producing DRI for sale. The Project Proponent now proposes expansion of this unit to enhance the capacity of the unit by backward and forward integration. Project configuration and product mix has been given below.

Table 3.1: PROJECT CONFIGURATION

SL NO FACILITY CONFIGURATION CAPACITY PRODUCT ENDUSE

Existing 1 DRI kiln 2x100 TPD 66,000 TPA Sponge Iron Use in IF Expansion cum Modification Phase-I 1 DRI kiln 2x100 TPD 72,000 TPA Sponge Iron Use in IF 2 SMS (IF & LRF 2 X 12 T IF 1,20,000 TPA Hot Billet & Use in IF & for with CCM) 1X30 T LRF Cold Billet Sale 2 Strands 3 Rolling mill 0.1 MTPA 1,00,000 TPA TMT Bar For sale 4 WHRB 2 MW 2 MW Power Use in Own plant 5 AFBC 2X4 MW 8 MW Power Use in Own plant Phase-II 1 Pelletisation 0.25 MTPA 2,50,000 TPA Pellet Use in DRI Phase-III 1 Beneficiation 0.85 MPTA 8,50,000 TPA Beneficiated Use in Pellet Iron Ore plant 2 Pelletisation 0.35 MTPA 3,50,000 TPA Pellet Use in DRI

3.4.1 Dri Kiln The existing capacity of DRI will not change but the company is planning for enhancing the production capacity from 66,000 TPA to 72,000 TPA. Process optimization in the DRI plant is done by maximizing production with minimum consumption of iron ore and coal. Coal is used as the source of heat energy as well as the source of CO gas required for removal of oxygen from iron ore (i.e. iron oxide) at 1050 deg. Celcius. Process parameters like temperature, gas pressure and gas flow volume are controlled with the help of PLC. It has been proposed to set up a WHRB Power Plant to recover waste heat from DRI flue gas. Solid Waste generated from DRI kilns in the form of Char shall be used as fuel in the proposed power plant project.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

3.4.2 Benificiation Process

To meet the input requirement of the pellet plant, it is proposed to set up an beneficiation plant having a throughput capacity of 8,50,000 tons/year. It will produce 6,00,000 tonnes of concentrate in a year. The average grade of iron ore fines (-10mm) will be Fe (total):58-62%, SiO2 & Al2O3:10%, which will be beneficiated to produce ore concentrate of average quality about 64% Fe(total). The concentrate so produced will be pumped to the pellet plant. 7.2 OPERATING REGIME The operating regime for the proposed beneficiation plant: Working days per year 330 Number of hours per shift 8 Number of shifts per day 3 Number of effective hours per day 24.

Feed and Product Quality

Quality requirement for iron ore concentrate production : Input – Iron Ore Fines ROM feed quantity : 850,000 t/yr. Particle Sizes < 10 mm Fe % 58-62 % Bulk Density 2.26 t/m3 Product – Iron Ore Concentrate Production Quantity : 6,00,000 t/yr Particle Size : - 300 mesh

Fe (total) : 64%

Process Flow

Beneficiation process mainly involves grinding of iron ore and separation of gangue to the extent possible within the required operational limits. Grinding of ore can be done in two alternatives viz. wet grinding and dry grinding. In view of the requirement of slurry transport, wet grinding system is a preferred option. It is envisaged that the beneficiation process will consist of primary grinding, hydrocycloning, two stage spiral classification, single stage high gradient magnetic separation, regrinding and thickening of concentrate received from both spirals and magnetic separators. The thickened concentrate at approximately 64% solids by weight will be pumped to storage tank. Tailings from the beneficiation plant will be transported through pipeline and discharged to a tailing pond. Iron ore fines from Koira & other sectors of Odisha will be transported by Road to the Beneficiation plant. Iron ore fines from the stockpile will be transported to silos and distributed with the help of a shuttle conveyor. The ball mill's discharge is pumped to hydro cyclone clusters. The over flow from the cyclone is sent to slime thickener. The cyclone under flow is fed to a bank of rougher spirals. The concentrate from the rougher spirals will be processed in cleaner spirals.

The tailings from the rougher and cleaner spiral are fed to intermediate slime thickener. The concentrate from cleaner spiral are pumped to secondary hydro cyclone. The under flow from secondary cyclone are fed to regrinding mills for further grinding to the required product size whereas the over flow from the cyclone is fed to concentrate thickener. The under flow from the concentrate thickener is pumped to two slurry storage tanks and from there it is pumped to filter cake machine. The under flow from intermediate slime thickener is pumped to a linear screen. The over size from the screen is feed to primary grinding mill.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

The under size from the screens is fed to High Gradient Magnetic Separator (HGMS) for recovery of concentrate from slimes. The concentrate from HGMS is further ground in the same regrinding mill, which is close circuited with secondary hydro cyclone. The concentrate over flow from hydro cyclone is thickened in concentrate thickener before pumping to slurry storage tanks provided with agitators. The tailing from HGMS is fed to a tailing thickener. The tailing thickener underflow is pumped to a tailing pond. The overflow from the tailing thickener is sent to process water tank for re-circulation in the process. Slime generated from the process is 1,97,494 TPA.

Service facilities

Beneficiation plant will be provided with the following facilities for smooth operation. i.) Water supply facility Make up water will be supplied at the rate of 31 m3/hour. Inside the plant there will be a storage facility. From the storage tank the pumping & water distribution systems has been proposed to cater the need of water on all screens and sumps. ii.) Electrical facility The power requirement of 1500 kW will be sourced from the centralized Power Supply System and will be connected to the MCC room. From there the power will be distributed to all drives & motors. iii.) Instrumentation & telecommunication facility

The entire beneficiation plant from the material feeding system to the product storage will be interlocked and operated from the control room by PLC. Proper instrument controls like density control, pressure gauge, weightometer etc have been envisaged for smooth running of the plant.

Fire detection & alarm system The plant will have microprocessor based analog addressable type automatic fire detection and alarm system comprising of detectors, fire alarm panel, manual call points etc.

AC & ventilation system To ensure the proper working environment for men and machines and to maintain necessary environmental conditions adequate ventilation, air conditioning & dust suppression system have been envisaged.

Computerization facility For greater visibility into operations and improve day to day high level information among the shop/offices an off line computer and data communication system has been proposed for the plant. The proposed system will cover key functions and operation of plant that enables the management to exercise better control over the resources.

Repair, maintenance & store facility To cater the day to day repair and maintenance need of plant and conveying system, a field repair shop with stores have been envisaged in plant however the major maintenance of the equipment will be carried out by the centralized work shop.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

3.4.3 Pelletization

Discharge from each intermediate bin is controlled by electronic weigh feeder. The charging is done automatically in accordance with a pre-set time schedule. The green pellets are formed in the discs with a diameter of 6mm~16mm. The inclination of each disc is variable and optimum setting is determined according to mixed material properties, green ball size and feed-rate. The rotary speed of the disc is also varied during operation by means of frequency-controlled motors. The green pellets are discharged onto a reversible belt conveyor. The material is recycled in exigency and also during start–up when the green pellets do not have the required properties. During normal operation the green pellets are discharged to the collecting belt conveyor. A belt weigh feeder is used for mass balancing and serves as a standby signal for the speed control of the induration machine. Green pellets are distributed onto the wide belt conveyor by the reciprocating head of belt conveyor.

The wide belt conveyor discharges the green pellets onto the double deck roller screen which consists of an upper and a lower roller deck. The upper deck screens out oversize green pellets (> 16 mm) and the lower deck screens out undersize green pellets of < 6 mm. Green pellets of size range 6 – 16 mm are evenly distributed over the width of the pallets of the induration machine. Undersize and oversize green pellets are recycled by belt conveyors back to the green pelletizing area. Belt weigh feeders measure the generation quantity of under and over size green pellets.

Drying of Green Pellets

Green pellets in the travelling grate are gradually heated and hardened over a period of 30 minutes. Uniform bed height is maintained to get consistency in quality. It is ensured by automatic control of grate speed though ultrasonic level measuring.

Induration of Pellets

Dry pellets are transferred to a rotary kiln for induration. The retention time is around 30 minutes and induration temperature is 1300 deg.C.

Cooling of Pellets

Hot pellets are passed through an annular cooler where it exchanges heat with cold air.

Product Screening & Storage

The indurated and cooled pellets are discharged from the annular cooler into the discharge bin, mounted on load cells. The product belt conveyors are equipped with a water spray system, which is used to cool down hot pellets > 120 0 C in case of emergency only. Undersize pellets are screened out for recycling in the plant. A sampler is installed in the discharge chute of product conveyor for laboratory analysis and quality control.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Pellet Plant Unit-1

It is envisaged that the proposed Pellet Plant Unit-1 will be of Grate-Kiln-Cooler technology with an annual production capacity of 2,50,000 TPA. It consists of iron ore fines drying, dry grinding, mixing, pelletisation, induration, cooling, product screening & storage systems. The operating period of the plant will be 300 days per year.

Plant & Process Description

The process utilizes iron ore fines by agglomeration to be used in blast furnaces and dri kilns. The manufacturing process is divided into eight stages:

1. Iron ore drying 2. Dry grinding 3. Mixing with additives 4. Pelletization 5. Drying of green pellets 6. Induration 7. Cooling 8. Product screening & storage

Iron Ore Drying

Iron ore fines with minimum 62% Fe(total) grade, max.14% moisture content in the size range of 0~10mm is fed into rotary dryer. It acts as a heat exchanger. Moisture content is brought down to less than 2% level.

Mixing

All the additives are electronically weighed and fed to the intensive mixer machine. There is also controlled addition of process water and recycled filter dust. The moisture content of the material is kept in the range of 9–10 %.

The mixed material is conveyed to the mixed material bins, installed directly above the discs.

Pellet Plant Unit-2 with Beneficiation

It is envisaged that the proposed Pellet Plant Unit-2 facilities shall be of grate-kiln technology of annual capacity of 3,50,000 TPA. It shall consist of mixing, pelletisation, induration, cooling, product screening and storage. The operating period of the plant will be 300 days per year.

Plant & Process Description

This is an iron-ore pelletising plant for a capacity of 3,50,000 TPA. The process utilizes iron ore concentrate by agglomeration to be used in blast furnaces and dri kilns.

The manufacturing process is divided into six stages: 1. Mixing with additives 2. Pelletization

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

3. Drying of green pellets 4. Induration 5. Cooling 6. Product screening & storage

Mixing & Pelletising

All the additives are electronically weighed and fed to the intensive mixer machine. There is also controlled addition of recycled filter dust. The moisture content of the material is kept in the range of 9–10 %. The mixed material is conveyed to the mixed material bins, installed directly above the discs.

Discharge from each bin is controlled by electronic weigh feeder. The charging is done automatically in accordance with a pre-set time schedule. A control loop, governed by the filling degree of the bins, is superimposed on this schedule for determining the destination of feed. The bins filling degree is measured by load cells. The green pellets are formed in the discs with a diameter of 6mm~16mm. The inclination of each disc is variable and optimum setting is determined according to mixed material properties, desired pellet size and feed-rate. The rotary speed of the disc is also varied during operation by means of frequency-controlled motors. The green pellets are discharged onto a reversible belt conveyor. The material is recycled in exigency and also during start–up when the green pellets do not have the required properties. During normal operation the green pellets are discharged to the green pellet collecting belt conveyor. A belt weigh feeder is used for mass balancing and serves as a standby signal for the speed control of the induration machine. Green pellets are distributed onto the wide belt conveyor by the reciprocating head of belt conveyor. The wide belt conveyor discharges the green pellets onto the double deck roller screen which consists of an upper and a lower roller deck. The upper deck screens out oversize green pellets (> 16 mm) and the lower deck screens out undersize green pellets of < 6 mm. Green pellets of size range 6 – 16 mm are re-rolled on the lower deck and evenly distributed over the width of the pallets of the induration machine.

Undersize and oversize green pellets are recycled by belt conveyors back to the green pelletizing area. Belt weigh feeders measure the quantity of under and over size green pellets.

3.4.4 Power Plant Facility

Co-generation of power in Coal based Sponge Iron Plants is very common these days. The waste heat of a sponge iron kiln can be effectively utilized in steam generation which in-turn can generate power. The total off-gas from the DRI kilns shall be around 60,000 Nm3/hr at a temperature of about 950-1000 °C. The same is proposed to be utilized to produce 4 MW of power. The waste char generated from the DRI Plant along with the purchased coal fines will also be utilized in generation of about 8 MW of power using AFBC Boiler.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

WHRB Boiler Based Power Plant

The proposed plant will comprise the following major system.

i. Waste Heat recovery steam generation plant and auxiliaries. ii. Steam turbine generator. iii. De-aerator and feed water system. iv. Electrics. v. Water supply system. vi. Instrumentation and controls. vii. Ash handling system. viii. Compressed air system. ix. Fire fighting. x. Tele-communication.

Waste Heat Recovery Boiler The waste heat recovery steam generation plant will comprise of two no of natural circulation semi-outdoor type twin drum waste heat boiler & its auxiliaries .The salient technical particulars of the boiler are given as follows.

The steam generation capacity of the boiler shall be 10 TPH each. The stream shall be generated at 42 ata and 420+ 5°C The boiler will be complete with evaporator steam drum, bank of super heaters economizer, air heater, air fans, ESP, internal piping etc. soot blowing and super heater will be also provided. The exhaust gases will be discharged in to atmosphere through existing ID fan and chimney. The Pressure drop in the boiler ducts and ESP will be kept to match with the requirement of existing fan .The boiler will be of semi out door type with a weather canopy and side covering of trapezoidal corrugated steel sheets.

AFBC Power Plant

It is proposed to install one 20 TPH Fluidized bed boiler for power generation. Char and coal fines shall be used as fuel for AFBC. Specifications for Fluidized Bed Boilers: Type of Boiler: Bi/Single Drum Top/Bottom Supported Natural circulation, Balance draft Furnace with atmospheric fluidized Bed combustion. Capacity & No. of Boilers : 2 × 20 TPH Steam Generating Capacity : 42 ata (at MSSV outlet) an 420+5°C Feed water temperature : 126°C for MCR at Economizer inlet. The boiler will be complete with evaporator steam drum, bank of super heaters economizer, air heater, air fans, ESP, internal piping etc. soot blowing and super heater will be also provided.

The exhaust gases will be discharged in to atmosphere through existing ID fan and chimney. The Pressure drop in the boiler ducts and ESP will be kept to match with the requirement of existing fan .The boiler will be of semi out door type with a weather canopy and side covering of trapezoidal corrugated steel sheets.

Annual Requirement of Raw Material The AFBC Boiler shall be designed to utilize char and coal fines. The annual requirement of raw materials for AFBC Power generation is as tabulated in the Table.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Annual Requirement of Raw Materials

Sl No Raw Material Total Qty, t/yr 1 Char 40,000 2 Coal Fines (purchased) 50,000

The specification of fuel is tabulated below.

Specification of Fuel for AFBC Boilers

Proximity Analysis Coal Fines Char Fixed Carbon 22 -25 % 18 -21% Volatile Matter 28- 32% 2 – 5 % Ash Content 40 -50 % 65– 70% Moisture 8%~12% - Average GCV Kcal/kg 3,000 1600

Steam Turbine generator

The board description of the 10 MW steam turbine generator envisaged are indicated below: The Steam turbine will be single, Horizontal, Singled bleed 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 42 ata and 420+5°C at emergency steam valve inlet is provided.

Deaerater and feed water system There will be a deaerator with feed tank. 2 numbers 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 ash handling, EOT crane, telecommunication, air conditioning and ventilation shall be adequately envisaged.

Details of Ash Handling and disposal: Ash Handling: The quantum of ash generation would depend on the plant load factor and the quality of coal being fed. Considering average ash content of 40% in coal fines and 80% ash in char about 52,000 tons per day of ash will be generated from power plant. Ash handling plant system design would be based on above estimated figures and bottom and fly ash equipment parameters would be guided by the following;  Bottom Ash generation(@64 % of total ash) : 32,000 TPA

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

 Fly ash generation (@ 36% of total ash): 20,000 TPA

Fly Ash: The fly ash from the proposed boilers will be collected in economizer hoppers, air heater hoppers, ESP hoppers and will be conveyed through dense phase pneumatic conveying system to silo. The fly ash to be disposed from the silo will be moistened to reduce the dust while collecting the ash. The system will be provided with telescopic chute and rotary feeder for loading the ash into covered trucks.

Bottom Ash: Bottom ash from proposed boiler will be carried through a submerged belt conveyor to silo. From Silo it will be disposed to ash dump area in covered trucks in moistened condition.

3.4.5 SMS (IFCCMLRF)

Steel will be manufactured through DRI-IF-LRF-CCM route with billet production capacity of 1,04,000 TPA.

Production Strategy for Phase-I

Sponge Iron, Scrap and Pig iron will be used as the charge mix. Proportion of sponge iron will vary from 50% to 85% depending on availability of scrap.

Product Data:

Steel Melting Shop-I Product: Billets Section Sizes Range:100 mm2 ~ 200 mm2 Length Range: 3m ~12m Grade: Low-medium carbon steel

Induction Furnace (IF):

Number of Induction Furnaces: 3 nos. Melting capacity of each furnace: 12 ton Power rating of each furnace: 4.5 MW Melting rate of each furnace: 12 ton/hr Number of heats: 8 per day Yield from charge to liquid steel: 86% Utilization: 80%

The utilization includes loss of time for the following heads:  Pig iron charging, de-slagging & pouring  Longer heat time after patching & relining  Breakdown of equipments

Laddle Refining Furnace (LRF):

Number of Electric Arc Furnaces: 01 Melting capacity of each furnace: 30 ton Power rating of each furnace: 7.5 MW

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Continuous Casting Machine (CCM):

Machine Type: Curved mould, bow type Number of strands: 02 Machine radius: 7 m Section design limits: 100mm ~200mm Laddle support: Turret Casting practice: Open metering

3.4.6 Rolling Mill

One rebar/section/wire mill of 1,00,000 TPA have been envisaged to convert the billets into long products. The mill will be working for about 300 days per year considering various mill delays such as mechanical and electrical failures, roll & guide change, mill setting & other normal operational interruptions.

Wire Rod Mill A single strand wire rod mill is proposed to be installed to produce plain and ribbed rods either in straight or coil form in the size range of 5.5mm dia to 40mm dia round. The mill will roll low and medium carbon steel.

Input Material: The input material to the mill will be continuously cast billets of section 100mmx100mm to 125mmx125mm and length of 3m to 12m. The mill will be designed to ensure an average material yield of about 96%.

Special features of mill: The envisaged mill be of modern state of art design and will have the following special features to ensure superior surface finish, close dimensional tolerances and physical properties of the products:

 Hot as well as Cold billet charging facilities  Billet weighing facility  Mill floor level at +0.00 level  High pressure water descaling facility  Single stand high speed continuous mill  Quick roll change carpet in finishing group of stands  Interstand tension control rolling  Online rapid water quenching unit  Facilities of 2 nos. of high speed finishing block for smaller bar production  Bundling & tying facilities  Mill automation and control

Majot Technological Parameter:

Type of Mill: Single Strand Continuous Mill Capacity of the Mill : 1,00,000 TPA Mill Floor Level : +0.00 m Rolling Speed : 20 m/s max. Operating Days : 300 days Billet to product yield : 98%

Auxiliary facilities:

Auxiliary system will be provided for the mill. The facilities such as hydraulic system, oil lubrication systems, compressed air systems, grease lubrication systems etc. have also

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha been envisaged which will be required for operation of the mill. The auxiliary systems will be housed below the mill floor level. High pressure water station for rapid descaling & water quenching of bars will be provided in the mill premises.

Roll & Repair Shop

A Roll & Repair Shop has been envisaged for the mill where grooving of new rolls, redressing of used rolls, dismantling/assembly of bearings, preparation of templates, grinding of tools etc. as well as minor repair jobs will be carried out. The roll & repair shop building will be located by the side of the mill main bay building and will house various types of machine tools such as turning lathes, shear blade & roll grinders, tanks and clearing equipments, roll storage racks, drilling machines, template cutting machines required for the above purpose. Tungsten Carbide groove grinding machines along with notch milling machine, wheel dressing unit, tool grinding machines have been provided to redress the rolls of no twist mill. To facilitate transportation of rolls/chocks from mill to repair shop, transfer cars have been provided.

Layout:

The layout of the bar mill will ensure smooth and unobstructed movement of man and material in the mill bays with minimum handling. The mill building will be mostly of steel structure and will comprise bays and rooms. The mill floor will be at +0.00m level. The various auxiliary and services facilities will be housed below the mill floor level in cellars.

3.5 RAW MATERIAL INVENTORY

Annual Raw Material Requirement

The annual requirement of major raw material for the plant after the proposed expansion is tabulated below.

Table 3.2: Raw Material Inventory Existing Expansion

Sl. Total of Grand Mode of Raw Material DRI Source No. Expansion Total Transport Iron Ore Koira & Joda 1 1,20,000 24,000 1,44,000 Truck Lumps in Odisha Koira & Joda 2 Iron Ore Fines 11,00,000 11,00,000 Truck in Odisha Odisha, 3 Dolomite/Lime 6,000 13,200 19,200 Chhatisgarh, Truck Gujurat 4 Bentonite 6,000 6,000 Rajasthan Truck non-Cokng Odisha, WB, 5 1,20,000 1,82,000 3,02,000 Truck/ Rail Coal Chhatishgarh 6 Coke 6,000 6,000 Imported Truck Odisha, WB, 7 MS Scrap 1,82,000 36,000 Truck AP, Gujurat 8 Pig Iron 6,000 30,000 Odisha Truck 9 Lime 36,000 7,000 Odisha Truck 10 Gypsum 30,000 4,000 Odisha Truck

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

11 Sand 7,000 19,000 Odisha Truck

Iron Ore:

The project envisages to use iron ore available from near by mines at Koira and Ghatkuri of the following specifications. Fe, % 60-62 SiO2, % 4-6 Al2O3, % 3-5 LOI, % 2~3

Coke:

Low Ash Coke shall be purchased from Coke manufacturers. The Coke shall be having the following specification: Carbon 80-84% Ash 10-12% VM 1 -2 % Moisture 5- 7 %

Limestone:

Limestone shall be sourced from Andhra Pradesh and shall conform to the following specifications: CaO + MgO 58 %

SiO2 6 % LOI 40%

Bentonite:

Bentonita will be procured from Kutch, Gujarat. The composition of bentonite will be as follows: Fe 2 %

SiO2 60%

Al2O3 24% CaO+MgO 5% LOI 8%

Most of the above raw material is available locally, in the state of Orissa. Hence procurement of these raw materials for the proposed expansion does not seem to have any problem for setting up the expansion project. Iron Ore will be sourced from near by mines of Koira, Keonjhar, Joda and Barbil area. Coal will be purchased from MCL, Dolomite will be sourced from Rajgangpur/ Biramitrapur.

Raw Material Receipt &

Most of the raw material shall be received by road. Separate store yard for the major raw materials such as iron ore and coal exists.

Mode of Transport (Raw materials & products)

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Transports will be done by the environmentally compliant trucks. Some raw materials & products will be done by train also. Bharat-III/ Euro-III trucks will be used in the transportation system. The raw materials & products shall be covered fully during the transportation to avoid spillage & fugitive emissions on the road.

Raw Material Storage & Handling

Product-Mix

The product-mix shall be 72,000 TPA sponge iron, 6,00,000 TPA iron ore pellet, 1,25,000 TPA billet and 1,00,000 TPA long steel products.

3.6 RESOURCE OPTIMIZATION /PROCESS FLOW SHEET

A material flow diagram of the proposed green field project is attached.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Fig 3.4: Material Balance Sheet:

3.7 WATER REQUIREMENT

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Table 3.3: Water Requirement after Expansion

Sl. No. Plant Facilities Required Water

1 DRI Plant-2X100 TPD (Existing) 205

2 Pellet Plant Unit-1 150

3 Pellet Plant Unit-2 1100

4 Power Plant 1000

5 Steel Making Shop 150

6 Rolling Mill 25

7 Domestic 21

8 Greenary (Plantation) 250

9 Loss in Treatment 75

Total 2976*

* For which EC and necessary permission is already granted.

3.8 ENERGY/POWER REQUIREMENT

Fuel

Major fuel required is about 18000 KL/ year of Furnace Oil. About 300 KL/year of LDO will be required for line flushing.

Power

The total load of the proposed project is about 30 MW which shall be met partly through own captive power plant 10 MW and balance 20 MW from the state grid.

Table 3.4: Power Requirement after Expansion

Sl. No. Plant Facilities Required Power

1 DRI Plant-2X100 TPD (Existing) 1

2 Pellet Plant Unit-1 5

3 Pellet Plant Unit-2 8

4 Power Plant 1

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

5 Steel Making Shop 13

6 Rolling Mill 2

Total 30 MW

3.9 WASTE GENERATION & MANAGEMENT

Table 3.5: Solid Waste Generation & Management

Sl. Waste Quantity Utilization/ Control Plant Facilities No. characterization in TPA Measures Fuel for the proposed 40,000 1 2X100 TPD DRI Dolochar power plant Accretion 3,000 Low land filling 2 Pellet Plant Unit-1 Pellet Fines 12,500 Recycled/ Used in DRI Pellet Fines 17,500 Recycled/ Used in DRI 3 Pellet Plant Unit-2 Slime cake 2,50,000 Stacking in yard Fly Ash 20,000 Brick making 4 Captive Power Plant Bottom Ash 32,000 Low land filling Slag 17,000 Road Construction 5 Steel Making Refractory 200 Low land filling Shop Damage mould 300 Recycled in IF Mill Scale 2,000 Recycled in IF 6 Damaged Rolls 25 Recycled in IF Rolling Mill Unit Miss-rolled bar 2,000 Recycled in IF Total 1,46,525

Waste Water Management

Table 3.6: Waste Water Management

Sl. No. Description Treatment System To Be Adopted 1 Cooling Tower Blow Down,  Treatment in common ETP consisting of Boiler Blow Down O & G Trap, Settling Tank with Chemical Dosing and Dual-Media Filtration. Cooling water is contaminated with oil and grease  The treated water will be taken to common basin / guard pond for reuse. 2 Mill stand bearing cooling, roller  Mill Scale will be collected from the cooling and quenching settling tank.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

circulation water

3 IF cooling & CCM cooling water  Mill Scale will be collected from the settling tank. 4 Back wash of filtration plant  Will be treated in settling tank and back to raw water reservoir. 5 DM Plant Effluent.  Neutralization and will be taken to common basin/ guard pond for reuse. 6 Domestic (workers canteen &  Canteen waste water will be treated in a separate ETP consisting of O & G trap, Administrative building). settling tank, anaerobic treatment system & gravity sand filter.

 Sewage from toilets will be treated in septic tank and discharged to soak pit. 7  From coal pile area will be routed Runoff water through settling pit.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-4 SITE ANALYSIS

4.1 CONNECTIVITY

The site is located at village Bad-Tumkela under Lahunipara police station of Sundargarh district in the State of Orissa. The location is well connected with road and rail. The NH- 23 is passing only at 2 Km away from the proposed site. The site is 47 Km distance from the Rourkela town. The nearest railway station Barsuan Railway station is about 20 Km away from the plant site. Brahmani River is flowing only 1.2 Km away from the project site and the company will draw water from the river to meet its water requirement. The site is geographically located at Latitudes 210 50' 17.66" N of Longitudes of 840 55' 38.61" E and 150 m MSL.

The site is well connected to the basic raw material source like coal & iron ore. The company will meet the coal & the iron sourced from Koira & Joda in Odisha.

4.2 LAND

The total land available for the proposed project is about 102 acres from which 94.5 Acres of land already been acquired & quantity of land to be acquired is 7.5 Acres.

4.3 TOPOGRAPHY

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Fig 4.1: Toposheet

4.4 LAND USE PATTERN

The project area is present at village- Bad-Tumkela, Sundargarh district of Odisha. It is also noted that the core zone i.e. the project boundary or the battery limit does not belong to part of any National Park, wild life sanctuary or Natural/ Biosphere reserve. It also does not contain any features of archaeological/ historical and cultural/aesthetic importance.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Table 4.1: Land Use Pattern after Modernization & Expansion*

Sl. Existing Land Proposed Total Land in Plant Facilities No. in Acre Land in Acre Acre 1 DRI Kiln 5 - 5 2 Pellet Plant Unit-1 - 3 3 3 Pellet Plant Unit-2 - 5 5 4 Beneficiation Plant - 8 8 5 Power Plant - 2 2 6 Steel Making Shop - 3 3 7 Rolling Mill Unit - 4 4 8 Raw Material Storage 1 3 4 9 Finished Product Storage 1 1 2 10 Solid Waste Disposal 20 5 25 11 Ash Disposal - 5 5 Administrative Building, canteen, 12 Roads etc 1 1 2 13 Water Reservoir - 2 2 14 Green Belt 6 26 32 Total 34 68 102 * This expansion-cum-modernization is within the land specified in the earlier EC and no extra land is acquired for the purpose.

4.5 EXISTING INFRASTRUCTURE

The growth of industrial sectors in 2x100 TPA DRI Plant, Office Building, Machine shop, Canteen, Material Handling Facility of the existing infrastructure developments.

4.6 CLIMATIC DATA FROM SECONDARY SOURCE

Secondary information on meteorological conditions has been collected from the nearest IMD station at Jharsuguda and IMD Book (1970-2000). Predominant wind direction is NE.

Table 4.2: Summarized Meteorological Data at site:

Relative Cloud Study Wind Speed Temperature Humidity Rainfall (mm) Cover Period(Winter (Km/Hr) (oC) (%) (Oktas) Season) Max Min Max Min Max Min 24 hr Max Total Mean December- Nil 12.0 0.2 27.6 12.3 69 47 Nil 0 2015 January- Nil 12.2 0.1 27.7 12.3 68 44 Nil 0 2016 February- Nil 12.3 0.3 30.6 15.1 59 35 Nil 0 2016

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-5 PLANNING BRIEF

5.1 PLANNING CONCEPT

The plant is an integrated steel plant having semi-mechanized operation. It is not a labor intensive project. However, depending on the production schedule, there will be additional technical labor engaged for operation.

The raw materials shall be transported through covered trucks by road up to the nearest siding for further transportation by rail. And the finished products will be transported by both rail and road. The transportation load will not add much to the existing load on the said road system.

As because there are several other similar industries around the buffer zone of this plant, therefore the Solid Waste management is been appropriately planned to segregate from others’ waste dumps.

Appropriate plantation program shall be undertaken along with the developmental program to at least cover the boundary areas with thick and tall plants for containment of the air borne pollutants within the premises, which is duly reflected in the land use plan.

There will not be any further infrastructural development other than needed for the commissioning of the total project component machineries. This expansion-cum- modification shall utilize the existing infrastructural facilities for all purposes.

Peripheral Development Plan

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Fig 5.1: MANAGEMENT HEIRARCHY

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-6 PROPOSED INFRASTUCTURE

6.1 INDUSTRIAL AREAL DISTRIBUTION

Proposed project will be planned in the existing plant premises. So, the area has already demarked as an industrial area. In the plant premises the area for industrial processing and ate area for the residential purpose will be facilitated in that premises of 102 acres of land.

6.2 GREENBELT DEVELOPMENT FACILITY

The following plantation schedule is proposed for the greenbelt development.

Table 6.1: Proposed Plan of Green Belt Development

Time No. of Area coverage Cumulative Percentage Coverage of Saplings in Acres project area Existing 15,000 7 6.9% 1st Year 3,000 5 11.8% 2nd Year 4,000 5 16.7% 3rd Year 5,000 5 21.5% 4th Year 6,000 5 26.5% 5th Year 6,000 5 31.3% Total 39,000 32 31.3%

6.3 CONNECTIVITY

For the proposed expansion project, no further new connectivity will be created because the plant is connected with roads such as NH-23 & NH-215 with distance of 2.4km & 3km respectively. The raw materials shall be transported through covered trucks by road up to the nearest siding for further transportation by rail. And the finished products will be transported by both rail and road. The transportation load will not add much to the existing load on the said road system.

6.4 INDUSTRIAL WASTE MANAGEMENT

6.4.1 Waste Water Management

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha sent to the Concentrate Bin. The filter water will be recycled back. The waste water from canteen and office toilets will be sent to a soak pit.

Sl. No. Description Treatment System To Be Adopted

1 Cooling Tower Blow Down,  Treatment in common ETP consisting of Boiler Blow Down O & G Trap, Settling Tank with Chemical Dosing and Dual-Media Filtration. Cooling water is contaminated  The treated water will be taken to with oil and grease common basin / guard pond for reuse.

2 Mill stand bearing cooling, roller  Mill Scale will be collected from the cooling and quenching settling tank. circulation water 3 IF cooling & CCM cooling water  Mill Scale will be collected from the settling tank. 4 Back wash of filtration plant  Will be treated in settling tank and back to raw water reservoir. 5 DM Plant Effluent.  Neutralization and will be taken to common basin/ guard pond for reuse. 6 Domestic (workers canteen &  Canteen waste water will be treated in a separate ETP consisting of O & G trap, Administrative building). settling tank, anaerobic treatment system & gravity sand filter.  Sewage from toilets will be treated in septic tank and discharged to soak pit. 7  From coal pile area will be routed Runoff water through settling pit.

6.4.2 Solid Waste Generation & Management

Sl. Waste Quantity Utilization/ Control Plant Facilities No. characterization in TPA Measures Fuel for the proposed 40,000 1 2X100 TPD DRI Dolochar power plant Accretion 3,000 Low land filling 2 Pellet Plant Unit-1 Pellet Fines 12,500 Recycled/ Used in DRI Pellet Fines 17,500 Recycled/ Used in DRI 3 Pellet Plant Unit-2 Slime cake 2,50,000 Stacking in yard Fly Ash 20,000 Brick making 4 Captive Power Plant Bottom Ash 32,000 Low land filling Slag 17,000 Road Construction 5 Steel Making Refractory 200 Low land filling Shop Damage mould 300 Recycled in IF 6 Rolling Mill Unit Mill Scale 2,000 Recycled in IF

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Damaged Rolls 25 Recycled in IF Miss-rolled bar 2,000 Recycled in IF Total 1,46,525

6.5 INDUSTRIAL POLLUTION CONTROL

6.5.1 Air Pollution Control It is envisaged to install state of the art air pollution control measures in the proposed project, as given below.

Table 6.2: PROPOSED AIR POLLUTION CONTROL FACILITIES

Sl No Plant/ Area Proposed Pollution Control Measure Raw Material Handling - Water sprinkling Raw Material Handling, 1 - Bag filter will be provided at the transfer Transfer Points, Junction points of material at flux and bentonite, Houses hearth layer separation bin, hearth layer silo. 2 DRI - ESP Pellet Plant Unit-1 Operated in a close circuit. Dust collected is Grinder used in the manufacturing process Pelletising is done in wet condition, hence no Pelletiser 3 dust generation Materials handled shall be wet, hence no dust Roller Screen generation. Flue gases will be released from the furnace after passing through ESPP. Collected dust is Induration Furnace re-used in the process.

Pellet Plant Unit-2 Slime is filterd and stored in the designated Beneficiation yard. It is wet grinding process & hence no Grinder generation of dust. Pelletising is done in wet condition, hence no 4. Pelletiser dust generation Materials handled shall be wet, hence no dust Roller Screen generation. Flue gases will be released from the furnace Induration Furnace after passing through ESP. Collected dust is re- used in the process. Captive Power Plant WHRB ESP 5. AFBC ESP – Stack

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

Sl No Plant/ Area Proposed Pollution Control Measure Coal Crushing & Handling Bag Filters & Water Sprinkling

ESP Dust Handling (AFBC & Pneumatic Conveying System, Pug Mill with Bag WHRB) Filter

Steel Making Shop Induction Furnace Bag Filter

6. LRF Exhaust Fan

CCM Exhaust Fan

Rolling Mill 7. Re-heat Furnace Stack

Stack of adequate height will be provided for proper dispersion of flue gas.

6.5.2 Water Pollution Control

There will not be any waste water from the process. The slime from washing screen will be sent to a settling pond and dewatered. The water will be recycled back.

The product slurry from Ball Mill will be passed through the filter press and concentrate cakes will be sent to the Concentrate Bin. The filter water will be recycled back. The waste water from canteen and office toilets will be sent to a soak pit.

6.6 MAN POWER REQUIREMENT

The total man power requirement for plant operation on completion of the proposed expansion will be around 954. The details are tabulated below.

Table 6.3: Requirement of Man Power for Plant Operation

Existing Expansion Sl. No. Raw Material DRI Total of Grand Total Expansion

1 Managerial 10 61 71

2 Skilled 50 303 353 3 Semi-skilled 25 152 177 4 Un-skilled 50 303 353

Total 135 819 954

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-7 REHABILITATION & RESETTLEMENT (R&R)

REHABILITATION & RESETTLEMENT

The proposed modification cum expansion units will implemented at the existing plant premises. The existing lands were already derived as industrial land. As no settlement is going to be affected so, no R&R facility will be anticipated.

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-8 PROJECT SCHEDULE & COST ESTIMATES

8.1 IMPLEMENTATION SCHEDULE

Start of construction and likely date of completion, and hence the project implementation schedule has been carefully planned.

Table 8.1: Tentative implementation schedule :

Unit Product Capacity Expected Date of Commissioning DRI Plant 2x100 TPD Sponge Iron 72,000 TPA Existing Kiln Pellet Plant Unit-1 Iron Ore Pellet 2,50,000 TPA Mar’18 (2,50,000 TPA) Pellet Plant Unit-2 Iron Ore Pellet 3,50,000 TPA Mar’20 (3,50,000 TPA) Power Plant Unit 1 Electricity 10 MWH Mar’19 (WHRB + AFBC) Steel Making Shop Billet 1,25,000 TPA Mar’17 (IF-LRF-CCM) Rolling Mill MS (TMT/ Section/ 1,00,000 TPA Mar’17 Wire)/

8.2 ESTIMATED PROJECT COST

Project Cost The cost of the project is estimated to be around Rs. 450 Crores

Capital Cost requirement for the pellet plant units, beneficiation plant, captive power plant, steel making shop and rolling mill has been given below.

Table 8.2: Total Project Cost

Sl. No. Cost Head Estimated Cost, Rs. in Crore 1 Land & Land Dev. 4 2 Civil & Structural 71 3 Plant & Machinery 240 4 Misc. Fixed Assets 16 5 Prel. Expenses 5 6 CSR 14 7 Pre-Operative Exp/IDC 60 8 Contingency 15 9 Margin for WC 25 Total 450

Mode of Financing Debt Equity Ration - 2:1 Equity - Rs.150 Crore Loan - Rs.300 Crore

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

CHAPTER-9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 FINANCIAL & SOCIAL BENEFITS

The proposed expansion project is expected to bring significant socio-economic and environmental benefits both at local and global level as listed below:

9.2 SOCIAL INFRASTRUCTURE

 Social awareness programmes will be further improved by the local authority such as sanitation and hygiene, HIV Prevention Program.  Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding area.  The proposed expansion project will set up training centre for the male and female youth group by considering their skills and qualification which will support the people for self employment.

9.3 EMPLOYMENT POTENTIAL

The project is going to create substantial employment and income. Due to this project activity, some persons in the project area will be recruited as skilled and semi skilled workers by the company as per its policy. Therefore, substantial amount of employment and income is likely to be generated for the local people. So, the project will contribute in a positive manner towards direct employment in the project area. Some employment potential benefits are given below:

 Expected to employ a workforce of 100 people during construction phase.  Long term employment of up to additional 205 people in the operation phase of the proposed expansion project.  Generating additional associated jobs due to establishment of the project.

9.4 BENEFITS TO THE REGION AND THE COUNTRY

Vikram Private Limited shall produce Iron Ore Pellets that is to be utilized is making Sponge Iron which is a prime raw material for steel making. The products are in demand and production shall contribute to the GDP growth of the country.

9.5 PERIPHERAL DEVELOPMENTS

Vikram Private Ltd. has already undertaken a lot of developmental work in the peripheral area. The Company will continue the peripheral development works and contribute to the Peripheral Development Societies as mentioned above.

It will promote the followings:

Techno Economic Feasibility Report of M/s Vikram Private Limited At: Badtumkela in Sundergarh district of Odisha

 Besides above, indirect benefits have also accrued to the region by way of increase in agriculture and industrial production.  Development of the local area in terms of an enlarged market will provide the local farmers a good outlet for their agricultural products and facilitate them to enjoy the price effect, which is likely to be strong enough to offset the impending local inflations through real-balance effect.

Thus, the proposed expansion project shall usher in the social and economic upliftment of the persons living in the vicinity of the project i.e. of society at large.