PRE-FEASIBILITY REPORT (as per MoEF&CC OM no. J-11013/41/2006-IA.II(I) dated 30.12.2010)

FOR

PROPOSED 3X9 MVA FERRO ALLOY PLANT

AT

VILLAGE: RADHA MADHAVPUR, MOUZA & P.O: CHOUSAL, DISTRICT: ,

JUNE, 2021 (Issue 1, Rev 0)

by

Nilkanth Ferro Limited Bhiringi, Opp. Telephone Exchange, Durgapur-713213, District Burdwan, West Bengal, Tel: +91-343-2587560, Telefax: +91-343-2583241 E-mail: [email protected], Website: www.nilkanthferro.com

Nilkanth Ferro Limited

CONTENTS

Sl. No. Description Page No.

1.0 Executive Summary ...... 1 2.0 Introduction ...... 1 2.1 Identification of project and project proponent ...... 1 2.2 Brief description of nature of the project ...... 2 2.3 Need for the project and its importance to the country and or region ...... 2 2.4 Demand-supply gap ...... 2 2.5 Export Possibility ...... 4 2.6 Domestic / Export markets...... 5 2.7 Employment generation (Direct and Indirect) ...... 5 3.0 Project Description ...... 5 3.1 Type of project including interlinked and interdependent projects ...... 5 3.2 Location with Coordinates ...... 5 3.3 Details of Alternate Sites & Environmental Considerations ...... 8 3.4 Size/Magnitude of operation ...... 9 3.5 Project description with process details ...... 9 3.6 Raw material required along with estimated quantity, likely source, marketing area of final product’s mode of transport of raw material and finished product ...... 17 3.7 Resource optimization/ recycling and reuse envisaged in the project ...... 17 3.8 Availability of water its source, energy / power requirement and source ..... 17 3.9 Quantity of wastes likely to be generated (liquid and solid) and scheme for their management /disposal ...... 18 3.10 Schematic Representations of the Feasibility drawing which give information of EIA purpose ...... 18 4.0 Site analysis...... 20 4.1 Connectivity ...... 20 4.2 Land form, land use and land ownership ...... 20 4.3 Topography ...... 20 4.4 Existing land use pattern ...... 20 4.5 Existing infrastructure ...... 20 4.6 Soil classification ...... 20 4.7 Climatic data from secondary sources ...... 21 4.8 Social infrastructure available ...... 21

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Sl. No. Description Page No.

5.0 Planning Brief ...... 21 5.1 Planning concept...... 21 5.2 Population projection ...... 21 5.3 Land use planning (break up along with green belt etc.) ...... 22 5.4 Assessment of infrastructure demand (physical & social) ...... 22 5.5 Amenities / Facilities ...... 22 6.0 Proposed Infrastructure ...... 22 6.1 Industrial area (processing area) ...... 22 6.2 Residential area (non processing area) ...... 23 6.3 Green belt ...... 23 6.4 Social infrastructure ...... 23 6.5 Connectivity ...... 23 6.6 Drinking water management (source & supply of water) ...... 23 6.7 Sewerage system & industrial waste management ...... 24 6.8 Solid waste management ...... 24 6.9 Power requirement & supply / source ...... 24 7.0 Rehabilitation And Resettlement Plan ...... 24 8.0 Project Schedule & Cost Estimates ...... 24 8.1 Project Schedule ...... 24 8.2 Cost of the Project ...... 24 9.0 Analysis Of Proposal (Final Recommendations) ...... 24

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB ii Nilkanth Ferro Limited

LIST OF TABLES

Table No. Particulars Page No.

Table 1: Trend in production for sale, import, export and actual consumption of finished steel in India (in million tonnes) ...... 4 Table 2: Coordinate of expansion area ...... 5 Table 3: Distance and direction (within 15 km) of water bodies, Forests from project boundary ...... 8 Table 4: Capacities of proposed units ...... 9 Table 5: Material Balance of Ferro Manganese ...... 12 Table 6: Energy Balance of Ferro Manganese ...... 12 Table 7: Material Balance of Silica Manganese ...... 13 Table 8: Energy Balance of Silica Manganese ...... 13 Table 9: Material Balance of Ferro Silicon...... 15 Table 10: Energy Balance of Ferro Silicon ...... 16 Table 11: Raw material and their source ...... 17 Table 12: Finished product details ...... 17 Table 13: Solid waste generation and management (TPA) and other parameters 18 Table 14: Break up of plot area ...... 22

LIST OF FIGURES

Figure No. Particulars Page No.

Fig 1: Location Map ...... 6 Fig 2: Plan showing coordinates of proposed area on Google Earth Image ...... 6 Fig 3: Process Flow sheet of Submerged Arc Furnance...... 16 Fig 4: Plant layout ...... 19

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB iii Nilkanth Ferro Limited

1.0 EXECUTIVE SUMMARY

Project name 3X9 MVA Ferro Alloy plant

Project proponent Nilkanth Ferro Limited

Location Village: Radha Madhavpur, Mouza & P.O: Chousal, District: Bankura, West Bengal

Latitude 23°28’15.90” to 23°28’23.48” N

Longitude 87°10’03.62” to 87°09’50.09” E

Total Area 12.68 acres (5.13 ha)

Product Ferro Manganese, Silico Manganese and Ferro Silicon

Working days 330

Manpower 350

Expected cost of the Rs. 4925.85 lakhs project

Water requirement Ferro Alloy Plant: 30 KLD Domestic: 10.5 KLD Total: 40.5 KLD

Source of water Borewell

Power requirement 25 MW DG Sets : 2 X 125 KVA (during power failure)

Power source Damodar Valley Corporation

Implementation 24 months after Environment Clearance. Schedule

2.0 INTRODUCTION

2.1 Identification of project and project proponent

Nilkanth Ferro Limited intends to come up with a 3 X 9 MVA Ferro Alloy Plant. The 3 X 9 MVA Ferro alloy plant had already obtained environmental clearance vide MoEF&CC’s letter no. J-11011/10/2011-IA-II (I) dated 26.09.2012, which expired its validity in 2019. Due to various reason, the

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 1 Nilkanth Ferro Limited

project has not been completed. The land requirement for the project is 12.68 acres. Acquisition of land and its development has already been completed along with boundary wall and establishment of greenbelt over 23% of the land.

Nilkanth Ferro Limited is a manufacturer and exporter of Silico Manganese and Ferro Manganese. It is a professionally managed organization that has raised itself to a higher pedestal with its quality products and focus on business processes for further improvement. They endeavour to manufacture high quality products that are delivered within stipulated time to their clients. Quality raw material, right type of equipment and quality control measures culminate into quality products. The company has spread its wings into vast overseas countries and have made indefatigable efforts to offer products of international standards.

Being a quality conscious company, it believes in adopting new production techniques to continually enhance our efficiency to offer quality products. The products are thoroughly checked in the quality control section to maintain highest quality standard. A team of experts maintains a strict vigil on the quality of the products before they are dispatched. The laboratory vis-a-vis quality control equipment are one of the standard per excellence.

2.2 Brief description of nature of the project

The nature of the project as per Schedule to EIA Notification, 2006 & its amendments is Item no. 3(a) for metallurgical industries (ferrous & non - ferrous). This is a Category A project.

2.3 Need for the project and its importance to the country and or region

As per the National Steel Policy, the objective is to build a globally competitive industry. It is anticipated that a crude steel capacity of 300 Million Tonnes will be required by 2030 based upon the demand projections. Thus, achieving crude steel capacity of up to 300 million Tonnes will require extensive mobilization of natural resources, finances, manpower and infrastructure including land.

The proposed project will assist in the endeavor to meet the projected demand of steel in the country by providing the necessary additives to the larger steel manufacturers.

2.4 Demand-supply gap

Ferro Alloys are used additives in steel making as de-oxidants and as alloying agent. These are added in steel production process not only for de- oxidation but also for grain size control as well as for improvement in the mechanical properties of steel. Depending upon the process of steel making and the type of steel being made, the requirement of Ferro Alloys varies widely.

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The product mix of the Ferro Alloy industry consists of Ferro manganese, Silico Manganese, Ferro Silicon, Ferro Chrome & Charge Chrome called Bulk Ferro Alloys. There is another group of ferro alloys called Noble Ferro alloys which consists of Ferro Molybdenum, Ferro Titanium, Ferro Tungsten, Ferro Vanadium, etc. As per Indian Ferroalloys Producers' Association (IFAPA), the total installed capacity of bulk Ferroalloys Industry in India is estimated at 5.10 million tonnes per annum and for noble ferroalloys it is 50,000 tonnes per annum1. Owing to high cost of power, Ferroalloys Industry has not been operating to its full capacity in India

Ferro alloys are used in production of mild steel, carbon steel, special alloy steel and stainless steel in the country. India’s steel production is increasing every year; thereby the consumption of ferro alloys is also increasing. The industry has enough capacity to produce ferro alloys required for domestic steel industry. However, certain basic raw materials, i.e., ores viz, manganese ore, chrome ore, roasted molybdenum ore and concentrate/ moly oxide, tungsten ore, wolframite ore, scheelite ore, nickel oxide, vanadium ore, vanadium pentoxide, etc need linkages and stable supplies.

The total production of ferromanganese in 2017-18 was about 5,18,000 tonnes which remained same in 2018-19. The estimated consumption of ferromanganese was 50,800 tonnes in 2017-18.

The production of silicomanganese (including medium-carbon & low carbon silicomanganese) which was about 3,11,326 tonnes in 2017-18 increased to 3,45,291 tonnes in 2018-19. In 2017-18, the total consumption of silicomanganese by all industries has been estimated at 1,22,600 tonnes.

The production of ferrosilicon in 2017-18 was about 90,000 tonnes which remained same in 2018-19. The domestic consumption of ferro silicon in the Organised Sector was estimated at 23,400 tonnes in 2017-18.

Imports of ferroalloys (total) decreased marginally by 7% to 5,08,008 tonnes in 2018-19 from 5,44,264 tonnes in the previous year. In terms of value, the ferroalloys imports increased to Rs. 7,573 crore in 2018-19 from Rs. 6,617 crore in 2017- 18. Out of total imports in terms of quantity, imports of ferrosilicon accounted for about 44% followed by ferromanganese (24%), ferronickel (17%), ferrochrome (6%) and chargechrome (4%). Other ferroalloys together accounted for the remaining 5% of the imports in 2018- 19. Imports were mainly from Bhutan (21%) followed by Malaysia (17%), China (14%), Indonesia & South Africa (9% each), Japan (4%) Korea Republic of, Russia & Singapore (3% each) and Brazil (2%).2

As per the steelworld report, ferroalloys Industry is estimated to grow at a CAGR of 5.9% between 2017 to 2025 and is expected to reach a valuation of US$ 188.7 Bn by 2025. India is expected to show strong growth in usage

1 Source: Indian Minerals Yearbook 2019 (part-II: metals & alloys), July 2020 of Indian Bureau of Mines available at https://ibm.gov.in/writereaddata/files/08012020124231Ferroalloys2019.pdf accessed 04.06.2021 2 Source: Indian Minerals Yearbook 2019 (part-II: metals & alloys), July 2020 of Indian Bureau of Mines available at https://ibm.gov.in/writereaddata/files/08012020124231Ferroalloys2019.pdf accessed 04.06.2021

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of steel in the coming years because of its robust economy, massive infrastructure needs and expansion of industrial production. India is expected to become one of the leading steel consuming nations in the next decade. In this scenario, the Ferro alloys Industry estimates that the consumption of ferroalloys will increase domestically and internationally in the coming years. Some of the Ferroalloy Producers have already gone for expansion and some new units are coming up.

2.5 Export Possibility

Owing to high cost of power, Ferroalloys Industry has not been operating to its full capacity in India. As per Indian Minerals Yearbook 2019 (part-II: metals & alloys), July 2020 of Indian Bureau of Mines, in 2018-19, exports of ferroalloys (total) decreased slightly to 19,42,134 tonnes in 2018- 19 from 19,55,751 tonnes in the previous year. In terms of value, the ferro-alloys exports increased to Rs. 14,962 crore in 2018-19 from Rs. 14,328 crore in 2017-18.

Out of total export, in terms of quantity, majority were exports of ferrochrome (44%) followed by ferrosilico-manganese (39%), ferromanganese (14%) and ferrosilicon (1%). The other ferroalloys together accounted for remaining 2% of exports in 2018-19. Exports were mainly to Republic of Korea & China (15% each), UAE (11%), Japan (10%), Taiwan (7%), Italy (4%), Thailand & Malaysia (3% each) and USA & Netherlands (2% each)

The Table 1 below shows the trend in production for sale, import, export and actual consumption of finished steel (alloy/ stainless + non‐alloy) in the country for the last five years.

TABLE 1: TREND IN PRODUCTION FOR SALE, IMPORT, EXPORT AND ACTUAL CONSUMPTION OF FINISHED STEEL IN INDIA (IN MILLION TONNES) Description 2014‐15 2015‐16 2016‐17 2017‐18 2018‐19 2019‐20*

Production 104.578 106.602 120.140 126.855 101.287# 76.326# (1.8) (finished steel)

Imports 9.32 11.712 7.227 7.482 7.834 5.51 (-6.7)

Export 5.596 4.079 8.242 9.620 6.361 6.52 (39.4)

Apparent steel 76.994 81.525 84.042 90.708 90.708 75.05 (3.8) use Source: Annual Report 2019‐20, Ministry of Steel, Government of India * Provisional; for April- December, 2019 # Crude steel equivalent

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2.6 Domestic / Export markets

The ferro alloy can be both sold in domestic market or exported.

2.7 Employment generation (Direct and Indirect)

Employment generation from the proposed project is envisaged to be around 105 persons during constructions and 350 persons during operation. Many more persons will also get employment in the ancillary & other services connected with this project.

3.0 PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects

There is no interlinked or interdependent project

3.2 Location with Coordinates

The project is proposed in village Radha Madhavpur, Mouza & P.O Chousal, District Bankura of West Bengal. No alternate site has been considered for the proposed project. The total land requirement for the proposed project is 12.68 acres (5.13 ha). The land required for the proposed project is already under possession of Nilkanth Ferro Limited. The location map of the proposed site is given in Fig 1.

The latitude and longitude of the proposed site based on Google earth are given in Table 2 and the corresponding map is shown in Fig 2:

TABLE 2: COORDINATE OF EXPANSION AREA Coordinate No. Latitude(N) Longitude(E)

A 23°28’23.48” N 87°09’53” E

B 23°28’18.44” N 87°10’03.62”E

C 23°28’15.90” N 87°09’57.19”E

D 23°28’18.40” N 87°09’50.09” E

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FIG 1: LOCATION MAP

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FIG 2: PLAN SHOWING COORDINATES OF PROPOSED AREA ON GOOGLE EARTH IMAGE

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3.3 Details of Alternate Sites & Environmental Considerations

No alternative sites under consideration. The proposed project will be incorporated within 12.68 acres (5.13 ha).

Environmental considerations: There are no National parks, Wildlife Sanctuary, Biospheres reserves within 15 km radius. The nearest Wildlife Sanctuary is Ballavpur WLS at a distance of 54.7 km in NE and its eco sensitive zone is at a distance of 54.4 km, NE. There are several water bodies and forest present within the study area of the project. The distance to various water bodies, forest, etc are given in Table 3.

TABLE 3: DISTANCE AND DIRECTION (WITHIN 15 KM) OF WATER BODIES, FORESTS FROM PROJECT BOUNDARY Name Distance (km) Direction Forests PF 9.4 NNW Gangajalghati PF 5.3 SW Gangajalghati PF 11.0 SSW Gangajalghati PF 12.6 SW Gangajalghati PF 13.2 S Gangajalghati PF 13.9 S Beliator PF 4.3 SE Beliator PF 10.3 SSE PF near Saharjora 10.4 SE Major River / Nala/ Streams/ Water Bodies 7.7 NE Nala 3.5 SE Tartora Nala 6.5 SE Sali Nala 10.8 SSW Chouphari Nala 5.9 W Barajuri Nala 3.7 N Gaighata Jhor 9.3 NNW Tamla Nala 12.3 NE Singaran Nala 10.0 NE Subhankari Nala 9.6 SE Napur Bil 12.6 NNW Mejia Bil 10.5 NW Baro Bil 13.3 ESE Right Bank Main Canal 12.4 E

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Name Distance (km) Direction Sali Reservoir 10.0 SW Nityanandpur Lake 3.3 SE DSP Reservoir 10.0 NE Jamgari Dam 3.5 SSW Several tanks & ponds in every Within 15 km As seen in village radius map

3.4 Size/Magnitude of operation

Plant area: 12.68 acres (5.13 ha)

The capacities of the proposed project are given in Table 4.

TABLE 4: CAPACITIES OF PROPOSED UNITS Sl. No. Plant Capacity Units 1 Submerged Arc Furnace 3 nos. X 9 MVA a Ferro Manganese 61,365 TPA b Silico Manganese 45,256 TPA c Ferro Silicon 21,049 TPA

3.5 Project description with process details

3.5.1 Ferro Alloy Plant (3X9 MVA)

Ferro alloys are consumables required to manufacture steel. Ferro alloys are used to manufacture various types of carbon and steel, essentially to impart certain physical and chemical properties in a particular grade of steel viz change of tensile strength, ductility, hardness, corrosion resistance, wear resisting or abrasion resistance properties etc.

Ferro alloys are also commonly used for de-oxidation and refining of quality steel. Ferro manganese (Fe-Mn) is primarily used for this purpose and its demand is proportional to the production of steel. It acts as a double deoxidizer and is ideally suited for steel making. Harden-ability, hardness ultimate strength and yield limit of steel increase and its toughness decreases with a higher content of manganese Steel containing about 1% C and 11-13% Mn are distinguished by high abrasion resistance.

Composition of Ores

Physico-chemical properties of manganese: manganese has an atomic mass of 54.9381, density 7.3, melting point 1244 °C. Iron and manganese in molten state are mutually soluble. Manganese ores to be used for smelting Ferro-manganese should meet the following process conditions ·

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 The content of manganese in ores should be 45%, a higher content of manganese ensures a high productivity of furnaces and a lower use of energy per ton of alloy.

 The content of silica in ore should be as low as possible. Silica increases the slag ratio and causes a larger loss of manganese to slag and a higher use of electric energy. The reductant for the process is usually coke breeze with not more than 12% ash, 11% (on average) moisture, 2% volatiles and less than 0.2% phosphorous; grain size from 3-15 mm.

The Submerged Arc Furnace is a versatile one and can produce either of the Ferro alloys viz. Silico Manganese & Ferro Manganese.

3.5.1.1 Manufacturing Process of Ferro-Manganese

High-carbon Ferro Manganese is made in three phases in an open or closed top furnace. The furnace has a power of 7,500- 16,500 kVA, linear voltage of 120-130 V, current of 33-38 kA, electrodes 900-1150 mm in a diameter, hearth and walls of the furnace are lined with carbon blocks, and the upper portion of walls, with fire clay bricks. The charge for making high- carbon Ferro Manganese is composed of manganese ore & coke breeze

Physico-chemical conditions of the Process: High carbon Ferro Manganese is smelted by a continuous process with the electrodes submerged deep into the charge. The following processes take place when High Carbon Ferro Manganese is being made:

1) Pre-heating of the materials 2) Drying and removal of volatiles and moisture from the charge and heating of the charge by the heat of burning gases which leave the furnace and after-burn at the top 3) Reduction of oxides 4) Melting of the elements reduced with the formation of molten Ferro Manganese 5) Formation and melting of slag 6) Reduction of silicon from slag

Melt Procedure: As has been mentioned earlier, melt for High Carbon Ferro Manganese is carried out with the furnace top being closed. For a furnace of 7,500 kW and voltage 164 V, the electrode depth is 800- 1000 mm in a melt for High Carbon Ferro Manganese. Slag is formed in the hearth, that is why there is a single large pool of molten metal under the electrodes, instead of individual 'pots' as is the case with slagless process for smelting Silicon alloys. Hygroscopic moisture of the charge materials is removed in 10-15 minutes upon charging, while the volatile matters are run- off in the temperature range of between 200-1000°C. The iron contained in the manganese ore is reduced to a high extent in the process. Ferric oxides are reduced with carbon monoxide and hydrogen at low temperatures. Ferrous oxide is first reduced with carbon monoxide and hydrogen at 500-

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600°C temperature and after that with solid carbon in the deeper zones of the bath. The reduction of manganese from pyrolusite occurs stepwise: MnO2> Mn3O4>MnO>Mn3C with a reducing atmosphere in the furnace, the dissociation of manganese oxides can take place at low temperatures. High Carbon Ferro Manganese can be smelted with addition of fluxes or by flux less process. In the latter case, a valuable by-product of the process is high manganese low phosphorus slag which is used in smelting Silica Manganese and Manganese metal.

Fe2O3 + 2SiO2 + 7C = 2FeSi + 7CO

The reducing conditions in the furnace ensure that phosphorus be reduced almost fully. The acid slag cannot absorb phosphorus, which is removed with furnace gases and 75-80% passes to the alloy. A great part of electric energy is lost in the slag, which raises the temperature of the slag above that of the metal. The mass of manganese ore in batch charge is established at 500-700 kg and the amounts of coke breeze & quartzite are taken according to a charging table which specifies the composition of manganese ore and coke breeze. Mixed charge is delivered to the furnace from furnace bays along four movable chutes. Three chutes serve to deliver the charge to spaces between the electrodes and the fourth, into the space between the central electrode and furnace wall. Charging is done periodically to allow the previous charge settled at the top, to move down. With normal run of furnace, yellow flames shoot up evenly all over the surface of the furnace top. The following measures are essential to maintain the top in normal conditions :

1) The charge should always have the specified composition 2) The charge should be given evenly to each phase electrode 3) Consumption of electric energy should strictly correspond to the number of unit charges without letting the top overheat 4) Charge cones should be pierced periodically.

Disturbances in the furnace run may be caused by various factors. Most often they are linked with an inappropriate consumption of the slag and with a deficiency or excess of the reducer in the charge. Each type of disturbance has quite typical external features such as deep or shallow position of the electrodes, an increase or decrease in the content of carbon or silicon, overheating or chilling of the top, evolution of white smoke at the electrodes ejects of coke breeze, intense slagging at the electrodes, etc. The electrodes are slipped every shift or sometimes twice a day. The metal and slag are tapped simultaneously three times a shift. The ladle for tapping is mounted on a carnage under the tap hole, the slag flows over the ladle nose into a slag pot installed on a parallel railway. During tapping, the top hole is often poked with an iron bar so as to let out the metal and slag completely from the furnace. The tap hole is packed with thick clay as soon as metal appears at the ladle nose (i.e. when the ladle is filled with metal).

The material and energy balance of the Ferro Manganese is given in Table 5 & 6 respectively.

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TABLE 5: MATERIAL BALANCE OF FERRO MANGANESE Input Quantity % Output Material Quantity % Material (TPA) (TPA) Mn Ore 1,15,750 71.16 Ferro Manganese 61,365 37.73 Coke Breeze 27,571 16.95 Slag 54,000 33.2 Dolomite 19,330 11.88 Moisture in Coke 4,140 2.55 Reduction loss 40,956 25.18 Bag Filter fines 2,190 1.35 Total 1,62,651 100 Total 1,62,651 100

TABLE 6: ENERGY BALANCE OF FERRO MANGANESE Electrical Energy Required (kWh/t) 2850 Heat Input % kWh/t Electrical Energy 59.06 2850 Heat Energy from coke combustion 31.81 1535 Heat Energy from volatiles 9.13 441 Total 100.00 4826 Heat Output % kWh/t Heat removed with alloy 50.69 2446 Heat losses by the furnace 5.43 262 Heat losses by electrical equipment and 9.87 476 furnace cooling Heat removed with slag 15.36 741 Heat removed with off gases 18.65 900 Total 100.00 4826

3.5.1.2 Manufacturing Process of Silica Manganese

Physico-Chemical Conditions of the Process: High Carbon Silico Manganese is smelted by a continuous process with the electrodes submerged deep into the charge. The smelting processes include the following stages

1. Removal of volatiles and moisture from the charge and heating of the charge by the heat of burning gases which leave the furnace and after-burn at the top 2. Reduction of iron and ores with simultaneous formation of metal carbides 3. Melting of the elements reduced with the formation of molten metal 4. Formation and melting of slag 5. Reduction of Manganese and Silicon from the slag.

Hygroscopic moisture of the charge materials is removed in 10-15 minutes upon charging, while the volatile matters are run-off in the temperature range of between 200-1000°C. The iron contained in the manganese ore is reduced to a high extent in the process. Ferric oxides are reduced with carbon monoxide and hydrogen at low temperatures. Ferrous oxide is first reduced with carbon monoxide and hydrogen at 500-600°C temperature

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and after that with solid carbon in the deeper zones of the bath. The reduction of manganese from pyrolusite occurs stepwise MnO2 > Mn3O > MnO > Mn3C. With a reducing atmosphere in the furnace the dissociation of manganese oxides can take place at low temperatures. Carbon monoxide and hydrogen can also reduce Mn3O4 to MnO at low temperatures. The process of smelting silico manganese essentially consists in Manganese and Silicon being simultaneously reduced from manganese silicates, slag, ore and quartz. The process relies on a higher temperature. The temperature at tapping is 1500°C. Apart from the high temperature, for successful reduction of silicon the process requires high concentration of silica in the slag. The metal and slag are tapped from the furnace every two hours. The metal and slag are tapped through two tap holes into a ladle or onto casting pans. The slag over flows and collects into another ladle or in casting pans. The manufacturing process will remain same as of Ferro Managanese.

The material and energy balance of the Silica Manganese is given in Table 7 & 8 respectively.

TABLE 7: MATERIAL BALANCE OF SILICA MANGANESE Input Quantity % Output Material Quantity % Material (TPA) (TPA) Mn Ore 55,190 42.75 Silico Manganese 45,256 35.05 Fe-Mn Slag 31,537 24.43 Slag 45,256 49.44 Coke Breeze 22,018 17.05 Moisture in Coke 1,321 3 Quartz 11,314 8.76 Reduction loss 35,427 2.61 Dolomite 9,051 7.01 Bag Filter Fines 1850 Total 1,29,110 100 Total 1,29,110 90

TABLE 8: ENERGY BALANCE OF SILICA MANGANESE Electrical Energy Required (kWh/t) 4000 Heat Input % kWh/t Electrical Energy 63.90 4000 Heat Energy from coke combustion 28.29 1771 Heat Energy from volatiles 7.81 489 Total 100.00 6260 Heat Output % kWh/t Heat removed with alloy 48.86 3059 Heat losses by the furnace 7.82 490 Heat losses by electrical equipment and 9.65 604 furnace cooling Heat removed with slag 12.78 800 Heat removed with off gases 20.89 1308 Total 100.00 6260

3.5.1.3 Manufacturing Process of Ferro Silicon

High Carbon Ferro Silicon is made by reducing quartzite with a carbonaceous reductant in a submerged arc furnace. The techno

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economics of the process of ferro silicon production improves considerably with increase in the capacity of the furnace. Silicon - bearing substances namely quartz, rock crystal, amethyst, opal, onyx, carnelian, jasper, sand and others are employed in the manufacture of ferro silicon. Quartz is the compact crystalline mineral with a specific gravity of 2.59-2.69 hardness. Its SiO2 content should be minimum 96%, Preferably 97-99%. Al2O3, MgO, CaO content should be minimum possible and P2O5 content should not exceed 0.02%. It should have no clay inclusion and its moisture absorption should not exceed 5%. On crushing or heating, it should not lose its mechanical strength. Charcoal having about 68% Carbon, 6-8% Ash, 20% Volatile Matter and 4-6% Moisture is a costly reductant and is used mainly for the production of high silicon alloy (90% ferro silicon) and crystalline silicon Quartz/ Quartzite should be crushed into lumps of 35-70 mm in size and fines should be sieved through a 20-30 mm sieve for better permeability of the charge.

Production of Ferro Silicon: The reduction of silicon from silica occurs by solid carbon at 1,500°C. Molten iron dissolves the reduced silicon and removes it from the reaction zone, thus allowing the reaction to proceed from left to right. Since an iron-silicon alloy does not dissolve carbon, the ferro silicon smelting furnace is usually lined with graphite.

Ferro silicon smelting is essentially a slag-less process. Still some slag formation takes place because of the presence of impurities in raw materials, namely, aluminium oxide, calcium oxide and magnesium oxide. Slag is generally viscous and hard to fuse.

Due to its high viscosity, some slag always remains in the furnace and causes accretions, which decreases the yield of the furnace and increases the specific power consumption. If excess slag accumulates in the furnace, it can be removed by addition of lime to furnace hearth. The lime dilutes the slag and permit its tapping. The net reaction of the silicon reduction process may be represented as follows :

SiO2 + 2C = Si + 2CO

The reaction begins at 1,500°C, and is practically complete at 1,800°C. A further rise in temperature causes considerable evaporation. In presence of iron, silica reduction produces ferro silicon according to the reaction:

SiO2 + Fe + 2C = FeSi + 2CO

The following reaction may occur when an excessive amount of reductant is charged into furnace:

SiO2 + 3C = SiC + 2CO

However, SiC is quickly destroyed by iron according to the reaction:

SiC + Fe = FeSi + C

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 14 Nilkanth Ferro Limited

Operating Considerations:

1. Ferro silicon is generally produced in submerged arc furnaces with rotating baths. 2. The silicon losses from evaporation are considerable. Therefore, deep and stable electrode and uniform evolution of gases over the whole charge surface are essential to minimize the silicon losses. 3. The electrical parameters namely electrode, secondary voltage and electrode current considerably affect the performance of the furnace, hence these should be approximately selected. 4. The furnace resistance is adjusted by increasing or decreasing the conductivity of the charge mix and increasing or decreasing electrode circle 5. Lack of reductant in the charge mix leads to the crusting of the furnace and the operation of tap hole becomes difficult, while an excess of the electrodes, absence of slag. Freezing of the reductant in the charge mix for a prolonged period of time will lead to the formation of caborundum.

Refining of Ferro Silicon:

The ferro silicon required for making steels. Electrical steels must have low content of aluminium, calcium, titanium and carbon. Their presence brings down the magnetic permeability and increases the core loss. Hence, commercial grade ferro silicon needs further refining for the production of silicon steels. The processes for refining of ferro silicon are

1. Solid / liquid oxide methods. 2. Oxidizing treatment with gaseous / enriched air 3. Refining with chlorine gas. 4. Purification by carbon dioxide gas

The material and energy balance of the Ferro Silicon is given in Table 9 & 10 respectively.

TABLE 9: MATERIAL BALANCE OF FERRO SILICON Input Quantity % Output Material Quantity % Material (TPA) (TPA) Quartz 21,891 48.37 Ferro Silicon 21,049 46.51 Iron Scrap 11,242 24.84 Slag 1,159 2.56 Pet Coke 12,124 26.79 Gases 21,343 47.16 Moisture in the coke 1,122 2.48 fines Silicon with the gases 299 0.66 Silicon monoxide with 285 0.63 the gases Total 45,257 100 Total 45,257 100

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 15 Nilkanth Ferro Limited

TABLE 10: ENERGY BALANCE OF FERRO SILICON Heat Input % kWh/t Heat introduced by electrical power 79.86 16.62 Same, by the charge 0.07 0.01 Heat from the oxidation of C to CO 15.46 3.22 Heat from exothermic reactions 4.51 0.96 Total 100.00 20.81 Heat Output % kWh/t Heat of dissociation of the oxides 45.00 9.37 Heat removed with alloy 5.74 1.19 Heat removed with slag 0.34 0.07 Heat removed with evaporating moisture 0.45 0.09 Heat removed with evaporation Si & SiO 0.52 0.11 Sensible heat of the top gases 2.10 0.45 Heat losses by the furnace shell 8.16 1.69 Potential energy of the gases and radiation 37.69 7.84 from the top Total 100.00 20.81

The process description of Submerged Arc Furnace is given in Fig 3.

FIG 3: PROCESS FLOW SHEET OF SUBMERGED ARC FURNANCE

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 16 Nilkanth Ferro Limited

3.6 Raw material required along with estimated quantity, likely source, marketing area of final product’s mode of transport of raw material and finished product

The raw material requirement and their sources are given below in Table 11:

TABLE 11: RAW MATERIAL AND THEIR SOURCE Sl. Raw Quantity In house Outhouse Source Distance Transporta- No. Material (TPA) source source (km) tion Road (TPA) (TPA) 1. Mn Ore 115750 0 115750 Nagpur, Maharashtra 1200 By Rail/Road 2. Coke 49,589 0 49,589 Dhanbad, Jharkhand 120 By Road Breeze 3. Dolomite 28,381 0 28,381 Jalpaiguri, West Bengal 610 By Road 4. Fe-Mn Slag 31,537 31,537 0 Inhouse 5. Iron Scrap 11,242 0 11,242 Durgapur, West Bengal 35 By Road 6. Pet Coke 12,124 0 12,124 Durgapur, West Bengal 36 By Road 7. Quartz 33,205 0 33,205 Bankura, West Bengal 15 By Road Total 250,291 TPA By Road

The finished product details are given below in Table 12.

TABLE 12: FINISHED PRODUCT DETAILS Sl. No. Finished Product Quantity (TPA) Remarks 1. Ferro Manganese 61,365 Sale 2. Silico Manganese 45,256 Sale 3. Ferro Silicon 21,049 Sale

3.7 Resource optimization/ recycling and reuse envisaged in the project

The treated industrial wastewater (3 KLD) will be reused in dust suppression, sprinkling and greenbelt watering. Domestic sewage will be collected in sewage treatment system and reused for the same purposes as the industrial waste water i.e. dust suppression, sprinkling and greenbelt watering (8.5 KLD). Excess water can be stored in the reservoir in north east corner for subsequent reuse. Thus, there will be no discharge from the proposed project.

Domestic waste shall be generated from the plant office, organic component of which shall be composted/ vermi composted. Wastes such as used oils/ spent oil shall be generated periodically, which shall be sold to authorized recycling vendors in drums.

3.8 Availability of water its source, energy / power requirement and source

The estimated make-up water requirement for the Ferro alloy plant is 30 KLD and for domestic consumption 10.5 KLD. Thus, the total water

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 17 Nilkanth Ferro Limited

requirement will be 40.5 KLD. The water will be sourced from borewell and the water withdrawal permission from State Water Investigation Directorate (SWID), Bankura has been obtained.

The power requirement for the Ferro alloy plant is 25 MW. The power will be sourced from Damodar Valley Corporation. 2 X 125 KVA DG sets are also proposed to be used during power failure.

3.9 Quantity of wastes likely to be generated (liquid and solid) and scheme for their management /disposal

The main solid waste generated is slag from ferro alloy plant. Bag filter system and dry fogging system will be installed in the ferro alloy plant. These air pollution control equipment will capture dust as well. Domestic waste shall be generated from the plant office, organic component of which shall be composted/ vermi composted. Quantities of waste generation are given in Table 13.

TABLE 13: SOLID WASTE GENERATION AND MANAGEMENT (TPA) AND OTHER PARAMETERS Sl. Source Total (TPA) Remarks No. Ferro Manganese 1 Slag 54,000 31,537 TPA will be reused in Silica Manganese plant and rest 22,463 TPA will be sold. 2 Bag Filter Sold to other users/ other sinter plant 2,190 fines Silica Manganese 3 Slag 45,256 Sold, useable by jigging plant for metal recovery 4 Bag filter 1,850 Sold to other users/ other sinter plant fines Ferro Silicon 5 Slag 1159 Sold, useable in cupola furnace

3.10 Schematic Representations of the Feasibility drawing which give information of EIA purpose

Process flow sheets have been given respective sections describing the processes. The layout plant is given in Fig 4.

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 18 Nilkanth Ferro Limited

FIG 4: PLANT LAYOUT

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 19 Nilkanth Ferro Limited

4.0 SITE ANALYSIS

4.1 Connectivity

The proposed plant is accessible by all weather roads from the DM office Bakura, which is located at a distance of 28.2 km in SSW. The national highway 14, Raniganj to Midnapore is at a distance of 3.2 km in W. The nearest railway station is Waria railway station at a distance of 10.8 km in NE and the nearest railway line is Raniganj to Mejia TPS at a distance of 4.0 km in W. The nearest airport is at Kolkata, which is about 158 km in SE direction.

4.2 Land form, land use and land ownership

The Company is already in possession of land required for the proposed project i.e. 12.68 acres (5.13 ha). Land use had been changed to industrial. The proposed Ferro Alloys Plant will be established in the this land only.

4.3 Topography

The topography of the proposed project area is flat with an average site elevation of 109 m amsl as per google earth.

4.4 Existing land use pattern

Same as per point 4.2.

4.5 Existing infrastructure

There are industrial sheds present in the project site covering an area of around 700 sq.m. These will be modified and added to for use as plant facilities. In case any dismantling is required after detailed designing, the steel will be reused or sold as scrap.

New supporting infrastructure like office building, roads, rest room, slag yard, raw material handling area, etc. are proposed.

4.6 Soil classification

The whole area is covered by thick lateritic alluvium originated as weathered residum over the country rock. The soil type is mainly mild acidic (pH 6.5) sandy loam derived from weathering and re-deposition of weathered residum overlying the anorthosite basement.

The soil depth is about 0.3 to 0.5 m. Water holding capacity is 13.5 mm. Average soil moisture during November to May is about 30-35%. During rainy season soil moisture reaches the field capacity level.

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 20 Nilkanth Ferro Limited

4.7 Climatic data from secondary sources

Temperature

As per the nearest IMD station, Bankura M.O. (1990 – 2007), the mean of the mean of minimum temperature ranges from 11.4°C in January to 26.6°C in June and the mean maximum temperature ranges from 25.1°C in January to 37.4°C in May.

Rainfall

The total average rainfall from 1990 to 2007 is 1563.9 mm monthly variation is from 9.1 mm in January to 363 mm in July.

Relative Humidity

The relative humidity is higher in the morning hours averaging 78% compared to night hours scoring 68% of average. The relative humidity varies from 63% in March to 87% in September during morning and from 45% in March to 83% in September and October during evening.

4.8 Social infrastructure available

There are schools, hospitals, health centers, etc. in the villages of the surrounding areas. Ghutgarya is the nearest census town. List of amenities in villages in 15 km is given in Annexure 3 of additional documents uploaded at end of Form 1 at parivesh.nic.in.

5.0 PLANNING BRIEF

5.1 Planning concept

The proposed project is a ferro alloy plant. Facilities required for the proposed project will be provided as per requirements for plant area, roads, green belt, utilities, water distribution, pollution management, etc. Transportation of raw material and final product will be done via road and rail network and cement concrete road will be developed within the plant premises. The proposed facilities are given in Table 14.

5.2 Population projection

The proposed project will require approximately 350 person’s to be directly employment. In addition to this, there will be indirect deployment of persons in the project. Many more persons will also get employment in the ancillary & other services connected with this project. Unskilled and semi skilled (after training) will be hired from in and around the plant while skilled, engineers, managerial staff and technical experts will have to be hired from outside.

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 21 Nilkanth Ferro Limited

5.3 Land use planning (break up along with green belt etc.)

Total plant premises area is 12.68 acres (5.13 ha). Break up of proposed land use are given Table 14.

TABLE 14: BREAK UP OF PLOT AREA Sl. No. Description Area (sq.m) % 1. Plant facilities 5477 10.67 2. Infrastructure and buildings 2327 4.53 3. Green Belt 16934 33.00 4. Water Storage 120 0.23 5. Water Reservoir 1648 3.21 6. Raw Material Handling yard 1458 2.84 7. Slag Handling Yard 1500 2.92 8. Road and Parking 10163 19.80 9. Open Area 11689 22.78 Total 51316 99.99

5.4 Assessment of infrastructure demand (physical & social)

Nilkanth Ferro Limited will assess the demand of infrastructure (Physical & Social) in nearby areas of the plant site during the preparation of the EIA through village level surveys. Accordingly, development activities will be undertaken under corporate social responsibilities (CSR) program for the upliftment of the nearby communities.

5.5 Amenities / Facilities

Education, hospitals, drinking water, power supply, post and telegraph, banks, communication and approach roads are present in the villages in buffer zone within 15 km of study area as seen in the list of amenities in Annexure -3 of additional documents uploaded at end of Form 1 at parivesh.nic.in. Additional amenities and facilities will be put by the company as a part of its CSR plan in due course, based on need assessment.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area)

The water and power related infrastructure proposed is already discussed in section 3.8 earlier. Following infrastructure will also be provided as following:

 Compressed Air Supply System  Parking will be provided in the plant premises for the parking of vehicles.

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 22 Nilkanth Ferro Limited

 Weigh Bridges  Air condition and ventilation system  Auxiliary infrastructural facilities such as workshop, general stores and empty bags stores  Administrative office cum Sales and Dispatch Office  Time and Security office  Canteen  Clinic  Rest Room  Electrical systems  Control, instrumentation & automation systems  Intercommunication equipment  Energy management system  Pollution control, waste water and solid waste management systems

6.2 Residential area (non processing area)

Direct and indirect employment will be generated due to this project. Some skilled manpower may be required from outside the area while remaining unskilled/semi- skilled manpower will be sourced from the local villages. No residential facilities are envisaged for the employees.

6.3 Green belt

The green belt equivalent to 33.% of the plot area shall be developed covering 11689 sq.m. land.

6.4 Social infrastructure

Proposed project will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure under CSR programs.

6.5 Connectivity

Refer section 4.1

6.6 Drinking water management (source & supply of water)

Refer section 3.8

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 23 Nilkanth Ferro Limited

6.7 Sewerage system & industrial waste management

The total waste water generation from the proposed ferro alloy plant will be 3 KLD. The same will be treated in the common monitoring basin and then reused in dust suppression, sprinkling and greenbelt development. The sewage and sanitary wastewater from toilets, washrooms and canteen will be to the tune of 8.4 KLD and shall be treated in dewage treatment system and reused for dust suppression, sprinkling and greenbelt. The plant has been designed based on maximum recycling and zero liquid effluent discharge.

6.8 Solid waste management

Refer section 3.9

6.9 Power requirement & supply / source

Refer section 3.8

7.0 REHABILITATION AND RESETTLEMENT PLAN

No rehabilitation and resettlement plan has been made as no displacement of population.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

The tentative project implementation schedule is 24 months from date of receipt of Environmental clearance.

8.2 Cost of the Project

The total investment for the proposed project works out to approximately INR 4925.85 lakhs. The estimated investment cost for the project is based on the requirement of fixed and non fixed assets.

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

Nilkanth Ferro Limited proposes 3X9 MVA Ferro alloy plant at village Radha Madhavpur, Mouza & P.O Chousal, District Bankura, West Bengal.

105 persons will be employed during construction and 350 persons will be employed during operation in the proposed project and further indirect employment shall be there in security, transportation, etc. The manpower would be mostly recruited in unskilled, semi skilled, office assistant categories etc. The local persons will be given preference in employment. Therefore, having a positive impact on the the economic condition of the local people. Furthermore, as part of CSR activities, development activities

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 24 Nilkanth Ferro Limited

shall be carried out in the villages, thereby improving their social and physical infrastructure.

Various air pollution control equipment shall be installed and the dust collected and sold to other users. The waste water shall be treated and reused in dust suppression, water sprinkling and greenbelt development. The plant will be maintained zero discharge.

Thus, with the advancement in technology and by adhering stringently to permissible limits of emission along with regular monitoring, it is possible to operate the plant with minimal impact on the environment.

PFR for 3X9 MVA Ferro Alloy Plant, Bankura, WB 25