Techno Economic Feasibility Report of M/S Super Smelters Ltd At: Jamuria Industrial Estate Under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

TECHNO ECONOMIC FEASIBILITY REPORT FOR EXPANSION CUM MODIFICATION PROJECT OF M/s. SUPER SMELTERS LTD

At-ADDA Industrial Estate, Mandalpur, Jamuria Dist-Burdwan, West Bengal

JULY-2016

Prepared by GLOBAL TECH ENVIRO EXPERTS PVT. LTD.

C-23, BJB NAGAR BHUBANESWAR-751014 PH.NO-06742433487 [email protected] [email protected] Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Contents

CHAPTER-1 ...... 3 EXECUTIVE SUMMARY ...... 3 CHAPTER-2 ...... 6 INTRODUCTION OF THE PROJECT ...... 6 2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT ...... 6 2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT...... 6 2.3 JUSTIFICATION FOR MODIFICATION ...... 7 2.4 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION ...... 7 2.5 GLOBAL STEEL SCENARIO ...... 8 2.6 DOMESTIC STEEL SCENARIO ...... 8 2.7 EMPLOYMENT GENERATION DUE TO PROJECT ...... 9 CHAPTER-3 ...... 10 PROCESS DESCRIPTION ...... 10 3.1 LOCATION OF THE PROJECT ...... 10 3.2 DETAILS OF ALTERNATE SITES ...... 12 3.3 SIZE OR MAGNITUDE OF OPERATION ...... 12 3.4 PROCESS DESCRIPTION ...... 12 3.5 RAW MATERIAL INVENTORY ...... 22 3.6 RESOURCE OPTIMIZATION /PROCESS FLOW SHEET ...... 24 3.7 WATER REQUIREMENT ...... 25 CHAPTER-4 ...... 29 SITE ANALYSIS ...... 29 4.1 CONNECTIVITY ...... 29 4.2 LAND ...... 29 4.3 TOPOGRAPHY ...... 29 4.4 LAND USE PATTERN ...... 30 4.5 EXISTING INFRASTRUCTURE ...... 31 4.6 CLIMATIC DATA FROM SECONDARY SOURCE ...... 31 CHAPTER-5 ...... 32 PLANNING BRIEF ...... 32 5.1 PLANNING CONCEPT ...... 32 CHAPTER-6 ...... 34 PROPOSED INFRASTUCTURE ...... 34 6.1 INDUSTRIAL AREAL DISTRIBUTION ...... 34 6.2 GREENBELT DEVELOPMENT FACILITY ...... 34 6.3 CONNECTIVITY ...... 34 6.4 INDUSTRIAL WASTE MANAGEMENT ...... 34 6.5 INDUSTRIAL POLLUTION CONTROL ...... 35 6.6 MAN POWER REQUIREMENT ...... 36 CHAPTER-7 ...... 37

1 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

REHABILITATION & RESETTLEMENT (R&R) ...... 37 CHAPTER-8 ...... 38 PROJECT SCHEDULE & COST ESTIMATES ...... 38 8.1 IMPLEMENTATION SCHEDULE ...... 38 8.2 ESTIMATED PROJECT COST ...... 39 CHAPTER-9 ...... 40 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ...... 40 9.1 FINANCIAL & SOCIAL BENEFITS ...... 40 9.2 SOCIAL INFRASTRUCTURE ...... 40 9.3 EMPLOYMENT POTENTIAL ...... 40 9.4 BENEFITS TO THE REGION AND THE COUNTRY ...... 40 9.5 PERIPHERAL DEVELOPMENTS ...... 40

2 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-1 EXECUTIVE SUMMARY

M/s Super Smelter Ltd., has existing Integrated Steel Plant at Jamuria Industrial Estate in village- Ikra, PO- Mondalpur, Dist:-Burdwan, West Bengal. The project is located at latitude 230 41’ 27.65’’ N and longitude 870 05’ 54.51’’ E.

M/s Super Smelters Ltd. is a well established company of Sai Group of Industries which is a group company has its own reputation in the manufacturing of steel billets and other steel products. This group is engaged in trading of minerals and other steel product since a long time. The company is also producing rolled product in the brand name of “Supershakti”. The following running units are located at different locations:

 Sai Sponge (India) Limited at Jhinkpani, Dist- Chaibasa, Jharkhand

 Sai Iron (India) Limited at Patna

 Super Smelters Limited, having three units

 Unit-I at Durgapur in West Bengal

 Unit-II at Jhumri Telaiya in Jharkhand

 Unit-III at Jamuria in West Bengal

This TEFR is for Unit-III at Jamuria in West Bengal. The Project has obtained EC for 0.85 MTPA integrated Steel plant vide letter No-J-11011/86/2008-IA II(I), 1st Aug, 2008 for following configurations.

0.9MTPA Coal washery, 0.5 MTPA Non-recovery Coke oven with dry quenching, 1x 0.6 MTPA pellet plant, 2x35m2 Sinter Plant, 1x120 TPD Oxygen Plant, 1200 TPD lime Plant1100 TPD DRI kilns, 2x380m3 MBF, 2x50T,1x40T EAF with LF, AOD, 6x9 MVA Ferro alloy Plant, 0.85 MTPA rolling mills and 160 MW CPP.

Some of the facilities granted in EC have already been commissioned and plant is running and taken extension of validity of EC till 2018 to complete other facilities. The proponent at this stage faced difficulties both technically and commercially in implementing balance configurations and proposes some modification & expansion in the project as per the market value of steel.

Now the company newly proposes 2 MTPA beneficiation plant, another 1X0.6 MTPA pellet plant, 2X500 TPD DRI kiln with enhancement of generation of power of CPP from 160 MW to 187 MW.

As to modification the company proposes to drop EAFs completely and install IFs instead, 1x380m3 MBF capacity to be reduced to 1x65m3, while configuration of sinter plant to be changed from 2x35m2 to 1x60m2 and 1x15 m2 sinter plant feeding to MBFs of different capacity as changed.

1x65m3 MBF with feed pig to IFS and through LF and AOD will produce MS and SS product while hot metal from 1x380m3 MBF will produce alloy steel through ladle Furnace refining and addition of Ferro alloys.

Required Raw materials are Iron Ore Fines, Dolomite/Lime, Bentonite, Coke, Gypsum, Manganese ore and Chromium ores. Most of the raw materials will be procured from nearby

3 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal states either by rail or 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. The raw materials & products shall be covered fully during the transportation to avoid spillage & fugitive emissions on the road. The raw material yard shall have provision to store around one months’ stock of material.

The product-mix shall be 0.3 MTPA Alloy steel, 0.3 MTPA Mild steel & 0.25 MTPA Stainless Steel. After enhancement of WHRB, total power generation from the project will be 187 MW which shall be produced from WHRB and AFBC/ CFBC

The source of water for the plant operations is Ajay River through ADDA. The total water requirement for the proposed modification and expansion will be met from within 26,760m3/day as granted in existing EC by recycling and reuse.

Total quantity of solid waste generation will be 3,11,236 TPA. From the solid wastes, some will be recycled in Induction Furnace, Ferro Alloy plant & DRI and others are used as low land filling material. BF slag and fly ash to be supplied to cement plants and brick manufacturers.

The waste water generation from the various processes will be sent to the waste water treatment. After treatment the treated water will be recycled for the processes again. The slime from washing screen will be sent to a settling pond and dewatered. The water will be recycled back. The product slurry 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 administrative building, canteen and office toilets will be sent to a soak pit.

The site is located at Jamuria Industrial Estate under Asansol Durgapur Development Authority, village- Ikra, PO- Mondalpur of Burdhwan district in West Bengal. The location is well connected with road and rail. NH-2 is about 4km from the plant site in South-West direction, and NH-60, in South- East direction, is about 4.4 km from the plant site. The nearest railway station Tapsi Railway station is about 3.8 Km away from the plant site. Raniganj & Asansol, opposite direction to each other are about 9 km & 9.2 km from the plant side respectively. Kazi Nazrul Islam International Airport, Andal:- 20 km in South West direction. The site is well connected to the basic raw material source like coal & iron ore.

Geographically, the average elevation is about 131 ft for the district Burdwan. The area mostly is a plain area and have not contain much platue regions. It is situated in between two major rivers of the districts known as Damodar & Ajay river. The nearby areas are developed cities and township areas due to the industrial built-up.

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 M/2 (F45D2). There is an open well-cultivated plain country land along the valley of the Damodar & Ajay River. There is no Reserve Forests are coming within the 15 km buffer zone project area.

The land available for the total project is about 288.44 acres. From the above available land area, about 240 acres of land is existing land, where all the units (which are obtained EC previously from MoEF) will be commissioned.

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 94.45

4 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal acres of land will be earmarked in the layout of the proposed expansion project which is about 33% of total land.

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

For waste water treatment: ETP, settling Tank etc.

The total man power requirement for plant operation on completion of the proposed expansion will be around 1850. The details are tabulated below.

The cost of the project is estimated for the proposed units to be around 2800 Crore.

5 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-2 INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

The company profile of M/s Super Smelters Ltd. (SSL), Jamuria is as follows:

 Sai Sponge (India) Limited at Jhinkpani, Dist- Chaibasa, Jharkhand

 Sai Iron (India) Limited at Patna

 Super Smelters Limited, having three units

 Unit-I at Durgapur in West Bengal

 Unit-II at Jhumri Telaiya in Jharkhand

 Unit-III at Jamuria in West Bengal

This PFR is for Unit-III at Jamuria in West Bengal. The Project has obtained EC for the integrated Steel plant for the unit in year 2008. The operation of the plant has been satisfactory over these years.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

M/s SSL has taken EC vide letter No-J-11011/86/2008-IA II(I), 1st Aug, 2008 for following configurations.

Now the company newly proposes only 2 MTPA beneficiation plant, 1X0.6 MTPA pellet plant, 2X500 TPD DRI kiln with enhancement of generation of power of CPP.

 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.

 For the total project land requirement along with solid waste management, greenbelt development & rain water harvesting is 288.44 acres from where about 240 acres of land is has already been acquired & others are being acquired.

6 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

2.3 JUSTIFICATION FOR MODIFICATION

The company now proposes some modifications of the previous Environmental Clearance component with expansion of some other units.

The modification configurations are-

 2X 35 m2 sinter plant to be changed to 1X60 m2 & 1X15 m2 sinter plant  2X380 m3 MBF to be changed to 1X380 m3 & 1X65 m3 MBF  2X50 T, 1X40 T EAF to be changed over to 4X20 T & 2X25 T Induction Furnace

Sinter plant configuration is planned to change as per availability of equipment specific in the market and requirement for the total production.

For Mini Blast Furnace capacity is planned to reduce as per requirement.

All Electric Arc Furnace (EAF) will be changed to the Induction furnace due to unavailability of quality scrap. The induction furnace capacity is planned matching with the existing & proposed for inventory control.

2.4 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.

7 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

The present investment plan of Super Smelters Ltd. relates to backward as well as forward integration projects with captive power plant. The company will be able to establish direct link with the ultimate consumer with the help of integrated project.

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.

2.5 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. According to the World Steel Dynamics (WSD) organization, global steel production (as also demand for it or consumption) will grow at an annual average compounded rate of growth of 1.28 per cent during 2015-2025 to reach only 1873 million tonnes by 2025. Other well known forecasts, this figure was to be achieved by 2020.

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.

2.6 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.  As per the report of the Working Group on Steel for the 12th Five Year Plan, there exist many factors which carry the potential of raising the per capita steel consumption in the country. 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 tonnes (mt) 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 Five Year Plan has projected that domestic crude steel capacity in the county is likely to be 140 mt by 2016-17 and has the potential to reach 149mt if all requirements 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]

8 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

2.7 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 1850 including all employees. Rather than those some contractual workers are to be employed for the construction & operational phase.

9 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-3 PROCESS DESCRIPTION

3.1 LOCATION OF THE PROJECT

The project site is located at Jamuria Industrial Eastate under ADDA, village- Ikra, PO- Modalpur, Jamuria in Burdwan district of West Bengal with coordinates of Latitude & longitude of 230 41’ 27.65’’ N & 870 05’ 54.51’’ E respectively.

Fig 3.1: Site Location Map

10 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Fig 3.2: Satellite imagery of location-Super Smelters Ltd.

11 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Fig 3.3: Project Site Layout

3.2 DETAILS OF ALTERNATE SITES

The proposed project is a part of the integrated steel plant of the existing plant site and EC was already obtained. So, no alternate site is chosen.

3.3 SIZE OR MAGNITUDE OF OPERATION

The proposed expansion project will be recommended at the existing plant site of 288.44 acres of land with about 2200 crore of total project cost. Existing land is 240 acres and other are in acquiring process.

3.4 PROCESS DESCRIPTION

M/s Super Smelters Ltd, Jamuria 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.

12 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Table 3.1: Project Configuration

EC granted Existing Final Justification (J- Configurat Configuratio 11011/86/20 ion(Units Proposed Modificati n 08-IA II (I), Commissi Expansion on in EC Sl. Plant 1st Aug, 2008) oned as Configurat configurat No. Facilities per EC) ion ion

1 Coal Washery 0.9 MTPA Nil Nil Nil 0.9 MTPA To be commissioned

Coke 0.5 MTPA To be commissioned Oven(Non- 2 recovery with Nil Nil Nil 0.5 MTPA Dry Quenching)

Iron Ore Nil Expansion 3 Nil 2 MTPA Nil 2 MTPA Beneficiation

4 Pellet Plant 0.6 MTPA 0.6 MTPA 0.6 MTPA Nil 1.2 MTPA Expansion

2X35 m2 1X60 m2 1X60 m2 This change is as 5 Sinter Plant Nil Nil per change in 2 2 1X15 m 1X15 m capacity of MBF

1X120 TPD 1 X400 Partly m3/hr commissioned and 6 Oxygen Plant Nil Nil 1X120 TPD balance will be (13TPD) commissioned.

7 Lime Plant 1200 TPD Nil Nil Nil 1200 TPD To be commissioned

3X100 TPD, Expansion (Existing), 2 X 100 2 X 100 TPD TPD 2X350 TPD 8 DRI unit 2X500 TPD Nil 3 X 300 TPD (proposed), 3 X 300 2 X 500 TPD 1X100 TPD TPD (proposed)

2X380 m3 1 X 380 m3 1 X 380 m3 Capacity reduced to 9 MBF Nil Nil meet IF & LF 1 X 65 m3 1 X 65 m3 requirement

Nil 4X20 T 4 X 20 T All EAF will be Induction 10 2 X 25 T Nil Furnace (IF) changed to IF due 2X25 T 4 X 25 T

13 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

1X50 T to (EAF+LF+CCM)  Inavailability 1X50 T of quality scrap EAF+AOD+C (EAF+AOD+LF 1 X 45 T  Matching with 11 existing for CM +CCM) AOD inventory control  Less polluting 1X40 T  No risk of (EAF+AOD+LF handling HMl +CCM)

4X9 MVA (Fe- 4X9 MVA (Fe- Partly Cr) Cr) commissioned and SAF (Ferro 12 2 X 9 MVA Nil Nil balance to be Alloy Plant) 2X9 MVA (Fe- 2X9 MVA commissioned Mn, Si-Mn) (Fe-Mn, Si- Mn)

0.3 MTPA (MS 0.3 MTPA (MS Partly products) products) commissioned and balance to be 0.3 MTPA (AS 0.3 MTPA (AS commissioned. 13 Rolling Mill products) 0.3 MTPA Nil Nil products)

0.25 MTPA (SS 0.25 MTPA products) (SS products)

34 MW DRI 20 MW Capacity DRI 22 MW enhancement to 14 CPP (WHRB) Nil 54 MW BF&COG-12 meet expansion MW

2X62.5 MW Capacity CPP 15 37 MW Nil 8.0 MW 133 MW enhancement to (CFBC/AFBC) meet expansion

3.4.1 DRI

Sponge iron, also known as "Direct Reduced Iron" (DRI) and its variant Hot Briquetted Iron (HBI) have emerged as prime feed stock which replace steel scrap in EAF/IF as well as in other steel-making processes. It is the resulting product (with a metallization degree > 82%) of solid state reduction of iron ores or agglomerates (generally of high grade), the principal constituents of which are metallic iron, residual iron oxides, carbon and impurities such as phosphorus, sulphur and gangue (principally silica and alumina). The final product can be in the form of fines, lumps, briquettes or pellets. Sponge iron when briquetted in hot condition at elevated temperature is called hot briquetted iron (HBI).Direct reduction processes available can be broadly grouped under two categories based on the type of reductant used. These are:

14 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

 Solid based processes  Gas based processes

M/s SSL has opted for 2X500 TPD coal based DRI kilns and has existing 2X100 TPD + 3X300 TPD DRI.

At DRI outlet fly ash is 21.17 tph and with 80% efficiency of DSC & with 90% efficiency of ESP. Hence flue gas will be 423tph.

The capacity of the Proposed plant has been divided based on the following table.

Technical parameters of DRI plant

No. of working days per annum : 320

No. of shifts per day : 3

Working hours per shift : 8

Productivity rate considering the installed capacity : 50 MT/h.

Achievable production/annum : 7,39,200 Tons per annum

Char generation : 1,03,488 tons per annum

In plant DRI consumption will be about 4,81,412 TPA for mild steel & stainless steel production. From total 2,57,788 TPA DRI will be planned for sale.

3.4.2 Coal Washery

The company proposes to establish a 0.9 MTPA coal washery and obtained Environmental Clearance for it. The proposed washery will incorporate the latest designs and the latest equipments and shall be a heavy media bath based coal processing unit.

ROM coal will be delivered to the truck dump station via tippers. The truck dump will be an elevated bunker with access for trucks to unload the ROM into the hopper.

The heavy media bath is the main coal washing device in the coal preparation plant. The deep flow bath already carrying media (water & magnetite powder) and the deslimed coal is received by the bath. In the bath the lighter (clean) is separated through the overflow and the heavier (rejects) is gathered and conveyed through the reject outlet of the bath to the reject screen. Thus the clean coal and reject are separated. In the first section of the screen (drain section) the water and magnetite slurry is drained partially. In the second section of the screen (rinse section) water jets are used to wash the coal of magnetite sticking to body of coal.

The reject coal from the reject D & R screen is discharged over the reject coal belt for suitable stock piling. The clean coal is discharged over the clean coal conveyer where the clean coal is blended with raw bypass coal in the ratio to give final ash content as required by the end user.

15 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Plant capacity

The Capacity of the Coal Washery is 0.9 million tons. Out of which 0.36 Million tons per annum of washed coal having 27 %ash will be generated from the throughput Raw coal. The technical parameters are provided in table below.

Technical Parameters of coal washery

Plant Capacity 175.8 TPH

No. of operating days in a year 320

No. of operating hours in a day 16 hours (Two shift operating excluding daily short maintenance at start up)

Annual throughput 175.8X16X320

= 9,00,096 tons/annum

( Say) = 0.9 Million tons/annum

Clean coal produced = 3,60,000 ton/annum

i.e. 0.36 million ton/annum

Reject produced 0.045 million ton/annum

The Raw Coal expected to be of 85% Lump & 15 % fines. Again lumps are separated into washed coal, fines, middling and rejects.

3.4.3 Iron Ore Beneficiation

SSL expects to get iron ore fines of about 58% of Fe content. For enriching of Fe content in iron ore fines from a level of 58% to 65% the process being considered is scrubbing / washing, closed circuit grinding, classifiers with dense media hydro cyclone, gravity separation spirals, high intensity magnetic separator, product and tailings thickeners.

Utilization of beneficiated iron ore

Technologies used to utilize fine Iron ores in steel making are as follows:

a) Sintering b) Pelletization

Sintering is an agglomeration-technique for enlarging the iron ore particle size. The use of iron ore sinter in a modern day blast furnace has become common due to various advantages associated with it.

Pelletization is a process of agglomeration of iron ore fines. The particles smaller than 200 µ of which nearly 50% bears 50 µ size are converted into 12-15 mm green pellets, a nodular shape, which on drying and firing become hard and strong to be used as feed for the blast furnace or DRI units.

16 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

3.4.4 Pelletization Plant:

The plant has already installed 0.6 MTPA pellet plant and the raw material are, high grade iron ore fines called as blue chips. It also proposes to set up a pellet plant with a capacity of 0.6 MTPA by utilizing low grade Iron Ore fines which are available in plenty in the region for meeting the requirement of DRI units and mini Blast furnaces. The required raw materials for the plant will be coming from the iron ore beneficiation plant.

The proposed plant will produce both DRI grade pellets with Fe content of 65%. The main input will be Fe-Ore fines of 58-60% Fe.

Pelletization Process

Pelletization process consists of number of key stages. Concentrate is fed along with a mixture of Bentonite and other chemical additives (such as lime stone, coal and coke breeze) and moisture, into balling devices like drum or disc to produce green pellets 9-11 mm dia. These pellets are loaded on to a moving grate and form a packed bed. Increasingly hot process gas is blown through it to dry and fire the pellets at 13000C. Then ambient air cools them back to room temperature.

There are two predominant forms of the Iron-Ore pellet, Induration process viz: Straight grate process and Grate kiln process.

Since iron ore slurry from beneficiation plant is used for pellet making, water content of the concentrate from the thickener is about 50%. In order to reduce moisture content ceramic vacuum disc filters are used and water content is reduce to 11% and water is recycled. Pre- determined quantity of concentrate bentonite, limestone / dolomite, coal is sent to intensive mixer to produce a homogeneous mixture. Ideal moisture content for pelletization is 75%. The capacity of the mixer shall be 215 t/hr.

3.4.5 Sinter Plant:

Sintering involves the heating of fine iron ore with flux and coke fines or coal to (1300 to 1480oC) produce a semi-molten mass that solidifies into porous pieces of sinter with the size and strength characteristics necessary for feeding into the blast furnace. Moistened feed is delivered as a layer onto a continuously moving grate or 'strand.' The surface is ignited with gas burners at the start of the strand, and air is drawn through the moving bed causing the fuel to burn. Strand velocity and gas flow are controlled to ensure that 'burn through' (i.e. the point at which the burning fuel layer reaches the base of the strand) occurs just prior to the sinter being discharged.

The proposed sinter plant complex will consist of on sinter machine of 60 m2 and 15 m2 grate area along with associated services facilities. The plant is rated for production of 2,60,000 TPA of gross sinter at a rated productivity of 1.25 t/m2 /hr. The sinter plant complex envisages receipt of blended mix, limestone, dolomite and coke breeze at the proportioning unit.

17 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Technical parameters of Sinter Plant

Sintering Area 65 m2 & 15 m2

Utilization Ratio 1.25 t/m2.h

Sinter Production 7,20,000 TPA

Sinter Quality

– T of Fe 57%

– FeO ~11%

– S 0.021%

– Alkalinity 1.8

– Temperature <1500C

– Grain Size 5-150 mm

3.4.6 MINI BLAST FURNACE:

Blast furnaces is a vertical shaft furnace that produces liquid metal from lump iron ore / pellet and sinter by the reducing action of carbon(coke) at a high temperature in the presence of a fluxing agent limestone. Iron making blast furnaces consist of several zones: a crucible-shaped hearth at the bottom of the furnace; an intermediate zone called a bosh between the hearth and the stack; a vertical shaft (the stack) that extends from the bosh to the top of the furnace; and the furnace top, which contains a mechanism for charging the furnace. The furnace charge, or burden, of iron-bearing materials (e.g., iron-ore pellets and sinter), coke, and flux (e.g., limestone) descends through the shaft, where it is preheated and reacts with ascending reducing gases to produce liquid iron and slag that accumulate in the hearth. It also comprises of Slag granulation system and pig casting machine.

BF gas has the following characteristics

 Very low calorific value (CV) in the range of 700 to 850 Kcal/Cu m. CV is very much dependent on the coke rate.  It has a high density. It is around 1.250 Kg/Cu m at the standard temperature and pressure (STP) which is 0 deg C and 1 atm. Pressure. This density is highest amongst all the gaseous fuel. Since the density is higher than the density of air it settles in the bottom in case of a leakage.  It has low theoretical flame temperature which is around 1455 deg C.  It has low rate of flame propagation. It is lower than any other common gaseous fuel.  BF gas burns with a non luminous flame.  BF gas has lower explosive limit (LEL) of 27% and upper explosive limit (UEL) of 75% in an air gas mixture at normal temperature and pressure.  The high top pressure of BF gas is utilized to operate a generator (Top gas pressure Recovery Turbine – i.e. TRT in short). TRT can generate electrical energy (Power) up to 35 kWh/ ton of hot metal without burning any fuel. Dry type of TRT can produce more power then wet type.

18 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Technological parameters of MBF is given in table below.

Technological parameters of MBF

No of blast furnace 2 Useful volume, m3 380 & 65 Productivity, t/d m3 3 Coke rate (dry), kg / thm 402 Coal dust injection, kg /thm 74 Slag rate, kg / thm 300 Top pressure, kg/cm2 (g) operating 0.8

3.4.7 Lime Plant

Raw lime stone and Dolomite will be screened and sized stone will be fed to Shaft kiln through skip hoist. There limestone will be calcined at a temperature 1050-11500C to achieve soft burnt lime. Fuel oil will be used for heating purpose. The discharge from the kiln will be routed through a closed loop screening system to separate out under size fraction and screened lime will be dispatched to SMS through a system of belt conveyors. The under sized fraction of lime will be dispatched in close container to sinter plant.

Description Quantity

No of kilns 1

Kiln capacity 1200 TPD

Kiln feed size 30-60mm

Calcinations temp. 1050-1150 0C

Specific fuel consumption 850K cal/kg of burnt lime

3.4.8 Oxygen plant

Oxygen will be required for blast furnace as well as LF in steel melting shop. Nitrogen will be required in secondary steel making units of SMS, shrouding in the tundish for the continuous casting plant, bell less top charging equipment, above burden probe etc. for BF, PCI, LF and coal dust transportation and occasionally of purging.

Capacity of the plant

In order to meet the demand of oxygen in the blast furnace and steel melting shop. One oxygen plant of 3502 m3/hr(120 TPD) capacity is envisaged.

Oxygen, nitrogen and argon will be produced by air separation process based on medium pressure cryogenic cycle and double column rectification system.

Air will be sucked from atmosphere, compressed to designed pressure and moisture and carbon dioxide to be separated. This will be cooled down by cold gas coming out of cold box.

19 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Then subsequent decompression, compression, cooling and decompression will make liquid air. Then fractional distillation will separate Nitrogen and Oxygen to be to be collected and stored separately. Argon will remain in gaseous form in distillation column to be collected and used in AOD.

The unit would be able to produce gaseous as well as liquid products. Argon requirement will be met from argon produced from the above oxygen plant.

3.4.9 SMS

IF-LRF-AOD

The various types of Induction Furnaces used for Steel making are medium frequency and high frequency. Mild steel, Stainless Steel and low and high alloy Steel can be made from these furnaces. Raw materials used are Steel melting Scrap and DRI. Alloying elements are added as per the requirement and the induction furnaces are provided with matching billet casters.2X25T+1X20T IF is proposed for production of 0.3 MTPA stainless steel, 2X25T+3X20T IF has been proposed to produce 0.3 MTPA Mild steel. Design Parameters of Induction Furnace

Sl. Parameter Unit Value/Feature No. 1. Liquid Steel Production T/yr 5,76,000 2. No. of Furnaces 6 4X25T, 4X20T 3. Type of furnace - A.C medium frequency coreless, twin shell each with common power pack per furnace. 4. Nominal Transformer Rating KW 5200 for 25T 4900 for 20T 5. Heats/Day/Furnace 10 6. Charge Mix  DRI % 52  Pig Iron % 46  Scrap % 2

Argon oxygen decarburization (AOD)

AOD process provides an economical way to produce stainless steel with a minimum loss of precious elements. It is a process primarily used in stainless steel making and other high grade alloys with oxidizable elements such as chromium and aluminum. The molten metal from IF/EAF is decarburized and refined in an AOD converter to less than 0.05 % carbon. The key feature in the AOD converter is that oxygen for decarburization is mixed with inert gas such as argon or nitrogen and injected through submerged tuyeres.

20 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

3.4.10 Ferro Alloy Plant

The company now proposes to expand its unit by setting up a 4 X 9 MVA Ferro-Chrome 2X9 MVA Silico Manganese/Ferro manganese Plant to produce 63,130 TPA ferro chrome and 38,135 TPA silico manganese/Ferro manganese. Ferro Manganese and Ferro Silicon can be manufactured as per the requirement.

Ferro Manganese/Silico Manganese:

High carbon Ferro-manganese/Silico Manganese is commercially produced by carbothermic reduction of manganese ores, primarily in electric submerged arc furnaces (SAF). The produced metal typically contains around 78% Mn, 7% Carbon and around 40% MnO (high MnO slag practice). An increasing part of the metal is refined to medium or low carbon manganese.

Ferro Chrome

Production of high carbon Ferro-chrome involves chemical reduction of the oxide ore with some carbonaceous material as reducing agent and using quartzite and lime and or/dolomite as fluxes.

The project will utilize briquettes utilizing Chrome-ore fines to the extent of 70%, lump and fine ores will be used to the extent of 20% and 5-10% respectively. Utilization of briquette charge will also optimize power consumption in the furnace.

3.4.11 Rolling Mill

In view of available infrastructure facilities the company proposes to set up a 0.3 MTPA Rolling mill to produce Mild steel bars, 0.3 MTPA rolling mill to produce alloy steel bars and 0.25 MTPA rolling mill to produce Stainless steel bars.

Process description Steel Billets/blooms from concast machine will be cut to desired sizes and either fed to hot rolling mill for processing or transferred to raw material shed store. Cold Billets are transferred to roller table and pushed through the Reheating furnaces by means of charging pusher & then these are heated and soaked up to 11500C that is above re-crystallization temperature and then discharged for rolling.

The Billets/blooms are then processed through roughing mill, intermediate mills and finishing mills to get the finished rolled products. Re heating of Billets will be done in reheating furnace by burning surplus BF gas.

Then rolled products are cropped & caught in required commercial length by hot saws. The products are finally cooled & taken to storage yard for sale.

3.4.12 Power Plant

A captive power plant (CPP) will be installed to operate the proposed integrated steel complex and to produce surplus power for meeting the requirement of future expansion of the plant of the plant.

21 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

The plant will be based on the utilization of waste heat of flue gases generated in coke oven plant and the blast furnace gas before their discharge to the atmosphere through waste heat recovery boilers as well as fuel fired circulating fluidized bed for steam generation and feeding to turbo generator sets.

For this purpose a 184 MW Power plant based on a combination of Waste heat recovery Boiler (WHRB) and Atmospheric Fluidised bed Combustion Boiler (AFBC)/Circulating Fluidised bed Combustion Boiler(CFBC) comprising two modules will be installed.

WHRB

1-Waste heat from flue gas of DRI Plant, BF and Coke oven Existing 22 MW

Proposed 54 MW

2-AFBC/CFBC Existing 125 MW

Proposed 133 MW

Total 187 MW

The stream generated from the waste heat boilers will be routed through a common header and joined with the steam header of CFBC boiler for feeding to the central turbo-generator station. Two turbo generators will comprise of two modules each of steam turbine and generator set with a rated capacity of 50 MW each.

3.5 RAW MATERIAL INVENTORY

Additional Annual Raw Material Requirement

Additional annual requirement of major raw material for proposed expansion and modification is as follows.

Table 3.2: Raw Material Inventory

Sl. No. List of Raw Materials Required Source Mode of Quantity in TPA transport

1 Iron Ore Fines 20,00,000 Odisha/Jharkhand Rail/Road (Beneficiation Plant)

2 Lime Stone/ Dolomite 10,000 Sundargarh Rail/Road (Odisha)

Char from 2x500 TPD DRI, coal fines and middling from washery will be utilized to generate 8 MW additional power in FBC

In addition to the above raw materials LDO/HSD, Electrode paste, Bentonite & lubricating oil will also be required.

22 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Raw Material Receipt & Store

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

Mode of Transport (Raw materials & products)

Transports will be done by the environmentally compliant trucks and covered trains 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 & rail line.

Raw Material Storage & Handling

Separate store yard for the major raw materials such as iron ore lumps, iron ore fines lime stone/ dolomite, quartz coal and Cr & Mn Ore etc are done. 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.

Product-Mix

The project is an integrated steel project. So, the final product is rolled products such as 0.3 MTPA mild steel, 0.3 MTPA stainless steel & 0.25 MTPA alloy steel. Apart from the rolled product the plant wants to sale extra pellets & DRIs. Total power generation from the project will be 184 MW which shall be produced from WHRB and AFBC/ CFBC. Total product mix after the expansion cum modification of the project is given in the following table.

Table 3.3: Total Product Mix

Final Product By Product in TPA Sl. Configuration Capacity in TPA No. Plant Facilities Coal Washery 0.9 MTPA 3,60,000 washed coal 3,60,000 middling 1 Coke Oven(Non- 5,00,000 coke 2 recovery with Dry 0.5 MTPA Quenching)

3 Iron Ore Beneficiation 2 MTPA 20,00,000 8,00,000 tailings

4 Pellet Plant 1.2 MTPA 12,00,000

1X60 m2 7,20,000 5 Sinter Plant 1X15 m2

6 Oxygen Plant 1X120 TPD 120 TPD Oxygen

7 Lime Plant 1200 TPD 2,15,040 CaO

2 X 100 TPD 6,72,000 1,03,488 char

8 DRI unit 3 X 300 TPD

2 X 500 TPD

23 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

1 X 380 m3 4,67,250 hot metal 1,40,175 BF slag 9 MBF 1 X 65 m3

4 X 20 T 5,76,000 hot metal 72,636 slag 10 Induction Furnace (IF) 4 X 25 T

4X9 MVA (Fe-Cr) Fe-Mn/Si-M - 30,000 26,694 slag

11 SAF (Ferro Alloy Plant) 2X9 MVA (Fe-Mn, Fe-Cr - 60,000 Si-Mn)

0.3 MTPA (MS 8,50,000 rolled 8,466 scrap products) product

0.3 MTPA (AS 12 Rolling Mill products)

0.25 MTPA (SS products)

54 MW 13 CPP (WHRB) 54 MW

133 MW 16 CPP (CFBC/AFBC) 133 MW

3.6 RESOURCE OPTIMIZATION /PROCESS FLOW SHEET

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

24 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Fig 3.4: Process Flow Sheet Diagram:

BAG FILTER 0.17 MTPA FOR SALE BAG CON. I O. FILTER I/O 1.2 MTPA 1.1 MTPA D R I BENEFICIATION PELLET 0.315 MTPA KILN I F PLANT PLANT R M 2 MTPA sponge iron 4X25T 0.30 MTPA I/O M. STEEL FINES 0.25 MTPA 0.8MTPA E S P WHRB TAILINGS L F C C M

E S P ARGON BAG I F FILTER A O D 4X20T L F 1X45T 0.67 MTPA I/O OXYGEN FINES SINTER SINTER 0.68 MTPA M B F P C M PLANT 1X65m3 C C M 1X380m3 0.068 MTPA PIG

HOT METAL B S G 0.39MTPA R M GRANULATED B F SLAG 0.25 MTPA FERRO S. STEEL C C M ALLOYS L F R M 0.33 MTPA A. STEEL

E S P C HAR

F B C MIDDLING C OAL PROCESS FLOW & CPP DIAGRAM SSL, JAMURIA

3.7 WATER REQUIREMENT

Total water requirement for the project as granted in existing EC is 26,760 m3/day. Expansion and modification water requirement will be adjusted from that amount by conservation, recycling and reuse of water. The permission is obtained from ADDA (Asansol- Durgapur Development Authority).

3.8 POWER & ENERGY REQUIREMENT

Power

The total power requirement for the existing & proposed project is about 166 MW and the other internal consumption is about 18 MW, which will be met from own internal generation from the captive power plants. So, total power generation will be 184 MW. Power Consumption Breakup is given in the following table.

25 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Table 3.5: Power Consumption Breakup

SL No Facility Power in MW

1 2200 TPD DRI kilns 7.0

2 75m2 Sinter Plant 5.0

3 1.2 MTPA Pellet Plant 4.7

4 1x380m3 & 1x65m3 MBF 8.4

5 4x25T & 4x20T IFs with LF, AOD & CCM 43.2

6 1200 TPD Lime Calcination plant 1.0

7 400 m3 Oxygen Plant 0.4

8 6x9 MVA Ferroalloy Plants 43.0

9 0.9 MPTA Coal washery 2.6

10 0.5 MTPA non recovery Coke oven 1.7

11 0.85 MTPA hot rolling mills 50.3

12 2 MTPA I/O beneficiation Plant 5.6

13 Domestic use and Road lighting 2.0

Total 174.9 ~ 175

Generation from own captive power plant - 187 MW Internal consumption for CPP is about - 17 MW Final Generation - 170 MW Total requirement for the total project - 175 MW

As all the machineries will not be running all the time and that too on full load the generation will meet the requirement.

26 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Energy

Energy consumption per ton in G.Cal is given in table below

Table 3.6: Energy Consumption

Sl. No. Units Per ton in G. Cal 1 DRI 2.3 2 Sinter 0.74 3 Pellet 0.30 4 Hot metal (From BF & IF) 6.02 5 Rolling mill 0.37

For finished steel= 6.39 G.Cal energy per ton will be consumed.

3.9 WASTE GENERATION & MANAGEMENT

Table 3.7: Solid Waste Generation & Management

Solid waste Quantity in TPA Utilization Measures

BF slag 1,40,175 Granulated & sold to cement plant

BF (Dust + sludge) 2,20,280 Brick, ceramics, Roof tiles & cement clinker as clay substitute. Iron ore tailings 8,00,000 Sale dry for tile making/land fill

Coal washery rejects 45,000 Briquette making

CPP Fly ash 1,28,278 Brick, sale to cement plant

CPP Bottom ash 85,519 Cement plant, Land fill

Fe-Mn slag 26,694 Use in Si-Mn production

Si-Mn Slag 27,320 To be sold to cement plant for production of alkali activated cement. Fe-Cr slag 54,067 Refractory material can be used in road construction. IF slag 72,636 River sand substitute, land fill

Dolchar 1,03,488 Use in AFBC for power generation

Dust & scrap - To be fully consumed in plant

Total 3,11,236

27 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

The total quantity of Solid wastes will be generated after the total project running and these will be fully utilized as per required.

Waste Water Management

28 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-4 SITE ANALYSIS

4.1 CONNECTIVITY

The site is located at Jamuria Industrial Eastate under Asansol Durgapur Development Authority, village- Ikra, PO- Mondalpur of Burdhwan district in West Bengal. The location is well connected with road and rail. NH-2 is about 4km from the plant site in South-West direction, which is also known as the Grand-Trunk road and NH-60, in South- East direction, is about 4.4 km from the plant site. Jamuria is the nearest town, which was developed because of the Industrial Estate. It is about 1.7 km in North-West direction. The nearest railway station Tapsi Railway station is about 3.8 Km away from the plant site. Raniganj & Asansol, opposite direction to each other are about 9 km & 9.2 km from the plant side respectively. Ajay River is flowing only 8.1 km away from the project site and the company will draw water from the river to meet its water requirement. Kazi Nazrul Islam International Airport, Andal:- 20 km in South West direction. The site is well connected to the basic raw material source like coal & iron ore.

4.2 LAND

The total land available for the proposed project is about 288.44 acres from which the existing units are situated in 149.24 Acres of land. For existing & proposed project from the total land area 128 acre is planned for the plant facility where approx. 94.45 acres of land is planned for the green belt development.

4.3 TOPOGRAPHY

The site is geographically located at Latitude 230 41’ 27.65’’ N and Longitude 870 05’ 54.51’’ E, 374 ft. MSL. Geographically, the average elevation is about 131 ft for the district Burdhwan. The area mostly is a plain area and have not contain much platue regions. It is situated in between two major rivers of the districts known as Damodar & Ajay river. The nearby areas are developed cities and township areas due to the industrial built-up.

29 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Fig 4.1: Toposheet

4.4 LAND USE PATTERN

The project area is present at Jamuria Industrial Estate, village- Ikra, PO.- Mondalpur, Burdwan district of West Bengal. 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.

30 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Table 4.1: Land Use Pattern for the total project

Sl. No. Different Units Area in Acre 1 Plant Facilities 128 2 Raw Material Storage 15.21 3 Water Storage & Treatment Facility 6.82 4 Rain water harvesting 5 5 Solid Waste disposal 12.84 6 Railway siding 10.41 7 Internal roads & parking facility 11.47 8 Green belt 94.45 Administrative building, Guest 9 4.24 House & Canteen Facilities

Total 288.44

From the above available land area 240 acres of land is existing land, where all the units (which are obtained EC previously from MoEF) will be commissioned.

4.5 EXISTING INFRASTRUCTURE

The growth of industrial sectors in 2x100 TPD and 3X 300 TPD DRI Plant, 0.6 MTPA pellet plant, 13 TPD oxygen plant, 2X25 T IF, 1 X 45 T AOD, 2 X 9 MVA Submerged Arc Furnace, 0.3 MTPA rolling mill, 59 MW of CPP with Administrative Building, Material Handling Facility of the existing infrastructure developments. The other units which are already obtained Environmental Clearance are going to be commissioned.

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). The seasons in Bardhwan are generally distributed as hot summer (April-May), monsoon (June-September) and 'Cold season' (November-February). The humidity is usually medium to high throughout the year and the rainfall, though not heavy, is usually well distributed. The average annual rainfall received by the district is around 1,300 mm-1400 mm.

31 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

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 shall utilize the existing infrastructural facilities for all purposes.

Peripheral Development Plan

M/s Super Smelters Ltd. will make sincere efforts to improve the socio-economic status of the local habitants. Already SSL has done some ESC activities for the nearby people like adopting a hospital with all treatment facilities and provide a homoeopathic doctor, a school & provide all the study materials for students and two time water supply facility etc. 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.

32 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Fig 5.1: MANAGEMENT HEIRARCHY

33 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-6 PROPOSED INFRASTUCTURE

6.1 INDUSTRIAL AREAL DISTRIBUTION

Proposed project will be planned in the extra land around the existing plant premises and the area is already within the Jamuria Industrial Estate. So, the area has already demarked as an industrial area. Total 288.44 acres of land will be available for the project proposal.

6.2 GREENBELT DEVELOPMENT FACILITY

In order to contain the air emission and also to improve the plant aesthetic, the company has already developed greenbelt and planned for extend it as the land will be enhanced for the total project. The total greenbelt development will be planned about 33% of land.

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-2 & NH-60 with distance of 4 km & 4.4 km 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

6.4.2 Solid Waste Generation & Management for total Project

Solid waste Quantity in TPA Utilization Measures

BF slag 1,40,175 Granulated & sold to cement plant

BF (Dust + sludge) 2,20,280 Brick, ceramics, Roof tiles & cement clinker as clay substitute.

Iron ore tailings 8,00,000 Sale dry for tile making/land fill

Coal washery rejects 45,000 Briquette making

CPP Fly ash 1,28,278 Brick, sale to cement plant

34 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CPP Bottom ash 85,519 Cement plant, Land fill

Fe-Mn slag 26,694 Use in Si-Mn production

Si-Mn Slag 27,320 To be sold to cement plant for production of alkali activated cement.

Fe-Cr slag 54,067 Refractory material can be used in road construction.

IF slag 72,636 River sand substitute, land fill

Dolchar 1,03,488 Use in AFBC for power generation

Dust & scrap - To be fully consumed in plant

Total 3,11,236

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 6.1: 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 MBF 3 - It will be utilized again in tuyers BF gas - Venturi Scrubber- Emergency Flaring Sinter Plant 4 Coke burning - ESP Fusion of coarse Iron Ore Pellet Plant - Operated in a close circuit. Dust collected is Grinder used in the manufacturing process - Pelletising is done in wet condition, hence 5 Pelletiser no dust generation - Materials handled shall be wet, hence no Roller Screen dust generation. - Flue gases will be released from the Induration Furnace furnace after passing through ESP. Collected dust is re-used in the process.

35 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

Sl. No. Plant/ Area Proposed Pollution Control Measure Captive Power Plant WHRB - ESP AFBC - ESP – Stack 6. Coal Crushing & Handling - Bag Filters & Water Sprinkling ESP Dust Handling (AFBC & - Pneumatic Conveying System, Pug Mill with WHRB) Bag Filter

Submerged Arc Furnace 7. Ferro Chrome - ESP Fe-Mn, Si-Mn - Bag Filter 8. Lime Plant - Bag filter & Cyclone Steel Making Shop Induction Furnace Bag Filter

9. LRF Exhaust Fan

CCM Exhaust Fan

Rolling Mill 10. 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 project will follow “zero discharge norm”

6.6 MAN POWER REQUIREMENT

The total man power requirement for plant operation on completion of the proposed expansion will be around 1850.

36 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-7 REHABILITATION & RESETTLEMENT (R&R)

REHABILITATION & RESETTLEMENT

The proposed expansion units will be carried out partly in existing plant premises and partly in new acquired land adjacent to the existing premises. The plant is situated in the Jamuria Industrial Estate. As no settlement is going to be affected so, no R&R facility will be anticipated.

37 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

CHAPTER-8 PROJECT SCHEDULE & COST ESTIMATES

8.1 IMPLEMENTATION SCHEDULE

Time schedule for completion of various activities is given below in Table 8.1. The zero date will commence after getting EC and consent to establish from SPCB.

Table 8.1: Tentative implementation schedule:

Sl. Activities Duration No.

1 Engineering

Concept Design 15 days

Basic Engineering 30 days

Detailed Engineering 150days

2 Civil Work

Land development 215 days

Finalization of layout & drainage 90 days

Construction of plant & auxiliary facilities 300days

3 Statutory Clearance for establishment

State clearance for establishment 20 days

State EC Clearance 90 days

4 Procurement

Place orders for long lead Equipments 90 days

Place orders for commodity items 30 days

Receipt of equipment 230 days

Installation of equipment & items 180 days

5 Erection & Commission

Inspection before commissioning 80 days

Commissioning & production trial run 40 days

Some works will proceed parallel and some in series. Critical Path Method (CPM) and Project Evaluation & Review Technique (PERT) will be followed for completion of project work. In short construction job will be completed within two years of time after getting consent to establish/EC from MoEF & CC.

38 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

8.2 ESTIMATED PROJECT COST

Project Cost The cost of the project is estimated to be around Rs. 2200 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. 72

2 Civil & Structural 132

3 Plant & Machinery 1210

4 Misc. Fixed Assets 184

5 Prel. Expenses 355

6 CSR 92

7 Pre-Operative Exp/IDC 100

8 Contingency 345

9 Margin for WC 310

Total 2800

39 GTEEPL

Techno Economic Feasibility Report of M/s Super Smelters Ltd At: Jamuria Industrial Estate under ADDA, Ikra, Mondalpur, Burdwan, West Bengal

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.

9.4 BENEFITS TO THE REGION AND THE COUNTRY

Super Smelters Ltd. shall produce steel rods to be utilized in construction & manufacturing activities. The products are in demand and production shall contribute to the GDP growth of the country.

9.5 PERIPHERAL DEVELOPMENTS

Super Smelters 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:

 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.

40 GTEEPL