Detailed Project Report - Welcome to Environment Project Report For Suraj Product Limited For...

Detailed Project Report For

Suraj Product Limited

For capacity increase by modernization of Mini Blast Furnace, installation of Ferro Alloys, Induction furnace

with CCM, Rerolling Mill, Iron Power through Tunnel Kiln, Coal Washery, Ore beneficiation, Cold briquetting, Brick

making and Captive Power Plant

At Village Barpali, Post- Kesramal, Rajgangpur District Sundergarh (Odisha)

(February 2015)

:: Prepared by :: Indus Technical and Financial Consultants Ltd. 205, Main Road, Samta Colony Raipur (CG) 492001 Tel: 0771 4266037, 3267187 Fax: 0771 2254188 Website: www.itfcl.com Email: [email protected]

Lalit Kumar Singhania Chief Consultant Email: [email protected]

INDEX

S . No. Heading Page No. 1 Executive Summary 1 2 Introduction of project/ Background information 7

2.1 Identification of project and proponent. 7 2.2 Brief description of the nature of the project 9 2.3 Need for the project and its importance to

the country and region. 9

2.4 Demand –Supply Gap 13 2.5 Imports Vs. Indigenous production 16 2.6 Export possibility 16 2.7 Domestic/ Export market 17 2.8 Employment Generation (Direct and

Indirect) due to the project 17

3 Project Description 20 3.1 Type of project including interlinked and

interdependent project, if any. 20

3.2 Location (map showing general location, specific location, and project boundary and project site layout) with coordinates

22

3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations.

27

3.4 Size and magnitude of the operation 27 3.5 Project description with process details (a

schematic diagram/ flow chart showing the project layout, components of the project etc.)

31

3.5.1 Manufacturing Process of Sponge Iron (DRI)

31

3.5.2 Manufacturing process of Pig Iron through Mini Blast Furnace

37

3.5.3 Process and Process Flow diagram of Iron Ore and other Mineral Ore Beneficaiton Plant

42

3.5.4 Process and Process Flow diagram of Coal Washery

49

3.5.5 Manufacturing process of reducing metallic mineral ore to metal power such as Iron Powder through Tunnel Kiln

59

3.5.6 Process and Process Flow diagram of Mineral Briquetting Plant

66

3.5.7 Manufacturing process of Ferro Alloys Plant

67

3.5.8 Manufacturing process of Semi finished i.e. Billet through Induction furnace based Steel Melting Shop with CCM

69

3.5.9 Manufacturing process of Rerolled steel through Rolling Mill

72

3.5.10 Process and Process flow diagram of Power generation through CFBC based Power Plant

74

3.5.11 Process and Process flow diagram of Brick making from waste

77

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 goods.

83

3.7 Resources optimization/ recycling and reuses envisaged in the project.

92

3.8 Availability of water its source, Energy/ power requirement and source.

93

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

97

3.10 Schematic representation of the feasibility drawing which gives information of EIA purpose.

100

4 Site Analysis 103 4.1 Connectivity 103 4.2 Land Form, Land use and Land ownership 103 4.3 Topography (along with map) 104 4.4 Existing land use pattern (agriculture, non-

agriculture, forest, waste bodies (including area under CRZ)), shortest distance from the periphery of the project to periphery of the forest, national park, wild life sanctuary,

109

eco sensitive areas, water bodies (distance from HFL of the river) CRZ.

4.5 Existing Infrastructure. 112 4.6 Soil classification 112 4.7 Climatic data from secondary sources. 112 4.8 Social Infrastructure available. 113

5 Planning Brief 114 5.1 Planning Concept (type of Industries,

facilities, transportation etc.), Town and Country Planning/ Development authority Classification

114

5.2 Population Projection 119 5.3 Land use planning (breakup along with

green belt etc.) 120

5.4 Assessment of Infrastructure Demand (Physical and Social)

120

5.5 Amenities/ Facilities 121 6 Proposed Infrastructure 122

6.1 Industrial Area (Processing Area) 122 6.2 Residential Area (Non Processing Area) 122 6.3 Green Belt 122 6.4 Social Infrastructure 122 6.5 Connectivity (Traffic and Transportation

Road/ Rail/ Metro/ Water ways etc.) 122

6.6 Drinking Water Management (source and supply of water)

122

6.7 Sewerage System 123 6.8 Industrial Waste Management 123 6.9 Solid Waste Management 123 6.10 Power Requirement and Supply/ source. 124

7 Rehabilitation and Resettlement (R&R) Plan 125 7.1 Policy to be adopted (Central/ State) in

respect of the project affected persons including home oustees, land oustees and landless laborers

125

8 Project Schedule and Cost Estimates 126 8.1 Likely date of start of construction and

likely date of completion (Time Schedule for the project)

126

8.2 Estimated project cost along with analysis in terms of economic viability of the project.

130

9 Analysis of proposal (Final Recommendations) 140 9.1 Financial and social benefits with special

emphasis on the benefit to the local people including tribal population, if any, in the area.

140

Figures Figure No.

Heading Page No.

1. District and Tahsil Location 23 2 Location Map of proposed site 24 3 Location and Layout of the Proposed Project 25 4 Road Network for Raw Material and Finished good

transportation 26

Appendix

Appendix No.

Heading Page No.

1 List of Sponge Iron Plants in Odisha 142 2 List of Sponge Iron Plants in Raigarh

(Chhattisgarh) 147

3 Mahanadi Coal field Limited’s Coal field in Orissa

148

4 List of Iron Ore Mines in Odisha 151 5 Estimation of Profit and Loss Account 155 6 Margin Money and Working Capital Calculation 156 7 Cash Flow Statement 157

Detailed Project Report Suraj Products Limited Village- Barpali, PO: Kesramal; Rajgangpur

District- Sundergarh (Odisha)

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Blast Furnace Modernization, SMS, Rolling Mill, Ferro Alloys, Power Plant, Ore Beneficiation, Coal Washery and Brick plant

1. EXECUTIVE SUMMARY: 1.1 Name of the Proposed Unit : Suraj Product Limited 1.2 Location : Village- Barpali (Laing),

P.O:- Kesramal Tehsil-Rajgangpur,

Distt.- Sundergath (Odisha) PIN 770017

1.3 Office (Regd.) : Village- Barpali, (Laing),

P.O.: Kesramal, Tehsil-Rajgangpur,

Distt.- Sundergath (Odisha) PIN 770017

1.4 Name of Promoters : Shri Yogesh Dalmia (Chairman) (Promoter )

Mrs Sunita Dalmia (Promoter ) 1.5 Product Mix, existing Installed Capacity and proposed expansion:

Existing Sponge Iron (DRI Kilns 50 TPD X 3 Nos.)

45000 TPA

Pig Iron (Mini Blast Furnace (23 m3)) 24000 TPA Iron Ore/ Mineral Ore Briquettes ( Cold Briquetting Plant -existing)

100000 TPA

Backup power generation (DG set installed for Emergency back up)

500 KVA X 3 Nos + 320 KVA x1 Nos.

= 1820kVA Proposed Expansion:



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Ore Beneficiation, Coal Washery, Sponge Iron, SMS, Rolling Mill, Ferro Alloys & Power Plant

Pig Iron [Mini Blast Furnace Modernization (increasing the volume to 40 m3 thus additional capacity increased by 36000 TPA, thus total capacity become 60000 TPA)]

36000 TPA

Iron Ore and Other Mineral Ore (Like Manganese; Chrome; Nickel Ore; etc) Beneficiation Plant input basis (throughput)

264000 TPA

Coal Washery 185000 TPA Reduced Metal Powder from metallic mineral ores such as Iron Powder and chrome ore, manganese ore etc. (through Tunnel Kiln process)

60000 MTPA

Iron Ore/ Mineral Ore Briquettes [Mineral Briquetting Plant (Proposed capacity addition) (100000 TPA existing + 100000 TPA proposed = total 200000 TPA]

100000 TPA

Ferro Alloys (25000 TPA) / Pig Iron (50000TPA) from Submerged Arc Furnace (7.5 MVA X 2 Nos)

Ferro Manganese/ Ferro Nickel/ Silico Manganese = 25000 TPA Or Pig Iron - 50000TPA

Semi Finished Steel [Steel Melting Shop (Through Induction Furnace)]

110000 TPA

Rerolled Steel [Rolling Mill (Structure / Rolled product)]

100000 TPA

Captive Power generation (CFBC Power Plant based on washery reject)

8 MW

Bricks (Brick making from waste) 66000 TPA Producer Gas plants two numbers for firing these Kilns

Each 1000 kg/hr or 6000 TPA coal



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gasification capacity or 3500 Nm3/hr i.e. 21 Million m3 per year producer gas.

1.6. Number of Shift : Three Shift Basis 1.7 Cost of Project : Existing : 4840.00 Lakhs Proposed

Phase-I : 6349.00 Lakhs Phase-II : 10890.00 Lakhs

Total : 22079.00 Lakhs



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(Rs.in Lakhs) Cost of Project Existing Proposed Total Amount

(In Rs. Lakhs) Phase-I

(Modernization of Blast Furnace,

SMS, Rolling Mill and

expansion of Cold

Briquetting Plant)

Phase-II ( Tunnel Kiln, Ore

Beneficiation, Coal Washery, Power Plant, Submerged

Arc Furnace ( Ferro Alloys Plant), Brick

making )

Land & Site Develop.

580.00 100.00 680.00

Building & Civil Work

746.00 849.00 1833.00 3428.00

Plant & Machinery & Other equipments

1249.00 3296.00 7642.00 12187.00

Misc. Fixed Assets auxiliary

1079.00 180.00 145.00 1404.00

Electrical Installations

508.00 625.00 175.00 1308.00

Pollution Control Equipment

678.00 500.00 222.00 1400.00

Pre. And Preoperative Exp.

421.00 269.00 690.00

Contingency 478.00 504.00 982.00 TOTAL :: 4840.00 6349.00 10890.00 22079.00

1.8 Means of Finance :

Means of Finance Total Amount (In Rs. Lakhs)

EQUITY Equity & reserve and surplus

a) Promoter contribution : 1600.00 b) Venture Capital fund : 1600.00 c) Public Issue : 3379.00

6579.00

DEBT Term Loan from Bank

15500.00

TOTAL :: 22079.00



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1.9 Capacity Utilisation : @ 60% in I Year @ 70% in II Year @ 80% in III Year

1.10 No. of Working Days : 330 Days 1.11 No. of Shifts : 3 Shifts 1.12 Man Power Utilization : Admin Staff : 66 persons Production Staff : 575 persons Total : 641 persons 1.13 Implementation Period : 60 Months

1.14 Financial Figures Particulars 1st Year 2nd Year 3rd Year Cost of Sales 44267.26 52310.73 59197.82 Gross Profit 7761.35 8389.32 10173.66 Operating Profit 1273.50 1337.24 2673.01 Taxation 0.00 0.00 184.25 Net profit after Tax 1204.50 1268.24 2419.76

1.15 Pay Back Period of Term Loan : 8 Years 1.16 Debt Equity Ratio of Term Loan : 2.36 :1 1.17 Break Even Point :

At 80% Utilization : 69.59% At 100% Utilization : 55.67%

1.18 Average Debt Service : 1.63 Coverage Ratio of Term Loan 1.19 Internal Rate of Return : 19.73%



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1.20 Consulting Organization : INDUS TECHNICAL AND FINANCIAL CONSULTANT LIMITED

205,Samata Colony, Raipur(C.G.) Email: [email protected]

Name of Consultants : Shri Lalit Kumar Singhania Chief Project Consultant Email: [email protected]



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2. INTRODUCTION:- 2. 1 Identification of project and project proponent:

The Company “Suraj Product Limited” is a Ltd. Company incorporated under The Companies Act 1956 with the object to setup an Iron & Steel Plant and Power Plant.

The Key promoter of the Yogesh Kumar Dalmia, who is a Chartered Accountant and having the experience in this field of more than 22 years. Other directors is Mrs. Sunita Dalmia having good experience, and knowledge about the industry. The Dynamic Synergy available with the promoters is indicated by establishment of an Existing Mini Blast Furnace and Sponge Iron kilns and proposed Steel Plant along with Power Plant.

M/s Suraj Product Limited is enjoying the existing production capacity of 3 Nos.X 50 TPD (45000 TPA) DRI kiln and 2 Nos. of 23 cum. (24000 TPA Pig Iron) Mini Blast Furnace, and Cold Briquetting plant of capacity 100000 TPA at located At– Village Barpali (Panchayat Laing), Post Kesramal, Tehsil Rajgangpur, District Sundargarh, Orissa.

The company proposes to add the following production/generation capacity as expansion:

Proposed Expansion: Pig Iron [Mini Blast Furnace Modernization (increasing the volume to 40 m3 thus additional capacity increased by 36000 TPA, thus total capacity become 60000 TPA)]

36000 TPA

Iron Ore and Other Mineral Ore (Like Manganese; Chrome; Nickel Ore; etc) Beneficiation Plant input basis (throughput)

264000 TPA

Coal Washery 185000 TPA



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Reduced Metal Powder from metallic mineral ores such as Iron Powder and chrome ore, manganese ore etc. (through Tunnel Kiln process) for present calculation Iron Powder from Iron Ore fines is considered,

60000 MTPA

Iron Ore/ Mineral Ore Briquettes [Mineral Briquetting Plant (Proposed capacity addition) (100000 TPA existing + 100000 TPA proposed = total 200000 TPA]

100000 TPA

Ferro Alloys (25000 TPA) / Pig Iron (50000TPA) from Submerged Arc Furnace (7.5 MVA X 2 Nos)

Ferro Manganese/ Ferro Nickel/ Silico Manganese = 25000 TPA Or Pig Iron - 50000TPA

Semi Finished Steel [Steel Melting Shop (Through Induction Furnace)]

110000 TPA

Rerolled Steel [Rolling Mill (Structure / Rolled product)]

100000 TPA

Captive Power generation (CFBC Power Plant based on washery reject)

8 MW

Bricks (Brick making from waste) 66000 TPA Producer Gas plants two numbers for firing these Kilns

Each 1000 kg/hr or 6000 TPA coal gasification capacity or 3500 Nm3/hr i.e. 21 Million m3 per year producer gas.

Village Barpali ( Panchayat Laing ) Tehsil Rajgangpur District Sundargarh



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Khasra number 2482/3528, 2497/3529, 2509/3530, 2510/3531,2496, 2482, 2494, 2481/3080, 376 (P), 2456, 2459,2451, 2479, 2480, 368, 2524(P),2493, 2454(P),374,3491,2492, 2500, 2457,2470, 2460,375, 394,395,2484, 2485, 2486, 2489, 25490, 2501, 2488,2487, 2523(P), 2483, 2458

Area 45.260 Acre Source of water Borewell & Pond Nearest Airport Ranchi about 180 KM Nearest Railway station Rajgangpur about 10 KM

2.2 Brief description and nature of the project:

The proposed project is expansion project towards backward forward and parallel integration of mini steel complex consisting of Iron Ore and Other Metal Ore Beneficiation; Iron Powder, Ferro Alloys, Induction Furnace, Steel melting Shop and Re rolling Mill, Coal washery and Power Plant etc..

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

region. Steel is one of the most important products of the modern world and is of strategic importance for any industrial nation. Historically, all nations during their industrialization phase have been supported by a strong steel industry of their own. From construction, industrial machinery to consumer products, steel finds a wide variety of applications. It is also an industry with diverse technologies based on the nature and extent of use of raw materials.

India is the 4th largest producer of steel in the world accounting for production of 81.54 million tons of crude steel in 2013-14. It also holds the third position in consumption of steel. Thus there is great potential in steel industry in India.

Honorable Prime Minister Shri Narendra Modi has envisage the growth of steel sector to attain a production capacity of 300 Million Tonnes by



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2020 hence in order to achieve this capacity it is essential to create the facilities based on local resources to produce steel.

The Honorable Prime Minister has also proclaimed the global commitment to fight Climate Change; hence the importance of creating the facilities to achieve highest energy efficiency in core sector industries is also very essential.

In view of these facts the proposed Steel Complex with Mineral

Beneficiation; Coal Washery; Tunnel kiln based metal ore reduction; Fine Ore Briquetting Machine capacity expansion; Blast Furnace Productivity enhancement, and Captive Power Plant with Ferro Alloys /Pig Iron production; Steel Melting Shop with Re Rolling mill having hot online re rolling facility becomes a project of national interest as the proposed technology to produce steel would be one of the most energy efficient technology in which direct online finished steel production in the form of TMT or Wire Rod is proposed by avoiding the reheating fuel required in the conventional rolling mills. , The captive power plant of 8 MW based on CFBC; is proposed with an intention to utilize industrial solid fuel waste like char-dolochar and coal middling as well as washery rejects to produce power. All these technologies make the project as a better energy efficient project. Due to which a substantial amount of GHG emission would be avoided or reduced than the baseline emission.

In addition to these the proposed coal washery is also going to add for promotion of cleaner technology in which a lower grade coal would be beneficiated to higher grade coal as result of which better energy efficiency will be achieved in the existing sponge iron kilns who would be utilizing high grade beneficiated coal and similarly better energy efficiency will be achieved in the thermal power plants which would be utilizing high energy content beneficiated coal. It is reported under a study that the beneficiated high calorie coal can bring down the GHG emission by more than 11%; by improving the energy efficiency. This also results in lower capital cost for handling and transport of fuel and ash at the non pit head power plants located beyond 1000kms distance.



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It also reduces the cost of fuel transport and reduces the burden of transport on Railway infrastructure too.

All these technology required to be promoted for securing a better energy efficiency and safer environment.

A brief note on the GHG emission reduction by the proposed project is also provided in the relevant section.

Several advantage to the nation with respect to the sponge iron plant and power plants sector by setting up Coal washery are presented herewith: WASHING COAL IS A MASSIVE WIN-WIN FOR ALL

(A) For Sponge Iron Plants - Use of hi-grade coal in sponge iron making, can reduce the

prevailing coal consumption of 1.85 MT/MT sponge iron to less than 1.2 MT coal per ton of sponge iron production.

- The metallization of sponge iron is drastically improved. - The campaign life of sponge iron kiln is greatly improved. - Water consumption in cooling of sponge iron in cooler

portion is reduced. - Waste generation in form of ABC bottom ash and CFBC

bottom ash and ESP dust is reduced. - The overall productivity of sponge iron plant and steel

plant is improved.

(B) For Power Plants - Power companies benefit from better efficiency, less coal

consumption, lower transportation cost, lower maintenance cost, better thermal efficiency, higher plant availability and less waste disposal cost.

- The country benefits from greater electricity supply and economic growth.

- Environment benefits – less CO2, ash and better air quality.



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- Reduced load on constrained transportation system rail and road- giving more coal supply for India.

Strong Environmental Case for Coal Washing - According to study from US department of Energy, the use

of washed coal reduced CO2 emission by as much as 11%. - Use of washed coal can increase generation from existing

plants by at least 10% which effectively reduced CO2 emission.

- India is likely to be one of the most impacted countries from climate change.

- According to the IFPRI, India will face the highest number of climate change related casualties.

- With the implementation of carbon credit, companies using washed coal would benefit from lower emission and higher profits.

- Washing will lower particulate air pollution- as India industrializes this will become a major problem.

Mandatory Washing of All Coal:

- Today it is only mandatory to wash coal transported above 1000 KM- enforcement is unclear.

- 100% coal washing should be mandatory within 5-7 years in the phased manner.

- India has been slower than other countries in implementing washed coal due to lack of emission standards and a misleading perception that coal washing adds to the cost of electricity generation.

- Unwashed coal encourages power companies to operate inefficient and highly polluting power plant.

- Washed coal encourages the use of efficiency super critical power plants which are better for the environment and for India’s goal of more electricity production.



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Advantages of the project • Value addition project by gainful utilization of wastes and

converting intermediate products into End-use product.

• Improved productivity of the existing process.

• Reduced operation cost due to sharing of infrastructures and manpower with existing unit reducing overhead by almost 30%

• Since the materials handling is similar to existing operation,

synergy of activities will bring economies to the unit.

• Dedicated and experienced workforce available.

• Ready market for the finished products. Easy accessibility to the thriving markets of Orissa, Madhya Pradesh, Bihar, UP and Chhattisgarh form another major locational advantage factor.

• Technology is not new and has already been successful tried

in number of plants.

2.4 Demand-supply cap: The Scenario of Steel Industry is clearly looking upward and the latest

data on Steel Industry is as follow :-

AN OVERVIEW OF STEEL SECTOR- (Source: Ministry of Steel, Government of India)

GLOBAL SCENARIO • In 2013 the world crude steel production reached 1606 million

tonnes (mt) and showed a growth of 3% over 2012. (Source: World Steel Association or WSA)



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• China remained the world’s largest crude steel producer in 2013 (779 mt ) followed by Japan (111 mt), the USA (87 mt) and India (81 mt) at the 4th position.

• WSA has projected Indian steel demand to grow by 3.3% in 2014 as compared to global steel use growth of 3% and Chinese growth of 3.1%. For 2015, further recovery is projected for world (3.3%) and India (4.5%) and a slowing down for China (2.7%).

• Per capita finished steel consumption in 2013 is estimated at 225 kg for world and 515 kg for China.

DOMESTIC SCENARIO • The Indian steel industry has entered into a new development

stage from 2007-08, riding high on the resurgent economy and rising demand for steel.

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

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



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

• The National Steel Policy 2005 is currently being reviewed keeping in mind the rapid developments in the domestic steel industry (both on the supply and demand sides) as well as the stable growth of the Indian economy since the release of the Policy in 2005.

Major Objectives of the National steel Policy 2012 are as follows: a) To attract investments in Indian steel sector from both domestic

and foreign sources and facilitate speedy implementation of investment intentions on board so far so as to reach crude steel capacity level of 300 million tonnes by 2025-26 to meet the domestic demand fully. \

b) To ensure easy availability of vital inputs and necessary infrastructure to achieve a projected production level of 275 million tonnes by 2025-26.

Demand Supply gap for Washed Coal:

As discussed above there are numerous advantages of using washed Coal. Thus looking at the need of Washed Coal in Sponge iron plants; Super thermal power plants; Super Critical Power Plants; existing as well as proposed capacity; will require to wash atleast 25% of Coal produced in India whereas at present the Coal washing capacity is only about 7% in India. In USA also



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50% of the Coal produced is used only after washing. Thus there is a great need to create facility for washing of Coal around the Coal mines.

2.5 Imports vs. Indigenous production

Iron ore is available in abundance in India whereas only non coking coal is also available in abundance but coking coal is no available in India. Thus steel production facilities added during last 10 years in India are well established based on coal based rotary sponge iron kilns. Prior to implementation of the sponge iron kiln based steel making the gap between demand and supply was being fulfilled by import of steel. The Chinese manufacturers are giving tough competition to Indian steel producers because of their cheaper production cost mainly due to abundantly available coking coal in their country. Therefore, in order to face the competition being poised by the Chinese manufacturer it is important to provide good quality washed coal to existing sponge iron plants in India and also provide good quality Iron ore / Pellets to the existing sponge iron plants. In view of this also the importance for a good quality washery becomes most essential. The Indian infrastructure sector is likely see a massive growth due to increasing economic status thus in order to keep the supply ready to match the demand of construction steel the additional capacity of TMT steel Bars is most immediate requirement of time.

2.6 Export possibility Export of Steel is always possible, the Government of India is also encouraging export of steel, however proposed quantity will be domestically consumed. The world steel market is for about 1500 Million Tonnes, out of which about 50% is being produced by China, the global demand even if increased by 2% per annum then it requires addition of 30 Million Tonnes additional production capacity. Since China has already reach to saturation level of increasing the production therefore India has better chance to share the world market by



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increasing it production in a energy efficient manner. The unit being located in the eastern sector can export the steel to Bangladesh; Bhutan; and Burma and Nepal also.

2.7 Domestic/ export Markets.

Domestic market with real estate, infrastructure project, industrial projects are available for purchase of steel which is estimated to be around 80 million tonnes per annum. The estimated growth in infrastructure is likely to increase the demand of steel to more than 150 million tonnes by the year 2020. In view of this it is required to make advance planning for creating the facility and infrastructure to meet this demand. The domestic market as well as export market both will require good quality steel, produced with minimum energy consumption and minimum cost of production. In order to achieve these objectives the proposed project has been designed to utilize waste resources to generate power and provides high grade beneficiated coal to the existing sponge iron plants and steel plants and power plants.

The project has potential to cater to the domestic demand as well as

export demand of steel and to provide washed coal to domestic as well as export oriented sponge iron / steel plants.

The tunnel kiln based reduced Iron Powder production technology is

likely to open new energy efficiency vista to the steel plants in India; by which the step of pelletization or sinter can be done away and directly produces the Reduced Iron Powder in most environment friendly manner. The same can also be used for experimenting to produce other reduced metals too. The Ferro Alloys plant will be able to meet the internal requirement of the Ferro Alloys as well as it is proposed to be tried to produce Pig Iron on trail basis; in case the trial is successful then it will be used to transfer the liquid Iron to produce steel in SMS.

2.8 Employment Generation (Direct and Indirect) due to the project

The unit will need additional Technical qualified personals for organizing the production and then several skilled workers for operating the unit and for working in workshop, etc. Besides all these type of



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workers a large number of additional semiskilled and unskilled workers will also be required for peripheral activities like transport, logistics, engineering, Services, commercial services etc. The industry is already having sufficient man power employed which mostly come from local areas. Most of these people are already well trained in the existing process operations. Also a large number of industries are already located in the region and the Orissa region has slowly and steadily become a major centre for steel production thus all these skilled and trained local workers are easily available in the region. Besides the production staff some more manpower shall be needed for administrative purposes. The local untrained manpower also will be trained to slowly take up to the Semiskilled and Skilled tasks. Initially the unskilled labor will be deployed from local area only. Subsequently they will be trained to take up higher responsibilities.

The list of likely employment due to project after expansion is given in table below, as per which following direct employment potential is likely to be generated:

• Administrative Staff 66 persons • Production Staff 575 persons

MONTHLY YEARLY S.No. PARTICULARS NOS. SALARY SALARY

A. ADMINISTRATIVE STAFF: 1 President Works 1 150000.00 18.00 2 Vice President Works 4 100000.00 48.00 3 Factory Manager 5 50000.00 30.00 4 Purchase/Sales/ personnel Accounts Officer 8 35000.00 33.60 5 Accounts Assistant 12 20000.00 28.80 6 Clerk 12 15000.00 21.60 7 Peon/ Security/ Drivers 24 7500.00 21.60

66.00 201.60 Add : Benefits 30.00% 60.48

262.08 B. PRODUCTION STAFF :

1 General Manager 3 75000.00 27.00 2 Dy. Gen. Manager 6 50000.00 36.00 3 D.G.M. Quality Control 6 50000.00 36.00



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4 Production Engineer 12 40000.00 57.60 5 Power Plant Engineer 16 40000.00 76.80 6 Steel Plant Engineer 10 40000.00 48.00 7 Sponge Iron Plant Engineers 12 40000.00 57.60 8 Environment; health safety engineers 12 40000.00 57.60 9 Coal Washery Engineer 6 40000.00 28.80

10 Production Foreman 12 30000.00 43.20 11 Production Supervisor 24 20000.00 57.60 12 Electrical Supervisor 15 20000.00 36.00 13 Mechanical Supervisor 15 20000.00 36.00 14 Laboratory attendants 12 15000.00 21.60 15 Workshop Attendant 24 15000.00 43.20 16 Skilled Workers 90 15000.00 162.00 17 Semi-Skill Workers 150 12000.00 216.00 18 Un-Skill Workers 150 9000.00 162.00

575.00 1203.00 Add : Benefits 30.00% 360.90

Sub Total :: 1563.90

GRAND TOTAL :: 641 1563.90



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3. PROJECT DESCRIPTION 3.1 Type of project including interlinked and interdependent projects,

if any. The project is an Existing Metallurgy project falling under “A” category. The project already has sponge iron; pig iron manufacturing trough Iron Ore and Coal, Iron Ore and Coke; It is proposed to add production of semi finished steel thru induction furnace route along with setting up a LRF as per the requirement of refining the steel ,in continuation to which CCM ( Continuous caster) with three strands and rolling of semi finished steel through rolling mill to finished steel in the form of TMT/Wire Rod/Structure will be set up. Along with these products facilities for production of Ferro Alloys through submerged electric arc furnace is also proposed. In the submerged arc furnace it is also proposed to carry out the development of technology to produce liquid iron in the pig iron form and convert the pig iron in liquid stage along with sponge iron in to steel with the help of induction furnace. Besides these a wet coal washery is planned to produce beneficiated coal with reduced ash content for seeking better energy efficiency in sponge iron and steel making. The circulating fluidized bed boiler with special provisions to combust high ash content low calorific value waste fuel like coal middling/ washery reject/ char-dolochar will be setup to produce power in the 8 MW captive power plant, which shall primarily be used for captive purpose. The expansion involves the Modernization of the both the Blast Furnace from 23 M3 to 40 M3 just by changing the BF shell which is likely to increase the hot metal production substantially ( @ 2.5ton/m3/day). In this expansion the following unique features are also proposed i.e. one to set up tunnel kiln with an objective to carry out research and development also for reduction of various kinds of Metal ores to directly reduced metal. It may be in the form of directly reduced Iron; Or Manganese or Partially reduced Nickel; Chrome or Mineral Based Pellets. The assessed capacity in terms of Iron is found to be 30000 tonnes in each kiln and two such kilns will provide 60000 TPA



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capacity. The Tunnel kilns will require the producer gas for the thermal energy so the Coal producer gas plants are proposed. Two producer gas plants for these two tunnel kilns will be built. These tunnel kilns are also being setup with a semi commercial intention to carryout technology development program also. In which reduction of various metallic mineral through direct reduction process is proposed to be attempted, as well as trial for producing pellets of iron ore or other mineral by way of indirect heat transfer through saggers are exposing to direct flame heat through the carrier trolleys is also proposed. For the sake of considering the viability the proposed capacity of tunnel kilns in form of Iron Powder is assessed as 60000 TPA for both the kilns in total, whereas, the capacity in terms of other mineral reduction may vary but not likely to beyond 60000 TPA. The fundamental technology proposed in the tunnel kiln is use of saggers in which reductent and mineral metal are filled in and pushed in to the staged trolleys in the tunnel kiln in which around 12000C temperature is maintained for reduction energy required. The thermal energy in the tunnel kiln is produced through the producer gas plants proposed in the project. The second important aspect of this expansion is mineral beneficiation, in which several types of metallic mineral such as low grade iron ore, manganese ore, chrome ore, nickel ore and such other ore for alloys steel or noble metal are proposed to be beneficiated through physical beneficiation process. The fundamental principle proposed for beneficiation in the following steps: 1. Separation due to differential breaking behavior for which

crushers of suitable capacity are proposed to be install by which partial beneficiation of some of the mineral is likely to be taken up at this stage.

2. Subsequent to the crushing screening with various sized of screen through vibrating screen is proposed.

3. After the screening, grinding of mineral to a particular fineness for physical separation of impurities is proposed.



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4. After grinding of mineral separation of impurities, by way of washing, froth floatation, hydro-cycloning is proposed.

5. In case of iron ore containing mineral magnetic separation is proposed.

6. According to the requirement of beneficiation process SPIRAL ZIGGER may be installed or the Vibratory Zigger may be installed, which shall be assessed as per the requirement of the mineral quality proposed to be beneficiated at the time of actual implementation of the project activity. For the time being the calculation are based on beneficiation of low grade iron ore of hematite nature, banded quartzite nature, magnetite nature.

7. Irrespective of the mineral proposed to be beneficiated, the entire mineral beneficiation process will be designed at Zero waste water discharge and 100% utilization of solid waste. The process will not required any fuel and entire beneficiation process will be design on the wet water stream. For the sake of present calculation wet water stream base iron ore beneficiation circuit is discussed in this DPR.

3.2 Location(map showing general location, specific location and project boundary and project site layout) with coordinates.

Details of area State Odhisa District/ Tehsil Tehsil- Rajgangpur, District- Sundargarh Village Barapali (Panchayat Laing), Post Kesramal Khasara No. Private Industrial Land:

Kh. No. : 2482/3528, 2497/3529, 2509/3530, 2510/3531,2496, 2482, 2494, 2481/3080, 376 (P), 2456, 2459, 2451,2479, 2480,, 368, 2524(P),2493, 2454(P), 374,3491,2492,2500, 2457,2470, 2460,375, 394, 395,2484, 2485, 2486,2489, 25490, 2501, 2488, 2487, 2523(P), 2483, 2458

Area 45.26 Acre

Toposheet No. 72 B/11 and 72 B/12 Geo-coordinates 22013’54”N 84037’22”

- Location Map, Layout, Road Network Map is give below:



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Figure :1 : District and Tahsil Location



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Figure :2 : Location and Layout of Proposed Project



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Figure No.3 : Plant Layout



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Figure-4- Road Network for Raw Material and Finished good

transportation



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3.3 Details of alternate sites considered and the basis of selecting the

proposed site, particularly the environmental considerations gone into should be highlighted. - Not required.

3.4 Size or magnitude of Operation

S.

No. Process Plant

Capacity of plant

Proposed Product name

Annual Capacity

a) Existing Direct Reduced Iron (Sponge Iron) from conventional DRI Kilns

Conventional DRI Kiln 50 TPD X 3 Nos = 150 TPD

Sponge Iron

45000.00 TPA

b) Mini Blast Furnace Existing PIG Iron from Blast Furnace of 23 m3

Pig Iron production capacity 80 TPD

Pig Iron

24000.00 TPA

Modernization in Mini Blast Furnace Proposed PIG Iron from Blast Furnace of 40 m3 each total Volume in two BF will become 80

Additional Pig Iron production capacity 120 TPD

Pig Iron

36000.00 TPA



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m3 Total Capacity of Blast Furnace after expansion

200 TPD 60000.00 TPD

c) Iron Powder and other direct reduced metal from ore; Like Manganese; Chrome; Nickel

Tunnel Kilsn based Iron Power making about 100 TPD x 2 Nos,= 200 TPD

Iron Powder

60000.00 TPA

d) Induction Melting Furnaces and LRF

12 MT X 3 Nos.Induction Furnace and 1 No. 25 MT LRF with three strand 4 meter X 8 meter Continues Casting Machine (CCM)

Mild Steel Billets

110000.00 TPA

e) Re-rolling mills

Direct hot charging facility with steel rerolling mill having about 300 TPD

Re Rolled Steel Products like; TMT; Wire Rod

100000.00 TPA

f) Power Plant

Circulating Fluidized Bed boiler with 8 MW STG based on washery reject

Electrical Energy in terms of generation capacity installed

8.00 MW



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g) Coal Washery

Wet process with heavy media bath with 50 T/hr capacity of coal washing

Raw Coal input Capacity i.e. raw Coal washing capacity

185000.00 TPA

h) Existing Cold Briquetting Plant

Cold Briquette of Iron Ore ore fines / waste mineral oxides in fine form approx 300 TPD

Iron ore fines / waste mineral oxides in fine form cold briquettes

100000.00 TPA

i) Proposed Cold Briquetting Plant

Cold Briquette of Iron Ore ore fines / waste mineral oxides in fine form approx 300 TPD

Iron ore fines / waste mineral oxides in fine form cold briquettes

100000.00 TPA

j) Iron Ore and other mineral Ore beneficiation plant

50.00 TPH two shift basis

Beneficiated Iron Ore

264000.00 TPA

k) Ferro Alloys plant

Submerged Arc Furnace with energy input capacity of 7.5 MVA each X 2Nos. ( Total 15 MVA) Furnace to produce Ferro Manganese/ Ferro Nickel/ Silico Manganese/ Ferro Silicon with a future provision for

Ferro Alloys; (Ferro Manganese/ Silico Manganese/ Ferro Silicon with a future provision for producing PIG Iron)

25000.00 TPA (Based on Silico Manganese)



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producing Pig Iron

l) Brick making from waste

Fly Ash and other waste material based Brick making unit of 200 TPD

Brick/Blocks 66000.00 TPA

m) DG sets for emergency back up

500 KVA X 3 No. and 320 KVA X 1 No. total three DG set

Electricity 1820 KVA



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3.5 Project description with process details: . 3.5.1 Manufacturing Process of Sponge Iron (DRI)

(i) RAW MATERIAL 1. IRON ORE It is available in India as commonly Hematite ore. However,

there are other two types of ore, which are known as Magnetite & Wustite.

HEMATITE : It’s chemical formula is Fe 2O3. For making

sponge iron, the ore should be lumpy, hard and massive and should not generate (–) 3mm fines more than 10 to 15% and (–) 1mm more than 2 to 3% inside the kiln. For making sponge iron the tumbling index should be (+) 90% but 88% may be accepted. The abrasion index of iron ore should be less than or maximum 2%. If the ore is flaky, formed in layers or friable, it generates lot of fines in the kiln. The fine gets reduced early when enters the final reduction zone, it tends to melt and stick to the well of kiln causing accretions.

The other important property of iron ore for making sponge iron

is its deductibility. Since the process of sponge iron manufacture is solid and gas reaction, the gas should penetrate the ore to take oxygen from ore. If the deductibility characteristics of iron ore are good, processing can be done at even a lower temperature and thus the problems of accretion can be avoided. Due to low temperature processing, consumption of coal per ton of sponge iron is also reduced and as a whole the campaign life becomes higher.



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The ideal iron ore to product sponge iron is as follows :

FeT 65 to 67%. SiO2 0.7 TO 1.0%. P 0.05% max. S 0.01% max. AL2O3 0.5 to 1.7%. MgO 0.02 to 0.03%. CaO 0.10%.

Physical Property

Tumbling Index More than 88%. Abrasion Index Less than 2%. Reductibility 7.00 to 10 hFE minimum.

Size 5mm to 20mm. The proposed sponge iron plant can also utilize the Iron ore

Pellets, which are now being manufactured by a large number of iron ore beneficiation cum pelletization plants. A number of units have already commence production in Odisha and West Bengal form whom substantial quantity of iron ore pellets is also available.

2. COAL : Coal is a combustible solid fuel formed by the burial of partially

decomposed vegetation in past geological ages. The coal used for sponge iron manufacture should be of the following property :

Volatiles 28 – 32% Ash 25 – 30% F.C. 40 – 42%

reactivity character. Lower the volatility lesser is the reactivity.

Higher the volatility higher is the reactivity. But too high volatility breaks the coal as a result of which the coal gets powdered and lots to the waste gas stream.



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Size of the coal also plays an important role. The size of the coal

to be fed from the feed and side should be of 5-20mm size. 10% of 20-25mm size can also be tolerable. Bigger size coal segregates and floats on the bed and gets burnt without going into the bed.

A given coal products char with certain reactivity. The char

reactivity is defined as the mass rate at which the carbon in char reacts with available CO2 to from the principal reductant CO (Carbon-mono-oxide). The char strength is also an important factor. Same char tends to break down which means loss of carbon.

The ash percentage in coal has also direct effects on the

production rate and coal consumption. Since the volume of the kiln is constant, the total volume Ore and Coal to be fed is constant. If the ash increases the fixed carbon reduces. When the fixed carbon reduces extra coal has to be given to make up for the less fixed carbon.

The property of coal ash is also important as it has direct bearing

on accretion formation. In view of this the washed coal available from the own coal washery will be used in sponge iron plant.

(ii) PROCESS OF SPONGE IRON MAKING For the direct reduction of iron ore, the main furnace used is

Rotary kiln. The rotary kiln is a refractory lined vessel on which several blowers are mounted. From the blowers, air pipes go thru the shell and refractory, vertically and deliver the required amount of air, required for the process axially. The kiln has conical out let and inlet holds the material in the kiln. Kiln is placed in a slope from feed end side at a slope of 2 ½%.

Iron ore, coal, dolomite/limestone is fed in the weighed quantity

and the kiln is rotated at a speed of about 0.5rpm. A temperature



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between 1000 deg.C to 1050 deg. C is maintained in about 70% of the kiln length towards discharge end side for required reaction.

After the reaction, the product is taken into an indirect cooling

drum cooler. The product is cooled to 100 deg. C and taken for product separation. The product is separated from the coal ash and coal char and then taken for final use.

The waste gas from the kiln contain lot of combustibles like coal

volatiles, unused CO, about 10 to 12% carbon particles and lot of other dust. The gas is taken to an after burner chamber and the combustibles are burnt is cooled to about 160 deg. C and taken to ESP for final dust separation, before going to stack via ID Fans.

The construction of kiln and cooler is made in such a way that no

outside air is allowed to go into the system. The outside air if goes to the kiln, re-oxidizes the product ultimately upsetting the temperature profile. To avoid this, ID Fan damper is throttled to maintain +ve pressure in the kiln. The pressure of about +5mm water column is maintained at kiln firing hood. However, checking the sponge iron fracture sample checks the setting of pressure parameter. If the sample shows a re-oxidized periphery the pressure may be increased.

The rotational speed of the kiln is adjustable as per the feed rate

and percentage of metallization. The % of inclination, rotational speed, the length of time the material is exposed to atmosphere, the kiln temperatures are all to be taken into consideration. So the kiln has three functions : A. It is a heat exchange. B. It is a vessel for chemical reaction. C. It is a conveyor of solids.



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REACTION VESSEL The kiln is also a reaction vessel. The following reaction takes

place inside the kiln : 3 Fe2O3 2 Fe3O4 6 FeO 6 Fe

The degree of reduction in each step is as follows :

3 Fe2O3 11% 2Fe3O4 22% 6 FeO 67% 6Fe The bye product of the above reaction is CO2. This carbon-di-

oxide reacts with carbon from coal to produce Carbon-mono-oxide:

CO2 + C = 2 CO The above reaction is known as Boudouvd reaction. So the

complete reaction is : CO2 + C = 2 CO 3Fe2O3 + CO = 2 Fe3O4 + CO2 CO2 + C = 2 CO Fe3O4 + CO = 3 FeO + CO CO2 + C = 2 CO FeO + C = Fe + CO2 The hydrocarbon of coal breaks down to hydrogen and carbon.

Some believed that Hydrogen also is used in Rotary Kiln as reductant. Since most of the kiln operates at +1000 deg. C the hydrogen being the lighter gas goes up quickly to the vacant space above the burden and helps in creating temperature.

The process of rate of reduction to final stage is effected by three

main factors viz : A . Quantity of reductant B . Temperature C . Residence time



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A . QUANTITY OF REDUCTANTS : From the chemical reactions it is seen that as the % of O2 reduces

in the ore, the % of carbon requirement increases. If there is a shortfall of carbon the reaction proceeds in a reverse way i.e. From reduction to oxidation. The reduction reaction is endothermic (absorbs heat) while the oxidation reaction is exothermic. In the absence of reductant the temperature goes up and sinter formation, ball formation and accretion starts.

For safe operating of the kiln about 0.45 to 0.50 MT of fixed

carbon is required per ton of total Fe input. Out of this 0.50 MT, 0.27 to 0.29 MT is given from feed end side and rest is given from kiln discharge end side. For safe operation and consistent quality, the carbon output per ton of Fe from kiln discharge is checked hourly and keeping this value at 0.10, final coal adjustment is done.

B. TEMPERATURE As the coal is mixed with iron ore, it passes from feed end side

and air is blown from the blowers into the kiln, the liberated CO reacts with oxide material. This reaction lowers the temperature of the bed due to its endothermic nature. It is necessary to generate sufficient heat before the bed temperature falls. The gases coming out from the bed are the mixture of decomposed and partially oxidized fuels. By adding air to these mixtures of gases, combustion and heat generation takes place and the heat is radiated to the bed, the mechanism of which has already been discussed earlier. As regards the temperature profile, the first 20 – 25% is preheat zone where the material is heated up to 850 deg. C and then to reduction temperature of about 1000 deg. C to 1050 deg. C. Iron ore once reaches 850 deg. C, the surface gets reduced and generates less fines. So it is required to heat up the ore to 850 deg. C as quick as possible and 70% of the kiln is taken to 1000 to 1050 deg. C for reduction purpose.



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C. RESIDENCE TIME The total residence time of the material in the kiln is a function of

the feed rate and kiln rpm. With each increment in feed rate, the kiln seed is increased to maintain a constant bed loading in the kiln.

3.5.2 Manufacturing process of Pig Iron through Mini Blast

Furnace The purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The blast furnace in this project is a Mini Blast furnace, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid slag and liquid iron. These liquid products are drained from the furnace at regular intervals. The hot air that is blown into the bottom of the furnace ascends to the top in 6 to 8 seconds after going through numerous chemical reactions. Once a blast furnace is started it continuously runs for oune to one and half years with only short stops to perform planned maintenance.

The Process



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Iron oxides is charged to the blast furnace plant in the form of raw ore, but pellets or sinter can also be charged. In the present Mini Blast Furnace the most unique process to charge the extruded ore fine briquettes has been successfully developed. This process gives the special environmental advantage to this Mini Blast furnace and also makes it unique and most energy efficient too. In future attempts will be made to utilize industrial wastes containing iron oxide for better utilization of the waste material.

Another raw material in the iron making process is limestone and dolomite. crushed and screened to a size that ranges from 0.5 inch to 1.5 inch is charged to become blast furnace flux . This flux can be pure high calcium limestone, dolomitic limestone containing magnesia or a blend of the two types of limestone.

Since the limestone is melted to become the slag which removes sulfur and other impurities, the blast furnace operator may blend the different stones to produce the desired slag chemistry and create optimum slag properties such as a low melting point and a high fluidity.

All of the raw materials are stored in an ore field and transferred to the stock house before charging. Once these materials are charged into the furnace top, they go through numerous chemical and physical reactions while descending to the bottom of the furnace.

The iron ore, briquettes, pellets and sinter are reduced which simply means the oxygen in the iron oxides is removed by a series of chemical reactions. These reactions occur as follows:

1) 3 Fe2O3 + CO = CO2 + 2 Fe3O4 Begins at 850° C

2) Fe3O4 + CO = CO2 + 3 FeO Begins at 1100° C

3) FeO + CO = CO2 + Fe Begins at 1300° C



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or FeO + C = CO + Fe

At the same time the iron oxides are going through these purifying reactions, they are also beginning to soften then melt and finally trickle as liquid iron through the coke to the bottom of the furnace.

The coke descends to the bottom of the furnace to the level where the preheated air or hot blast enters the blast furnace. The coke is ignited by this hot blast and immediately reacts to generate heat as follows:

C + O2 = CO2 + Heat

Since the reaction takes place in the presence of excess carbon at a high temperature the carbon dioxide is reduced to carbon monoxide as follows:

CO2+ C = 2CO

The product of this reaction, carbon monoxide, is necessary to reduce the iron ore as seen in the previous iron oxide reactions.

The limestone descends in the blast furnace and remains a solid while going through its first reaction as follows:

CaCO3 = CaO + CO2

This reaction requires energy and starts at about 1600°F. The CaO formed from this reaction is used to remove sulfur from the iron which is necessary before the hot metal becomes steel. This sulfur removing reaction is:

FeS + CaO + C = CaS + FeO + CO

The CaS becomes part of the slag. The slag is also formed from any remaining Silica (SiO2), Alumina (Al2O3), Magnesia (MgO) or Calcia (CaO) that entered with the iron ore, pellets, sinter or coke. The liquid slag then trickles through the coke bed to the



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bottom of the furnace where it floats on top of the liquid iron since it is less dense.

Another product of the iron making process, in addition to molten iron and slag, is hot dirty gases. These gases exit the top of the blast furnace and proceed through gas cleaning equipment where particulate matter is removed from the gas and the gas is cooled. This gas has a considerable energy value so it is burned as a fuel in the "hot blast stoves" which are used to preheat the air entering the blast furnace to become "hot blast".

The remaining gas not burned in the stoves is sent to the chimney for being flared up. It is proposed to put this gas also into use for utilizing the available energy in future for the drying of wet mineral or for some other heating purpose .

In summary, the blast furnace is a counter-current realtor where solids descend and gases ascend. In this reactor there are numerous chemical and physical reactions that produce the desired final product which is hot metal. A typical hot metal chemistry follows:

Iron (Fe) = 93.5 - 95.0%

Silicon (Si) = 0.30 - 0.90%

Sulfur (S) = 0.025 - 0.050%

Manganese (Mn) = 0.55 - 0.75%

Phosphorus (P) = 0.03 - 0.09%

Titanium (Ti) = 0.02 - 0.06%

Carbon (C) = 4.1 - 4.4%



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The Blast Furnace Plant

At present the liquid pig iron is being casted in Pigs and sold in market. In future after the Steel melting facilities are created then the Liquid Iron will be transferred to SMS area for the production of liquid steel. For this the cast house will be bye passed and the Laddles will be used for transfer of liquid iron.



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3.5.3 Process and Process Flow diagram of Iron Ore and other

Mineral Ore Beneficiation Plant Process Flow Chart

Hopper & Screener Vibrating screens are used to separate bulk materials in a mixture of different sized particles. For example sand, gravel, river rock and crushed rock, and other aggregates are often separated by size using vibrating screens. Screener one of the unique product or equipment manufactured and is used for separating the stuff. Screener is compiled of mainframe, eccentric bock, and screen web, rub spring, electric motor, coupler and some more.

-

Hop

per

Scre

en

Ball

Mill

(Gri

ndin

g)

Mag

netic

Sep

arat

or

Rin

ser

Mix

er(w

ash

with

wat

er)

Cyc

lone

(sep

arat

es

Mat

eria

l)

Dew

ater

ing

Scre

en

& F

inal

Pro

duct

(C

once

ntra

te)



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Ball Mill - A Ball Mill a type of grinder is a cylindrical device used in grinding

(or mixing) materials like ores, chemicals, ceramic raw materials and paints. Ball Mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. Different materials are used as media, including ceramic balls, flint pebbles and stainless steel balls. An internal cascading effect reduces the material to a fine powder. Industrial ball mills can operate continuously fed at one end and discharged at the other end. Large to medium-sized ball mills are mechanically rotated on their axis but small ones normally consist of a cylindrical capped container that sits on two drive shafts (pulleys and belts are used to transmit rotary motion.

-



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Magnetic Separator: Hi Gauss magnetic separator will be used for separation of Iron bearing oxides from the grounded ore. This magnetic separator will also be useful in beneficiating other metal ores also in which Iron bearing oxides form an essential impurity which requires to be removed. The magnetic separation step will be deployed as per the quality of the mineral being processed. The magnetic separation also will be done on the wet slurry stage. The outflow of Magnetically selected sludge will then be passed thru the Rinser to remove the dissolved clay with the Ores.



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Rinser Machine or Sand Washer - Rinser/Sand washer consists of wide decantation tank in which twin

row bucket wheel arrangement is positioned. The rotating bucket wheel carries the input sand in the perforated buckets. Due to the agitation created by moving the material inside the water the fines gets separated and is carried by the free flowing water through spill way to the sedimentation tank from where the water is recycled. The washed material is delivered to dewatering screen which delivers the washed sand on the conveyor. The good material if any moved along with water is pushed back into the bucket area by the spiral. The extracted water from dewatering screen goes back in to the decantation tank as the dewatering screen is integral part of it. Specially constructed motor & gearbox ensure reliable maintenance free operation. The bucket wheel speed can be controlled through VFD (Variable Frequency Drive) as per the washing quality needed.

-



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Cyclone Machine - In closed circuit grinding system, it features high classification

efficiency and fine over fall fineness under high mine concentration. (Hydrocyclone)Classification efficiency is higher for 5-10% than common screw grader. It benefits for enhancing grader utilizing. Fine materials, in gangue cannot be used as dam materials during selecting mine. After the classification by cyclone, coarse granule left in the bottom of dam, fine granule move to the tail of gangue. (Hydrocyclone) Fine granule graded naturally during the movement. There is section full of clean water, which can be used for calling back of water. In the process of filling tail, we utilize hydro cyclone for grading and concentrating to separate coarse granule so that to reduce load of filtering machine and to reach at the best effect. (Hydrocyclone) Use cyclone to finish dam and filling work so that to solve problems such as leaking mine, sink and over proof water discharged. So it can receive obvious economic and social benefit.



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De-Watering Screen Dewatering is an important process in mineral beneficiation processing. The purpose of dewatering is to remove water absorbed by the particles which increases the pulp density. This is done for a number of reasons, specifically, to enable ore handling and concentrates to be transported easily, allow further processing to occur and to dispose of the gangue. The water extracted from the ore by dewatering is re-circulated for plant operations after being sent to a water treatment plant. These processes increase in difficulty and cost as the particle size decreases. Dewatering screens operate by passing particles over a screen. The particles pass over the screen while the water passes through the apertures in the screen. This process is only viable for coarse ores that have a close size distribution as the apertures can allow small particles to pass through. Sedimentation operates by passing water into a large thickener or clarifier. In these devices, the particles settle out of the slurry under the effects of gravity or centripetal forces. These are limited by the surface chemistry of the particles and the size of the particles. To aid in the sedimentation process, flocculants and coagulants are added to reduce the repulsive forces between the particles.



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Process Flow Diagram for Iron Ore Beneficiation - 70% low grade will be more than 1 mm size

Low Grade Ore .

Hopper

Less than 1 mm

More than 1

Ball Mill

Rinser/ Sand Washer

Hydro Cyclone

De-watering Screen

Tailing Ore + Water

Water

Water

Wet Screen

Water + Ore

Washed Material + moisture Concentrate Ore with Water/Clay

Over Flow

Under Flow water with Iron Ore concentrate

Washed Material + moisture

Ore + Water

Rec

ycle

d to

Bal

l Mill

Magnetic Separator



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3.5.4 Process and Process Flow diagram of Coal Washery The selection of Wet Coal washing process depends mainly upon the following criterion. Washability Characteristics of input Coal Size and quality Ash and Moisture requirement of products Indian coal have very high near Gravity Material (NGM). Presence of high NGM (more than 20 units) in ROM coal makes the washing of coal very difficult . Hence, selection of suitable washing process is of paramount importance for Indian Coal. “Birds” classification of NGM visa-avis suitable washing process are indicated as below;

NGM Type of Coal Process 0-7 Simple Coal Jig 7-10 Moderate Coal Baths tables spirals 10-15 Difficult to wash 15-20 Very difficult 20-25 Exceedingly difficult >25 Formidable

From the above table is clear that HY Bath process is the suitable process for treating high NGM Indian Coal. Moreover from the efficiency point also the HM Bath process is most suitable process which gives lowest EQ (Escort probable –means Error probable) Lowest misplacement .A comparison of EP achievable in various processes are given below.

HM Cyclone/Bath --- 0.025 to 0.035 Jig --- 0.10 to 0.12 Barrel --- 0.09 to 0.10

The process misplacement which is depicted by the partition curve also shows minimum misplacement in case of HM clone process. All these factor contributes to higher yield by HM Bath process which is about 10 to 15% more than jig or Barrel process.



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Heavy Media Cyclones and Bath. Although all technologies have its own positives and negatives, the selection largely depends on typical application for which the coal is beneficiated and the sensitivity of each of the system. Most of the trials in India during the past one decade (the period where coal washery technology started spreading its population) has proved Heavy Media technology has an edge over all other technologies while dealing with typical Indian coal. Now, HM barrels are more successful in coking coal as compared to Power grade coal and cross migration of clean and rejects are more in percentage as compared to Cyclones and Bath. Also, it is sensitive to presence of fines in the feed.

It is proven that HM Cyclones/Bath is best suited technology for Indian coal. Also cyclones can take large feeds and give a fine cut off the Good and Bad coal. Same is the results found with HM Bath. Cyclones are sensitive to larger fractions like (+) 50-55 mm but reasonable percentage of fines won’t create any problems in cyclones. Since Cyclones will require high end slurry pumps the maintenance cost in a Cyclone technology can be a little more than any other technology.

Thus we have zeroed in with HM Bath technology due to its consistent performance, relatively lesser maintenance cost and easy to operate.

Process It is proposed to procure install and commission a 1.85 LTPY (35 TPH) coal processing unit for SPL. The 35 tph plant is likely to run in two shifts for 330 days to cater to the need of the internal requirements of washed Coal. The proposed washery shall incorporate the latest designs and the latest equipments and shall be a heavy media cyclone/bath based coal beneficiation processing unit.

ROM shall be delivered to the truck dump station via tippers and the capacity of the truck dump hopper shall be 25tons and above. The truck



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dump shall be an elevated bunker with access for trucks to unload the ROM into the hopper. The nominal size of ROM shall be 0 mm-250 mm. Dry Screening Section The crushed raw coal received of size (-) 50 mm will be first fed to dry screening for separation at 10mm. The undersize of the screen (-)10 mm will be fed on conveyor and it will be mixed with washery reject to make middling product for use in power plant. The oversize from dry screening will fall on dry screen discharge conveyor and will go to washery section for further beneficiation. Desliming screen circuit The raw coal entering the preparation plant from the dry coal screening section will be classified at 0.5 mm on raw coal desliming screen. The (-) 0.5 mm under size from the desliming screen will report to the classifying cyclone feed sump for further pumping to classifying cyclone. Rotary Breaker: It is also proposed to set up a Rotary breaker by which it will be possible to remove the shell and stone to a great extent and the semi beneficiated coal will be further washed for the improvement of quality. Deslimed coarse coal washing circuit The (-) 50 mm (+) 0.5 mm raw coal slurry shall be pumped from heavy medium cyclone feed sump to heavy medium cyclones. Heavy media cyclone over flow known as washed coal will undergo for medium recovery and dewatering by clean coal drain and rinse screen. The clean coal is then gravitates to centrifuge for dewatering. The reject from the under flow of the heavy medium cyclones will undergo for medium recovery and dewatering on reject D&R screen and then to reject centrifuge to achieve lower moisture in reject product. Both clean coal and reject are onward disposed by separate belt conveyors.



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Deslimed fine coal washing circuit The (-) 0.5 mm fraction coal will be pumped from the classifying cyclone feed sump to classifying cyclone. The over flow from the classifying cyclone will gravitate to thickener. The under flow from the classifying cyclone will report to high frequency screen. The high frequency screen overflow is taken as fine coal product. The high frequency screen under flow will report to the thickener. The thickener underflow will be pumped to belt press for dewatering of fines. The dewatered fine from the belt press will join the product from high frequency screen over flow. Thickener over flow water will be recycled in the washery for optimum utilization of process water. The belt press product and high frequency screen over flow joining together will be onward disposed by belt conveyor on reject conveyor. Water Recovery Circuit The refuse thickener shall be used to concentrate the waste slurries and recover water for reuse in the plant. A flocculent dosing system will be provided for water clarification. The lamella thickener under flow slurry will be pumped to belt press for dewatering and producing the dewatered cake. Filtrate will be re-circulated to the thickener for optimum utilization of process water. Make-up water shall be supplied by the customer to supplement clarified water overflowing the thickener weir. Re-circulated water shall be pumped from the clarified water sump to the screen sprays, sumps and distributors within the plant. A separate pump shall provide wash down water to the refuse belt press.



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Magnetite Recovery Circuit A magnetite recovery system shall be provided. The first portion of the sinks and floats drain and rinse screens shall collect the medium which drains from the coal particles. This drained medium shall be taken to the heavy medium cyclone feed sump for reuse in circuit. To prevent slimes build-up, bleed lines shall be provided to direct some of the re-circulated medium to the dilute medium circuit. A separate pan section under later part of each drain and rinse screen shall collect the heavy medium which has been rinsed and diluted with screen spray water. This dilute medium shall be collected in the dilute medium sump and pumped to one magnetic separator for recovery of the magnetite. Recovered magnetite from the separators and the fresh dry magnetite from the raw magnetite storage bin shall be directed to the heavy Medium cyclone feed sump The tailings from the magnetic separator shall be piped to raw coal desliming screen for use as sluice push water. Specific Gravity & sump level control circuit The density of medium returning to the Heavy medium Cyclone Feed sump shall be monitored. when specific gravity of the medium fall below the set point, dry magnetite shall be added until the medium gravity reaches the set point, at which time the addition of magnetite shall cease. Sump level control shall be maintained via differential pressure transmitters (DP cells) and auto control valves. A DP cell shall be mounted on to each process sump. The output of the DP cell shall operate an auto-electric on/off water valve. When the sump level drops below the set point, the DP cell shall signal the valve to admit water to the sump. On reaching set point the DP cell shall signal the valve to close. The reject coal from the reject D&R screen is discharged over the reject coal belt conveyor for suitable stockpiling. The clean coal is discharged over the clean coal belt conveyor where the clean coal



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may be blended with the raw bypass coal if required in the ratio to give final ash content as required by the end user. The product on conveyor is carried to a clean coal load out bin which has Clamshell gate at the discharge for loading coal onto trucks.

The effluent treatment plant consists of one Hi-rate thickener and its associated flocculent dosing system, underflow sludge carrying pump and a multi roll belt press.

The effluent from the plant, which reports (Flows) to the hi-rate thickener is collected in the thickener tank. This tank is dosed with suitable amounts of flocculent which aids settlement of suspended solids and helps to give a clearer overflow.

The settled solids are collected at the bottom cone of the thickener tank by rotating rake arms the height of which can be adjusted if the amount of solids in the effluents increases.

The solids which are collected in the bottom of the thickener is pumped using a special centrifugal pump to the multi roll belt press for reclamation of water. The dried cakes are blended with the rejects.

The overflow of the thickener, which is clear water is pumped back to the preparation plant for re-circulation.

The proposed plant is a zero effluent plant and the process selected ensures minimum generation of dust.

1. FUGITIVE EMISSION STANDARDS (as per CPCB):

The difference in the value of suspended particulate matter, delta (D), measured between 25 and 30 meter from the enclosure of coal crushing plant in the downward and leeward wind direction shall not exceed 150 microgram per cubic meter. Method of measurement shall be High Volume Sampling and Average flow rate, not less than 1.1 cubic meter per minute, using upwind downwind method of measurement.



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2. EFFLUENT DISCHARGE STANDARDS

Effluent discharge standards as per CPCB are given below: the unit shall comply with all these standards.

• The coal washeries shall maintain the close circuit operation

with zero effluent discharge. • If it becomes necessary to discharge the effluent to sewer /

land / stream, due to some genuine problems like periodic cleaning of the system, heavy rainfall etc, the effluent shall conform to the following standards at the final outlet of the coal washer : S.NO Parameter Limits 1. pH 5.5 -- 9.0 2. Total suspended Solids 100 mg/l. 3. Oil & grease 10 mg/l. 4. B.O.D at 27oC, 3 days 30 mg/l. 5. COD 250 mg/l. 6. Phenolics (C6H5OH) 1.0 mg/l.

3. NOISE LEVEL STANDARDS

Noise level standards as per CPCB are given below: the unit shall comply with all these standards.

Operational / working zone--85dB(A) Leq For other places like office / community place / boundary line--70 dB(A) Leq

The ambient air quality standards in respect of noise as notified under Environmental (Protection) Rules, 1986 shall be followed at the boundary line of the coal washery.



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4. CODE OF PRACTICE FOR COAL WASHERY

• Water or chemical mixed water shall be sprayed at all strategic coal transfer points, such as conveyors, loading / unloading points etc. As far as practicable, conveyors, transfer points, such as conveyor, loading / unloading points etc. As far as practicable, conveyors, transfer points etc shall be provided with enclosures and bag filters.

• Crushing / pulverisation of coal should be crushed out in enclosures fitted with suction arrangement followed by bag filter before the sucked air is finally emitted through a stack of minimum height of 30 m and conforming to particulate matter emission standard of 150 mg/Nm3.

• Water sprinkling arrangement shall be carried out by fine atomizers / nozzles or) the coal heaps and on land around the crushers.

• Area in and around the coal washery shall be pucca either asphalted or concreted.

• Green belt must be developed along the road side, coal handling plants, residential complexes, office building and all around the boundary line of the coal washery.

• Coal washery must operate on close circuit.

• Water consumption shall be 1 - 1.5 m3/tonne of coal.

• For the recovery of fine / ultrafine coal particle effectively, polymeric flocculants in proper doses shall be employed.

• Settling ponds shall be so designed and provided to ensure 90% removal efficiency.



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• Slurry ponds shall be adequate to take care of the overflows.

• The plant and machinery of the coal washery shall be properly maintained and shall be fitted with adequate noise abatement measures.

• Chutes in the coal handling plant shall be properly lined.

• Workers shall be provided with ear plugs / Mufflers etc if working in high noise area.

• Storage bunkers, hoppers, rubber decks in chutes and centrifugal chutes shall be provided with proper rubber linings.

• Vehicles movement in the coal washery area shall be regulated effectively to avoid traffic congestion. High pressure horn shall be prohibited. Smoke emission from heavy duty vehicle should conform to the standard prescribed under Motor Vehicle Rules, 1989.

• Heavy noise generating machinery should be enclosed in noise proof enclosures.



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Process Flow Diagram for Coal Washery



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3.5.5 Manufacturing process of reducing metallic mineral ore to

metal powder such as Iron Powder through Tunnel Kiln The process was developed in 1908, which uses coal as a reductant. The carbothermic reduction of iron ore takes place in horizontal tunnel kiln.

Reduction mix, consisting of coal or coke fines of the size 3 mm or below, anthracite, and limestone, is charged with iron ore in ceramic muffles/saggers. Ceramic saggers give life of about 8-10 heats. For better life (about 100-120 heats) and improved heat transfer, many plants use silicon carbide (SiC) saggers. The materials are arranged in alternate layers in the form of concentric rings within a sagger. Figure 1 depicts the sagger with iron ore and coal in a concentric manner. Also, in some processes alternate layers of coal-ore-coal are placed.

Empty Silicon Carbide (SiC) Saggers



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Above Figure shows unfilled SiC saggers. Individual saggers are then stacked on one above the other. Arrays of such units are formed above the kiln car. Schematic of the arrangement of the saggers above the car is shown in Figure 3 (a). Figure 3(b) depicts the actual photograph of car trolley along with array of saggers. The plant in which silicon carbide saggers are used, the empty saggers are first placed one above the other, and then the concentric feeding of coal and iron ore fines is carried out.

Schematic of arrangement of saggers on the trolley and Stake of SiC saggers mounted on trolley, entering into tunnel kiln

Car pushing system



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The cars are then pushed through the tunnel kilns. Figure 4 shows the photograph of car pushing system. The time between two cars entering the kiln is called the "pushing time". The tunnel kiln consists of three zones; the preheating zone, the reduction zone, and the cooling zone. Schematic of the tunnel kiln is depicted in Figure 5. The kiln cars first travel through the preheating zone, then through the reduction zone, where the ore is reduced into iron at a constant high temperature of 1100-1200°C. The kiln cars are then cooled in the cooling zone of the kiln. It takes approximately 28-36 hours for a kiln car to travel through a kiln. The time of travel may vary from plant to plant. The combustion air flows in the opposite direction of the kiln cars. Cold fresh air first cools the hot cars and after passing through the reduction zone, hot exhaust gases preheat the incoming cars before the gases exit the kilns. Because of concentric feeding of raw material inside the sagger, the coal ash and sponge iron, a product, remain separate inside the sagger. The product, thus formed, can be separated easily. Figure 6 shows the iron powder in the form of a cylinder.

Schematic of the tunnel Kiln

The efficiency of the iron powder process is defined as the energy needed for the reduction reactions compared to the energy added to the system. Large amount of heat demand for the process is fulfilled by coke mix and natural gas, while the maximum heat is consumed by the reduction reactions. The



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process efficiency of s process is about 40%, which decreases slightly with decreased pushing time.

Consumption of raw materials and energy per tonne of iron powder for Hoganas process is as follows : • Iron ore concentrates : 1350 kg • Coke : 500 kg • Lime : 125-130 kg • Energy consumption : 14.5 GJ

As against the above consumption parameters the raw material and fuel mix in the proposed Iron Powder plant would be as below: • Iron ore concentrates : 1600 kg • Coal as reductant : 700 kg • Coal for producer Gas : 200 kg • Lime : 50 kg Typical analysis (%) of Hoganas iron powder is, • Fe (metallic) : 93.0 • Fe (total) : 97.0 • Metallization : 95.9 • C : 0.2 • S : 0.008 • P : 0.012 • Gangue : 1.6

The consumption norms will vary as per the quality of input raw materials. Instead of coke if coal is used then the quantity will further increase. With Chinese/anthracite coal the consumption is about 0.9 to 1.1 tonnes per tonne of iron powder. With Indian coal, the consumption is expected to be more. However the use of Washed Coal will ensure that the total consumption of Coal does not exceed 0.9 tonnes per tonne of Iron powder produced. Out of



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the total coal, 75% will be utilized for iron ore reduction and the remaining 25% will be used to produce coal gas.

The product of tunnel kiln

Looking at the overall scenario of tunnel kiln process it can be said that tunnel kiln process is capable of reducing iron ore fines using coal/coke fines. Consumption of the coal per tonne of production of iron powder is considered as coal required for reduction and coal required generating coal gas. With thorough study of fluid dynamics and proper circulation of the coal gas and hot air within the kiln helps in improving the thermal efficiency of the kiln.

Advantages of Tunnel Kiln:

• Low capital investment • Easy operation and low maintenance cost • In place of sized graded iron ore, tunnel kiln process uses

iron ore fines, and • Performance can further be improved by using composite

green pellets.



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3.5.5.1 Producer gas Plant: Two PG plants each with 1000 kg/hour Gassification capacity will be

built for supply of required thermal Fuel energy to the Tunnel kiln; Producer gas Plant Process: Producer gas plant is equipments or a combustion furnace in which coal

is fired with steam saturated partially heated up air in insufficient quantity, so as to provide about 50% of the steochmatric air required for full combustion, thereby generating a gas which is rich in combustible gases called producer gas. The plant consist of a rotating ash pan on which a combustion rotating hearth is installed over which cylindrical shell with water jacketed cylinder is provided in which the steam saturated combustion air is fired from the bottom and producer gas is collected from the top. The coal is charged from the top through a air sealed continuous feeding device.

The vertical bet of coal forms three layers which is called as

combustion layer, reduction layer and gasification layer. The combusted ash is discharged from bottom of the ash pan. It is

proposed to setup two number of producer gas plant each with 1000 Kgs/hr coal gasification capacity.

The next generation gasification system are equipped with LTC shaft

and 100% top off take of producer gas conversion system. In which Low Temperature Carbonization (LTC) is the term for the conversion of organic substance of volatile matter into carbon and light carbon-containing compound through low temperature destructive distillation of feed coal. As about 90% heavy organic compound (sticky tar) of the total volatile matters of Coal convert in to free hydrogen, carbon and lighter hydrocarbon (Free Flow Tar) which makes gas free from heavy hydrocarbon vapor (Sticky TAR). The objective of new generation gasification is to produce a clean and consistent quality producer gas of higher calorific value from any grade of Indian Coal of A to F grade. With this objective in view, a deep



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coal– bed has been introduced above the insignificant product gas space and minimal distillation zone of the single stage gas-producer the product gas has been diverted fully through this extended coal bed to come out from the top of the extended shaft at a temperature much below the cracking temperature of sticky TAR.

The drawing of a producer gas plant is given below:



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3.5.6 Process and Process Flow diagram of Mineral Briquetting Plant

The promoter of the company Mr. Y.K. Dalmia has evolved a unique concept of utilizing fine and waste mineral resources, for which he has taken assistance of a world renowned machine manufacturer from USA who has been the business of clay extrusion since the year 1889. The family having more than 100 years of experience in the subject took up the challenge to manufacture a iron ore fines cold extrusion type briquetting machine. The company has installed a machine with 100000 TPA capacity, in which iron ore fines available from steel plants in the form of flue dust or other type of dust etc. have been tried and successfully extruded to produce iron ore briquettes for using in the blast furnace. The process involves addition of small quantity of additive @2.5% are added and water is added to provide adequate moisture\ and the mix is then extruded through extruder to form the cold briquettes. The coke fines can be added to a certain ratio to the mix as per requirement. The extruded briquettes are left in the shed for air drying and curing. After about 3 days of air curing, the briquettes are used for reduction in blast furnace and in future when tunnel kiln is setup it can be used in tunnel kiln for reduction.

It is proposed to setup one more set of similar extrusion type briquetting

machine for briquetting the iron ore fines or flue dust or blue dust. The new machine will also be provided with facility to dry out briquetting of other fine mineral ores. The process is completely a physical process carried out in ambient temperature and does not involve any fuel or thermal energy for fusion or binding.



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3.5.7 Manufacturing process of Ferro Alloys Plant Standard High Carbon Ferro/Silico Manganese is smelted at

about 1700-1800OC. A conventional Submerged Arc Electric Furnace achieves this. The three carbon electrodes, partially submerged in the charge, are supported on hydraulic cylinders for upward and downward movements to maintain the desired electrical conditions in the furnace.

The body of the furnace is cylindrical in shape, and is lined with firebricks, silicon carbide bricks and carbon tamping paste. Two tap-holes are provided at 120O. Apart for draining out both the molten alloy and the slag. During the repair works of one of the tap holes the other will function as standby.

The raw materials are thoroughly mixed in the proper proportion before being charged into the furnace. Manual poking rods or stroker car are used for stoking the charge on the furnace top. As the charge enters the smelting zone, the metal alloy formed by chemical reactions of the oxides and the reductant, being heavy gradually settles at the bottom. The slag produced by the unreduced metal oxides and the flux, being relatively lighter, floats on the metal alloys surface.

At regular intervals the furnace is tapped. The tap hole is opened by Oxygen lancing pipe and after tapping is completed, it is closed by clay plug. The liquid Silicon manganese and the slag flow the C.I. Pan. The slag being lighter overflows from the C.I. pan and is taken into the sand mould.

The alloy cake from C.I. pan is removed and broken manually with hammer to required lump size.

The slag produced in the process is generally free from metal thus after cooling the slag is shifted to slag dump.



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It is also proposed in future to try to produce Pig Iron from Submerged Arc Furnace by using lower grades Iron Ore and Magnetite Iron Ores and take the liquid Iron to Induction Furnaces for production of steel. This when implemented would bring additional energy efficiency in the Induction Furnaces, by reduced electricity consumption. Since the exact process is still not finalized hence the Pig Iron production is not considered at this point for the sake of financial calculations.

Process Flow Diagram for Ferro Alloys Plant



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3.5.8 Manufacturing process of semi finished steel i.e. Billet

through Induction Furnace based Steel Melting Shop with CCM

(i) The manufacturing process identified for the proposed unit is one which is well established and proven and presently being followed by majority of similar manufacturing units mostly in small or medium scale sector.

In order to achieve high energy efficiency three numbers of 12

MT capacity Induction Furnaces with higher power input capacity of .5 MVA each will be setup with completely automatic charging facility as well as power sharing panel also. Electronic software will be installed to monitor the input power and maintaining power factor to almost unity level.

The melting process involves taking sample of Sponge Iron & Pig Iron; Iron Powder and mild steel scrap, end cutting from rolling mills or scrap from user units is taken from raw material storage. This is than tested for its chemical composition and noted. Before preparation of charge necessary ingredients like Ferro Manganese, Ferro Silicon etc. are added by weight, Flux is taken up in crucible and then charge is put into it. Melting of steel along with other alloying element is accomplished in the crucible of coreless M.F. Induction Furnace. The high A.C. Current is passed through the copper oil wrapped around the outer periphery of crucible. By transformer action the A.C. Current induces much higher secondary current at 1000 herts in charge through the coil. Enormous heat it thus developed by resistance which causes the melting of charge. As soon as the molten pool is formed very pronounced stirring action in the molten metal takes place which helps in accelerating the melting. Deoxidizing agents and sometimes specific alloying elements are also added at suitable intervals during melting. Melting of



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homogenous mass occurs at 1600 C. If necessary superheating up to 1650 C as done for specific time. After completion of melting cycle of an hour the homogeneous molten mass is poured hydraulically into the ladle.

(ii) LRF (Ladle Refining Furnace):

Subsequent to the production of molten steel the production of quality requires refining of the same for which one Ladle Refining Furnace with 15 MT ladle will be setup with three electrode arcing facility with complete provision to carry out de-sulphurization, if required, and de-phosphorization if required.

The liquid steel containing in the ladle will be brought to LRF and after due processing of the liquid steel the ladle will be transferred to CCM.

The slag generated during the Melting as well as refining is removed manually through BELCHAS (Steel Spatulas) Accumulated Slag is used for land fill.

(iii) CCM: The ladle containing liquid steel will be placed on the CCM platform and continuous casting of hot billet will be carried out in the same for which one 3 strand CCM with 4 mtr x 8 mtr radius will be setup, the casting will be done through a highly automated controlled cooling software governed mechanism by which the casted billet will be so cooled that the temperature of billets do not fall below 10500C. The case formation in the CCM mould starts with drop in surface temperature below 15200C, the liquid metal inside the case contains enough energy for maintaining the overall temperature of billet for hot online rolling. In the CCM section hot billet shearing machines will be installed with each casting strand, so as to facilitate the cutting of billets to proper length for feeding in to the rolling mill.



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`



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3.5.9 Manufacturing process of Rerolled Steel through Rolling Mill

1. Raw Material i.e. Billet coming from CCM in red hot condition is cut either by Gas Cutting or automatic hot billet Shearing Machine. In the proposed plant automatic hot billet shear machines are going to be installed with each strand. The gas cutting facility will be maintained as a backup to the hot billet shearing machine,

2. After the Billet is cut into required length, then pushed out to

rolling stands for re-rolling. Steel Pieces are rolled through all stands in order to get required shape of finished goods i.e. TMT/Wire rod/ Bars. It is proposed to produce TMT bars at present; however in future the Mills may be used to produce Wire Rod or Structure also.

3. In case of production of TMT the rolled bars are passed through

the TMT quenching machine and then after quenching of TMT are transferred to Cooling Bed for Cooling.

4. After Cooling, Wire rod Coils/TMT /Bars are Shifted to Decoiling machine and after inspection, Bundled are ready for dispatch.

5. The rerolling capacity of the proposed mill assessed around 20 MT per hour and based on 1 hours availability of liquid metal / hot billets the estimated daily production capacity will by 300 MT per day.



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PROCESS FLOW CHART FOR ROLLING MILL

Hot Cutting of Raw Material (Billet)

Maintaining temperature above 10500C

Discharge from CCM / Hot Shearing Machine by Roller Conveyor

Passed through Rolls fitted on to the Stand

In case of TMT passed through quenching line

Discharged on the cooling bed after finished stand.

Cooled in the atmospheric condition

Ends are cut

Carried to the finished Yard



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3.5.10 Process and Process flow diagram of Power Generation through CFBC based Power Plant

[J] POWER PLANT

A steam power plant continuously converts the energy stored in fossil fuels (coal, oil, natural gas) or hot gases in to shaft work and ultimately into electricity. The working fluid is water which is sometime in liquid phase and sometimes in vapour phase during its cycle of operation. Power plant is a bulk energy converter from fuel to electricity using water as a working medium. Energy released by the burning of fuel is transferred to water in the BOILER (B) to generate steam at a high pressure and temperature, which then expands in the TURBINE (T) to a low pressure to produce shaft work. The steam leaving the turbine is condensed into water in the CONDENSER (C) where cooling water from air cooled cooling tower carry away the heat released during condensation.

The condensed water (condensate) is then fed back to the boiler by the PUMP (P), and the cycle goes on repeating itself. The working substance water, thus follows along B-T-C-P path of the cycle interacting externally. Since the fluid is undergoing a cycle process, there will be no net change in its internal energy over the cycle and consequently, the net energy transferred to the unit mass of fluid as heat during the cycle must equal the net energy transfer as work from the fluid. Using Washery Rejects for Power Generation:

• Ash content in Washery Rejects is generally >50% • Pulverized coal combustors have limitation in using coal with

Ash >50% • Technological developments have facilitated using coal with ash

>50% in fluidized bed combustors. • Principle: the fuel is burnt in fluid bed maintained by blowing air

through and inert bed into which the coal is introduced.



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• Types of Fluidized Bed Combustion Boilers: • Atmosphere Fluidized Bed Combustors (AFBC) • Bubbling Fluidized Bed Combustors (BFBC) • Circulating Fluidized Bed Combustors (CFBC) • Pressurized Fluidized Bed Combustors (PFBC) Circulating Fluidized Bed Boiler (CFBC) In circulating fluidized bed boiler the air velocity is much higher, causing the inert particles and ahs to blown out of the top of the boiler. They are then captured by a cyclone and returned to the bed. The higher air velocity enables the CFBC to cope the larger capacity and boiler of this type are commonly in use up to 200 MWe. In addition, higher ash coal can be more easily burnt and the boiler is less sensitive to variation in feed quality. Flow of Circulating Fluidized Bed Boiler (CFBC)



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STEAM TURBO GENERATOR: The steam turbine is a primary mover, which continuously converts the energy of high pressure high temperature steam supplied by a steam exhausted to a condenser. This energy conversation essentially occurs in two steps.

1) The high pressure, high temperature steam first expends in the nozzles and comes out at a high velocity.

2) The high velocity jets of steam coming out the nozzles, impinge on the blades mounted on a wheel, get deflected by an angle and suffer a loss of momentum, which is absorbed by the rotating wheel in producing torque.

Deoxidation:

Steam from the turbine is fed from the bottom. By contact, the steam condenses and the feed water is heated to the saturation temperature. Dissolved oxygen and carbon di-oxide gases gets released from the water and leave along with some vapour, which is condensed back in the vent condenser, and the gases are vented out. To neutralize the effect of residual dissolved oxygen and carbon-di-oxide gases in water, sodium sulphite (Na2SO3) is injected in suitable calculated doses into the feed water at the suction of the boiler feed pump (BFP)

Generator:

The mechanical shaft power generated in steam turbine is converted by the generator in to electricity which is generated at 11 KV. The generated power is then boosted to 33 KV for internal consumption as well as grid synchronization. The generated power being mainly for captive use thus the synchronization at 33 kV is sufficient. However if for any reason the plant is not able to consume the power then the surplus power will be exported to the grid at 33 kV itself. The grid connectivity at 33 kV will be obtained from nearest substation at Rajgangpur.



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FLOW DIAGRAM FOR POWER GENERATION

3.5.11 Process and Process flow diagram of Brick making from

waste Fly ash, Lime sand and Gypsum are manually fed into a pan mixer, where water is added in the required proportion for intimate mixing. The proportion of the raw material is generally in the ratio 70% of fly ash, 10% lime, 5% Gypsum and 15% sand, depending upon the quality of raw material. After mixing the mixture is shifted to hydraulic/ mechanical presses. The bricks are carried on wooded pellets to the open area where they are dried and cured by autoclave machine. The bricks are tested and sorted before dispatch.



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Flow for Brick making



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POLLUTION CONTROL MEASURES:- Being an integrated steel project, the following equipment will be installed :

- At all the transfer points, Dust Collector will be installed,

along with the Bag Filter.

- All the conveyor will be fully enclosed.

- Bag filters will be installed at the coal crusher and rotary breaker in the coal washery area.

- E.S.P. is proposed for control of Air Pollution, in the iron powder Kilns as well as CFBC

- Bag filter is proposed for Ferro Alloys plant with Air cooler.

- Water spraying will control the fugitive emissions in the entire coal storage area, as well as in the internal open storage yards.

- For handling of Ash – Pneumatic Ash Handling system will be installed & the ash will be used as Waste for Land Leveling, supply to Cement & Brick manufacturers.

- The fly ash silo will be installed at the boundary of unit by which a gravity ash flow pipe will facilitate immediate delivery of fly ash to all the bulkers coming in for carrying fly ash to cement plants.



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List of proposed Air Pollution Control Equipments:

S. No.

Name of Process Type of Equipment

Emission controlled

1 Sponge Iron plant ESP Particulate matter less than 50 mg/m3

2 Blast Furnaces Bag Filters Particulate matter less than 50 mg/m3

3 CFBC power plant ESP Particulate matter less than 50 mg/m3

4 Ferro Alloys Plant ESP Particulate matter less than 50 mg/m3

5 Iron Powder Kilns, Coal Crusher, Ore beneficiation, Conveyor System, Loading Hopper, Ash delivery point

Bag filter with central dust collection system

Particulate matter less than 50 mg/m3

6 Iron Ore Beneficiation, and Coal Washery at unloading point, conveying transfer points, hoppers, crushers, screens

Bag filter with central dust collection system

Particulate matter less than 50 mg/m3

7 Induction Furnace, LRF, Bag filter Particulate



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CCM area with central dust collection system

matter less than 50 mg/m3

8 Coal storage yard/ shed/ stacker reclaimer

Water sprinkling system

Particulate matter to be maintained less than 150 mg/nm3

Additional measures will be adopted to reduce/control pollution control:- Approach roads will be frequently sprinkled with water. Most of the materials including coal as well as iron ore will be

stored under covered shed. In case of storage of Ore/ Coal in open, it will be covered by

tarpaulins to prevent spread of dust from it during transportation. Regular maintenance of vehicles and machineries will be carried

out in order to control emissions. Green belt development would be taken up all along the haul

roads, plant premises etc. Green belt will also be developed on the sides of approach road. Protective appliances will be provided to all the workers exposed

in dusty atmosphere. Avoiding overloading of the trucks. Workers will be equipped with all personal protective devices

like Gum Boot; hand gloves; Safety helmet; Safety goggles, earplugs at work place.

By controlling the speed of the truck. Proper gradient of approach roads to reduce cumulative noise. Transportation of materials will be limited to day hours only. Periodical maintenance of process machinery.



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Medical and Health:- The project proponent shall provide facilities for medical check-up of its workers and employees through a visiting Physician. They will also provided first-aid facilities at plant time office. If necessary and in case of emergency, the medical aid can also be provided by hospitals situated Rajgangpur which is nearly 5.0 Kms. from proposed plant. Work related health hazard has been identified. Measures for respiratory disease will be taken by providing goggles; mask and earplugs. Awareness for malaria and health Hazard due to dust emission shall be created among plant workers. Worker health checkup program will be carried out on Six monthly basis.

Socio Economic Objectives:- The company shall also participate and support the various social activities, held in the nearby villages of the plant. It shall take active part in the social upliftment program like Swachchta Abhiyaan, skill development program, construction of toilets in schools, colleges, panchayats, supply of good quality drinking water, and women empowerment programmes. It will also support the cultural programs like Jaggannath Puja, Durga Puja Dusshera occasional Bhandara etc. organized by villagers of surrounding villages. The company is also committed to contribute in the upliftment of the population of the nearby villages. The company shall be maintaining good environmental atmosphere in the plant premises and taking steps to make further improvement in this area. The company shall also provide the employment facility to the local villagers.



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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.

Estimated raw material quantity likely to be source from outside, mode of transportation are given as below:

Input MT/Annum Source Mode of

traspor-tation Sized Iron Ore from Outside

72000.00 From outside Iron Ore Mines.

By road through covered truck For internal use transported through covered trucks.

Dolomite 15988.78 From market. By road through covered truck For internal use transported through covered trucks.

Silicon Carbide saggers

600.00 From market. By road through covered truck For internal use transported through covered trucks.

Coke 44950.00 From market. By road through covered truck For internal use transported through covered trucks.

Quartz 3125.00 From market. By road through covered truck For internal use



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transported through covered trucks.

Un Washed Coal (ROM)

177834.86 From market. By rail/road through covered truck For internal use transported through covered trucks.

Heavy Media (Magnetite)


Low grade Iron Ore

264000.00 From outside iron ore mines. (list of iron ore mines in Odisha is provided in Appendix 4)

By rail/road through covered truck For internal use transported through covered trucks.

Mn Ore 46700.00 From market. By road through covered truck For internal use transported through covered trucks.

Manganese Slag 4670.00 From market. By road through covered truck For internal use transported through covered trucks.

Paste 583.75 From market. By road through covered truck



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For internal use transported through covered trucks.

Cannasters ( Paste casings)


LIME 9600.00 From market. By road through covered truck For internal use transported through covered trucks.

GYPSUM 1980.00 From market. By road through covered truck For internal use transported through covered trucks.

Total= 642752.64 Details of raw material required in various process is given as below:

Sponge Iron Plant (Existing) Raw Material Total

quantity required

Internally transferred

Net to be purchased from outside

Sized Iron Ore from Outside 72000.00 0.00 72000.00 Washed Coal 54000.00 54000.00 0.00 Dolomite 1350.00 0.00 1350.00



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Iron Powder through Tunnel Kiln

Raw Material Total quantity required



Beneficiated Iron Ore 96000.00 96000.00 0.00 Silicon Carbide saggers 600.00 0.00 600.00 Washed Coal 42000.00 42000.00 0.00 Coal for Producer Gas 12000.00 12000.00 0.00

Pig Iron through Mini Blast Furnace (Existing)-




Beneficiated Iron Ore in the form of briquetts/ size ore 36000.00 36000.00 0.00 Coke 13200.00 0.00 13200.00 Dolomite 3360.00 0.00 3360.00 Quartz 1250.00 0.00 1250.00

Pig Iron through Mini Blast Furnace (Proposed):-




Beneficiated Iron Ore in the form of briquetts/ size ore 54000.00 54000.00 0.00 Coke 19800.00 19800.00 Dolomite 5040.00 5040.00 Quartz 1875.00 1875.00



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M.S. Billet through Steel Melting Shop, Induction Furnace, LRF:- Raw Material Total

quantity required



Iron Powder from Tunnel Kiln 51600.00 51600 0.00 CI / Pig Iron 57600 57600 0.00 Internal Melting Scrap Used 816 816 0.00 Ferro Alloys 1650 1650 0.00 Coke 275 0 275.00 Consumable for CCM and Ladle etc Rs per Ton @ Rs.1250.00 /MT Refining cost at LRF 1500 Rs/MT

Rerolled Steel through Rolling Mill:-




Hot metal 110000 110000 0.00 Consumable for CCM and Ladle etc Rs per Ton @ Rs.800.00 /MT

Captive Power Plant:-




Char Dolochar 9000.00 9000.00 0.00 Chared Coal 9000.00 9000.00 0.00 Washery reject 12950.00 12950.00 0.00 Coal Middling 46250.00 46250.00 0.00 Coal 1755.16 1755.16 0.00 Dolomite 401.28 0.00 401.28



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Coal Washery:-




ROM Coal required

177834.86 0.00

177834.86

ROM coal required from job provided

7165.14 0

7165.14 (to be provided

by Job provider)

Iron Ore briquettes through Cold Briquetting (Existing):- Raw Material Total

quantity required



Iron ore fine 100000 100000 0 Additive 2500 0 2500

Iron Ore briquettes through Cold Briquetting (Proposed):-




Iron ore fine 100000 100000 0 Additive 2500 0 2500

Ore Beneficiation Plant:- Raw Material Total

quantity required



Low grade Iron Ore ( Other mineral Ore not used for present

264000 0 264000



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calculation) (Other mineral may be like Manganese Ore; Nickel Ore; Chrome Ore etc)

Ferro Alloys Plant:-




Mn Ore 46700.00 0.00 46700.00 Manganese Slag 4670.00 0.00 4670.00 Coke 11675.00 0.00 11675.00 Washed Coal ( From Washery) 5837.50 5837.50 0.00 Dolomite 5837.50 0.00 5837.50 Paste 583.75 583.75 Mill Scale 5500.00 5500.00 0.00 Cannasters ( Paste casings) 350.25 0.00 350.25

Marketing area of final product/s, Mode of transport of Finished Product



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Name of finished product

Net quantity available for sale, after utilizing it for internal use in industry (IN mt)

Marketing area Mode of Transportation

Sponge Iron

45000.00 Quantity it will be sold to Induction Furnaces in nearby area as well as Induction Furnaces of Chhattisgarh state.

By road through covered truck For internal use transported through covered trucks.

Rerolled Products

100000.00 All over Odisha, Jharkhand, Chhattisgarh etc. The demand of Re-rolled product are huge, the rerolled steel market is dealer and distributor based, thus marketing to dealer and distributor is only required, they will taken care of retail market. The major market places are All over Odisha, Jharkhand, Madhya Pradesh and Chhattisgarh etc.

By road through trucks

Silico Manganese / Ferro Manganese/ Ferro Silicon

23350.00

Entire Odisha, Chhattisgarh in induction furnaces and steel plant

By road through covered truck



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Power Surplus power

As the power plant is implemented for captive use, thus there will no significant quantity of power available for export constantly but for technical reason the grid connectivity for export is maintained to operate safely and to export the surplus power.

Through cables for internal consumption and grid connectivity at 33 KV overhead transmission line will be provided till grid sub-station at Banbahal.

Fly Ash Bricks

66000.00 Internally consumed and remaining quantity will be sold in local market through brokers etc.

By road through trucks



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3.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined. - Reverse osmosis process will be adopted to minimize the wastage of

water caused due to chemical neutralization process. The entire quantity of RO backwash will be used in coal washery plant.

- 100% of waste water will be recycled and Zero discharge condition will be maintained.

- 100% waste low grade coal material generated from beneficiation process will be used in own power plant or given to nearby CFBC based power plants or shall be return to the job provider for washing of coal.

- The fly ash generated shall be given free to cement industry and remaining ash if any will be given to bricks making units.

- The CFBC bottom ash as well as ABC (After Burning Chamber) bottom ash will be given to cement plants for iron oxidized supplementation their process.

- The furnace slag will be given to units for metal recovery.

- The Ferro Alloy slag will be used for road making, as the slag has good mechanical strength for road making.

- Ferro manganese slag will be used for production of silico manganese.

- Char- dolochar from sponge iron plant will be used for power generation in own power plant.



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- The liquid steel produced will be used in a manner to produce hot billet suitable for rerolling, thus online hot rerolling practice will be adopted.

- The waste water generated from reverse osmosis system will be used in coal washery.

- Mill scale generated in the rolling mill will 100% be used in ferro alloys plant.

- It is also proposed in future to produce Pig Iron in sub merged arc furnace and use the liquid hot metal for transferring in to steel melting shop (induction furnace) to produce steel. This will greatly reduce the power consumption in steel melting.

3.8 Availability of water its source, Energy/ Power requirement and

source: - The project site is situated near to Kansbahal and Mandria, thus as

per hydrological report this area is lying in safe zone, as water tabled is quite high. Thus industry has already obtained water withdrawal permission up to 600 m3/day. Thus preferably borewell will be used as main source of water. The Mandria Dam is just about 4 KM in South direction and Kansabahal Dam is just about 3 KM South East direction from the site.

- The daily makeup water requirement in peak situation at 100% Capacity utilization is estimated to be 750 KL/day out of which 15 KL is estimated for human consumption. The proposed project is likely to operate at 80% Capacity utilization thus the permission sought by the unit to draw ground water looks to be adequate.



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Estimation of Water Requirement

Prodn /Annum Water Required Total Water

(MT/ MW) KL/Ton required a) Sponge Iron Plant 45000.00 MT 0.10 KL/MT 4500.00 KL b) Iron Powder 60000.00 0.10 KL/MT 6000.00 KL b) Blast Furnace 60000.00 MT 0.10 KL/MT 6000.00 KL c) Steel Production 110000.00 MT 0.10 KL/MT 11000.00 KL d) Power Production 46334.05 MWH 2.00 KL/MWH 92668.09 KL e) Ferro Alloys 25000.00 MT 0.15 KL/MT 3750.00 KL f) Coal washery 185000.00 MT 0.20 KL/MT 37000.00 KL g) Ore Beneficiation 264000.00 MT 0.20 KL/MT 52800.00 KL h) Cold Briquetting Plant 200000.00 MT 0.05 KL/MT 10000.00 KL i) for Re-rolling Mill complex 100000.00 MT 0.10 KL/MT 10000.00 KL j) Fly Ash brick Making 5500.00 MT 0.10 KL/MT 550.00 KL g) Human Consumption considering

641 persons @ 25 Ltr/day for 330 days 5288.25 KL

f) Misc. for Gardening workshop etc. 2000.00 KL

241556.34 KL/Year

g) Water cost Rate 25.00 Rs/ KL 60.39 Lakhs Rs/year

h) Daily required based on 330.00 days 731.99 KL/day Say= 750.00 KL/day

i)

Hourly requirement 24.00 hrs. 31.25 KL/hr.

Say= 31.00 KL/hr.



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Hydrogeology status of State of Orissa:

The State is underlain by diverse rock types ranging in age from Archaean to Recent. The State can be hydrogeologically sub divided into consolidated, semi-consolidated & unconsolidated formations. The consolidated formations include hard crystallines and compact sedimentary rocks whereas semi-consolidated formations include weathered and friable Gondwana sedimentaries and loosely cemented Baripada beds. The unconsolidated formations include laterites and recent alluvium. The yield of tube wells tapping granite gneisses ranges between 10-35 m3/hr whereas other consolidated formations, it ranges between 5-18 m3/hr. The yield of tube wells in semi-consolidated formations range between 20-115 m3/hr.

Dynamic Ground Water Resources Annual Replenishable Ground water Resource

23.09 BCM

Net Annual Ground Water Availability

21.01 BCM

Annual Ground Water Draft 3.85 BCM Stage of Ground Water Development 18 % Ground Water Development & Management Over Exploited NIL Critical NIL Semi- critical NIL Ground Water User Maps 30 districts Artificial Recharge to Ground Water (AR)

Area identified for AR: 8095 sq km

Quantity of Surface Water to be Recharged: 06 MCM

Feasible AR structures: 569 percolation tanks, 761 converted percolation tanks, 698 sub surface dykes, 809 nala contour



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bunds, 679 check dam weir, 1981 water spreading/ flooding structures, 668 induced recharge, 334 recharge shafts, RTRWH structures (1 lakh).

AR schemes completed during IX Plan: 3

Central Ground Water Authority Area notified for Regulation of ground water development: Nil Ground Water (1999-2000)

Total Replenishable ground water resources (m ha m/yr) 2.00014 Provision for Domestic, Industrial & other Uses (m ha m/yr) 0.30002

Available Ground Water resources for Irrigation in Net terms m ha m/yr)

1.70012

Utilizable Ground Water on Resource for Irrigation in Net rms(mham/yr)

1.53009

Gross Draft estimated on prorate basis (m ha m/yr) 0.20447 Net Draft (m ha m/yr) 0.14313 Balance Ground Water Resource future use in net terms (m ha /yr)

1.55699

Level of Ground Water Development (%) 8.42

Weighted Average Delta (m) 0.34-0.44 Utilizable irrigation Potential for development (m.mh) 4.20258

Source- Central Ground Water Board Website

Power Requirement Power requirement will be around 32.73 MW and out of which Captive Power Plant of 8 MW will be built within the project balance power will be drawn from electricity board (WESCO).



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3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their Management/disposal:. - 100% of waste water will be recycled and Zero discharge condition

will be maintained.

- 100% waste low grade coal material generated from beneficiation process will be used in own power plant or given to nearby CFBC based power plants or in case of a job work; shall be returned to the job provider for washing of coal.

- Char- dolochar from sponge iron plant and Chared Coal from Tunnel kiln will be used for power generation in own power plant.

- Blast furnace slag will be Sold to Cement Plants as usual or used in Brick making.

- The fly ash generated shall be given free to cement industry and remaining ash if any will be given to bricks making units.

- The CFBC bottom ash as well as ABC (After Burning Chamber) bottom ash and spent heavy media reject will be given to cement plants for iron oxidized supplementation their process

- The Induction furnace/LRF slag will be given to units for metal recovery or in case used internally for the same then the ground slag will be used to making bricks.

- The ferro alloy slag will be used for road making, as the slag has good mechanical strength for road making.

- Ferro manganese slag will be used for production of silico manganese.

- The liquid steel produced will be used in a manner to produce hot billet suitable for rerolling, thus online hot rerolling practice will be adopted.



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- The waste water generated from reverse osmosis system will be used in coal washery.

- Mill scale generated in the rolling mill will 100% be used in ferro alloys plant.

Waste for disposal sent outside:

Qty. MT/Year

Utilization /disposal method

CFBC bottom Ash 38.42 Given to cement plant for iron oxide supplementation

Shale & Sand Stone 5550.00 Either returned to job provider or will be disposed for road making or land fill

Broken Saggers 600.00 Sold in market Low Grade Ore 66000.00 To be given to cement

plants like OCL Fly Ash Bricks 66000.00 Used by metal recovery

plants and land filling Granulated Blast Furnace Slag

12000.00 To be given to cement plant or brick plants

Slag Generated due to Ferro Alloys

20000.00 Used by metal recovery plants and land filling

Non Granulated Induction Furnace Slag


Misc Dust like ESP 600.00 To be given to cement plant or brick plants

Defective billets, miss-rolls generated

4683.67 Used by metal recovery plants

Disposal of waste to be carried out outside the plant premises are as below: 1. The used oil and waste oil estimated to be around 10 KL/year will

be given to authorized recycler having authorization from competent authority.



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2. The lead acid batter or dry battery will be given to authorized recycler having authorization from competent authority.

3. E-waste generated from the plant will be given to authorized recycler having authorization from competent authority.

4. The refractory waste generated from relining of induction furnace, sub merged arc furnace, sponge iron plant, boiler maintenance etc. will be given to the refractory units for recycling located in the state of Odisha.

5. The Broken Saggaers will be sold to Silicon Carbide making units or may also be sold to Induction Furnaces; it may also be used internally in Silico manganese making Ferro Alloys plant or in Induction Furnace.

6. The broken electrodes of sub merged arc furnace shall be used in induction melting furnace for supplementing carbon requirement.

7. The domestic sewage outflow from toilets will be treated in septic tank and overflow will be used for green belt irrigation.

There is no other liquid or solid waste likely to be generated.



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3.10 Schematic representations of the feasibility drawing which give

information of EIA purpose

S.No. Process Aspect

Environment regime affected

Remediation proposed

1 Change in land use.

The possible greenery on the land and natural recharge is affected

The Area is already an Industrial area and the additional land acquired is a barren land area, devoid of vegetative tree cover and having only the grass cover. Part of the land will be covered by tree plantation to the extent of 33% of area being brought under industrial activity. The greenery will be taken up within the plant boundary and additionally outside the plant boundary. The ground water level is saturated being in the close water shed of number of man made Dams in command area. Thus recharge is not affected. The existing three dams around the project site compensate the summer draw down of water table.

2 Transportation of material

The existing network of

The area is thinly populated and not having



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transport gets pressurized

much transport density. There is not going to be substantial addition in the transportation load.

3 Land oustee The occupational resource due to transfer of land is affected.

The land was a barren land, thus was really not a substantial occupational resource for the land owners. However the employment generated during project will provide a better opportunity.

4 Gaseous and particulate Emission to the atmosphere

Air quality All the steps are proposed to minimize the emission from point sources as well as fugitive sources. Thus the standards of ambient air quality will be maintained.

5 Discharge of effluent

Impact of water quality.

Zero discharge is proposed.

6 Withdrawal of ground / surface water

Availability of ground/surface water is affected.

It is proposed to draw ground water through bore wells and from own water reservoir (Pond) during lean period.

7 Operation of equipment and vehicles likely to generate noise.

Noise regime All the process equipments will be installed on anti vibration pad with sufficient provisions to minimize generation of noise. The high noise generating equipment like turbine and generator will be



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enclosed with noise suppressing enclosures. The buildings as well as boundary wall and green belt will ensure the attenuation of noise outside the boundary within the prescribed limits.

8 Fire Hazard due to storage of fuel etc.

Risk to the surrounding habitation.

The project site is well isolated and there are no nearby habitats. However all the precautions to prevent fire and all the provisions to fight fire shall be provided.

9 Employment to outsiders

Socio-economic disparity with local community

Priority of employment will be given to local people, as already sufficient qualified and trained local youth area available.

10 Cultural impact

Local population feels isolated

The promoters proposed to employ local masses in the project hence no such impact on cultural diversity is likely to take place.



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4. SITE ANALYSIS 4.1 Connectivity.

The area is located at Village Barpali (Laing), Tehsil-Rajgangpur, District- Sundergrh, Nearest Railway station Rajgngpur about 10 KM in W direction and nearest Air port is Ranchi about 180 Km. The project site can be reached from nearest Rajgangpur through a road leading to Rourkela. The project well connected to road. The nearest railways station is in main Howrah Mumbai rail track at about 5 KM distance.

4.2 Land Form, Land use and Land ownership. The proposed expansion project is proposed on the existing land and additional land in total 45.26 Acre Land. This land is available as per details given below: Khasara No.: 2482/3528, 2497/3529, 2509/3530, 2510/3531, 2496, 2482, 2494, 2481/3080, 376 (P), 2456, 2459, 2451, 2479, 2480,, 368, 2524(P),2493, 2454(P), 374,3491,2492, 2500, 2457,2470, 2460,375, 394, 395,2484, 2485, 2486, 2489, 25490, 2501, 2488, 2487, 2523(P), 2483, 2458. The proposed site comprises of barren land devoid of vegetative cover from trees, and only grass cover is available. Area Statement for proposed project for different use is as follows:



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Area Statement for Proposed Plant After implementation

Land Use Statement Area in Sq.meter

Green Belt 60400 Road 5400 storage area 9100 open area 9100 Factory Shed 82300 residential 0 Parking 3600 Water Storage 10000 Admin building and Laboratory, Workshop etc 3200 Total Area 183100

4.3 Topography (along with map)

Geographically the district is not a compact unit and consists to widely dissimilar tracts of expansive and fairly open country dotted with tree-clad isolated peaks, vast inaccessible forests, extensive river valleys and mountainous terrain. Broadly speaking, it is an undulating tableland of different elevations broken up by rugged hil ranges and cut up by torrential hill streams and the two main rivers IB and Brahmani. The general slope of the district is from North to South. Because of this undulating, hilly and sloping nature of landscape, the area is subject to rapid runoff leading not only to soil erosion but also to scarcity of water for both agriculture and drinking purpose.



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SUNDARGARH DISTRICT AT A GLANCE :-

(1) TOPOGRAPHY :- 1 Topographic Location Latitude - 21º36’ N to 22º32’ N

Longitude- 83º32’E to 85º22’E (Toposheet No. : 72 B/11 and 72 B/12)

2 Geographical Area 9712 SqKms (Second largest district in the State accounting for 6.23% of the total area)

3 Normal Rainfall 1657.1 mm 4 Forest Cover 4232.57 SqKms

(Second largest in the State accounting for 8.53% of the State total )

5 Major River Brahmani Sankh & Koel – Tributary of Brahmani IB- Tributary of Mahanadi

6 Major Soil Type Alluvial and Lateritic (2) DEMOGRAPHY (As per 2011 Census) 1 Population 2,080,664

2 Males 1,055,723 3 Females 1,024,941 4 Density 214 (2011) 5 Sex Ratio (No. of Females per 1000

Males) 971

3. SOCIO-ECONOMIC FEATURES :- 1 Cultivated Land 3,36,000 Hects High 1,86,000 Hects Medium 95,000 Hects Low 55,000 Hects 2 No. of cultivators 1,97,019 3 No. of Agricultural labourers 91,068 4 Average size of operational holdings 1.73 Hects 5 Class-wise number of operational



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holdings Class Number Marginal 65,281 Small 51,767 Semi-medium 35,696 Medium 12,279 Large 984 TOTAL 1,66,007 6 Per capita availability of food grains Qtls.1.55

4. HEALTH UNITS :-

1 No. of Medical Institutions 85 2 District Headquarters Hospital 1 3 Sub-Divisional Hospital 2 4 Other Hospitals 11 5 PHCs 10 6 CHCs 6 7 UPHCs 2 8 PHC (N) 53 9 MHU 1 10 Ayurvedic Dispensaries 33 11 Homoeopathic Dispensaries 25 12 No. of Sub-Centers 345 13 No. of VHG 324 14 No. of TBA 1619 15 No. of AW Centers 1864



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Project Site

Project Site in Satellite Imagary

Project Site in Toposheet

Project Site



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The Barhajore River flows from South to North at distance of about 1.5 KM from the project site, and joins the Shankh river after travelling around 3.5 KM towards East site. The Shankh river flow from West to East. The project site is located about 207 meter above MSL whereas the Shankh river flows around 190 meter above MSL. The area is plain with moderate slope and having forest cover in small patches.



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4.4 Existing land use pattern (agriculture, non agriculture, forest,

water bodies ( distance from HFL to the river ), CRZ. In case of notified industrial area, a copy of Gazette Notification should be given :- - Existing land use is non-agriculture land. There is no land use plan

notified for this area. However the land use is already converted to industrial purpose..

Land use pattern of District Sundergarh:

LAND UTILISATION PATTERN

Block W ise Land Utilisation Pattern of Sundargarh District.

Sl. No Block Geo.area

Misc.Tree crops & grooves

Permanent pastures &

other grazing

area

Cultivable waste

Land put to non agril. uses

Barren & cultivable

land

Current fallow

Other fallow

Forest area

Net area sown

1 Hemgir 93238 250 3050 1122 2568 2709 8166 1925 21833 19324

2 Lephripara 64022 733 2024 1639 2092 638 4259 2391 12331 16174

3 Tangarpali 24966 693 1878 919 2786 445 3105 2987 2143 17251

4 Sundargarh 35988 315 1566 900 2869 1076 4697 3256 10128 19176

5 Subdegga 32428 642 1128 3889 3009 4466 1356 1763 6641 16607

6 Balisankara 108476 71 2030 6725 2602 893 1342 4063 10922 18418

7 Bargaon 35661 256 2445 959 2295 692 4380 2291 5883 16314

8 Kutra 31885 141 1090 1947 2859 305 3905 1167 3476 19433

9 Rajgangpur 34897 167 3360 2071 4656 2647 2774 2911 5251 18865

10 Lathikata 74904 22 1550 956 3610 1471 3679 1939 6832 24695

11 Kuarmunda 57672 79 1925 3955 5366 1934 2019 1697 12517 22519

12 Nuagaon 38888 70 1228 1816 2707 2407 4651 2582 2360 27480



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13 Bisra 22560 12 874 508 1405 115 944 2509 1625 9364

14 Lahunipara 77768 46 1435 3135 2733 3160 4068 2708 8080 19244

15 Bonai 27077 314 985 1756 1939 535 1801 1103 9883 17088

16 Gurundia 125874 86 2144 2783 3146 6741 3862 2875 22394 16779

17 Koida 84940 - 1637 4865 2607 11428 6100 3158 18284 14269

Total 971244 3897 30349 39945 49249 41662 61108 41325 160583 313000



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AGRO CLIMATIC INFORMATION

Agroclimatic zone

Area(in '000 ha)

% of Geo.area

of the dist.

Name of the AES

Area (in '000 ha)

% of Geo.area

of the dist.

Name of the Blocks covered

Area (in ha.)

% of the AES zone

Nor

th W

este

rn P

late

au

1315

.861

13

73.8

1

AES-I Low Rainfall Lateritic Soil

157551 22.81

Hemgir Subdega,

Kutra, Lephripara

93238 35988 31885 64022

59.10 22.84 18.06 39.14

AES-II

Medium Rainfall Red & Black soil

163557 16.84

Tangarpali Bargaon Nuagaon

Sundaregarh

24966 35661 38888 35988

15.26 21.80 23.80 14.33

AES-III

High Rainfall Lateritic Soil

251130 25.85 Balishankara Kuarmunda Lahunipara

108476 57672 48994

43.19 22.96 19.52

AES-IV Medium Rainfall Black & Brown

forest Soil

169474 17.44

Rajgangpur Bisra Bonei Koira

34897 22560 27077 84940

22.59 13.31 15.98 50.12

AES-V High Rainfall

Black & Brown forest Soil

229552 17.06 Lathikata Gurundia

Lahunipara

74904 125874 28774

32.63 54.83 12.54

Special group of AES-III & V High Rainfall

Lateritic, Blacvk & Brown forest

Soil

Lahunipara



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4.5 Existing Infrastructure

- The proposed project is expansion of a unit in which existing production capacity of 3 Nos.X 50 TPD (45000 TPA) DRI kiln and 2 Nos. of 23 cum. (24000 TPA Pig Iron) Mini Blast Furnace, and Cold briquetting plant of capacity 100000 TPA; with the DG back up with three DG sets is located near village – Village and Post Barpali (Panchayat Laing), Post Kesramal, Tehsil Rajgangpur, District Sundargarh, Orissa. The project can be reached by the State Highway No.10 connecting Rourkela to Sundargarh.

- The industry already has sufficient space for proposed expansion. - It has already has sufficient water supply sources, electric supply

source, backup DG sets, approach road for connecting to the nearest State highway and sufficient laboratory facilities as well as all the amenities required for present and future manpower utilities requirement.

4.6 Soil Classification The climate, vegetation, parent rock, topography and other biotic factors have considerably influenced the genesis of soil and consequently great variation in soil type in different parts of the district has been observed. Red and yellow soils are mostly found in blocks like Sundargarh, Kutra, Koira and Lephripara, where as Black soil is distributed in all the blocks, but in small area

4.7 Climatic data from secondary sources

The area falls in regional meteorological laboratory at Bhubneshwar and the climatologically data available from Meteorological Lab at Bhubhneshwar, shows that area is under good monsoon coverage with sever summer and extreme winter having following parameters:

Rainfall Normal (RF) mm Normal Rainy days (number)

SW Monsoon (June to Sep)

1229.2 55.1

NE Monsoon (Oct. to Dec.)

80.6 4.8



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Winter (Jan. to March) 56.0 4.7 Summer (Apr. to May) 56.6 4.4 Annual 1422.4 68.4

At an average temperature of 34.6 °C, May is the hottest month of the year. In December, the average temperature is 19.3 °C. It is the lowest average temperature of the whole year.

4.8 Social Infrastructure available The area falls under village Barpali (Laing)/ Laing at a distance of about 1 km. The rural area is semi industrialized due to location of the present industry and a few more sponge iron plants. The Village is having Primary to Secondary school education with Primary health Centre also. The nearby town of Rajgangpur provides all the social amenities related to health; Education and enetertainmnet as well as religion too.



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5 Planning Brief 5.1 Planning concept (type of industries, facilities transportation Town

and Country Planning Development authority Classification. Project concept: The project is conceptualized in accordance to the present challenge of minimizing Green House Gas (GHG) emissions from core sector of industries like steel, power, mining etc. It is known that, India is not having coking coal therefore it largely depends on imported stock of coking coal to meet out the coke requirement of blast furnaces, which drains valuable foreign currency of the nation. During last 15 years of industrial growth largest capacity addition had been in steel making through sponge iron route, which was quite successful in bailing out the nation from wrath of costly steel import if these facility would have not be created. However, the sponge iron industry also faced a great limitation of good quality coal from the non-coking coal mines due to which the energy efficiency of these sponge iron plants were badly affected and therefore the financial viability also got badly affected. It is a known technological limitation in sponge iron making process that poor quality coal results in to faster accretion in the kiln resulting in to poorer capacity utilization and frequent breakdowns. The simplest solution for this is to utilization only high grade coal, which is obtained from beneficiation of poor grade raw coal available from Indian mines. The second problem faced by the sponge iron industry was non-availability of good quality iron ore at consistent prices. This bottleneck has been now overcome by inception of a large number of iron ore beneficiation cum pelletizatioin plant. This has made ample



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availability of well sized and well defined and sustained availability of proper quality of ore in the form of pellets at much reasonable rates. However the pelletization process also has certain limitation. The Promoters have thus proposed to use the available low grade ore for beneficiation and then use the beneficiated powder ore for the briquetting and then use this to convert into Iron Powder in Tunnel Kiln. In the backdrop of these scenario the project proponent planned to setup a Ore beneficiation plant; Coal washery; Tunnel Kilns to produce Iron Powder; with CFBC power; Ferro Alloys and SMS with Rerolling Mill in the existing mini steel complex already having three sponge iron and two blast furnaces . For sponge iron kilns to meet the requirement of good quality coal setup its own coal washery Since, the coal washery generates substantial amount of rejects and middlings which have very low calorific value and disposal of the same as waste is a national loss of valuable natural resources, therefore, the promoters decided to setup a power plant of 8 MW based on Circulating Fluidized Bed Combustion Boiler which can ensure the use of not only washery reject but also the char-dolochar from sponge iron kiln. Since the generated power of 8 MW from CFBC would be difficult to sell in to grid thus it was decided to plan its utilization for captive purpose by setting up sub merged arc furnace which can withstand to great fluctuation of power generation. At the same time in order to use the sponge iron produced it was also decided to create melting facility. Thus induction furnaces are planned. Since the consultants of the present project have themselves experienced in direct hot charging of liquid steel through CCM in to rolling mill therefore establishment of rolling mill was decided.



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The objective of creating above facilities is to integrate the different process to achieve highest energy efficiency at the same time utilize all the available resources as waste also. The brief concept of planning is integrated manufacturing facility to produce finished steel, along with captive power generation and coal beneficiation; to achieve highest energy efficiency and highest resource efficiency. In view of these facts and as per globally accepted mandate; that proper ( better) quality of fuel will result in to better energy efficiency in terms of power generation as well as any process efficiency also. Even Government of India imposed restriction on the quality of coal to be used in power plants beyond a certain limit of ash percentage; located beyond 1000 KM of coal mines. The smaller capacity Coal washery are found to be financially viable for captive use thus the promoters have proposed a matching capacity Washery with input washing capability of 1.85 lakh tonnes per annum only. The Coal washery will mainly be undertaking beneficiation of Coal for the own sponge iron plant and Tunnel Kilns. The following aspects are important for considering the creation of Coal washing capacity:



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Projected Generation Capacity in India in GW

Projected Coal Demand in India in Million tons



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Coal quality: Power sector concerns/Need for Beneficiation Power plants are designed for a particular coal quality range and deviation in quality adversely affects the performance and efficiency of the plant. The key areas of concern are: 1. Ash in coal – As high as 45% 2. Inconsistency in Quality of Coal

a. Chemical Quality b. Physical Quality

3. These issues can by and large be addressed y resorting to Coal beneficiation.

4. Need for using beneficiated coal further assumes importance for compliance to environment requirement which stipulated that power houses situated beyond 1000 Kms from pithead coal mine must use coal having less than 34% ash.

5. Besides the foregoing improvement in plant availability/ increased life and economy in long distance transportation also warrants coal beneficiation.

Coal Washery Scenarion in India



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Using Washery Rejects for Power Generation:

• Ash content in Washery Rejects is generally >50% • Pulverized coal combustors have limitation in using coal with

Ash >50% • Technological developments have facilitated using coal with ash

>50% in fluidized bed combustors. • Principle: the fuel is burnt in fluid bed maintained by blowing air

through and inert bed into which the coal is introduced. The area has adequate facilities to transport the small and large quantity of raw material as well as processed finished products as well as some solid waste generated in the industry. The Rail net work as well as Road net work is adequate. The Power transmission lines are also close bye. Town and Country Planning Development authority Classification The project falls in rural area bit it is surrounded by a few Industries. Town and country planning department has already classified land as industrial.

5.2 Population Projection. The existing industry is providing employment to about 280 peoples and by completing the expansion employment to about additional 400 people. Since the plant is located in the Sundergarh district in which trained manpower are already available therefore the employment will be mostly given to local people therefore there is no going to be any substantial increase in the population of local villages.

However, due to increase economic growth the local youth will get employed. And additional population influx of around 1000 people in the 10 KM radius of plant can at best be estimated, which includes the addition of persons dependent on the job seeking persons.



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5.3 Land use planning (breakup along with green belt etc). - Around 33 % (i.e. 6.04 Hect) of industrial land will be used for

green belt development. The details of land use planning is as below:

Land Use Statement Area in Sq.meter

Green Belt 60400 Road 5400 storage area 9100 open area 9100 Factroy Shed 82300 residential 0 Parking 3600 Water Storage 10000 Admin building and Laboratory, Workshop etc 3200 Total Area 183100

5.4 Assessment of Infrastructure Demand:

- The proposed project is expansion of a mini steel complex activity for which no substantial additional infrastructure is required. The available road network, and natural sources of water supply and drainage system are adequate.

- However in order to have smooth transport of men and material the new approach Road between project site as marked in the road map will be constructed.

- In order to ensure smooth and adequate water supply in additional borewells will be drilled. As the area is water rich area because of surrounding dams and river so there is no problem due to drawing of ground water.

- Only the part of the required power will be generated from captive power plant and deficient power when required will be drawn from the existing grid supplying power. For this the existing 33 kV transmission line will be augmented from Rajgangpur substation to the Project site.



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- The DG set with about 1820 kVA (500 KVA X3 Nos and 320 KVA X1 No) capacity is already installed for emergency backup supply to meet the contingencies of power cut and power failure. Thus no additional emergency arrangement is required.

- There is no other major infrastructural requirement for the project.

5.5 Amenities/Facilities: - The project does not require additional large amenities or facilities.

As it already has necessary arrangement for proposed expansion for meeting water supply for drinking purposes, toilet facilities for workers as well as inward/outward transport operators, parking facilities, as well as small canteen for workers and guests. The septic tank has been built for disposal of domestic effluent generated. A canteen with rest room is also available for the supply of tea; snacks; food to the workers and drivers, visitors etc. Sufficient parking space is already created for the parking of Trucks; cars etc.



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6. Proposed Infrastructure 6.1 Industrial Area (Processing Area)

Out of the total 183100 Sq.meter area, about 82300 Sq.meter land will be used for constructing total shed including the existing sheds remaining area will be for open space as well as road development, water storage and green belt development etc as given in land use statement.

6.2 Residential Area (Non Processing Area) There is no residential area proposed in the plant area; as the existing villages have adequate facilities accommodate the additional manpower residential requirements. Most of the local people will only be employed so the need of the additional residential colony in the plant is not there.

6.3 Green Belt. A greenbelt in around 60400 Sq.meter area will be planted, having local species with broad leaves and higher canopy. The ever green plants will be selected for the purposed of green belt.

6.4 Social Infrastructure: The project area lies within the district of Sundergarh and Tahsil

Rajgangpur. there is no requirement to built any social infrastructure within the plant area, however, a small temple already exists and the infrastructure for amenities to the workers such as kitchen, canteen, rest room etc are already provided which will be further augmented with the expansion of the project.

6.5 Connectivity (Traffic and Transportation Road, Rail/Metro/Water ways etc) The 1 Kilometer approach road connecting to the road network will be strengthen to facilitate the movement of material and man.

6.6 Drinking Water Management (Source & Supply of water)

Ground water will be used for supply of drinking water. The maximum demand of water is assessed to be 750 KL/day.



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6.7 Sewerage system

The project will involve about 641 people employment on three shift basis however around 100 people additionally may be visiting in project site as truck drivers or cleaners or visitors etc. thus considering 741 people daily disposing the domestic effluent a septic tank with soak pit of suitable capacity will be built. There is no need to build a separate sewage system, as the overflow will be used for irrigation in green belt.

6.8 Industrial Waste/ Solid Waste Management.

100% of Industrial Solid waste will be used in the following manner:

Waste for disposal sent outside:

Qty. MT/Year

Utilization /disposal method

CFBC bottom Ash 38.42 Given to cement plant for iron oxide supplementation

Shale & Sand Stone 5550.00 Either returned to job provider or will be disposed for road making or land fill

Broken Saggers 600.00 Sold in market Low Grade Ore 66000.00 To be given to cement

plants like OCL Fly Ash Bricks 66000.00 Used by metal recovery

plants and land filling Granulated Blast Furnace Slag

12000.00 To be given to cement plant or brick plants

Slag Generated due to Ferro Alloys


Non Granulated Induction Furnace Slag


Misc Dust like ESP 600.00 To be given to cement plant or brick plants

Defective billets, miss-rolls generated

4683.67 Used by metal recovery plants



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6.10 Power Requirement & Supply/source. The project is not power intensive, thus power requirement will be around 32.73 MW, which will be met through captive power plant of 8 MW and grid connection and for 1820 KVA emergency DG sets for backup will be used.



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7 Rehabilitation and Resettlement (R&R) Plan 7.1 Policy to be adopted (Central/ State) in respect of the project

affected persons including home oustees, land oustees and landless laborers ( a brief outline to be given): The proposed project does not have any directly displaced persons, due to acquisition of land. There are also no land oustees or project affected persons or home oustees, thus R&R plan is not separately prepared for this purpose. However, the priority for employment will be given to local persons living in the adjoining villages. In addition to this promoter will also contribute for the welfare of the people of local surrounding.



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8. Project schedule & Cost Estimates 8.1 Likely date of start of construction and likely date of completion:

The project expansion work is likely to be started immediately after receive of Environment Clearance and completed in two phases first phase will take about 1 year and 8 months to complete and second phase will also take about 2 years to complete. It is hoped that environment clearance will be granted by October 2015, and the construction will thus be began from October 2015 itself. However, the dates cannot be forecasted thus the schedule of implementation is works out from Zero date to progressive time required in months. The Schedule of implementation of the Plant is most reasonable time during which the project can be implemented. This take into account the time required for various activities i.e. Acquisition of Land, Detailed Engineering of the Unit including Architectural and Structural Designs, Civil Construction, Procurement of Equipment and Machinery including Utilities and Service, Erection of Equipment, Testing and Trial Runs Etc. While estimating the time for the implementation of the Project, the time required for all these activities has to be taken into consideration. The estimates also consider the lead time required for the equipment delivery, procurement of building materials like cement, steel etc., time required for getting the Power connection etc. The estimated time required for each of the major activities has been shown as per details given below, considering the date of receiving Environment clearance, from MOEF and from the state Government as Zero date. The implementation of the entire project is envisages in two phases, in first phase Blast Furnace Modernization; Steel Melting Shop, Rerolling Mill and expansion in Cold Briquetting, will be setup over a period of 18 to 20 months as per estimated schedule given below:



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The implementation schedule of first phase facilities is as given below:

PHASE I : Modernization of Blast furnace; Steel melting Shop with Re Rolling Mill and expansion in Cold Ore Briquetting Plant. Commencement Completion (Month and year) (Month and year) (i) Acquisition of land 0000 acquired (ii) (a) Development of land 1 4 (b)Seeking Environment Clearance 1 7 (iii) Civil works - Factory building 8 14 Machinery foundation 7 9 Miscellaneous civil works 9 14 (iv) Plant and Machinery : Imported -placement of order -delivery at site Indigenous-Placement of order: 4 6 -delivery at site : 10 14 (v) Arrangements for power: 4 8 (vi) Arrangements for water: 4 5 (vii) Erection of equipment 14 16 viii) Commissioning : 16 18 (ix) Procurement of raw material 16 18 (x) Training of personnel : 17 18 (xi) Trial runs : 18 19 (xii) Commercial production: 20



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In the second phase Tunnel Kiln ( Iron Powder) ; Coal beneficiation Plant; Ore Beneficiation Plant, Power Plant and Ferro Alloys plants will be setup. But in this phase the production of Iron Powder and Beneficiated Iron Ore will require further 20 months to complete as per given schedule PHASE II (A) - Tunnel Kiln and Ore Beneficiation Plant Commencement Completion (Month and year) (Month and year) (i) Development of land 21 23 (ii) Civil works - Factory building 23 28 Machinery foundation 27 29 Miscellaneous civil works 29 34 (iii) Plant and Machinery : Imported -placement of order -delivery at site Indigenous-Placement of order: 24 26 -delivery at site : 30 34 (iv) Arrangements for power: 24 28 (v) Arrangements for water: 24 25 (vi) Erection of equipment 34 36 vii) Commissioning : 36 38 (viii) Procurement of raw material 36 38 (ix) Training of personnel : 37 38 (x) Trial runs : 38 39 (xi) Commercial production: 40 However n the second phase the construction and civil work and placement of orders for setting up Power Plant 8 MW (8 MW from CFBC), Submerged Arc Furnace ( Ferro Alloys Plant), and Brick making, and Coal Washery, will be done simultaneously. But due to higher lead time for supply of Boiler and Turbine it will require further 10 months to complete as per given schedule below:



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PHASE II (B) - Power Plant, Submerged Arc Furnace , Brick making plant, Coal Washery Commencement Completion (Month and year) (Month and year) (i) Development of land 21 23 (ii) Civil works - Factory building 23 28 Machinery foundation 27 29 Miscellaneous civil works 29 34 (iii) Plant and Machinery : Imported -placement of order -delivery at site Indigenous-Placement of order: 24 26 -delivery at site : 26 30 (iv) Arrangements for power: 24 28 (v) Arrangements for water: 24 25 (vi) Erection of equipment 32 36 vii) Commissioning : 35 38 (viii) Procurement of raw material 35 38 (ix) Training of personnel : 36 39 (x) Trial runs : 37 39 (xi) Commercial production: 40

With the above schedule of implementation it is estimated that the proposed expansion in the plant with complete facilities will be able to start production by 50th month, if the required land water, power & finance is made available in time. We wish the promoters all success and speedy implementation of the proposed project expansion.



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8.2 Estimated project cost along with analysis in terms of economic viability of the project. FINANCIAL ANALYSIS:- (Rs.in Lakhs)

Cost of Project Existing Proposed Total Amount (In Rs. Lakhs)

Phase-I (Modernizati

on of Blast Furnace,

SMS, Rolling Mill and

expansion of Cold

Briquetting Plant)

Phase-II ( Tunnel Kiln, Ore

Beneficiation, Coal Washery, Power Plant, Submerged

Arc Furnace ( Ferro Alloys Plant), Brick

making )

Land & Site Develop.

580.00 100.00 680.00

Building & Civil Work

746.00 849.00 1833.00 3428.00

Plant & Machinery & Other equipments

1249.00 3296.00 7642.00 12187.00

Misc. Fixed Assets auxiliary

1079.00 180.00 145.00 1404.00

Electrical Installations

508.00 625.00 175.00 1308.00

Pollution Control Equipment

678.00 500.00 222.00 1400.00

Pre. And Preoperative Exp.

421.00 269.00 690.00

Contingency 478.00 504.00 982.00 TOTAL :: 4840.00 6349.00 10890.00 22079.00

Means of Finance Total Amount (In Rs. Lakhs)

EQUITY Equity & reserve and surplus

d) Promoter contribution : 1600.00 e) Venture Capital fund : 1600.00 f) Public Issue : 3379.00

6579.00

DEBT Term Loan from Bank

15500.00



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TOTAL :: 22079.00

Estimation of Power Requirement

Annual Production

Per Ton power required

Total Power required per year in MWh

Sponge Iron 45000.00 100.00 kWh/ton 4500.00 MWh Induction Furnace with LRF 110000.00 750.00 kWh/ton 82500.00 MWh Rolling Mill 100000.00 100.00 kWh/ton 10000.00 MWh

Power Plant 10% lost in auxiliary equipments 6019.20 MWh

Coal Beneficiation 185000.00 40.00 kWh/ton 7400.00 MWh Ferro Alloys 25000.00 4500.00 kWh/ton 112500.00 MWh Iron Ore Beneficiation 264000.00 40.00 kWh/ton 10560.00 MWh Ore Briquetting 200000.00 20.00 kWh/ton 4000.00 MWh IRON POWDER THROUGH TUNNEL KILN 60000.00 90.00 kWh/ton 5400.00 MWh Blast Furnace 60000.00 250.00 kWh/ton 15000.00 MWh Fly Ash brick Plant 66000.00 20.00 kWh/ton 1320.00 MWh 259199.20 MWh

Total Power requirement 32.73 MW



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Estimation of Sales (Rs.in lacks)



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Estimation of Raw Material (Rs.in lacks)



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Projected Balance Sheet

(Rs.in lacks)

L I A B I L I T I E S 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year

Equity Share Capital Value 6579.00 6579.00 6579.00 6579.00 6579.00 6579.00 6579.00 6579.00

Reserve & Surplus:

a) Profit & Loss A/c. 1204.50 2447.38 4818.74 5231.50 5004.61 4834.22 4748.51 4767.52

Term Loan 15500.00 13285.72 11071.44 8857.16 6642.88 4428.60 2214.32 0.00

Working Capital Loan 10762.43 12356.30 14095.30 14096.30 14096.30 14096.30 14097.30 14097.30

34045.93 34668.40 36564.48 34763.96 32322.79 29938.12 27639.13 25443.82

A S S E T S 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year

Fixed Assets.(Net) 19507.11 17434.22 15361.33 13288.44 11215.55 9142.66 7069.77 4996.88

Current Assets 14349.90 16698.30 19048.30 19049.30 19049.30 19049.30 19050.30 19050.30

Deposits/Investments 110.00 110.00 110.00 110.00 110.00 110.00 110.00 110.00

Cash & Bank Balance 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06 1286.64

T O T A L : 34045.93 34668.40 36564.48 34763.96 32322.79 29938.12 27639.13 25443.82



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OTHER FINANCIAL PARAMETERS:

Debt Service Coverage Ratio:

D.S.C.R. has been calculated for first 8 years because, the repayment of term loan gets completed within 7 years in 12 half yearly installments, after giving 1 years moratorium. The average DSCR has come to 1.63 which shows the sound and surplus position of reparability of term loan and its interest.

(Rs.in lacks)

Particular 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year

SERVICES a) Net Profit After Tax 1204.50 1268.24 2419.76 1763.83 1782.46 1840.11 1926.52 2033.38

b) Interest On Term Loan 1937.50 1799.11 1522.32 1245.54 968.75 691.97 415.18 138.40

c) Depreciation 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89

T O T A L : 5214.89 5140.24 6014.97 5082.26 4824.10 4604.97 4414.59 4244.67 D E B T a) Interest On Term Loan 1937.50 1799.11 1522.32 1245.54 968.75 691.97 415.18 138.40

b) Installment of T.L. 0.00 2214.28 2214.28 2214.28 2214.28 2214.28 2214.28 2214.32

T O T A L : 1937.50 4013.39 3736.60 3459.82 3183.03 2906.25 2629.46 2352.72

D.S.C.R. during the year 2.69 1.28 1.61 1.47 1.52 1.58 1.68 1.80 Average D.S.C.R. 1.63



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Break Even Point:

Break Even Point has been calculated in Annexure F-VIII of this report. Based on III year working i.e., at 80% production level the BEP comes to 69.59%, thus at 100% production it is estimated to be 55.67%. It shows that the Unit has much high flexibility and at times of crisis it can survive with lower capacity running also.

(Rs.in lacks)

S.NO. P A R T I C U L A R S AMOUNT (A) VARIABLE COSTS 1. Raw Material Consumed 43227.92 2. Utilities 10396.68 3. Wages 1892.32 4. Interest On Working Capital 3523.83 5. Selling Expenses 3657.30 6. Repairs and Maintenance 772.77 7. Salary of Administrative Staff (50%) 158.56

Total :: 63629.37 (B) SEMI VARIABLES & FIXED COST 1. Salary of Administrative Staff (50%) 158.56 2. Administrative Expenses 242.00 3. Depreciation 2072.89 4. Interest On Term Loan 1522.32

Total :: 3995.77 (C) SALES REALISATION 69371.48 (D) CONTRIBUTION (C-A) 5742.11 (E) BREAK EVEN POINT 69.59% (F) BREAK EVEN POINT AT 100% PRODUCTION 55.67%



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Internal Rate of Return:

As shown in Annexure F-X of this report, the Internal Rate of Return when discounted at 19.73% will be zero in fifteen years. It shows the financial sound health of the Unit.

(Rs.in lacks) YEARS GROSS INVENT- TOTAL OPERATING

INTER- DEPREC- GROSS NET DISCOUNTED

FIXED -ORIES INVEST- PROFIT -EST -IATION CASH CASH VALUE AT ASSETS -MENT INFLOW FLOW 25% 30%

0 22079.00 22079.00 -

22079.00 -22079.00 -22079.00 1 14349.90 14349.90 1273.50 3282.80 2072.89 6629.19 -7720.71 -6176.565 -5939.005 2 2348.40 2348.40 1337.24 3343.65 2072.89 6753.78 4405.38 2819.445 2606.735 3 2350.00 2350.00 2673.01 3284.23 2072.89 8030.13 5680.13 2908.227 2585.403 4 1.00 1.00 2731.66 3007.58 2072.89 7812.13 7811.13 3199.439 2734.894 5 0.00 0.00 2995.45 2730.79 2072.89 7799.13 7799.13 2555.619 2100.533 6 0.00 0.00 3260.23 2454.01 2072.89 7787.13 7787.13 2041.350 1613.308 7 3260.23 2454.01 2072.89 7787.13 7787.13 1633.080 1241.006 8 3260.23 2454.01 2072.89 7787.13 7787.13 1306.464 954.620 9 3260.23 2454.01 2072.89 7787.13 7787.13 1045.171 734.323

10 3260.23 2454.01 2072.89 7787.13 7787.13 836.137 564.864 11 3260.23 2454.01 2072.89 7787.13 7787.13 668.909 434.511 12 3260.23 2454.01 2072.89 7787.13 7787.13 535.128 334.239 13 3260.23 2454.01 2072.89 7787.13 7787.13 428.102 257.107 14 3260.23 2454.01 2072.89 7787.13 7787.13 342.482 197.775 15 3260.23 2454.01 2072.89 34231.99 34231.99 1204.431 668.778

-6731.58 -10989.91 = 4258.33 I.R.R. = 19.73%

On Considering most of the financial parameters and indicating factors, the Unit shows a very healthy financial pattern.



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9. ANALYSIS OF PROPOSAL & FINAL RECOMMENDATIONS:

9.1 Financial and social benefits with special emphasis on the benefit to

the local people including tribal population in the area.

On overall assessment of the project with technical and financial aspects it is concluded that the existing project for production of Sponge Iron with Pig Iron thru Blast furnaces being expanded by addition of , Steel melting Shop, Rerolled Steel, Ferro Alloys, Coal Washery with CFBC Power Plant is technically highly feasible and financially highly profitable.

The project is of utmost importance as it is going to drastically reduce the GHG emission & promote sustainable development with a great saving in energy consumption. In addition the project being located away from the urban areas will avoid pollution-addition to the densely populated areas, at the same time promote the growth of the backward area.

The strength of the project lies on the use of washed coal in DRI making, and use of thermal energy in liquid steel to maintain re-rollable temperature in rolling of steel along with Captive Power Generation technology based on the Waste Coal and Char Dolochar and the technical strength of the promoters.

The abundance of raw material in surrounding areas at very cheaper rate will give the company a great financial strength, which is further substantiated by Captive Power Generation at cheaper rates.



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A sincere approach adopted for the Air Pollution Control and Resource conservation by recycling the 100% waste water also gives the additional advantage to the company. Power generation from Waste Coal will give financial strength to the Company and Protect Environment.

The project proponents have decided to give topmost priority for employment to local people within the plant, and outside the plant in direct and indirect employments. Out of over 641 people to be employed the company would be employing more than 250 people from local area, which would naturally involve tribal people also who are more than 40% in population and also are now well qualified as well as competent to take the employment in the proposed industry. The local population is likely to be benefited by payment of salary and wages approximately amounting to more than 500.00 Lacs per annum even on considering about 30% payment to the local community employed.

In view of these factors we fully recommend the project as technically feasible, environmental safe and financially viable. We wish the promoters all success and most profitable operation, Date: 28/01/2015 For, Indus Technical and Financial Place: Raipur (CG) Consultants Ltd. [Lalit Kumar Singhania] Chief Consultant

XXX



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Appendix. 1 : List of Sponge Iron Plant in Odisha S. No. Name Of Industry District State

1. Adhunik Metalic Private Limited Rourkela Odisha 2. Aditya Spone & Power Private

Limited Keonjhar Odisha 3. Agrasen Sponge Private Limited Sundargarh Odisha 4. Arati Steel & Power Limited Cuttack Odisha 5. Aryan ispat & Power Private Limited Sambalpur Odisha 6. B K Steel & Power Private Limited Keonjhar Odisha 7. B R Sponge & Power Limited Rourkela Odisha 8. Bajrang Sponge Iron Private Limited Rourkela Odisha 9. Beekay Steel & Power Limited Keonjhar Odisha 10. Bhagwati Steels Private Limited Jharsuguda Odisha 11. Bhaskar Steels & Ferro Alloys Sundargarh Odisha 12. Bhusan Power & Steel Limited Sambalpur Odisha 13. Bhushan Steel & Strips Limited Dhenkanal Odisha 14. Bindal Sponge Limited Angul Odisha 15. Brand Alloys Limited Keonjhar Odisha 16. BRG Steel Company Private Limited Dhenkanal Odisha 17. Crakers India Alloys Limited Keonjhar Odisha 18. Deepak Steels & Power Limited

(Topadihi) Keonjhar Odisha 19. Deepak Steels & Power Limited

(Uliburu) Keonjhar Odisha 20. Dinabandhu Steel & Power Limited

(formally yazdani steel and power) Jajpur Odisha 21. Ganesh Sponge Private Limited Angul Odisha 22. Govindam Project Private Limited Sundargarh Odisha 23. Grewal Associates Keonjhar Odisha 24. Jagannath Sponge Private Limited Sundargarh Odisha 25. Jai Balaji joyti Steel Limited Sundargarh Odisha 26. Jai Hanuman Udyog Limited Jharsuguda Odisha 27. Jai Iron & Steel Limited Sundargarh Odisha



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28. Jai Jagannath Steel & Power Limited (formally known TR Chemical Limited) Sambalpur Odisha

29. Jain Steel & Power Limited Jharsuguda Odisha 30. K J Ispat jajpur Odisha 31. Kalinga Sponge Iron Limited Sundargarh Odisha 32. Kaushal Ferro Metal Privae Limited Sundargarh Odisha 33. Khederia Ispat Limited Sundargarh Odisha 34. KJS Ispat (formally known as Hima

Ispat Limited) Keonjhar Odisha 35. Kusum Power Met Private Limited Keonjhar Odisha 36. L.N. Metelic Private Limited Jharsuguda Odisha 37. M S P Sponge Iron Limited Keonjhar Odisha 38. Maa Sakumbari Sponge Private

Limited Sundargarh Odisha 39. Maa Samleshwari Industries Limited Sambalpur Odisha 40. Maa Samleshwari Sponge Iron

Limited Sambalpur Odisha 41. Maa Tarini Industries Private Limited Sundargarh Odisha 42. Maa Vaishnvi Sponge Limited Sundargarh Odisha 43. Maa Vision Sponge Limited Rourkela Odisha 44. Mahakali Ispat Sundargarh Odisha 45. Maheshwari Ispat Limited Cuttack Odisha 46. Maithan Steel Limited Jajpur Odisha 47. Mayur Electro Ceramics Private

Limited Mayurbhanj Odisha 48. Meta Sponge Private Limited Sundargarh Odisha 49. MGM Steel Limited Dhenkanal Odisha 50. Monika Holding Private Limited Sundargarh Odisha 51. MSP Metalic Limited Jharsuguda Odisha 52. MSP Sponge Iron Private Limited Keonjhar Odisha 53. N K Bhojani Private Limited Keonjhar Odisha 54. Narbheram Power & Steel Industries

Limited (formally known as Scaw Industries) Dhenkanal Odisha



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55. OCL India Limited (SID) Sundargarh Odisha 56. OMDC Limited (SID) Keonjhar Odisha 57. Ores ispat Private Limited Sundargarh Odisha 58. Orissa Sponge Iron & Steel Limited Keonjhar Odisha 59. Papuri Engineering & Consultancy

Service Keonjhar Odisha 60. Patnayak Minerals Private Limited Keonjhar Odisha 61. Patnayak Steels & Alloys Keonjhar Odisha 62. Pawanjai Sponge Iron Limited Sundargarh Odisha 63. Pawansut Sponge Iron Privae Limied Jharsuguda Odisha 64. Pooja Sponge Private Limited Sundargarh Odisha 65. Prabhu Sponge Iron Private Limited Sundargarh Odisha 66. R B Sponge Iron Limited Sambalpur Odisha 67. Rana Sponge Limited Dhenkanal Odisha 68. Rathi Steel & Power Project Limited Sambalpur Odisha 69. Reliable Sponge Sundargarh Odisha 70. Reliable Sponge Iron Private Limited Rourkela Odisha 71. Rexon Strips Sundargarh Odisha 72. Rungta Mines Limited (karakola) Keonjhar Odisha 73. Rungta Mines Limited (Komando) Sundargarh Odisha 74. Sai Shraddha Steel Private Limited Sundargarh Odisha 75. Samleshwari Ferro metal Private

Limited Sambalpur Odisha 76. Scan Steels Limited Sundargarh Odisha 77. Seven Star Steels Limited Jharsuguda Odisha 78. Shiv metalic Sundargarh Odisha 79. Shiva Shakti Sponge Iron Limited Mayurbhanj Odisha 80. Shree Hari Sponge Sundargarh Odisha 81. Shree Jagannath Steels & Power

limited Keonjhar Odisha 82. Shree Metalic Limited Angul Odisha 83. Shri Ganesh Metalic Limited Sundargarh Odisha 84. Shri Madhav Ispat Private Limite Jharsuguda Odisha 85. Shri Mahavir Ferro Alloys Private

Limited Sundargarh Odisha



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86. Shristhi Ispat Limited Sundargarh Odisha 87. Shyam DRI Power Limited Sambalpur Odisha 88. Singhal Enterprises Private Limited Jharsuguda Odisha 89. Sita Sponge Iron Limited Sundargarh Odisha 90. SMC Power Generation Limited Jharsuguda Odisha 91. Sponge Udyog Private Limited Sundargarh Odisha 92. SPS Sponge Iron Limited Jharsuguda Odisha 93. Sree Metelics Limited Keonjhar Odisha 94. Sri Balaji Metalic Private Limited Sundargarh Odisha 95. Sri Ganesh Sponge Iron Limited Keonjhar Odisha 96. Sri Hardev Steel Private Limited Cuttack Odisha 97. Sri Saleswar Ores & Mineral Rourkela Odisha 98. Sumrit Metalic Limited Keonjhar Odisha 99. Suraj Product Limited Sundargarh Odisha 100. Surendra Mining Industrids Private

Limited Sundargarh Odisha 101. Surya Sponge Iron Limited Jajpur Odisha 102. Swastik Ispat Private Limited Sundargarh Odisha 103. Tata Sponge Iron limited Keonjhar Odisha 104. Thakur Prasad Sao & Sons (Formally

known as Estern Seetl & Power Limited) Jharsuguda Odisha

105. Thakur Prasad Sao & Sons (Formaly known as Manglam Isapt Private Limited) Sundargarh Odisha

106. Thakur Prasad Sao & sons Private Limited (Formerly known as Bajrang Ispat P. Ltd) Sundargarh Odisha

107. Times Steel & Power Limited (Previsouly known as Nixon Steel & Power) Sundargarh Odisha

108. TR Chemical Limited Sundargarh Odisha 109. Utkal Metalic Sundargarh Odisha 110. Vasundhara Metalic Sundargarh Odisha 111. Vedvyas Ispat Limited Sundargarh Odisha



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112. Vikram Steel & Ferro Alloys Private Limited Sundargarh Odisha

113. Viraj Steel & Energy Limited Sambalpur Odisha 114. Viraja Steel & Power Private Limited

(formally known as shiva metalic private limited) Cuttack Odisha

115. Visa Steel Limited Jajpur Odisha 116. Vishal Metalic Private Limited Sundargarh Odisha



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Appendix 2 : List of Sponge Iron Plant in Raigarh (Chhattisgarh) S. No. Name Of Industry District State

1. Ambika Ispat (India) Pvt. Ltd. Raigarh CHHATTISGARH 2. Anjani Steel Ltd. Raigarh CHHATTISGARH 3. B. S. Sponge Pvt. Ltd. Raigarh CHHATTISGARH 4. Ind Synergy Limited Raigarh CHHATTISGARH 5. Jindal Steel and Power Ltd. Raigarh CHHATTISGARH 6. Maa Kali Alloys Udyog Pvt. Ltd. Raigarh CHHATTISGARH 7. Mangala Ispat Pvt. Ltd. Raigarh CHHATTISGARH 8. Mekko Steel & Power Pvt. Ltd. Raigarh CHHATTISGARH 9. Monet Ispat Ltd. Raigarh CHHATTISGARH 10. MSP Steel and Power Ltd. Raigarh CHHATTISGARH 11. N.R. Ispat and Power Pvt. Ltd. Raigarh CHHATTISGARH 12. Nalwa Sponge Irion Limited Raigarh CHHATTISGARH 13. Navdurga Fuels Pvt. Ltd. Raigarh CHHATTISGARH 14. Raigarh Iron Industries Ltd. Raigarh CHHATTISGARH 15. Raigarh Ispat and Power Ltd. Raigarh CHHATTISGARH 16. Rameshwaram Steel and Power Pvt.

Ltd. Raigarh CHHATTISGARH 17. Salasar Sponge and Power Pvt. Ltd. Raigarh CHHATTISGARH 18. Scania Steel & Power Ltd. Raigarh CHHATTISGARH 19. Selino Steel Ltd. Raigarh CHHATTISGARH 20. Shakambari Steel and Power Pvt. Ltd. Raigarh CHHATTISGARH 21. Shivshakti Steel Pvt. Ltd. Raigarh CHHATTISGARH 22. Shyam Ispat (India) Pvt. Ltd. Raigarh CHHATTISGARH 23. Sidhi Vinayak Sponge Iron Pvt. Ltd. Raigarh CHHATTISGARH 24. Singhal Energy P Ltd. Raigarh CHHATTISGARH 25. Singhal Interprises Pvt. Ltd. Raigarh CHHATTISGARH 26. Sunil Ispat and Power Lts. Raigarh CHHATTISGARH



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Appendix.3 : Coal field in Orissa COALFIELD IN ORISSA (Geological Reserve 75.072 BT as on 01.04.2014 ) Out of 47 Gondawana & 14 Tertiary coalfields for the national inventory of coal, Orissa state has only two coalfields. Yet its share in the reserve are so far established in the country amounts to 24.89%( 75.07).

In Terms of spatial spread of prognostical coal bearing area, thecoalfields of the state of Orissa have about 7.6% area (2723Sq.Km). This goes to illustrate the high ratio of coal to non coalstrata in the two hitherto known coal bearing basin viz.lb Rivercoalfield and Talcher coalfield. As a sequel to which thresecoalfields have an added advantage of being accorded mostfavoured coalfields status by the nature as far as quarriablepotentiality is concerned.

Historically Talcher coalfield was discovered by Lt. kittoe in 1839



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and lb River coalfield by V.Ball in 1871 yet the real impetus forresource assesment by systematic exploration efforts wasaccorded only in the post nationalisation era of the coal industrysince 1973, the importance of Orissa coalfields further enhanceddue to their vicinity to east coast.

COALFIELD of ORISSA Talcher Coalfield (Geological Reserve 50.874 BT As on 01.04.2014 )

Talcher Coalfield was first discovered at Gopalprasad in the 1837. Lateron GSI surveyed and mapped in 1855. M/s East India Prospecting Syndicate in Talcher Town in 1920 Handidhua Colliary was opened by M/s Villiers Ltd in 1921. NCDC opened mines at South Belanda, Nandira & Jagannath in the year 1960,1962 and 1972 respectively. After formation of CIL all mines were in CCL then in SECL before formation of MCL in 1992. Production of coal raised from 0.91 M.T. in 1972-73 to 63.973 M.T. in 2013-14.



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IB Valley Coalfield (Geological Reserve 24.198 BT As on 01.04.2014)

IB Valley Coalfield was first discovered by B N Railway while constructing bridge over lb river in the year 1900. M/S Himgir Rampur Coal company opened colliery in the year 1909. Many more mines were opened in the year 1940, 1954 and after the nationalization of coal mines the mines came under WCL. Later on it came under SECL and then under MCL in the year 1992 after its formation. Production of this field was 0.55 M.T. in 1972-73 which has increased upto 46.467 M.T. in the year 2013-14



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Appendix 4 : List of Iron Ore Mines in Odisha S. No. Name of the Lessees Location of the Lease

1. M/s. Adhunik Metaliks Ltd. Deojhar, Kulum & Mahadevnasa

2. M/s Bhanja Mineral(P) Ltd Deojhar

3. M/s Essel Mining & Industries Ltd. Jilling- Langalota

4. M/s Gandhamardan Sponge Iron (P) Ltd. Putuli pani

5. M/s K.N. Ram & Co. Roida - II

6. M/s Kalinga Mining Corpn. Jurudi


8. M/s Kalinga Mining Corpn. Jurudi 9. M/s Kaypee Enterprises Thakurani

10. M/s Mid East Int. Steel Ltd. Roida- 1 (Sidhamath)

11. M/s Mineral Trading Syndicate Bhalubeda

12. M/s Narayani Sons (P) Ltd. Surguturia

13. M/s Narayani Sons (P) Ltd. Laupada

14. M/s O.M.C. Ltd. Gandhamardan -B

15. M/s O.M.C. Ltd. Khandbandh

16. M/s O.M.C. Ltd. Sekradihi

17. M/s O.M.C. Ltd. Balda-Palsa-Jajang

18. M/s O.M.C. Ltd. Banspani

19. M/s O.M.C. Ltd. Gandhamardan-A

20. M/s O.M.C. Ltd. Unchabali, Balda, Nayagarh

21. M/s O.M.D.Co. Bagiaburu M-Block

22. M/s O.M.D.Co. Kolha-Roida

23. M/s Patnaik Minerals Pvt. Ltd Jaribahal

24. M/s Rungta Sons (p) Ltd. Bandhabeda

25. M/s SAIL Bolani



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26. M/s Sarda Mines (P) Ltd. Thakurani Block-B

27. M/s Sirrajuddin & Co. Balda Block

28. M/s T.B. Lal & Co. Jajang

29. M/s T.B. Lal & Co. Kasia-Kolha-Barapada 30. M/s Tarini Minerals (P) Ltd. Deojhar

31. M/s TATA Steel Ltd. Joda East

32. R.P. Sao Guali

33. S.C. Padhi Gurubeda

34. M/s Essel Mining & Industries Ltd. KasiaÂ

35. Â R.P. Sao Chormalda

36. M/s BPMEL Dalki - KS Group

37. M/s FACOR Ltd. KatasahiÂ Â



40. M/s O.M.C. Ltd. Roida-D

41. M/s O.M.C. Ltd. Parelipada

42. M/s O.M.C. Ltd. Roida-Sidhamath

43. M/s O.M.C. Ltd. Dubna

44. M/s Patnaik Minerals Pvt. Ltd Jaribahal (Palsa)

45. M/s Rungta Sons (P) Ltd. Katasahi

46. M/s Sirrajuddin & Co. Gurda

47. M/s TATA Steel Ltd. Manmora

48. M/s TATA Steel Ltd. Guruda & Tringpahar

49. S. N. Paul Katasahi, Kolha-Rudukela

50. S.N. DasMohapatra Katasahi-Kolha-Rudkela

51. B.L. Newatia Tikarpada

52. G.P. BeheraÂ Jamudiha

53. S.C. Mallick Raduan



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54. B.L. Newatia Madrangjodi

55. M/s D.M. Minerals (P) Ltd. Medinapur

56. M/s Keonjhar Minerals (p) Ltd. Amjore

57. M/s Keonjhar Minerals (p) Ltd. Bhaliadihi 58. M/s Sovan Minerals (P) Ltd. Ambadhara

59. M/s Utkal Minerals (P) Ltd. Nitigotha

60. B.K. Mohanty Parsala

61. Raju V. J. (G.L. Chowda) Chauthia

62. S.N. Mohanty Raruanguda

63. M/s J.K.& K.P. Jhunjhunwala Jaganathprasad

64. M/s HINDALCO Industries Ltd. Maliparbat

65. M/s NALCO Ltd. Panchpatmali (South Block)

66. M/s NALCO Ltd. Panchpatmali (North Block)

67. P. Laxmanswamy Udiyaguda

68. P. Laxmanswamy Hatasuku

69. M/s IDC of Orissa Ltd. Ampavalli

70. M/s O.M.C. Ltd. Umpavaley

71. M/s V. Gimpex Mining (P) Ltd. Mastiput

72. M.B. Chakra Ramgiri 73. R.R. Mohanty Marthapara

74. M/s Dharampal & Co. Gudiali

75. M/s Hamco Mining &Smelling Goliaguda

76. K.K. Chaurasia Nandabasa

77. Ajit Samantrahy Ramachndrapur

78. Bibhudatta Sahu Kumbharapundigundi

79. D.C. Dagara Hizli

80. K.P. Singhania Chanchabani

81. M/s Arun UdyogÂ Jashipur



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82. M/s J.M. & M.(P) Ltd. Kadadiha

83. M/s Mayur Electro Potteries (P) Ltd. Jamda

84. M/s O.M.C. Ltd. Dumuria

85. P.D. Agrawal Khaprasahi 86. S.K. Allauddin Gadapalasa Block A

87. S.K. Allauddin Gadapalasa Block B

88. S.K. Allauddin Gadapalasa Block C

89. D.C. Dagara Brukhyabhanupur

90. J.K. Choubey Budhrajpahar

91. B. K. Das Kasiabera

92. B.C. Dagara Suleipat

93. B.C. Dagara Bhitaramda

94. D.C. Dagara Ghusuria

95. D.C. Das Maharajpur

96. G.S. Choubey Nangalsila

97. M/s G.S. Mishra & Sons Gorumahisani

98. J.K. Choubey Purunapani-Bhuyanbasa

99. M/s Lal Traders & Agencies (P) Ltd. Badampahar

100. S.A. Karim Ashanbani



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Appendix 5 : Estimates of Profit and Loss (Rs.in lacks) P A R T I C U L A R S 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year

No. Of Working Days

330 330 330 330 330 330 330 330 No. Of Shifts 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 Installed Capacity 270749 270749 270749 270749 270749 270749 270749 270749 (in tonnes) Capacity Utilisation 60% 70% 80% 80% 80% 80% 80% 80% Sales Realization 54859.48 64002.73 73145.98 73145.98 73145.98 73145.98 73145.98 73145.98 Less: Net Excise Duty Payable 2830.87 3302.68 3774.50 3774.50 3774.50 3774.50 3774.50 3774.50 Add: Modvat Receivable 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 Net Sales 52028.61 60700.05 69371.48 69371.48 69371.48 69371.48 69371.48 69371.48 Cost Of Production a)Raw Material 32420.94 37824.43 43227.92 43227.92 43227.92 43227.92 43227.92 43227.92 c)Salary & Wages 1563.90 1720.29 1892.32 1892.32 1892.32 1892.32 1892.32 1892.32 d)Power and water 7797.51 9097.10 10396.68 10396.68 10396.68 10396.68 10396.68 10396.68 e)Repairs & maintenance 772.77 772.77 772.77 772.77 772.77 772.77 772.77 772.77 f)Depreciation 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 g) Pollution control expenses 210.00 220.00 231.00 242.00 254.00 266.00 279.00 292.00 g) Consumable & Stores 812.25 812.25 812.25 812.25 812.25 812.25 812.25 812.25

T O T A L : 45650.26 52519.73 59405.82 59416.82 59428.82 59440.82 59453.82 59466.82 Add : Opening Stock of 1383.00 1592.00 1800.00 1801.00 1801.00 1801.00 1802.00 Finished Goods

45650.26 53902.73 60997.82 61216.82 61229.82 61241.82 61254.82 61268.82 Less : Closing Stock of 1383.00 1592.00 1800.00 1801.00 1801.00 1801.00 1802.00 1802.00 Finished Goods

44267.26 52310.73 59197.82 59415.82 59428.82 59440.82 59452.82 59466.82

Cost Of Sales

44267.26 52310.73 59197.82 59415.82 59428.82 59440.82 59452.82 59466.82 Gross Profit

7761.35 8389.32 10173.66 9955.66 9942.66 9930.66 9918.66 9904.66

Administrative Expenses a) Admn. Staff 262.08 288.29 317.12 317.12 317.12 317.12 317.12 317.12 b) Admn. Expenses 200.00 220.00 242.00 242.00 242.00 242.00 242.00 242.00 Selling Expense 5.00% 2742.97 3200.14 3657.30 3657.30 3657.30 3657.30 3657.30 3657.30 Financial Expenses a)Intt.On Long Term Loan 1937.50 1799.11 1522.32 1245.54 968.75 691.97 415.18 138.40 b)Interest on W.C. 1345.30 1544.54 1761.91 1762.04 1762.04 1762.04 1762.16 1762.16 G R A N D T O T A L

6487.85 7052.08 7500.65 7223.99 6947.20 6670.42 6393.76 6116.98

Operating Profit 1273.50 1337.24 2673.01 2731.66 2995.45 3260.23 3524.90 3787.68 Amortization of Preliminary 69.00 69.00 69.00 69.00 69.00 69.00 69.00 69.00 Expenses Profit before tax 1204.50 1268.24 2604.01 2662.66 2926.45 3191.23 3455.90 3718.68 Taxation 0.00 0.00 184.25 898.83 1143.99 1351.12 1529.38 1685.30 Net Profit after tax 1204.50 1268.24 2419.76 1763.83 1782.46 1840.11 1926.52 2033.38 CSR Expenses as per companies act 2% 0.00 25.36 48.40 35.28 35.65 36.80 38.53 40.67 Dividend % 0% 0% 0% 20% 30% 30% 30% 30% Dividend (Withdrawal) 0.00 0.00 0.00 1315.80 1973.70 1973.70 1973.70 1973.70 Surplus during the year 1204.50 1242.88 2371.36 412.76 -226.89 -170.39 -85.71 19.01 Cumulative Surplus 1204.50 2447.38 4818.74 5231.50 5004.61 4834.22 4748.51 4767.52



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Appendix 6 : Estimated of Margin Money

(Rs.in lacks)

PARTICULARS Period 1st 2nd 3rd 4th 5th 6th 7th 8th (days) Year Year Year Year Year Year Year Year

Raw Material 30 3242.10 3782.00 4323.00 4323.00 4323.00 4323.00 4323.00 4323.00 Consumables 30 77.30 77.30 77.30 77.30 77.30 77.30 77.30 77.30 Goods-in-process 10 1418.50 1647.00 1876.00 1876.00 1876.00 1876.00 1876.00 1876.00 Finished Goods 10 1383.00 1592.00 1800.00 1801.00 1801.00 1801.00 1802.00 1802.00 Receivables 45 8229.00 9600.00 10972.00 10972.00 10972.00 10972.00 10972.00 10972.00

TOTAL CURRENT ASSETS 14349.90 16698.30 19048.30 19049.30 19049.30 19049.30 19050.30 19050.30 LESS : BANK FINANCE 75.00% 10762.43 12356.30 14095.30 14096.30 14096.30 14096.30 14097.30 14097.30 MARGIN 26.00 3726.00 4342.00 4953.00 4953.00 4953.00 4953.00 4953.00 4953.00



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Appendix 7 : Cash Flow Statement (Rs.in lacks)

SOURCES OF FUND CONST. 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year Net Profit before 4487.30 4611.89 5888.24 5670.24 5657.24 5645.24 5633.24 5619.24 taxes with intt. added back but after depreciation

Increase in Share capital 6579.00 Depreciation 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89 2072.89

Unsecured Loan 0.00

Inc.in Term Loan 15500.00 Inc.in W.C.Loan 10762.43 1593.88 1739.00 1.00 0.00 0.00 1.00 0.00

T O T A L : 22079.00 17322.62 8278.66 9700.13 7744.13 7730.13 7718.13 7707.13 7692.13

DEPOSITION OF FUND CONST. 1st 2nd 3rd 4th 5th 6th 7th 8th Year Year Year Year Year Year Year Year Increase in Capital expenditure 21580.00

Increase in 14349.90 2348.40 2350.00 1.00 0.00 0.00 1.00 0.00 current assets

Deposits/Investments 110.00

Decrease in Term Loan 0.00 2214.28 2214.28 2214.28 2214.28 2214.28 2214.28 2214.32

CSR Expenses as per companies act 0.00 25.36 48.40 35.28 35.65 36.80 38.53 40.67 Dividend (Withdrawal) 0.00 0.00 0.00 1315.80 1973.70 1973.70 1973.70 1973.70

Interest 3282.80 3343.65 3284.23 3007.58 2730.79 2454.01 2177.34 1900.56

Taxation 0.00 0.00 184.25 898.83 1143.99 1351.12 1529.38 1685.30

T O T A L 21690.00 17632.70 7931.69 8081.16 7472.76 8098.41 8029.91 7934.23 7814.55

Opening Balance 389.00 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06 Net Surplus (A-B) 389.00 -310.08 346.96 1618.97 271.37 -368.28 -311.78 -227.10 -122.42 Closing Balance 389.00 78.92 425.88 2044.85 2316.22 1947.94 1636.16 1409.06 1286.64

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