PROPOSED 1x15 MW CAPTIVE POWER PLANT, 5000...

OF

PROPOSED 1x15 MW CAPTIVE POWER PLANT,

5000 TPA FERRO TITANIUM, 3000 TPA FERRO MANGANESE,

12 TPD ALUMINIUM POWDER

AND

2.4 TPA SCANDIUM OXIDE RECOVERY PLANT

FOR

M/M/M/M/ssss SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD. At: Chatrapur, Dist- Ganjam, Odisha.

JULY 2016

PREPREPREPRE----FEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORT

Centre For Envotech and Management Consultancy Pvt. Ltd.

AN ISO: 9001: 2008 and BS OSHAS 18001: 2007 certified company,

Empanelled with OCCL, Govt. Of Odisha, OSPCB as Category “A” Consultant Organization,

Accredited b y NAB ET, Qual ity Counc i l o f Ind ia for EIA stud ies

As Category “A” Consultant Organization.

Regd. Off: N5/305, IRC Village, Bhubaneswar, Odisha Tele: 0674 - 2360344, E-mail: cemc_consultancy @yahoo.co.in, [email protected]

Website: www.cemc.in

CEMCCEMC

Contents

CHAPTER NO CHAPTER NAME PAGE NO

CHAPTER-1 EXECUTIVE SUMMARY 1-5

1.1 Introduction 1 1.2 Project Site 1 1.3 Plant Layout 1 1.4 Brief Project Description 1 1.5 Raw Materials 2 1.6 Water Requirement & Source 3 1.7 Solid Waste Generation & Management 3 1.8 Green Belt Development 4 1.9 Amenities/Facilities 4 1.10 Project Cost 5

CHAPTER-2 INTRODUCTION OF THE PROJECT/BACKGROUND

INFORMATION 6-9

2.1 Identification of the project & project proponent 6

2.2 Nature, size and magnitude of project 7

2.3 Need for the project 8

2.4 Project Objective and Its Importance to The Country/ Region

8

2.5 Demand supply gap 8

2.6 Employment generation (direct and indirect due to the project)

9

CHAPTER-3 PROJECT DESCRIPTION 10-23

3.1 Type of project including interlinked and interdependent projects

10

3.2 Location and Accessibility 10

3.3 Details of alternate sites and selection of the site 12

3.4 Size or magnitude of operation 12

3.5 Process Description 12

3.5.1 Plant Layout 12

3.5.2 Process Description of Ferro Titanium 14

3.5.3 Process Description of Ferro Manganese 14

3.5.4 Process Description of Scandium Oxide Recovery Plant 15

3.5.5 Process Description of Captive Power Plant (CPP) 16

3.5.6 Process Description of Aluminium Powder Plant 17

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

17

3.7 Resource optimization/recycling and reuse envisaged in the project

18

3.8 Availability of water its source, energy/power 18

requirement and source 3.9 Energy 19

3.10 Environment Management 20

CHAPTER-4 SITE ANALYSIS 24-26 4.1 Connectivity of the site 24

4.2 Land form, land use and land ownership 24

4.3 Topography 24

4.4 Existing Land use Pattern 24

4.5 Existing Infrastructure 25

4.6 Climate Data 26

CHAPTER-5 PLANNING BRIEF 27-28 5.1 Planning concept 27

5.2 Manpower Projection 27

5.3 Land use 27

5.4 Amenities/facilities 28

CHAPTER-6 PROPOSED INFRASTRUCTURE 29-30

6.1 Industrial area (processing area) 29

6.2 Residential area (Non-processing area) 29

6.3 Green belt 29

6.4 Social infrastructure 29

6.5 Connectivity 29

6.6 Drinking water management 30

6.7 Sewerage system 30 6.8 Industrial waste management 30 6.9 Solid waste management 30 6.10 Power requirement & its source 30

CHAPTER-7 REHABILITATION & RESETTLEMENT (R & R)

PLAN 31

CHAPTER- 8 PROJECT SCHEDULE & COST ESTIMATES 32-34

8.1 Project Implementation 32

8.2 Project cost 34

CHAPTER-9 ANALYSIS OF PROPOSAL

(FINAL RECOMMENDATIONS) 35

9.1 Financial and social and Socio benefits 35

9.2 Other Benefits 35

Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.

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1.1 INTRODUCTION

Saraf Agencies Private Limited (SAPL) is a holding company owning a group

of companies known as Saraf Group companies. The group is well diversified,

owning and operating large industrial plants. The group is establishing a Special

Economic Zone (SEZ) at Chatrapur in the district of Ganjam, Odisha and proposes

to set up the Titanium Complex to manufacture various Titanium products like

High Titanium Slag, Titanium Dioxide Pigments, Ferro-Titanium, Ferro manganese

etc.

To optimize the cost of production and attain operational ease, it is proposed to

set up a Captive Power Plant (CPP), Ferro-Titanium, Ferro Manganese, Scandium

Oxide Recovery Plant and Aluminium Powder Plant for the Titanium Complex.

The existing project is coming under category ‘A’ project and requires

Environmental Clearance from MoEF, Govt. of India as per EIA Notification 2006.

1.2 PROJECT SITE

The Proposed Plant is located in the village Mayapatna near Chatrapur of Ganjam

district of Odisha. The area is situated in the survey of India Topo Sheet No. 74

A/15 and between latitude 190 20’ 03” North and Longitude 840 57’ 32” East. The

site is well connected with NH-16 which is passing at a distance of 0.6 km from

the project site. Nearest Railway Station is at Chatrapur is at about 6.0 km from

the project site. Paradeep port is about 260 Km while the Vizag port is at a

distance of 250 Km from the project site. The nearest Airstrip is Rangelunda

(Bhanja Vihar) at a distance of about 5 Km from project site and the nearest

airport is located at Bhubaneswar, which is at about 150 Km from the project site

and Berhampur town is at a distance of 17 Km towards the West direction.

1.3 PLANT LAYOUT

The SEZ (Specially Economic Zone) will be developed on 260 Acres of land for

Titanium Complex. The layout plan for proposed project has been prepared in

such a way that space is properly and purposefully utilized, process flow is

maintained and adequate circulation space is provided for operation and

maintenance. The plant layout map, which shows the layout of Titanium Slag

Plant, Titanium Dioxide Pigment Plant, Captive Power Plant, Ferro Titanium Plant

& Ferro Manganese Plant Aluminum Powder plant, Administrative Building, waste

disposal area, raw material storage yard, rain water harvesting pond, RWTP and

green belt etc.

1.4 BRIEF PROJECT DESCRIPTION

M/s Saraf Agencies Private Limited has proposed 1x15 MW Nett (Gross 17 MW)

Coal Based Captive Power Plant, 5000 TPA Ferro-Titanium, 3000 TPA Ferro

Manganese, 2.4 TPA Scandium Oxide Recovery Plant & 12 TPD Aluminium Powder

Plant at Village - Kanamana, Chandrapada, Tikiriaberhampur, Arjyapalli,

Sriramachandrapur near Chatrapur, in Ganjam district of Odisha.


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1.5 RAW MATERIALS

Ferro Titanium:

Table No. C1-1: Raw Material Requirement for Ferro Titanium Plant

Sl.

No.

Item Consumption in Kg per MT

of Fe Ti

a) Ilmenite Concentrate 1500

b) Sodium Nitrate 45

c) Lime 120

d) Aluminium Powder 680

e) Mill Scale 150

f) Fluorspar 30

Ferro Manganese:

Table No. C1-2: Raw Material Requirement for Ferro Manganese Plant

Sl.

No.

Item Consumption in Kg per MT

of Fe Ti

a) Mn Ore 1250

b) Mn Ore Unroasted 250

c) Lime 130

d) Aluminium 490

e) M.S. Shots 130

f) Fluorspar 25

Scandium Oxide Recovery Plant:

Main Raw material for Scandium recovery project would be waste Titanium

Dioxide Hydrolysis acidic solution which will contain about 228 ppm of scandium

oxide. Waste acid generated from the proposed 30,000 TPY pigment plant would

be around 17548 cubic meter/year at 20% H2SO4. With 60% recovery during the

process about 2.4 TPY of Scandium Oxide of 99.99 % purity will be produced.

Aluminium Powder Plant:

Table No. C1-3: Raw Material Requirement for Aluminium Powder Plant

Sl. No. Item Sources

a) Aluminium Srap Market

b) Fuel Market

Captive Power Plant:

Imported coal from Indonesia is considered as fuel for the CPP. Coal from

Indonesia would be transported by sea route to the Paradeep Port at a distance of

260 km from the project area and then brought to the plant by rail/trucks. The

port at Gopalpur (crow fly distance of 2 km from the site) under construction may

be used after it starts its operation. Based upon the expected imported coal

characteristics the maximum daily coal requirement for the proposed CPP of 15


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MW would be about 229 TPD @ MCR and annual fuel requirement is estimated at

0.71 lakh tons per annum at 85% plant load factor.

Alternately, coal from Talcher coal fields in Odisha may be considered. Coal would

be transported by road from the Talcher coal fields. Approximately, 338 TPD Coal

will be required from Talcher Coal Field in Odisha. Annual coal requirement is

estimated at 1.05 lakh Te per annum at 85% load factor.

1.6 WATER REQUIREMENT & SOURCE

Total consumptive water requirement for the proposed station size of 1x15 MW is

128 m3/hr when water cooled condenser is considered. Alternatively when air-

cooled condenser is considered it is 44 m3/hr respectively. Total water

requirement for Ferro Titanium & Ferro Manganese plant will be 10 m3/day. Water

requirement for Scandium Oxide Recovery Plant will be 100 m3/day. Water will be

sourced from Rushikulya River.

Estimated make up water requirement to replenish the process and treatment

losses for the facilities

Table No. C1-4: Total Plant Raw Water Requirement

Items Total water requirement

Captive Power Plant 128 m3/hr

Ferro Titanium & Ferro Manganese 10 m3/day

Scandium Oxide Recovery Plant 100 m3/day

Aluminum Powder plant 4 m3/day

1.7 SOLID WASTE GENERATION AND MANAGEMENT

Table No. C1-5: Solid Waste Generation and Management

Sl.

No Process unit Solid waste

Quantity

MT/Month Mode of disposal

1. Captive Power

Plant

Bottom Ash 362.1 Bottom ash would be

disposed in slurry form to

ash disposal area.

Fly Ash 3258.9 Fly ash would be disposed in

slurry form to ash disposal

area.

2. Ferro Titanium Slag 3000

Which will be mitigated with

disposal of Ash from Captive

Power Plant

3. Scandium Oxide

Recovery Plant

Minor quantity solid waste

generated will be mitigated

with waste of Titanium

Dioxide Plant

Land Use:

The SEZ will be developed over 260 Acres of land approximately out of which

around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land will


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be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18

Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium Oxide

Plant. All the land involved in the project site was private & Govt. land. The entire

land is now in the name of the plant and converted to industrial use.

Table No. C1-6: Details of Land use break up for Proposed Plant

Sl. No Purpose Area requirement in acres

1. Captive Power Plant 26.0

2. Ferro Titanium & Ferro

manganese and Aluminum

powder plant.

6.18

3. Scandium Oxide Plant 1.0

Total Area 33.18

1.8 GREEN BELT DEVELOPMENT

Appropriate type of trees like Mango, Mahua, Sal suitable for this region are

planted in compliance of conditions of environmental clearance. With a view to

attenuate air pollutants, to resist noise propagation from power generation units

and uptake of treated effluent to some extent, the green belt all around the

periphery of project sites and in vacant areas (34.3 % of the total acquired land)

is being developed. Tree plantation has been undertaken in a large scale on land

vacated after cessation of construction activities. Open spaces, where tree

plantation is not possible are planted with flowering shrubs and grass which act

as soil binders and also helpful in preventing erosion of topsoil.

1.9 AMENITIES/FACILITIES.

1.9.1 In-Plant Facilities

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and

restrooms according to norms laid down in relevant factories act. The above

facilities are adequately furnished and equipped.

1.9.2 Employment Generation

• Establishment of small and medium scale engineering ancillaries, with

cascading employment opportunities;

• Increased revenue to the state by way of taxes and duties;


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• Improved green cover;

• Better communication and transport facilities;

The proposed project has enhanced the prospects of employment. Recruitment

for the unskilled workers for the plant is from the nearby villages. The basic

amenities viz. roads, transportation, electricity, drinking water, proper sanitation,

educational institutions, medical facilities, entertainment, etc. are developed as

far as possible.

1.9.3 Medical Facilities/ Health care camps

• Medicines are provided at the first aid centre present within the plant

premises, which cater to the needs of adjoining population.

• Periodic health camps like: Eye camp and Health camps for treatment of

other diseases will be conducted by the company doctors.

1.10 PROJECT COST:

Table No. C1-7: Project Cost Break Up

Sl.

No. Head

Estimated Cost in

Crores


2. Ferro Titanium and Ferro manganese Plant

& Aluminium powder plant.

13.20

3. Scandium Oxide Recovery Plant 77.75

Net Total 190.3 Crores


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2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

M/s Saraf Agencies Private Limited (SAPL) is a holding company owning a

group of companies known as Saraf Group companies. The group is well

diversified, owning and operating large industrial plants. The group is establishing

a Special Economic Zone (SEZ) at Chatrapur in the district of Ganjam, Odisha and

proposes to set up the Titanium Complex to manufacture various Titanium

products like High Titanium Slag, Titanium Dioxide Pigments, Ferro-Titanium,

Titanium Sponge Metal at Village - Kanamana, Chandrapada, Tikiriaberhampur,

Arjyapalli, Sriramachandrapur near Chatrapur, in Ganjam district of Odisha. The

area comes in survey of India Topo Sheet No. 74 A/15 and between latitude 190

20’ 03” North and Longitude 840 57’ 32” East.

Table No. C2-1: Contact Address

Address for

correspondence

M/s Saraf Agencies Pvt. Ltd.

Saraf House, 4/1 Red Cross Place

Kolkata (West Bengal)

Pin - 700 001

Works (Plant Site

Address)

M/s Saraf Agencies Pvt. Ltd.

At- Chatrapur,

District- Ganjam, Odisha

2.1.1 COMPANY BACKGROUND

Saraf Agencies Private Limited is a holding company owning a group of

companies known as Saraf Group Companies. The objective of the company is to

promote new business ventures, taking over sick companies and turning them

into a viable and profitable venture.

Saraf Group is a well-diversified Group, owning and operating large Industrial

plants, as well as Real Estate development, directly employing more than 2000

workmen engaged in their various plants and construction sites.

The group is setting a Titanium Industrial complex in the state of Orissa, under

Saraf Titanium Industry, (A Unit of Saraf Agencies Pvt. Ltd.) India to manufacture

various Titanium products like, High Titanium slag, Titanium dioxide pigments,

Ferro-Titanium, Titanium sponge metal etc.

2.1.2 ABOUT THE PROJECT

M/s Saraf Agencies Pvt. Ltd. is establishing a Special Economic Zone (SEZ) at

Chatrapur, in Ganjam district of Odisha and proposes to set up the Titanium

Complex to manufacture various Titanium products. The area comes in survey of

India Topo Sheet No. 74 A/15 and between Latitude 190 20’ 03” North and

Longitude 840 57’ 32” East. The present project consists of three products namely

Ferro Titanium, Ferro Manganese & Scandium Oxide. It will have also a Captive

Power Plant of capacity 1x15 MW (Gross 17 MW).

The proposed production capacity of the company as envisaged is as under:


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Table No. C2-2: Production capacity

Sl.

No.

Plant Facility Plant configuration Capacity

1. Captive Power Plant 1 x 15 MW 17 MW

2. Ferro Titanium 5000 TPA

3. Ferro Manganese 3000 TPA

4. Scandium Oxide Recovery Plant 2.4 TPA

5. Aluminium Powder 12 TPD

Land:

The plant has acquired total 260 Acres Land. All the land involved in the project

site was private & Govt. land. The entire land is now in the name of the plant and

converted to industrial use.

Water:

Total make up water requirement for the project is 7700 m3/day, out of which

128 m3/hr for Captive Power Plant, 10 m3/day for Ferro Titanium & Ferro

Manganese Plant, 100m3/day for Scandium Oxide Recovery Plant and Balance

water will be used for Existing Plant (Titanium Slag Plant & Titanium Dioxide

Pigment Plant). The water will be sourced from Rushikulya River. The company

has already submitted the application to Irrigation Department, Govt. of Odisha

to draw required water. At present this permission is under process.

Power:

Power will be generated at the CPP at 11 kV. It shall be stepped up to 33 kV for

supply to the Titanium Project. Start-up power and construction power shall be

received at 132 kV and shall be stepped down to 33 kV to feed 33 kV switchyard.

Power from the grid will be received from 132 kV Chatrapur sub-station of OPTCL

for which a LILO connection will be taken from the 132 kV transmission line

running parallel to the eastern boundary. Power requirement for Ferro Titanium

plant will be 250kwh/T. Power shall be supplied from a feeder available in the

complex. Power will be distributed in the Plant. Power requirement for the

Scandium Recovery Plant shall be nominal. Connected load will be around 400

KVA including Quality Control Laboratory. Power shall be supplied from the

complex. Power will be distributed in the Plant.

In order to operate and maintain the plant facility, including the technical and

general administrative needs, 174 personnel are engaged for proposed plant.

Priority is given to local people during employment of the un-skilled and semi

skilled workers.

The plant site is well connected through road and rail ways.

2.2 NATURE, SIZE AND MAGNITUDE OF PROJECT:

Saraf Agencies Private Limited is establish a High Titanium Slag Plant of 36000

TPA, Titanium Dioxide Pigment Plant of 30000 TPA & Pig Iron of 20000 TPA an

addition 1x15 MW Nett (Gross 17 MW) coal based Captive Power Plant, 5000 TPA

Ferro-Titanium Plant, 2.4 TPA Scandium Oxide Recovery Plant & 12 TPD

Aluminium Powder Plant in its existing plant premises at Chatrapur in Ganjam

district of Odisha.


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The Environment Clearance for the existing High Titanium Slag, Titanium Dioxide

Pigment & Pig Iron Plant was granted by MoEF vide File No. J-11011/658/2007-IA

II (I) dated 16.03.2016.

2.3 NEED FOR THE PROJECT:

• Security of power supply through self-generation

• Reduced costs through high fuel efficiency, particularly when in CHP

configuration

• Improved environmental performance resulting from fuel efficiency.

2.4 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/

REGION:

Ferro-Titanium & Ferro Manganese:

SAPL is proposing to expand its activity in adding values to Ilumenite, a mineral

of Titanium available in Odisha, so far not being explored due to lack of

entrepreneurship and availability of proper technology.

SAPL is contemplating of a plant having capacity of 5000 TPA Ferro Titanium.


Our present proposal is to be set up a plant to recover Scandium Oxide from

Waste acid generated in the Titanium Dioxide Plant and finally treat it to a purity

level of 99.99 %. The Scandium Recovery Plant will have to have a modern

Laboratory having testing and analytical facilities for assessment of quality

recovered Scandium and also to conduct future R & D activities related to

Scandium.

Scandium oxide and scandium alloys are used in varieties of uses including

aerospace, sports equipment, lamps for photography etc.

Aluminium Powder Plant:

Aluminium Powder is one of the principal Raw Materials for Aluminium Thermit

Process. About 720kg of Aluminium Powder will be required per tones of Fe-Ti.

Although there are few organized sectors for manufacturing of Aluminium

Powder. There are many unorganized sectors/ small scale Industries producing

Aluminium Powder.

2.5 Demand and Supply Gap (Market Scenario)

Ferro-Titanium:

Ferro Titanium is used for the following purposes

• As clearing agent

• In deoxidizing, desulphurization & denitrification as Fe-Ti is highly reactive

with S, C, O2 & N2 forming insoluble compound and sequestering them in slag.

• Grain refiner as Fe-Ti promotes finer grain structure with steel matrix.

The plant aims at producing 30% Ti grades of Ferro-Titanium from Ilumenite.

From records, it is gathered that Indian production was in the range of 1500-

2100 Tonnes/year during 2007-2011. Import varied from 450 T to 1650

Tonnes/year during 2007-2011.


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There is potential for growth of Ferro Titanium from new production facility.


Scandium is a rare metal and is expensive due to its scarcity. Due to its chemical

nature it is active and its physical characteristic (MP 1541°C BP 2536°C density

2.985) and other features make it important material for various uses.

Scandium has also gained importance for use of scandium stabilized zirconia as a

high efficiency electrolyte in solid oxide fuel cells. In aerospace industry scandium

is used as Al-Sc Alloy and also in sports equipment as bicycle frames finishing

rods golf equipment basket ball bats etc.

As the commercial uses for scandium continue to expand there is need for

improved for selectively recover scandium.

Few year back global trade of scandium (in the form of oxide) was of the order of

10 tonnes/year. Demand of scandium is on the rise for different new cutting edge

technologies.

Recovery of Scandium to the time of 2.4 Tonnes/year from hydrolysis waste acid

of 30000 TPY Titanium Dioxide plant would meet some gap in increasing global

demand of scandium for use in existing & new cutting edge technologies.

2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Total Manpower engaged during operation of the Ferro Titanium & Ferro

Manganese plant is 75, for Scandium Oxide Plant is 54, for Captive Power Plant is

30 and for Aluminium Powder Plant is 20.

Table No. C2-3: Employment status

Sl. No Category No. of Employees

01. Ferro Titanium & Ferro Manganese 80

02. Scandium Oxide 54

03. Captive Power Plant 30

04. Aluminium Powder Plant 20

Total 179


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3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

PROJECTS

M/s Saraf Agencies Pvt. Ltd. is establish a Special Economic Zone (SEZ) at

Chatrapur, in Ganjam district of Odisha and proposes to set up the Titanium

Complex to manufacture various Titanium products like high Titanium Slag,

Titanium Dioxide Pigments, Pig Iron, Ferro-Titanium, Ferro Manganese etc. The

company is already granted Environment Clearance for Titanium Slag Plant, Pig

Iron Plant & Titanium Dioxide Pigment Plant now company proposed for another

unit i.e. Captive Power Plant, Ferro Titanium, Ferro Manganese, Scandium Dioxide

Plant & Aluminium Powder Plant. The area comes in survey of India Topo Sheet No.

74 A/15 and between Latitude 190 20’ 03” North and Longitude 840 57’ 32” East.

3.2 LOCATION AND ACCESSIBILITY

The Titanium complex is located in the village Phuljhar of Keonjhar district of

Odisha. The area is situated in the survey of India Topo Sheet No. 74 A/15 and

between Latitude 190 20’ 03” North and Longitude 840 57’ 32” East. The site is well

connected with NH-16 which is passing at a distance of 0.6 km from the project site.

Nearest Railway Station is at Chatrapur is at about 5.0 km from the project site.

Location details of the Project Site:

Village : Kanamana, Chandrapada, Tikiriaberhampur,

Arjyapalli, Sriramachandrapur

Tehsil : Chatrapur

District : Ganjam

State : Odisha

Latitude : 190 20’ 03” North

Longitude : 840 57’ 32” East

Topo sheet No. : 74 A/15

Elevation of site : Average Elevation 27.2 m AMSL

a. Road Connectivity: The Plant site is well connected with NH-16 which is passing

at a distance of 0.6 km from the project site.

b. Rail Connectivity: Nearest Railway Station is at Chatrapur, about 4.0 km from

the proposed project site.

c. Airport: Nearest Air port Biju Pattnaik International Airport is at Bhubaneswar

which is about 150 km from the project site.

d. Port: Nearest port is at Gopalpur about 12 km from project site.


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Fig.No.C3-1: Vicinity map of the study area


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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

SELECTING THE PROPOSED SITE / SITE SUITABILITY:

This is a proposed expansion project within the existing plant premises of the

Titanium Slag Plant & Titanium Dioxide Pigment Plant. The project site conforms

to the environmental setting guidelines as per MoEF and has enough existing

infrastructure facilities to be selected for the expansion project. The site has

advantages of availability of raw material and other infrastructural facilities like

skilled labour, power, transportation, and water required for such type of

industries. Hence, no alternative site has been considered.

3.4 SIZE OR MAGNITUDE OF OPERATION

M/s Saraf Agencies Pvt. Ltd. has expansion of Titanium Project i.e. Captive Power

Plant, Ferro Titanium, Ferro Manganese & Scandium Oxide Recovery Plant. The

size of the project is following.

Table No. C3-1: Size of the Plant

Sl. No. Unit/Plant Capacity/Size

1 Captive Power Plant 1x15 MW

2 Ferro Titanium 5000 TPA

3 Ferro Manganese 3000 TPA

4 Scandium Oxide Recovery Plant 2.4 TPA

5 Aluminium Powder Plant 12 TPD

3.5 PROCESS DESCRIPTION

3.5.1 Plant Layout

The layout has been developed keeping in view the need for unidirectional and

streamlined movement of materials. A streamlined road network has been

proposed to provide easy road access to different plant units.

The major parameters considered to develop the layout are as given below:

i) Adequate area for locating Captive Power Plant, Ferro Titanium Plant, Ferro

manganese Plant & Scandium Oxide Plant.

ii) Adequate area for storage and handling of different raw materials.

iii) Adequate area for various auxiliaries and ancillary facilities.

iv) Approach road, Power Sub-station and Water supply etc.

v) Dump area for storage of waste materials.

vi) Adequate road and parking space ensuring safe and smooth movement of

man and materials within the plant premises.

vii) Raw water Reservoir and Rain water harvesting

viii) Area for Green belt.

ix) Administrative building


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Fig No.C3-2: Plant Layout


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3.5.2 Process Description of Ferro Titanium:

Ferro Titanium is produced by Alumino-Thermic Process. The process involves

reduction of Ilmenite concentration in the presence of Iron Oxide/Scrap/Mill Scale

& Flux additive. The process is well suitable for small furnace for meeting of Low

Carbon Grade.

This process compared to Induction Melting Furnace process method of

production is cheaper. Hence this process is preferred for Low volume production.

Thus the composition is Titanium is lower at 30% & also it content 4 to 6%

aluminum metal. The reactions of the process are

TiO2 + /sAl = Ti + 2/3Al2O3

Fe2O3 + 2Al = 2Fe + Al2O3 (1) FeO + 2/sAl = Fe + 1/3Al2O3

These reactions result in a molten bath of FeTi with a slag layer floating on top.

Flow Diagram:

Raw Material:

Source Potential of various major raw materials is given below:

Raw Materials Source

Ilmenite IREL

M.S. Shots Market

Aluminium Powder Market

Fluorspar Market

Sodium Nitrate Market

Lime Market

3.5.3 Process Description of Ferro Manganese

The production of Low Carbon Ferro Manganese is Alumino Thermic method is

used i.e. Reduction of manganese ore by Aluminum. For this process the ore have

more than 46% Mn. The Mn/Fe ration is 9 or at least more than 6. Phosphorous &

Sulphur is as low as possible. Al2O3 should be lower but not more than 4%. For

this process if the ore is used as its is, i.e. MnO2, the reaction is violent because

the heat available is much more than the heat required. Also ore is reduced to

MnO the material becomes more inert. Therefore, it is essential that the ore is

reduced to Mn3O4 or Mn2O3. Lime is added to decrease the formation of

Crucible

Ilmenite

Cooling & Slag

Separation

LC Alloy

Separation

Packing &

Dispatch

Aluminum

Powder

Lime Fluorspar

Sodium

Nitrate


CEMC Pvt. Ltd. 15

Aluminates as this loss of metal oxide. The addition of Fluorspar (CaF2) helps in

lowering the viscosity.

Lime viscosity should be around 1.2 to reduced SiO2, roasting of ore at 950°C to

convert ore to Mn3O4 will give better yield.

Flow Diagram:

Raw Material

No.

Item Consumption in Kg per

MT of Fe Ti

a) Mn Ore 1250

b) Mn Ore Unroasted 250

c) Lime 130

d) Aluminium 490

e) M.S. Shots 130

f) Fluorspar 25

Manganese ore will be sourced from Manganese Ore (I) Ltd. or other mines.

3.5.4 Process Description of Scandium Oxide Recovery Plant

During manufacturing of Titanium Dioxide Pigment, Sulphuric Acid is added to

Ilmenite/Titanium Dioxide for hydrolysis & during the process weak acidic waste

solution is generated which contains around 22.85 mg/litre of Scandium Oxide &

around to 4 tonnes considering the production 30000 TPA of Titanium Dioxide

Pigment. This is based on 80 PPM scandium in Ilmenite (or grade). Considering a

recovery of 60% about 2.4 TPA of Scandium Oxide @ 99.99 % purity can be

recovered.

The waste acid contains TiO2 (Titanium Oxysulphate, Metatitanic Acid, Ferrous

Sulphate etc.) from which Scandium Oxide is separated/Solvent Extraction.

The solvent used for extraction is Di 2 ethyl hexyl phosphoric acid and Tributyl

phosphate. Kerosene is added as catalyst or modifier to organic solvent.

In a solvent extraction column (Mixer Settler Type) the waste fed from the

bottom & solvent is fed from top. The extract phase contains scandium will be

treated in a stripping column and the extract will be recycle back to solvent &

refinating phase will be treated with oxalic acid. This will precipitate containing

scandium oxalate which will remove in a plate & frame filter press. The cake will

contain 1-5% of scandium oxide.

Crucible

MnOre

Cooling & Slag

Separation

LC Alloy

Separation

Packing &

Dispatch

Aluminum

Scrap

Lime Iron Shots

Fluorspar


CEMC Pvt. Ltd. 16

The solution will be again treated & solution again treated in solvent extraction

column to enrich scandium content in the loaded organic.

The aqueous phase will be treated with Sodium Hydroxide and Scandium

Hydroxide precipitate. This will be again treated with hydrochloric acid & solvent

extracted and treating with Sodium Hydroxide containing 99.99 % Scandium

Oxide (Sc2O3) and the filter cake will be roasting for final product.

Flow Diagram:

3.5.5 Process Description of Captive Power Plant (CPP)

15 MW steam generator and turbine generator would deploy Rankine Cycle for

generating steam & power for proposed CPP. Steam Generator with Fluidized Bed

Combustion (FBC) technology has been proposed. Atmospheric Fluidized Bed

Combustion (AFBC) boiler capacity of 65 TPH will be use.

CPP may be operated both on island mode or interconnected with grid. However,

to optimize capital cost and energy charge it is proposed to operate the station by

floating on the state grid. The capacity of the boiler will be of 65 TPH.

The steam turbines would be standard multi-stage, 3000 rpm, tandem

compound, regenerative, condensing, multi-cylinder unit with three uncontrolled

extractions for regenerative feed water heating. The unit will be equipped with all

auxiliaries as per good engineering practice.

The condenser will be single-flow box-type surface condenser. It will be located

below the turbine and form an integral part. Each condenser unit would be

transverse mounted and would condense exhaust steam by circulation of cooling

WASTE ACIDIC

HYDROLYSIS SOLUTION SLOVENT EXTRACTION

BACK TO WASTE ACID TANK RAFFINATE

(AQUOUS)

STRIPING

EXTRACT

STRIPPING CHEMICAL

MAKE UP SLOVENT

SLOVENT

AQOUS SOLUTION PRECIPITATING CHEMICAL FILTRATION WASTE

CAKE

DISSOLUTION WITH HCL SLOVENT EXTRACTION

RAFFINATE (WASTE)

ORGANIC

SCRUBBING

STRIPPING

MAKE UP

SLOVENT

AQOUS SOLUTION OXALIC ACID

FILTRATION

SCANDIUM OXALATE DRYING & ROSTING HIGHLY PURITY SCANDIUM OXIDE

HCL

Zr. TI CONTANING

SOLUTION (REJECT)


CEMC Pvt. Ltd. 17

water (inlet temperature 33 ºC max.) in a recirculating cooling water system

using wet type cooling tower. Clarified water would be the cooling medium in the

condenser. Stainless steel heat exchanger tubes are envisaged.

The proposed plant will be equipped with all auxiliaries plant systems like Plant

Water System, Coal Handling System and Ash Handling System.

338 TPD coal as raw material will be sourced from Talcher area which will be 1.05

lakh tons per annum at 85% load factor.

3.5.6 Process Description of Aluminium Powder Plant

The process is simple. Aluminium scrap is melted in an oil fired furnace equipped

with burners and allied items and the temperature is mentained between 720⁰ -

760⁰C. Then molten aluminium is atomized into small particles by air jet.

Atomizer system consists of atomuzer tube fitted with nozzle, headers, pipe,

fittings and collecting/cooling system. Aluminium powder will conform to IS-438.

Raw Material:

Sl. No. Item Sources

a) Aluminium Srap Market

b) Fuel Market

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.

3.6.1 Source of Major Raw Material with mode of transport

Raw Materials Source Mode of transport

CPP

Coal Indonesia/Talcher By Sea/Road

Ferro Titanium

Ilmenite IREL

M.S. Shots Market By Road

Aluminium Powder Market By Road

Fluorspar Market By Road

Sodium Nitrate Market By Road

Lime Market By Road

Ferro Manganese

Mn Ore Roasted Manganese Ore (I)

Ltd.

By Road

Mn Ore Unroasted Manganese Ore (I)

Ltd.

By Road

Lime Market By Road

Aluminium Market By Road

M.S. Shots Market By Road

Fluorspar Market By Road

Scandium Oxide Recovery Plant

Carbon powder Market By Road

Solvent (TBP or DEHPA) Market By Road

Kerosene Market By Road

DL-2-Octanol Market By Road

Ethanol Market By Road


CEMC Pvt. Ltd. 18

Sulphuric Acid (98%) Market By Road

Hydrogen Peroxide Market By Road

Caustic Soda Market By Road

Oxalic Acid (99%) Market By Road

Organophosphours (P350 or

equivalent

Market By Road

Calcium Carbonate / Lime Market By Road

33% Hydrochloric Acid Market By Road

Aluminium Powder Plant

Aluminium Scrap Market By Road

Fuel Market By Road

Ilmenite is the titanium bearing mineral. It is the raw material required for

production of Titanium products. Ilmenite is recovered from Beach Sand as one of

the Constituent of Heavy Mineral Concentrate. Indian Rare Earths Ltd (IREL) is

holding mining lease rights over 32 km stretch of Coastal Belt near Gopalpur Port,

for mining of Beach Sand Minerals. IREL have set up a large mining and mineral

separation plant known as OSCOM plant at Chhatrapur for recovery of Heavy

Mineral Concentrate, including Ilmenite from Beach Sands. Currently OSCOM

Plant’s annual production of Ilmenite is about 2,20,000 tonnes ilmenite from IREL

will be used for this Project. Indian Rare Earths Ltd. (IREL) has also other mining

units at Chavara, Kerala (1,54,000 TPA ilmenite). Manvala Ruridhi, Tamilnadu

(90,000 TPA Ilmenite).

Besides, Kerala Minerals & Metals Limited is also engaged in ilmenite production

at Chavara (ilmenite 40,000 TPA).

M/s. Trimex Sands, Chennai has separation plant at Srikakulam, AP and having

2,00,000 TPA ilmenite production. Trimex Sands is contemplating expansion by

another 2,00,000 TPA ilmenite production.

Other players are VV Minerals, Beach Minerals Co., Indian Ocean Garnet Sands in

Tamilnadu producing around 4,00,000 TPA ilmenite totally.

One month’s inventory for ilmenite shall be provided. Ilmenite will be received

through trucks.

3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED

IN THE PROJECT

Waste generation in the proposed CPP is in the form of fly ash and bottom ash

which would be disposed in slurry form to ash disposal area. Slag form Ferro

titanium plant will be mitigated with disposal of Ash from Captive Power Plant.

Hence, there will be resource optimization in the proposed project.

3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER

REQUIREMENT AND SOURCE

3.8.1 Source of water

The consumptive water required for the station will be drawn from Rushikulya

River which is 10 km away from project site. Rushikulya River is 165 km long has

a catchment area of 8900 sqr. km. and perennial in nature.


CEMC Pvt. Ltd. 19

3.8.2 Summary of Plant Water Requirement

Total 128 m3/hr water is require for the proposed 15 MW CPP when water cooled

condenser is considered. Alternatively when air-cooled condenser is considered it

is 44 m3/hr respectively. Total water requirement for Ferro Titanium & Ferro

Manganese plant will be 10 m3/day. Water requirement for Scandium Oxide

Recovery Plant will be 100 m3/day. Water will be sourced from Rushikulya River.

Estimated make up water requirement to replenish the process and treatment

losses for the facilities

Total Plant Raw Water Requirement

Items Total water requirement

Captive Power Plant 128 m3/hr

Ferro Titanium & Ferro Manganese 10 m3/day

Scandium Oxide Recovery Plant 100 m3/day

Aluminium Powder plant 4m3/hr

3.8.3 External water system

The consumptive water required for the station will be drawn from the common

intake pump house proposed to be constructed on the Rushikulya River for

Titanium Project with necessary augmentation.

3.8.4 Plant water system

As per the available data on river water quality, a cycle of concentration of 5 is

considered in the estimation. As an alternative, Air Cooled Condenser (ACC) may

be used for the water scare region. ACC may be of direct type or indirect type.

For water cooled system, evaporative cooling is deployed but in case of air cooled

system steam (for direct type) or DM water (for indirect type), primary coolant,

would be cooled by convection and/ or radiation by passing cooled air by the

fans. ACC is pitted with higher condenser pressure and thus loss of generation.

Secondly, ACC is more cost intensive and the revenue cost is marginally higher.

On overall basis, depending on ambient parameters cost of energy 4 to 5%

higher. With loss of generation, marginally higher energy cost air cooled

condenser is deployed in a ‘No Project Situation’ due to inadequate availability of

water. For ACC as option, consumptive water requirement will be around 44 m3/

hr. With the water quality available, water treatment plant would comprise

clariflocculation, sand bed filtration and demineralization plant.

3.9 ENERGY:


supply to the Titanium Project. Start-up power and construction power shall be

received at 132 kV and shall be stepped down to 33 kV to feed 33 kV switchyard.

Power from the grid will be received from 132 kV Chatrapur sub-station of OPTCL

for which a LILO connection will be taken from the 132 kV transmission line

running parallel to the eastern boundary.


CEMC Pvt. Ltd. 20

3.10 Environment Management

a. Air pollution control measures

Construction phase:

Construction phase will be for a short period and hence the impacts will also be

for a short and temporary period. During construction activities, mainly emission

of dust and gases from movement of vehicles and construction activity is

expected. However, following measures will be taken to reduce / contain such

emissions:

• Water will be sprinkled on loose top soil to prevent re-suspension of dust into

ambient air due to movement of vehicles etc.

• Separate civil construction material storage yard will be created within the site

and it will be enclosed.

• Possibility of raising green belt along with construction activity will also be

explored.

• Transport vehicles and construction equipments / machineries will be properly

maintained to reduce air emissions.

• Vehicles and equipments will be periodically checked for pollutant emissions

against stipulated norms.

• Idle running of vehicles will be minimized during material loading / unloading

operations.

• All construction workers will be provided appropriate Pollution Protection

Equipments like dust mask, ear plug, helmet, safety belt etc. and made to

wear them during working hours.

Operation phase:

Ferro Titanium & Ferro Manganese:

Proper care will be taken by installing Bag filters followed by Stack to control

source emission. Hence there will not be any major deposition of pollutants into

air, land and water.

To control fugitive dust emissions due to vehicular movement water sprinkling

and spraying system will be installed. Internal roads will be asphalted.


An efficient electro-static precipitator (separation efficiency of about 99.89%)

along with a properly designed boiler would keep the stack emission of particulate

matters within acceptable limits. With average quality of coal and 6 to 7 field ESP,

SPM emission shall be restricted to 1 kg per hour considering imported coal and 5

kg per hour considering indigenous coal. The final emission level will meet

statutory limit i.e. 50 mg/m3. Following measures are proposed to mitigate

negative impact of operation phase of the project on the surrounding air

environment:


CEMC Pvt. Ltd. 21

• All transfer points will have bag filter attached to them to control and capture

dust emission.

• Height of all the stacks will be as per statutory requirement. All the stacks will

have stack monitoring facility (SMF) consisting of sampling port-hole, platform

and access ladder.

• Adequate spares of critical components of dust collection systems will be kept

to ensure trouble – free operations and continuous compliance to emission

norms.

• A comprehensive plan for fugitive emission control based on CPCB guidelines

is prepared and its details are given following section.

• Possibility of use of vehicles using cleaner fuel will be explored and if found

feasible will be implemented on a large scale.

• Transport vehicles will be properly maintained to reduce air emissions.

• Vehicles will be periodically checked for pollutant emissions against stipulated

norms.

• Idle running of vehicles will be minimized during material loading / unloading

operations.

b. Water pollution control measures

Construction stage:

The drainage system of construction site will be connected to the existing

drainage system at an early stage. Salient features of water quality management

comprise the following:

• All the debris resulting from the site shall be disposed off separately.

• A sediment trap shall be provided to prevent to discharge of excessive

suspended solids.

• An oil trap shall be provided in the drainage line to prevent contamination by

accidental oil spillage.

• To prevent contamination from accidental spillage of oil, the storage areas will

be bonded and will be inspected and cleaned at regular intervals.

• Proper storm water management system shall be integrated in design phase

and civil works shall be carried out accordingly at project site. Efforts will be

made to reduce the suspended solids content of storm water run offs by

routing the storm water drains through settling pits.

• Three nos. of toilets will be provided for construction workers and waste water

generated from toilets will be treated in septic tank.


CEMC Pvt. Ltd. 22

Operation stage:

Ferro Titanium & Ferro Manganese & Aluminum Powder plant:

Total water requirement for Ferro Titanium & Ferro Manganese plant will be 10

m3/day. For Aluminum Powder plant, water requirement will be 4m3/hr.

Scandium Oxide Plant:

Water requirement for Scandium Oxide Recovery Plant will be 100 m3/day. In

Scandium Oxide Recovery Plant after solvent extraction acidic waste hydrolysis

solution will be sent back to the TiO2 pigment plant will be mitigated along with

the effluents in pigment plant.


It is envisaged that the liquid wastes from CPP collected in the guard pond shall

be treated and adequate retention time permitted. The treated waste water from

the guard pond would be recycled to less priority areas for reuse. Attempt would

be made to attain zero discharge of waste water from the plant during normal

operation.

c. Solid waste Management

Ferro Titanium & Ferro Manganese:

Process unit Solid waste Quantity


Ferro Titanium Slag 3000

Which will be mitigated with

disposal of Ash from Captive

Power Plant

Scandium

Oxide Recovery

Plant

Minor quantity solid waste

generated will be mitigated with

waste of Titanium Dioxide Plant

Scandium Oxide Plant:

Process unit Mode of disposal

Scandium Oxide Recovery

Plant

Minor quantity solid waste generated

will be mitigated with waste of

Titanium Dioxide Plant


Process unit Solid waste Quantity


Captive Power

Plant Bottom Ash 362.1

Bottom ash would be disposed

in slurry form to ash disposal

area.

Fly Ash 3258.9 Fly ash would be disposed in

slurry form to ash disposal area.


CEMC Pvt. Ltd. 23

d. Green Belt Development

Appropriate type of trees like Mango, Mahua, Sal suitable for this region are

planted in compliance of conditions of environmental clearance. With a view to

attenuate air pollutants, to resist noise propagation from power generation units

and uptake of treated effluent to some extent, the green belt all around the

periphery of project sites and in vacant areas (34.3 % of the total acquired land)

is being developed. Tree plantation has been undertaken in a large scale on land

vacated after cessation of construction activities. Open spaces, where tree

plantation is not possible are planted with flowering shrubs and grass which act

as soil binders and also helpful in preventing erosion of topsoil.


CEMC Pvt. Ltd. 24

CCHHAAPPTTEERR--44

SSIITTEE AANNAALLYYSSIISS

4.1 CONNECTIVITY

Road

The site is well connected with NH-16 which is passing at a distance of 0.6 km

from the project site.

Rail Linkage


Port

Paradeep port is about 260 Km while the Vizag port is at a distance of 250 Km

from the project site. The nearest Airstrip is Rangelunda (Bhanja Vihar) at a

distance of about 5 Km from project site and the nearest airport is located at

Bhubaneswar, which is at about 150 Km from the project site and Berhampur

town is at a distance of 17 Km towards the West direction.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP


around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land will

be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18

Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium Oxide

Plant. All the land involved in the project site was private & Govt. land. The entire

land is now in the name of the plant and converted to industrial use.

Table No. C4-1: Details of Land use break up for Proposed Plant

Sl. No Purpose Area requirement in acres


2. Ferro Titanium & Ferro

manganese & Aluminum

powder.

6.18

3. Scandium Oxide Plant 1.0

Total Area 33.18

4.3 TOPOGRAPHY

The topography of the proposed land is generally flat and well suited for

development of industrial projects.

4.4 Existing land use pattern, shortest distances from the periphery of

the project to periphery of the forests, national park, wildlife

sanctuary, eco sensitive areas, water bodies (distance from the

HFL of the river), CRZ.


around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land

will be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18


CEMC Pvt. Ltd. 25

Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium

Oxide Plant. This area does not form part of any National Park, Wild Life

Sanctuary and Natural/Biosphere reserve.

Table No. C4-2: Environmental Setting

Sl.

No.

Areas Name/

Identity

Aerial distance

(within 10km.)

Proposed project

location boundary

1 Areas which are

important or sensitive for

ecological reasons –

Wetlands, water courses

or other water bodies,

coastal zone, biospheres,

mountains, forests

The Rushikulya rookery is

the second largest site of

Olive Ridley Turtle in the

Orissa coast. It lies along

the extreme south of the

Orissa coast, around 15 km

north of the Gopalpur port,

i.e more than 17 km from

project site

More than 17 km

3 Areas used by protected,

important or sensitive

species of flora or fauna

for breeding, nesting,

foraging, resting, over

wintering, migration

No

4 Inland, coastal, marine or

underground waters No

4.5 EXISTING INFRASTRUCTURE

Land

Total land requirement for the proposed unit is about 33.18 acres.

Utilities

Power: Power will be generated at the CPP at 11 kV. It shall be stepped up to 33

kV for supply to the Titanium Project. Start-up power and construction power

shall be received at 132 kV and shall be stepped down to 33 kV to feed 33 kV

switchyard. Power from the grid will be received from 132 kV Chatrapur sub-

station of OPTCL for which a LILO connection will be taken from the 132 kV

transmission line running parallel to the eastern boundary. Power requirement for

Ferro Titanium plant will be 250kwh/T. Power shall be supplied from a feeder

available in the complex. Power will be distributed in the Plant. Power

requirement for the Scandium Recovery Plant shall be nominal. Connected load

will be around 400 KVA including Quality Control Laboratory. Power shall be

supplied from the complex. Power will be distributed in the Plant.

Water: Total make up water requirement for the project is 7700 m3/day, out of


CEMC Pvt. Ltd. 26

which 128 m3/hr for Captive Power Plant, 10 m3/day for Ferro Titanium & Ferro

Manganese Plant, 100m3/day for Scandium Oxide Recovery Plant,4m3/day for

Aluminum powder plant and Balance water will be used for Existing Plant

(Titanium Slag Plant & Titanium Dioxide Pigment Plant). The water will be

sourced from Rushikulya River. The company has already submitted the

application to Irrigation Department, Govt. of Odisha to draw required water. At

present this permission is under process.

Transport: The site is well connected with NH-16 which is passing at a distance

of 0.6 km and all modes of transports are available.

4.6 CLIMATE DATA

The cold season from December to February is followed by hot season from March

to May. The period from June to September marks the South West Monsoon and

70% of annual precipitation is received during this period. The normal rain fall of

this district is 1444 mms. May is the hottest month. With the arrival of the

monsoon by about the second week of june the day temperature decreases

slightly while the night temperature continue as it was in the summer. Towards

the end of September, after the withdrawal of south west monsoon, temperature

decreases progressively. December is the coldest month. The relative humidity

are high throughout the year specially in coastal areas. Winds are fairly strong

particularly in coastal regions in summer and mansoon months.


CEMC Pvt. Ltd. 27

CCHHAAPPTTEERR--55

PPLLAANNNNIINNGG BBRRIIEEFF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES AND

TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/

DEVELOPMENT AUTHORITY CLASSIFICATION

The Proposed Plant is located in the village Mayapatna near Chatrapur of Ganjam

district of Odisha. Plant provide many facilities is given below,

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and

restrooms according to norms laid down in relevant factories act. The above

facilities are adequately furnished and equipped.

5.2 MANPOWER PROJECTION

• Establishment of small and medium scale engineering ancillaries, with

cascading employment opportunities;

• Increased revenue to the state by way of taxes and duties;

• Improved green cover;

• Better communication and transport facilities;

The proposed project has enhanced the prospects of employment. Recruitment

for the unskilled workers for the plant is from the nearby villages. The basic

amenities viz. roads, transportation, electricity, drinking water, proper sanitation,

educational institutions, medical facilities, entertainment, etc. are developed as

far as possible

5.3 LAND USE


around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land

will be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18

Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium

Oxide Plant. All the land involved in the project site was private & Govt. land


CEMC Pvt. Ltd. 28

5.3.1 GREEN BELT DEVELOPMENT

With a view to attenuate air pollutants, to resist noise propagation from power

generation units and uptake of treated effluent to some extent, the green belt all

around the periphery of project sites and in vacant areas (34.3 % of the total

acquired land) is being developed. Tree plantation has been undertaken in a large

scale on land vacated after cessation of construction activities.

5.4 AMENITIES/FACILITIES

Plant will source water from Rushikulya River. Canteen, transportation system,

health center facilities etc. will be provided by plant for their employees.

Medicines are provided at the first aid centre present within the plant premises,

which cater to the needs of adjoining population. Periodic health camps like: Eye

camp and Health camps for treatment of other diseases will be conducted by the

company doctors.


CEMC Pvt. Ltd. 29

CCHHAAPPTTEERR--66

PPRROOPPOOSSEEDD IINNFFRRAASSTTRRUUCCTTUURREE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The setting up of CPP, Ferro titanium and Ferro manganese plant, Scandium Oxide

Recovery Plant, storage area, internal road, green belt area etc required 33.18

Acres land. Company uses nearest road and railway siding for goods

transportation and equipped with all other required facilities.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

The area around the site is developed with reasonably good communication

facilities. Some area of plant is envisaged for staff canteen, toilet and bath room,

vehicle stand etc.

6.3 GREEN BELT DEVELOPMENT

With a view to attenuate air pollutants, to resist noise propagation from power

generation units and uptake of treated effluent to some extent, the green belt all

around the periphery of project sites and in vacant areas (34.3 % of the total

acquired land) is being developed.

6.4 SOCIAL INFRASTRUCTURE

SAPL will commence a lot of infrastructure developmental works in the periphery

area. Some glimpses of the developmental activities are presented below:

� Improving and building road network in the adjoining villages.

� Strengthening School buildings with playgrounds.

� Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program.

� Through this project, adult education and female education will be provided to

the illiterate adults and backward females of the villages in the project

surrounding area.

� The proposed project will set up training centre or tie up with Industrial

Technical Institutes to educate local youth as skilled labour.

6.5 CONNECTIVITY

Road

The site is well connected with NH-16 which is passing at a distance of 0.6 km

from the project site.

Rail Linkage


Port

Paradeep port is about 260 Km while the Vizag port is at a distance of 250 Km

from the project site. The nearest Airstrip is Rangelunda (Bhanja Vihar) at a

distance of about 5 Km from project site and the nearest airport is located at


CEMC Pvt. Ltd. 30

Bhubaneswar, which is at about 150 Km from the project site and Berhampur

town is at a distance of 17 Km towards the West direction.

6.6 DRINKING WATER MANAGEMENT

Drinking water facilities will be provided for employees. A water treatment plant

is envisaged for providing potable water to the employees. After ensuring the

drinking water standards prescribed by CPCB water will be supplied for drinking

purpose.

6.7 SEWERAGE SYSTEM

A garland drain around the plant is envisaged to collect surface run-off during

rainy season.

6.8 INDUSTRIAL WASTE MANAGEMENT

The liquid wastes from CPP collected in the guard pond shall be treated and

adequate retention time permitted. The treated waste water from the guard pond

would be recycled to less priority areas for reuse. Attempt would be made to

attain zero discharge of waste water from the plant during normal operation.

Total water requirement for Ferro Titanium & Ferro Manganese plant will be 10

m3/day. Water requirement for Scandium Oxide Recovery Plant will be 100

m3/day. In Scandium Oxide Recovery Plant after solvent extraction acidic waste

hydrolysis solution will be sent back to the TiO2 pigment plant will be mitigated

along with the effluents in pigment plant.

6.9 SOLID WASTE MANAGEMENT

362.1 MT/Month bottom ash and 3258.9 MT/Month fly ash will be generate for

proposed CPP. 3000 MT/month slag will generate form Ferro Titanium plant.

Bottom ash and fly ash would be disposed in slurry form to ash disposal area.

Slag will be mitigated with disposal of Ash from Captive Power Plant. Minor

quantity of solid waste from Scandium Oxide Recovery Plant will be mitigated

with waste of Titanium Dioxide Plant.

6.10 POWER REQUIREMENT & SUPPLY/SOURCE


supply to the Titanium Project. Power requirement for Ferro Titanium plant will be

250kwh/T.


CEMC Pvt. Ltd. 31

CCHHAAPPTTEERR--77

RREEHHAABBIILLIITTAATTIIOONN && RREESSEETTTTLLEEMMEENNTT ((RR && RR)) PPLLAANN

The project is going to come up on 33.18 acres area. There is no existence of

displaced habitants in the identified area as additional plant install within the

existing land. Land is also devoid of any vegetation. Local people will be engaged

for construction and operation activities.


CEMC Pvt. Ltd. 32

CCHHAAPPTTEERR--88

PPRROOJJEECCTT SSCCHHEEDDUULLEE && CCOOSSTT EESSTTIIMMAATTEESS

8.1 PROJECT IMPLEMENTATION

Planning Of Activities

Careful planning of all the activities is one of the pre-requisite for timely

completion of the project. Following activities will be given special attention.

Pre Project Activities

• Management Approvals.

• Selection of location

• Land acquisitions

• Statutory Clearances

• Financial Approvals and Tie ups.

• Selection of Consultants

• Conceptual Design

• Preparation of main machinery tender

• Evaluation of tenders

Project Activities (Implementation Stage)

• Firm up basic design

• Main Machinery Order placement

• Detailed engineering of the project

• Statutory approvals of Building Plans.

• Preparation of Tender, Evaluation of tenders received and Order placement for

balance machinery

• Completion of procurement activities on time

• Release of civil drawing for civil construction

• Civil construction

• Supply of mechanical & electrical equipment

• Inspection of major machinery at supplier’s works

• Erection of all plant & machinery

• Commissioning of the plant

Statutory Clearances

The proposed project will require various statutory approvals and clearances from

various authorities of the Government. Clearances required for the proposed


CEMC Pvt. Ltd. 33

project shall be identified in due course and necessary action will be taken to obtain

the same.

Project Schedule

The total project implementation schedule for CPP is 24 months and 9 months for

Ferro titanium and Ferro manganese project and 15 months for Scandium Oxide

Recovery Plant from start of basic project engineering. The external agencies such

as consultants, machinery suppliers, contractors of civil construction and

equipment will be selected carefully well in advance. An effective project team has

been formulated with an experienced Project Manager as its leader.

The project schedule has been contemplated as below:

Table C8-1: Project Schedule

Sl. No. Task Time Taken

CPP

1. Pre-project Activities & coming into

force of contract (-) 6 to 0 months

2. Technology supply & completion of

Basic Engineering 0 to 2 months

3. Detailed Engineering 2 to 3months

4. Tendering, Procurement Action &

supply of Plant & Equipment &

Electricals

3 to 5 months

5. Civil & Structural Work 4 to 18 months

6. Erection of Equipment 18 to 20 months

7. Trial run & Commissioning 20 to 21 months

Ferro Titanium and Ferro manganese Plant & Aluminum powder

Plant.

1 Process know-how & Basic

Engineering

0-1 month

2 Approval of Basic Engineering by

SARA

1-2 months

3 Detailed Engineering 2-3 months

4 Tendering, Procurement action,

Supply of Plant & Equipment

3-4 months

5 Civil & Structural Work 4-6 months

6 Erection of Equipment 6-8 months

7 Trial Run & Commissioning 8-9 months

Scandium Oxide Recovery Plant

1 Process know-how & Basic

Engineering

0-2 month

2 Approval of Basic Engineering by

SARA

2-3 months

3 Detailed Engineering 2-8 months

4 Tendering, Procurement action, 3-10 months


CEMC Pvt. Ltd. 34

Supply of Plant & Equipment

5 Civil & Structural Work 4-10 months

6 Erection of Equipment 9-13 months

7 Trial Run & Commissioning 13-15 months

8.2 PROJECT COST

An indicative estimated capital cost of the proposed Plant is Rs. 190.3 Croers

including the pre-operative expenses, contingency and interest during

construction.

A broad break-up of the indicative estimate of the Project capital cost is provided

below:

Table No. C8-2: Project Cost

Sl.

No.

Head Estimated Cost in

Crores


2. Ferro Titanium, Ferro manganese &

Aluminium Powder Plant

13.20

3. Scandium Oxide Recovery Plant 77.75

Net Total 190.3 Crores


CEMC Pvt. Ltd. 35

CCHHAAPPTTEERR--99

AANNAALLYYSSIISS OOFF PPRROOPPOOSSAALL ((FFIINNAALL EECCOOMMMMEENNDDAATTIIOONNSS))

9.1 Financial and social benefits

9.1.1 Improvements in the Physical Infrastructure

SAPL has envisaged a lot of infrastructure developmental works in the periphery

area.

� Improving and building road network in the adjoining villages.

� Strengthening School buildings with playgrounds.

� Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure

� Social awareness programme will further improve by the local authority such

as sanitation and hygiene, HIV Prevention Program.

� Through this project, adult education and female education will be provided to

the illiterate adults and backward females of the villages in the project

surrounding area. Sponsor the education to Poor Students of the Proposed

Area.

� Provide & conduct the Free Eye & Health Check up Programmes.

9.1.3 Employment

It is estimated that the additional requirement of manpower for the project will be

179.

Table No. C9-1: Category-wise Manpower

Sl. No. Category Man Power

1 Captive power plant 30

2 Ferro titanium & Ferro Manganese 80

3 Scandium Oxide Recovery Plant 54

4 Aluminium Powder Plant 20

Total 179

9.2 OTHER BENEFITS

• Development of the local area in terms of an enlarged market.

• Besides above, indirect benefits have also occurred to the region by way of

increase in industrial production.

PROPOSED 1x15 MW CAPTIVE POWER PLANT, 5000...

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