Techno Economic Feasibility Report of M/s Spintech Tubes Pvt...

Techno Economic Feasibility Report of M/s Spintech Tubes Pvt Ltd

At: Dhsal, P.O-Bahadurpur, Dist-Burdwan, West Bengal

Global Tech Enviro Experts

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TABLE of CONTENTS

CHAPTER-1 .......................................................................................................... 5

EXECUTIVE SUMMARY ........................................................................................... 5

CHAPTER-2 .......................................................................................................... 6

INTRODUCTION OF THE PROJECT ........................................................................... 6

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT .................................. 6

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ....................................... 6

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION...................... 6

2.3.1 DOMESTIC SCENARIO ............................................................................. 7

2.3.2 GLOBAL STEEL SCENARIO ................................................................. 10

2.4 EMPLOYMENT GENERATION DUE TO PROJECT ............................................ 10

2.5 METHODOLOGY OF THE STUDY .................................................................... 10

2.6 ENVIRONMENTAL MANAGEMENT PLAN: ..................................................... 12

2.8 AUTHORIZATION .................................................................................... 14

2.9 ACKNOWLEDGEMENT: ............................................................................. 14

CHAPTER-3 ........................................................................................................ 15

PROCESS DESCRIPTION ....................................................................................... 15

3.1 TYPE OF THE PROJECT: ........................................................................... 15

3.2 LOCATION OF THE PROJECT ..................................................................... 15

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING

THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE

INTO SHOULD BE HIGHLIGHTED. ....................................................................... 16

3.4 SIZE OR MAGNITUDE OF OPERATION ........................................................ 16

3.5 PROCESS DESCRIPTION .......................................................................... 17

Table 3.1: PROJECT CONFIGURATION & PRODUCT MIX ................................. 17

Fig 3.1 Flowsheet of the process ................................................................... 18

3.5 MAJOR RAW MATERIAL INVENTORY .......................................................... 27

Table 3.2: Raw Material Inventory .............................................................. 27

3.6 WATER REQUIREMENT ............................................................................. 28

3.7 POWER REQUIREMENT ............................................................................ 28

3.8 SOLID WASTE: ....................................................................................... 28

Table 3.3: Solid Waste Generation & Management ........................................ 28

3.9 MANPOWER ............................................................................................ 29

CHAPTER -4........................................................................................................ 30

SITE ANALYSIS ................................................................................................... 30

4.1 CONNECTIVITY ....................................................................................... 30

4.2 LAND FORM, LAND OWNERSHIP ............................................................... 30




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Table 4.1: Land Use Pattern for the proposed plant ....................................... 30

4.3 TOPOGRAPHY ......................................................................................... 30

4.4 LAND USE PATTERN ................................................................................ 31

Table 4.2 Land use pattern of buffer zone .................................................... 31

Fig- 4.1: Topography of the area .................................................................. 32

4.5 EXISTING INFRASTRUCTURE .................................................................... 33

4.6 SOIL CLASSIFICATION: ........................................................................... 33

4.7 CLIMATIC DATA FROM SECONDARY SOURCE .............................................. 33

Table 4.3: Summarized Meteorological Data Collected from Durgapur IMD: ..... 33

CHAPTER -5........................................................................................................ 34

PLANNING BRIEF................................................................................................. 34

5.1 PLANNING CONCEPT ............................................................................... 34

5.2 PERIPHERAL DEVELOPMENT PLAN ............................................................. 34

Fig 5.1: MANAGEMENT HEIRARCHY ............................................................... 35

5.3 LAND USE PLANNING .............................................................................. 35

Table 5.1: Land Use Pattern for the proposed project .................................... 36

5.4 ASSESSMENT of INFRASTRUCTURE DEMAND .............................................. 36

CHAPTER -6........................................................................................................ 37

PROPOSED INFRASTRUCTURE .............................................................................. 37

6.1 INDUSTRIAL AREA DISTRIBUTION ............................................................. 37

6.2 GREENBELT DEVELOPMENT ...................................................................... 37

6.3 CONNECTIVITY ....................................................................................... 37

6.4 DRINKING WATER MANAGEMENT: ............................................................. 37

6.5 INDUSTRIAL WASTE MANAGEMENT ........................................................... 37

6.5.1 WASTE MANAGEMENT ....................................................................... 37

6.5.2 SOLID WASTE GENERATION & MANAGEMENT ....................................... 37

6.5.3 POWER REQUIREMENT ...................................................................... 38

6.6 INDUSTRIAL POLLUTION CONTROL ........................................................... 38

6.6.1 AIR POLLUTION CONTROL.................................................................. 38

Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES ......................... 38

6.6.2 WATER POLLUTION CONTROL ............................................................ 38

6.7 MAN POWER REQUIREMENT ..................................................................... 39

CHAPTER -7........................................................................................................ 40

REHABILITATION & RESETTLEMENT ...................................................................... 40

REHABILITATION & RESETTLEMENT ................................................................... 40

CHAPTER -8........................................................................................................ 41

PROJECT SCHEDULE ............................................................................................ 41




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8.1 IMPLEMENTATION SCHEDULE ................................................................... 41

Table 8.1: Tentative implementation schedule: ............................................. 41

8.2 ESTIMATED PROJECT COST ...................................................................... 42

CHAPTER-9 ........................................................................................................ 43

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ............................................. 43

9.1 FINANCIAL & SOCIAL BENEFITS ............................................................... 43

9.2 SOCIAL INFRASTRUCTURE ....................................................................... 43

9.3 EMPLOYMENT POTENTIAL ........................................................................ 43

9.4 BENEFITS TO THE REGION AND THE COUNTRY ........................................... 43




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CHAPTER-1

EXECUTIVE SUMMARY

M/s SPINTECH TUBES PVT. LTD., is one of the flagship company of M/s Gagan Group,

well known in the Eastern India for their quality products viz. TMT Bars, Billets, Ingots,

Sponge Iron Industrial Oxygen & Nitrogen Gas.

M/s Spintech Tubes Pvt Ltd. proposesto setup 0.524 MTPA Integrated Steel Plant at

Dhasal, PO- Bahadurpur, Dist: -Paschim Burdwan, West Bengal. The project is located at

latitude230 40’ 53.52’’ N and longitude 870 07’ 55.92’’ E with 101m AMSL.

The proposed project is a green field integrated steel project of category-A, proposing to

setup 2x0.6 MTPA Iron Ore Beneficiation cum Palletisation Plant, 1x45m2 Iron Ore Sinter

Plant,2x600 TPD DRI Kilns, 6x20T IF with LF & CCM,1x20T EAF with LRF & AOD,

1x350m3 MBF, 2x12 MW CPP (WHRB), 60 MW CPP (AFBC), 2x600T Rolling Mill, 120 TPD

Oxygen Plant and 4x18 MVA SAF for manufacture Bulk Ferroalloys.

The proposed project will be setup in200 acres of land which 100 Ac have already been

acquired and balance is in process of acquisition. Total project cost is about 920 crores.

The project after execution will produce 0.256 MTPA TMT rods & Coils, 0.128 MTPA

Ductile Iron Pipes and 0.140 MTPA SS rods & Plates.

Total fresh water requirement for the project is estimated to be about 202 m3/hr (4848

m3/day) which will be sourced from Ajay river. The company has already been granted

permission to draw 4000 m3/day of water.

The waste water generated from the various processes will be sent to the waste water

treatment. After treatment the treated water will be recycled for the processes again.

The slime from I/o washing screen will be sent to a settling pond and dewatered. The

water will be recycled back. The product slurry will be passed through the filter press

and concentrate cakes will be sent to the Concentrate Bin. The filter water will be

recycled back. The waste water from administrative building, canteen and office toilets

will be sent to a soak pit.

Power requirement for the project on full load running will be about 132 MW and captive

generation will be 84 MW, hence about 48 MW will be purchased from India Power

Corporation Ltd. Agreement for supply of power is in progress for 50 MVA.

The project will plan to give more employment opportunities to skilled & unskilled

workers by Direct & Indirect Employment. The total man power requirement for plant

operation on completion has been estimated to be 2000including 600 direct

employment. Besides this some contractual workers are to be employed to manage

canteen, security and housekeeping during construction as well as operation phase.

The estimated project cost is about 920 crores. Cost of the project includes cost

towards land and site development, buildings, plant and machinery, engineering

expenses on drawings and documents, miscellaneous fixed assets, preliminary and pre-

operative expenses, provision for contingencies and margin money for working capital.

Project is planned to be completed within 2 years after obtaining EC.




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CHAPTER-2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

M/s SPINTECH TUBES PVT. LTD., is one of the flagship company of Gagan Group well

known in the Eastern India for their quality products viz. TMT Bars, Billets, Ingots,

Sponge Iron Industrial Oxygen & Nitrogen Gas.

Shakambhari Overseas Trades Pvt. Ltd. (SOTPL) is the flagship Company of Gagan

Group operating the unit at: Angadpur and Gagan Ferrotech Ltd.(GFL) Is operating with

its installed facilities at Jamuria.

M/s Spintech Tubes Pvt. Ltd. Is proposing to set up a 0.5 MTPA green field Integrated

Steel Plant at Dhasal in Jamuria and manufacture 0.25 MPTA TMT rods and coils, 0.12

MTPA Ductile Iron Pipes & 0.14 MTPA Stainless Steel Rods &Pipes. TheIntegrated steel

plant is proposed to be located on 80.92ha of barren land atDhasal, a region in state of

WB, endowed with easy access to rich and abundant resources of iron ore and well

connected to the market and major industrial centre.

Shri Vinay Kumar Agarwal is promoter of the Gagan Group. He has three decades of

experience in steel Industry and is a well-known for pioneering steel industry in the

secondary sector.

The group companies have progressed phenomenally under the valuable guidance of

Shri Vinay Kumar Agarwal. The company has started with 1x8T IF and by now owns

steel & integratedsteel plants in the district of Burdwan in West Bengal.

The group’s turnover has increased from Rupees 60 Crores in 2002-03 to Rupees 878

Crores in 2016-17. The reserve and surplus of the group at present is Rupees 268

Crores.

With this financial background and long experience in steel field, the Group now intends

to set up a green field Integrated Steel Plant at Dhasal, P.O. Bahadurpur, Dist. Paschim-

Burdwan to meet the growing demand of steel to some extent.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project is a green field integrated steel project of category-A, proposing to

setup 2x0.6 MTPA Iron Ore Beneficiation cum Palletisation Plant, 1x45m2 Iron Ore Sinter

Plant,2x600 TPD DRI Kilns, 6x20T IF with LF & CCM, 1x20T EAF with LRF & AOD,

1x350m3 MBF, 2x12 MW CPP (WHRB), 60 MW CPP (AFBC), 2x600T Rolling Mill, 120 TPD

Oxygen Plant and 4x18 MVA SAF for manufacture Bulk Ferroalloys.

All the units of the proposed project will be set up on 80.92 ha of barren land already

acquired at Dhasal.

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND

REGION

TMT rod, and coil products are normally used in constructional/structural work due to its

workability & has high market demand. Ductile Iron pipe which has high market demand

for underground water lines. Stainless steel rods and pipes have demand in industries,




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where corrosion or contamination from pipe lines carrying material is not desired.Ferro

alloys have demand in all steel manufacturing units going for steel, value added special

steel or stainless steel.Hence all the products proposed to be manufactured have high

market demand.

Steel is a basic commodity for all industrial activity and its consumption marks industrial

prosperity. The steel industry has tremendous forward and backward linkages in terms

of material flow, income and employment generation.

Steel is a core industry and thus its demand is strongly linked to the overall economic

activity of the nation. Given the inherent long-term potential of the Indian economy and

its cyclical nature, the long-term prospects of the steel industry are fairly comfortable.

The demand and production has been growing at a healthy rate for the last few years

and the forecast for the next decade and half is also very promising.

It has been estimated by certain major investment houses such as Credit Suisse that

India’s steel consumption will continue to grow at 16 % rate annually fuelled by demand

for construction projects worth US $1 trillion. The scope for raising the total consumption

for steel is huge, Per capita consumption of steel at current levels is about 65 kg. As a

comparison per capita steel consumption in China is 430 kg and the world steel

consumption per capita average is 180 kg.

By 2020-21 the demand at 7 % and 8 % GDP growth is estimated to be 123 million tons

and 137.5 million tons respectively. Taking a mean figure of 130 million ton, there is a

need of 65 million ton in 10 years’ time. This translates into an average growth

requirement of about 10 million tons per year.

2.3.1 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 3rd largest producer of

crude steel in 2015 and the country continues to be the largest producer of

sponge iron or DRI in the world.

As per the report of the Working Group on Steel for the 12th Five Year Plan, there

exist many factors which carry the potential of raising the percapita steel

consumption in the country. These include among others, an estimated

infrastructure investment of nearly a trillion dollars, a projected growth of

manufacturing from current 8% to 11-12%, increase in urban population to 600

million by 2030 from the current level of 400 million, emergence of the rural

market for steel currently consuming around 10 kg per annum buoyed by projects

like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas

Yojana among others.

India produced 88.97 million tons(mt) , 89.79 mt and 96 mt of crude steel during 2014,

2015 and 2016 respectively. India’s steel exports grew 150.0 per cent year-on-year to

0.75 MT in February 2017, while steel imports declined 46 per cent year-on-year to 0.49

MT. Total consumption of finished steel grew by 3.4 per cent year-on-year to 76.22 MT

during April 2016-February 2017.




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This was on account of higher output by the major Indian steel companies. The

imposition of Minimum Import Price (MIP) encouraged the producers to increase their

output. Care Ratings said that the consumption of steel, on the other hand, grew by just

3.2% to 73.75 MT during April-December 2016.

The National Steel Policy 2017, released by the government, aims to increase steel

production. Thus, both production and consumption of steel is expected to remain

buoyant in 2017-18, the report said.

The major factors driving the growth of steel demand in India are

Manufacturing sector is expected to grow @ 12–15% as compared to 10% at

present

Construction sector is slated to grow @ 10% from 8% at present

Significant growth in Auto sector – Production of Passenger cars @ 9% and 2-

wheelers @ 16% during 2005-15.

Major infrastructure initiatives with impact on steel demand :

Electrification of all villages, Expansion and Modernization of Distribution Systems

of National Grids, Mass Transport Systemsin major cities, National Distribution

Network for Natural Gas,

Dedicated Railway Track for Freight Movement between metrocities, Expansion of

National Highways Network, Modernisation/New Sea and Air ports.

Affordable investment requirement for such mini steel plants, and

Increasing demand for construction steel, which can be profitably produced from

such mini steel plants

Out of new capacity for steel production, 60% is expected to come through Blast Furnace

route, 33% through Sponge iron – Electric Arc Furnace route and balance through other

routes. This has to be met by expanding capacity of the existing plants as well as by

installing green field steel plants. Large and medium capacity steel plants have adopted

the BF route.

Government Initiatives

Some of the other recent government initiatives in this sector are as follows: The Government of India has approved a joint venture (JV) between MSTC Ltd

and Mahindra Intertrade Ltd, for setting up India's first green field auto shredding

and recycling facility, which will aide in saving of foreign currency, as a result of

import substitution of scrap.

Union Minister of Steel, Mines, Labor and Employment, has launched the National

Mineral Exploration Policy (NMEP), which will help to adopt comprehensive

exploration of non-fuel and non-coal mineral resources that would give a major

boost to the economy.

Metal Scrap Trade Corporation (MSTC) Limited and the Ministry of Steel have

jointly launched an e-platform called 'MSTC Metal Mandi' under the 'Digital India'

initiative, which will facilitate sale of finished and semi-finished steel products.

The Parliament of India has cleared amendments to the Mines and Minerals

Development and Regulation (MMDR) Act, which will enable companies to transfer

captive mines leases similar to mines won through an auction, and which is

expected to lead to increased Mergers and Acquisitions (M&A) of steel and cement

companies.




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The Ministry of Steel has announced to invest in modernization and expansion of

steel plants of Steel Authority of India Limited (SAIL) and Rashtriya Ispat

NigamLimited (RINL) in various states to enhance the crude steel production

capacity in the current phase from 12.8 MTPA to 21.4 MTPA and from 3.0 MTPA to

6.3 MTPA respectively.

The Minister of Steel & Mines has reiterated commitment of Central Government

to support the steel industry to reach a production target of 300 Million Tonne Per

Annum (MTPA) in 2025.

The Ministry of Steel is facilitating setting up of an industry driven Steel Research

and Technology Mission of India (SRTMI) in association with the public and

private sector steel companies to spearhead research and development activities

in the iron and steel industry at an initial corpus of Rs 200 crore (US$ 30 million).

The Central Board of Excise and Customs (CBEC) has issued a notification

announcing zero export duty on iron ore pellets, which will help the domestic

industry to become more competitive in the international market.

Government has planned Special Purpose Vehicles (SPVs) with four iron ore rich

states i.e., Karnataka, Jharkhand, Orissa, and Chhattisgarh to set up plants

having capacity between 3 to 6 MTPA.

SAIL plans to invest US$ 23.8 billion for increasing its production to 50 MTPA by

2025. SAIL is currently expanding its capacity from 13 MTPA to 23 MTPA, at an

investment of US$ 9.6 billion.

Some of the major investments in the Indian steel industry are as follows:

Tata Steel has signed an agreement to purchase a majority 51 per cent stake in

Creative Port Development (CPDPL), which has a concession agreement with the

Odisha government to develop a 10 million-tonnes-per-annum (MTPA)

Subarnarekha port at Chamukh village in Balasore district of Odisha.

Tidfore Heavy Equipment Group, the China-based infrastructure giant, is looking

to enter the Indian market by signing an investment agreement worth US$ 150

million with Uttam Galva Metallics, to expand its Wardha unit along with South

Korean steel major Posco.

ArcelorMittal SA is looking to set up a joint venture (JV) factory in India with

state-owned Steel Authority of India Ltd (SAIL), to manufacture high-end steel

products which could be used in defence and satellite industries.

JSW Group plans to invest around Rs 10,000 crore (US$ 1.5 billion) at Salboni in

West Bengal to set up 1,320 Megawatt (MW) coal-based power plant, 4.8 million

tonne cement plant and paints factory over a period of next five to seven years.

National Mineral Development Corporation (NMDC) has planned to invest Rs

40,000 crore (US$ 6 billion) in the next eight years to achieve mining capacity of

75 Million Tonnes Per Annum (MTPA) by FY2018-19 and 100 MTPA by FY2021-22,

compared to 48 MTPA current capacity.

Posco Korea, the multinational Korean steel company, has signed an agreement

with Shree Uttam Steel and Power (part of Uttam Galva Group) to set up a steel

plant at Satarda in Maharashtra.

ArcelorMittal, world’s leading steel maker, has agreed a joint venture with Steel

Authority of India Ltd (SAIL) to set up an automotive steel manufacturing facility

in India.




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Iran has evinced interest in strengthening ties with India in the steel and mines

sector, said ambassador of the Islamic Republic of Iran, Mr Gholamreza Ansari in

his conversation with Minister of Steel and Mines, Mr Narendra Singh Tomar.

Public sector mining giant NMDC Ltd will set up a greenfield 3-million tonne per

annum steel mill in Karnataka jointly with the state government at an estimated

investment of Rs 18,000 crore (US$ 2.7 billion).

JSW Steel has announced to add capacity to make its plant in Karnataka the

largest at 20 MT by 2022.

2.3.2 GLOBAL STEEL SCENARIO

Steel production in the world is dominated by China followed by Japan. In 2016, the

world crude steel production reached 1628 million tonnes (mt) and showed a growth of

0.8% over 2015.

China remained world’s largest crude steel producer in 2016 (808 mt) followed by

Japan (105 mt), India (96 mt) and the USA (79 mt).

World Steel Association has projected Indian steel demand to grow by 5.4% in 2016

and by 5.7% in 2017 while globally, steel demand has been projected to grow by

0.2% in 2016 and by 0.5% in 2017. Chinese steel use is projected to decline in both

these years - by 1% in 2016 and by 2% in 2017.

Per capita finished steel consumption in 2015 is placed at 208 kg for world and 489 kg

for China by World Steel Association

Steel is a key driver of the world's economy. The industry directly employs more than

two million people worldwide, with a further two million contractors and four million

people in supporting industries. According to the World Steel Dynamics (WSD)

organization, global steel production (as also demand for it or consumption) will grow

at an annual average compounded rate of growth of 1.28 per cent during 2015-2025

to reach only 1873 million tonnes by 2025. Other well-known forecasts, this figure

was to be achieved by 2020.

[Source: Ministry of Steel]

2.4 EMPLOYMENT GENERATION DUE TO PROJECT



operation on completion of the proposed project will be around 2,000including 600 direct

employment. Contractual workers are to be employed to manage canteen, security and

housekeeping during construction as well as operation phase.

2.5 METHODOLOGY OF THE STUDY

Environmental issues must be addressed during project planning before the actual

project is executed. In the same way as economic, financial, institutional, or technical

analysis, Environmental Impact Assessment (EIA) is an integral part of the project. EIA

is the process in which environmental factors are integrated into project planning and

decision-making so as to achieve ecologically sustainable development. Best-practice EIA

identifies environmental risks, lessens conflicts by promoting community participation,




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minimizes adverse environmental effects, informs decision makers, and helps lay the

base for environmentally-sound projects. Benefits of integrating EIA have been observed

in all stages of a project, from exploration and planning, through construction,

operations, decommissioning, and beyond site closure.

The process of EIA usually consists of the following stages:

Screening

Scoping

Baseline Study

Environmental Impact Identification, Prediction and Assessment.

Environmental Management Plan

Decision making relative to the proposed action.

Study Documentation

Screening:Assessment the need for an EIA. Whether there is any possibility of

significant stress or shock on the supportive and assimilative capacity of the surrounding

environment.

Scoping: Identification of issues and impacts to be considered in the EIA study

Baseline Study: Conducting necessary field studies for generation baseline

data to define the pre-project environment. The baseline study to be donein

non-monsoon period as per the approved TOR conditions given by MoEFCC.

For Impact Prediction and Assessment, the details of most of the baseline

data will be collected during the study period of 03 months to be undertaken

during non-monsoon period. There will be elaborate data collection with

respect to geology,geomorphology, hydrogeology, drainage pattern; land use

pattern etc. and the subsequent satellite map will be prepared with a 10 km

radius buffer zone.

Details of the micro-meteorological data will be collected with respect to

hourly wind speed & wind direction, humidity, temperature, cloud cover,

rainfall data etc. The corresponding frequency distribution of wind behaviour

with wind rose diagram has been prepared. This will form the meteorological

data input to Air Quality Prediction Model.

The existing ground level concentration of Particulate Matter (PM10 and

PM2.5), Sulphur Dioxide (SO2), Nitrogen Oxide (NOx) and Carbon Monoxide

(CO) are analysed during the study period in the core zone as well as buffer

zone including at least one in the down wind direction. The air sampling

location and others will be chosen studying the wind rose and using standard

procedures.

Surface water & ground water analysis is done in core zone and buffer zone

as per the parameters in relevant standard.

The soil testing is done in core and buffer zone.

The average noise quality both in day and night.




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All the procedure of collection of sample, frequency of collection, analysis

procedures etc are done as per CPCB norms.

Details of the ecological survey are taken up with respect to flora and fauna

including avifauna and aquatic fauna with an emphasis on endangered

species in the core zone as well as in the buffer zone.

Socio-economic data of the region is collected with respect to literacy,

economic status, occupation, living standard, health etc. of the local

population. There are detailed data collections about infrastructure facilities

like transportation, communication, education health etc.

Detailed survey of the 15 Km. region around the project is conducted to find

out any location of sensitive areas like wild life sanctuaries, historical

&archaeological sites, defence installations etc.

Environmental Impact Identification, Prediction and Assessment

Different environmental impact areas are identified and expressed in matrix

form.

Qualitative prediction of impact is done with respect to land use, ecology and

noise and socio-economic.

Details of water and waste water inventory are to be prepared to find out

their impact on the environment.

Solid wastes Inventory (both hazardous and non-hazardous in nature) will be

done to predict and assess their impact on environment.

Detailed information about stacks with respect to height, diameter, flue gas,

temperature, velocity and flow and the inter stack distances will becalculated.

Emission inventory with respect to PM, SO2, NOxwill becalculated.

Micro-meteorological data along with stack and emission inventory data is

input to the air quality prediction modelling software.

Quantitative prediction of air pollutants in the form of incremental ground

level concentration (GLC) is done by Air Quality Prediction Modelling Software

(ISC-AEROMOD-ISCST-3) developed by USEPA.

Maximum resultant GLC will be calculated at locations taking into

consideration of background GLC and precipitation due to plant operation

depending on predominant wind direction.

Subjective impact assessment using matrix method is carried out to calculate

the total impact score without mitigation measures.

This has been done as per the approved TOR conditions given by MoEFCC.

2.6 ENVIRONMENTAL MANAGEMENT PLAN:

Following environmental management plan is proposed to reduce the predicted adverse

impacts and to make provision to compensate for any residual adverse impact

Air Pollution control Equipments (APCE) to be setup.

Disposal management of the solid waste and effluents generated from

these APC equipments will be chalked out.




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Fugitive dust emission from the different storage & transfer point and haul

road emissions and their detailed control aspects shall be covered.

Considering water as important and valuable utility, company will formulate

a water management plan for minimum use of the fresh water.

Waste water management dealing with treatment methodologies and

recycling/reuse of treated waste will be prepared.

Storage of storm water in the monsoon in water harvesting ponds and the

use of the same water in lean season will be planned.

Zero discharge norms with a comprehensive water and waste water

management plan will be evaluated.

A detail of the solid waste inventory, its characterization and their usage

potentiality will be discussed. Solid waste plant process and reuse of the

solid waste for different purposes will be examined.

Noise control devices with different equipments at design stage, protective

measures at work zone sites and supply of protective gears to affected

personnel will given in detail.

Realizing the need for the greenbelt cover as a very good sink for pollutants

and the aesthetical aspects the company will go for a comprehensive

plantation program as per MoEFCC Norms.

Detailed plan for greenbelt development with respect to allocation of area,

fund allocation, selection of the species and maintenance plan will be

covered. Peripheral development plan that includes development in

infrastructure, health education and socio-cultural aspects will be

emphasized.

Details of the EMP cell with respect to monitoring laboratory, technical man

power and fund allocation is discussed. Details of monitoring program with

respect to pollutant parameters. Monitoring scheduled and reporting as per

statutory requirement will be planned.

Safety and disaster management plan with onsite emergency plan to deal

with the unforeseen accidents will be covered.

Beneficial aspects of project with respect to direct and indirect employment,

business opportunities and peripheral development will be discussed.

Trickledown effect of all the project benefits to affected local population will

be analysed.

Taking in to consideration of the environmental degradations due to the

project implementation and the consequent environmental management

plan followed by the post project benefits, the subjective assessment with a

Total Impact Score will be analysed to draw a summary conclusion.

2.7 LITIGATION/COURT CASE AGAINST THE COMPANY

No, litigation or court cases are pending against the project and/or no direction/order

has been passed by any court of law against the project.




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2.8 AUTHORIZATION

M/s. Spintech Tube Private Ltd has entrusted M/S Global Tech Enviro Experts Pvt. Ltd.,

Bhubaneswar for the preparation of TEFR for their green field integrated steel project. In

accordance to the scope of work, M/s. GTEEPL team visited the project site to take

general view and will again will visit the project site and collect base line data like Air,

Water, Soil & Noise from the project site and availability of infrastructure facilities like

raw materials, water, power and transportation facilities in detail.

The team will also make socio-economic study of 10km buffer zone of the project site to

know existing status of the locality and flora & fauna.

2.9 ACKNOWLEDGEMENT:

M/s GLOBAL TECH ENVIRO EXPERTS PVT LTD, Bhubaneswar expresses its deep

gratitude to M/s. Spintech Tubes Private. Ltd for the assignment entrusted to them.

.




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CHAPTER-3 PROCESS DESCRIPTION

3.1 TYPE OF THE PROJECT:

0.524 MTPA Integrated Steel Plant, green field project of M/s Spintech Tubes PvtLtd. will

be a primary metallurgical Plant manufacturing 0.256 MTPA TMT rods & Coils, 0.128

MTPA Ductile Iron Pipes and 0.140 MTPA SS rods & Plates. Besides this 4x18 MVA bulk

Ferroalloys plant will be setup.

This project is independent plant without any interlink or interdependence.

3.2 LOCATION OF THE PROJECT

M/sSpintech Tubes Pvt Ltd. proposes0.524 MTPA Integrated Steel Plant at Dhasal, PO-

Bahadurpur, Dist:-Paschim Burdwan, West Bengal. The project is located at latitude230

40’ 53.52’’ N and longitude 870 07’ 55.92’’ E with 101m AMSL.




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The corner co-ordinates of project site are as follows.

Pt 1: 23041’ 7.76” N and 870 07’ 44.72” E

Pt 2: 230 40’ 39.87” N and 870 07’ 48.64” E

Pt 3: 230 40’ 42.41” N and 87008’ 13.10” E

Pt 4: 230 41’ 08.06” N and 870 08’ 21.06” E

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS

OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE

HIGHLIGHTED.

Any other site has not taken into consideration. A single patch of 200 acres of barren

land having existing Infrastructural facilities was not available. The site is nearer to

existing running plant Gagan Ferrotech Limited. The plant will be located which is

endowed with easy access to rich and abundant resources of iron ore and various other

minerals. Rail connectivity, nearness to the market and well-established communication

network are other criteria in selecting the plant site. Availability of water, electric power

and labor is also important. Favorable climatic conditions and good rainfall is conducive

to high labor. So no alternate site has been taken into consideration.

3.4 SIZE OR MAGNITUDE OF OPERATION

The proposed project will be setup in200 acres of land which has already been acquired

with total project cost of about 920 crores. The project after execution will produce

0.256 MTPA TMT rods & Coils, 0.128 MTPA Ductile Iron Pipes and 0.140 MTPA SS rods &

Plates.




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3.5 PROCESS DESCRIPTION

M/s Spintech Tubes Pvt Ltdnow proposes an Integrated Steel Plant with following

configuration.

Table 3.1: PROJECT CONFIGURATION & PRODUCT MIX

Sl. No. Plant Facilities Configuration Production Capacity (in

TPA)

End Use

1 DRI Kilns 2 x 600 TPD 3,84,000 Sponge Iron

– IF & EAF

2 Induction

Furnace with LF

& CCM

6 x20 T, 10 H 3,84,000 HM- DI Pipes

& TMT

3 EAF with LRF 1 x 20 T, 22 H 1,40,000 Hot Metal- RM

4 MBF 1 x 350 m3, 2.4

t/m3/d

2,94,000

5 Pellet Plant 2 x 0.6 MTPA 9,60,000 DRI

6 Sinter Plant 1 x 45 m2 , 1.24

t/m2/h

4,28,000 MBF

7 Submerged Arc

Furnace

4 x 18 T (Fe-

Mn,Si-Mn,Fe-Cr,

Fe-Si)

Max-1,65,000 (Fe-Mn)

Min-52,000 (Si-Mn). All

or any one depending

on Market Demand

8 Di Pipes 1,28,000 spun

pipes

1,28,000 - spun pipes Sale

9 Rolling mill 2 x 600 TPD 5,24,000 2,56,000-

TMT rods

1,40,000-SS

rods

10 C C M - - Billet for RM

11 Oxygen Plant 120 TPD -

12 Power Plant 84 MW

[24MW(WHRB)

60MW(CFBC)]

24 MW power Internal

Consumption




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Fig 3.1 Flowsheet of the process




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A. DRI kilns

Sponge iron is the metallic form of iron produced from reduction of iron oxide below the

fusion temperature of iron ore (1535 ◦C) by utilizing hydrocarbon gases or carbonaceous

fuels as coal. The reduced product having high degree of metallization exhibits a

‘honeycomb structure’, due to which it is named as sponge iron. As the iron ore is in

direct contact with the reducing agent throughout the reduction process, it is often

termed as direct reduced iron(DRI).

Sponge iron, also known as "Direct Reduced Iron" (DRI) and its variant Hot Briquetted

Iron (HBI) have emerged as prime feed stock which replace steel scrap in EAF/IF as well

as in other steel-making processes. It is the resulting product of solid state reduction of

iron ores or agglomerates (generally of high grade), the principal constituents of which

are metallic iron, residual iron oxides, carbon and impurities such as phosphorus,

sulphur and gangue (principally silica and alumina). The final product can be in the form

of fines, lumps, briquettes or pellets. Direct reduction processes available can be broadly

grouped under two categories based on the type of reductant used.These are:

1)Solid based processes

2)Gas based processes

Indigenous solid (coal) based Process

In India, the coal based DRI production process employs a rotary kiln as the main

reactor wherein the process of reduction of the iron oxide is carried out with coal as

reductant. Refractory lining of about 150-200 mm thickness is given inside the kiln to

protect the shell. The kiln has a general slope of 2.5 - 3% down towards the discharge

end. There are air blowers mounted on the kiln shell having dampers to provide required

air for combustion at different heating zones.

M/s Spintech Tubesproposed to set up2 x 600 TPD DRI kilns.

B. IF

The various types of Induction Furnaces used for Steel making are medium frequency

and high frequency. Raw materials used for Steel making from IF are Sponge Iron, Pig

ironand Scrap. Alloying elements are added as per the requirement and the induction

furnaces are provided with matching billet casters

M/s Spintech Tubes is now proposing to set up 6 x20T IFs

Proposed design Parameters of Induction Furnace

Sl.

No.

Parameter Unit Value/Feature

1. Liquid Steel Production T/yr 3,84,000

2. No. of Furnaces 6 20T each with 10 crucibles

3. Type of furnace - A.C medium frequency coreless,

twin shell each with common

power pack per furnace.

4. Nominal Transformer Rating KW 4900

5. Heats/Day/Furnace - 10

6 No. of working days Annum - 320




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C. FERRO ALLOY PLANT

The companyproposes to set 4x18 MVA SAF to produce Fe-Mn, Fe-Cr,Fe-si and Si-Mn

Ferro Manganese/Silico Manganese:

High carbon Ferro-manganese/Silico Manganese is commercially produced by

carbothermic reduction of manganese ores, primarily in electric submerged arc furnaces

(SAF). The produced metal typically contains around 78% Mn, 7% Carbon and around

40% MnO (high MnO slag practice). An increasing part of the metal is refined to medium

or low carbon manganese.

Ferro Chrome

Production of high carbon Ferro-chrome involves chemical reduction of Chromites ore

with some carbonaceous material as reducing agent and using quartzite, lime and

or/dolomite as fluxes.

The project will make briquettes utilizing Chrome-ore fines to the extent of 70%, lump

and fine ores will be used to the extent of 20% and 5-10% respectively. Utilization of

briquette charge will also optimize power consumption in the furnace.

D. ROLLING MILL

In view of available infrastructure facilities, the company proposes 2 x 600 TPDrolling

mills and at the same time red hot billet from CCM will be directly fed to Rolling mill. TMT

rods and wires of different diameter will be manufactured. Passing red hot rods/weirs

through water bath for short duration will produce thermos- mechanically treated (TMT)

products which will have excellent workability.

E. EAF

The company has proposed 1x20T EAF with 22 H. This will melt pig iron, DRI and hot

metal from MBF which after removal of excess carbon, Sulphur and Phosphorous on

oxidation by Oxygen will be casted produce to stainless steel.

F. PELLETIZATION & BENEFICIATION PLANT:

Palletisation:

It is proposed to set up two pellet plants with a capacity of 2 x 0.6 MTPA by utilizing low

grade Iron Ore fines which are available in plenty in the region for meeting the

requirement of DRI units and mini Blast furnaces.

The proposed plant will produce both DR grade pellets with Fe content of 65%. The main

input will be Fe-Ore fines of 58-60% Fe.

There are two technologies available for palletisation, straight kiln process and grate kiln

process. While straight kiln process are suitable for large palletisation plants (2MPTA and

above), grate kiln process is more effective for small size plants.

Beneficiation:




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In India most of the high grade(>65% Fe) hematite iron ore are subjected to dry

process of beneficiation at mine end to meet the size requirement involving multistage

crushing and screening to obtain calibrated lumps. Fines are dumped their near mines.

In dry cum wet process the fine fractions obtained after dry processing are further

processed in mechanical classifiers, hydro-cyclones etc. to obtain-10+0.15mm size

products that constitute the feed for sintering.

Wet process is generally selected for low/medium grade hematite iron ire. The process

consists of multistage crushing followed by different stages of washing in the form of

scrubbing and/or wet screening, classification etc. SIPL has selected this wet process of

beneficiation.

G.SINTER PLANT:

Sintering process is a pre-treatment step in the production of iron, where fine particles

of iron ores, Coke, Flues viz., Lime stone & Dolomite and also secondary iron oxide

wastes (collected dusts, mill scale), are agglomerated by combustion. Agglomeration of

the fines is necessary to enable the passage of hot gases during the subsequent blast

furnace operation.

Sintering involves the heating of fine iron ore with flux and coke fines or coal to (1300 to

1480oC) produce a semi-molten mass that solidifies into porous pieces of sinter with the

size and strength characteristics necessary for feeding into the blast furnace. Moistened

feed is delivered as a layer onto a continuously moving grate or 'strand.' The surface is

ignited with gas burners at the start of the strand, and air is drawn through the moving

bed causing the fuel to burn. Strand velocity and gas flow are controlled to ensure that

'burn through' (i.e. the point at which the burning fuel layer reaches the base of the

strand) occurs just prior to the sinter being discharged.

The solidified sinter is then broken into pieces in a crusher and is air-cooled. Product

outside the required size range is screened out, oversize material is re crushed, and

undersize material is recycled back to the process. Sinter plants that are located in a

steel plant recycle iron ore fines from the raw material storage and handling operations

and from waste iron oxides from steel plant operations.Waste Gasses coming outside the

wind boxes are treated in an APC equipment Viz., ESP & dust so collected is again

reprocessed to produce courser sinter. However, Sinter dust collected in final field is

usually dumped in land fill due to high Alkali content.

The proposed sinter plant complex will consist of on sinter machine of 45 m2 grate area

along with associated services facilities. The plant is rated for production of 4,28,000 TPA

of gross sinter at a rated productivity of 1.24 t/m2 /hr.The sinter plant complex

envisages receipt of blended mix, limestone, dolomite and coke breeze at the

proportioning unit.

1. Flux and fuel crushing and screening system

2. Proportioning unit

3. Mixing and nodulizing unit

4. Sintering and cooling unit

5. Waste gas dedusting unit




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6. Main exhaust fan unit

7. Sinter size stabilizing unit

8. Plant dedusting unit

The above units will be interconnected by conveyor galleries and junction houses for

conveying sinter mix, finished sinter, hearth layer and sinter returns fines.The Sinter Plant

of the following main parameters is proposed to meet the Hot Metal (HM) requirement.

The technical parameters are given in table below.

Technical parameters of Sinter Plant

Sintering Area 45 m2

Utilization Ratio 1.24 t/m2.h

Sinter Production 4,80,000 TPA

Sinter Quality

– T of Fe 57%

– FeO ~11%

– S 0.021%

– Alkalinity 1.8

– Temperature <1500C

– Grain Size 5-150 mm

RETURN

FINES COK

E

FINES

LIM

E STO

NE

FINES

BLE

ND ORE

SPIKED

ROLL CRUSHER

SINTER STRAND W I N D B O X E S

E S

P HOT

SCREEN RETURN FINES

ROTARY COOLER

SINTER

MIXING DRUM

RAW MIX HOPPER

IGNITI

ON HOOD

BURN

THROUGH AREA

55m

STACK

STRAND

DRAUGHT FAN

PRIMARY

SINTER PLANT FLOW SHEET




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H. Mini Blast Furnace:

Blast furnaces is a vertical shaft furnace that produces liquid metal from lump iron ore /

pellet and sinter by the reducing action of carbon(coke) at a high temperature in the

presence of a fluxing agent limestone.

PCI system

The Pulverized coal dust injection system will be adopted to reduce costly coke

consumption.

Raw coal will be ground to produce coal of 80% below 75 microns. Inert atmosphere will

be maintained in the ball mill for safety. The gases from ball mill will be vent to

atmosphere bag filter. The powder coal will be stored in the fine coal silo and injected

through tuyeres.

BF gas has the following characteristics

Very low calorific value (CV) in the range of 700 to 850 Kcal/Cu m. CV is very

much dependent on the coke rate.

It has a high density. It is around 1.250 Kg/Cu m at the standard temperature

and pressure (STP) which is 0 deg C and 1 atm. Pressure. This density is highest

amongst all the gaseous fuel. Since the density is higher than the density of air it

settles in the bottom in case of a leakage.

It has low theoretical flame temperature which is around 1455 deg C.

It has low rate of flame propagation. It is lower than any other common gaseous

fuel.

BF gas burns with a non luminous flame.

Auto ignition point of BF gas is around 630 deg C.

BF gas has lower explosive limit (LEL) of 27% and upper explosive limit (UEL) of

75% in an air gas mixture at normal temperature and pressure.

The high top pressure of BF gas is utilized to operate a generator (Top gas

pressure Recovery Turbine – i.e. TRT in short). TRT can generate electrical

energy (Power) up to 35 kWh/ ton of hot metal without burning any fuel. Dry

type of TRT can produce more power then wet type.

Technological parameters of MBF

No of blast furnace 1

Useful volume, m3 350

Productivity, t/d m3 2.4

Coke rate (dry), kg / thm 480

Coal dust injection, kg /thm 80




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Slag rate, kg / thm 310

Top pressure, kg/cm2 (g) operating 0.8

I. Power Plant:

Dolchar coming out of DRI kilns still have calorific value in the tune of 1800kcal/kg, a

potential source of heat to generate steam for power generation.

This dolchar with additional support of fresh boiler grade coal will be subjected to grate

firing in AFBC boilers. The combustion will sustain with 50% support of fresh coal to

dolchar and it is estimated that about 60 MW power can be generated from the steam

produced on combustion. Steam from DRI Kilns will generate 24 MW Power. Total Power

will be 84 MW

J. TMT

Coal based DRI kilns will produce sponge iron utilizing lumpy hematite iron ore, DRI grade

coal and dolomite. Sponge iron will be melted in Induction Furnace along with Pig iron

from MBF and heavy melting iron scraps purchased from market and in plant generation. A

part of hot metal from IF will be utilized to manufacture DI pipes for sale.

In MBF iron sinter will be melt in combustion heat of coal and hot metal will be mostly

used to manufacture DI pipes and balance to be cast to pig iron in PCM. Pig iron will be

utilized in IF and EAF.

EAF will melt DRI, Pig iron and scrap to produce hot metal. Hot metal from IF will join with

it and refined in LF. Phosphorus the enemy of steel and Sulphur will be removed on

oxidation, carbon will be reduced and Ferro alloys may be added to impart quality and

thus required grade steel melt will be prepared. This melt will be cast in CCM to produce

hot billets. Finally hot billets will pass through series of rolling mills and iron rods and

angles will be produced which on short period water quenching will be converted to TMT

rods, highly suitable for construction purpose.

Adequate size Vacuum Degassing unit is to be provided for alloy addition and production of

special grade steel.

Since the liquid steel is largely continuously cast in the present day practice, precise

control of temperature is absolutely essential for smooth casting and better surface quality

This is achieved by the application of ladle metallurgy technology.

K. DI Pipes

Ductile iron pipe is a pipe made of ductile cast iron commonly used for potable

water transmission and distribution. This type of pipe is a direct development of

earlier cast iron pipe, which it has superseded. The ductile iron used to manufacture the

pipe is characterized by the spheroidal or nodular nature of the graphite within the iron.

Typically, the pipe is manufactured using centrifugal casting in metal or resin lined moulds.

https://en.wikipedia.org/wiki/Pipe_(material)

https://en.wikipedia.org/wiki/Ductile_iron

https://en.wikipedia.org/wiki/Potable_water



https://en.wikipedia.org/wiki/Cast_iron_pipe

https://en.wikipedia.org/wiki/Centrifugal_casting_(industrial)




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Hot metal from MBF shall undergo Spheroidization in a special ladle at about 1500 °C by

tundish treatment and 2.1 % of Fe=Si & Mg metal will be added to it. molten iron will then

pass through Centrifugal Casting machine for production of Ductile Iron Spun pipes.

In the beginning of casting cycle a core is placed in the bellend of the moulds. The moulds

moves to the pouring position encompassing a long narrow pouring through, which is then

sprayed to the wall of the moulds. Then the pipe extractor is actuated to remove the pipe

from the moulds.

To remove the rust in the internal surface of a mold, it will be grounded with sand wheel

before its dotted with peening head to increase its crack resistance. Annealing

process consists of heating section, heat holding section, slow cooling section and fast

cooling section. Ductile iron pipe will be entered to a long machine and rolled on it.

Certainly its temperature will be controlled.

Adhesive molten zinc will be coated to external surface of pipe. It is mandate that a

minimum zinc content of 135 g/m2 and a minimum average finishing layer thickness of 70

µm to be adhered to.

Protective internal linings is applied to ductile iron pipes to inhibit corrosion, the standard

internal lining is cement mortar.

The pipe then tested with hydraulic pressure of 30 to 60 kg/cm2 depending on nominal

bore. The company proposes to manufacture DI pipes of NB 80 to 1100 mm and length of

5.5 to 6.0m

https://en.wikipedia.org/wiki/Cement-mortar_lined_ductile_iron_pipe




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LAYOUT OF THE PROPOSED AREA




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3.5 MAJOR RAW MATERIAL INVENTORY

Table 3.2: Raw Material Inventory

Sl.No Material Quantity in

TPA

Source Mode of

transport

1 Ulta fines iron ore for

Beneficiation

14,50,000 Odisha Rail/Road

2 Fine Iron Ore for Sinter 4,00,000 Local Road

3 DRI grade Coal 4,60,000 Local/own Road

4 Coke 1,40,000 Local Road

5 Mn Ore 3,75,000 Local/import Rail/Road/ship

6 Coal 3,80,00 Import/MCL Ship/Road

7 Lime 70,000 Sundargarh

Odisha

Road

H2SO4 for DM plant and LDO for start-up of DRI & Boilers.

Raw Material Receipt & Store

Most of the raw material shall be received by rail or road. Separate store yard for the

major raw materials such as iron ore and coal exists and will be done by the

requirement.

Mode of Transport (Raw materials & products)

Transports will be done by the environmentally compliant Bharat-III/ Euro-III trucks.

Coal will be imported from South-Africa/Indonesia and local or e-auction. The raw

materials & products shall be covered fully during the transportation to avoid spillage &

fugitive emissions on the road.

Raw Material Storage & Handling

Separate store yard for the major raw materials such as iron ore lumps, iron ore fines

lime stone/ dolomite, quartz coal and Cr & Mn Ore etc are done. The material shall be




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unloaded manually from the trucks in the stock yard. The yard shall have provision to

store around one months’ stock of material.

3.6 WATER REQUIREMENT

Total fresh water requirement for the project is 202 m3/hr(4848 m3/day) which will be

sourced from Ajay river. The company has already been granted permission to draw

4000 m3/day of water.

Waste Water Management

The waste water generation from the various processes will be sent to the waste water

treatment. After treatment the treated water will be recycled for the processes again.

The slime from washing screen will be sent to a settling pond and dewatered. The water

will be recycled back. The product slurry will be passed through the filter press and

concentrate cakes will be sent to the Concentrate Bin. The filter water will be recycled

back. The waste water from administrative building, canteen and office toilets will be

sent to a soak pit.

3.7 POWER REQUIREMENT

Power requirement will be about 132 MW and captive generation will be 84 MW, hence

about 48 MW will be purchased from India Power Corporation Ltd. Agreement for supply

of power is in progress for50 MVA.

3.8 SOLID WASTE:

Table 3.3: Solid Waste Generation & Management

Rolling mill scraps, mill scale are to be recycled to IF for remelting with fresh charge. The

Solid wastes will be treated as by products and these will be fully utilized.

Solid waste Quantity in TPA Utilization Measures

Char 57,000 To be burn in FBC to produce steam for

power

Fly Ash-DRI 1,53,000 To be sold to brick/cement

manufacturers

Fly Ash-Power Plant 1,25,000 To be sold to brick/cement

manufacturers

Tailing 4,35,000 Cake Ceramics, Tiles

Fe-Mn Slag 1,60,000 Use in Si-Mn

Bottom Ash 83,000 Cement Plant




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3.9 MANPOWER



operation on completion 2000including 600direct employees.Besides this some

contractual workers are to be employed to manage canteen, security and housekeeping

during construction as well as operation phase




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CHAPTER -4

SITE ANALYSIS

4.1 CONNECTIVITY

M/s Spintech Tubes Pvt Ltd. proposes0.524 MTPA Integrated Steel Plant at Dhasal, PO-

Bahadurpur, Dist:-Paschim Burdwan, West Bengal. The project is located at latitude230

40’ 53.52’’ N and longitude 870 07’ 55.92’’ E with 101m AMSL.

The location is well connected by road and Rail. The site is only 0.3 km away from the

NH 60. Ikrah railway station is 2.0 km away. Block Development Office is only 0.4 km

away from the site.Kazi Nazrul Islam Airport is about 13 km away from the site.

4.2 LAND FORM, LAND OWNERSHIP

The total land available for the proposed project is about 200 Ac (80.93 hectares).

Table 4.1: Land Use Pattern for the proposed plant

SL

NO

Facilities Total Land in

Ha

1 Facilities 14.0

2

Raw Material Yard &

Finished products 6.42

3

Office & other permanent

structures 0.7

4 Internal Road 0.5

5

Rain Water harvesting

system 4.0

6 Water Reservoir 3.4

7 Green Belt 26.7

8 Vacant Space 25.21

Total 80.93

4.3 TOPOGRAPHY

The topography is undulating. The area has thin alluvial cover and the soil is mainly

reddish and not very much fertile. It is a transitional zone having hard rock as well as

alluvial terrain which are flat and gently sloping.




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Jamuria is characterized by undulating topography with rugged hilly terrains in the

western parts. The western half of the area resembles a promontory jutting out from the

hill ranges of Chotonagpur plateau and consists of barren, rocky and rolling country with

a Laterite soil rising into rocky hillocks, the highest being 227 m. Ajay-Barakar divide is a

convex plateau, the average altitude being 150 m from the mean sea level. The gradient

is westerly to the west and to the east it is northerly towards Ajay and southerly towards

Damodar below the latitude. The average elevation of Burdwan plain is about 104 m

above the Mean Sea Level (MSL). This area is a low lying alluvial plains with riverine

aggregates.

4.4 LAND USE PATTERN

The project area is present at Dhasal, Bahadurpur, Paschim-Burdwan district of West

Bengal. It is also noted that the core zone i.e. the project boundary or the battery limit

does not belong to part of any National Park, wild life sanctuary or Natural/ Biosphere

reserve. It also does not contain any features of archaeological/ historical and

cultural/aesthetic importance.

Table 4.2 Land use pattern of buffer zone

LANDUSE CATEGORY AREA IN SQ.KM.

RURAL SETTLEMENT 14.1

URBAN SETTLEMENT 12.4




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RIVER SAND 12.3

INDUSTRIAL SITE 2.4

COLLERIES 33.2

DISUSED COLLIERIES 15.1

CROP LAND 175.5

FALLOW LAND 17.2

DEVELOPING AREAS 16.2

RIVER / WATER BODY 10.4

WATER LOGGED AREA 5.2

Total 314.0

Fig- 4.1: Topography of the area




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4.5 EXISTING INFRASTRUCTURE

The site is located at Dhasal, Bahadurpur, and Dist: Burdwan, in the state of West

Bengal.The location is well connected by road and Rail. The site is only 0.3 km away

from the NH 60. Ikrah railway station is 2.0 km away. Block Development Office is only

0.4 km away from the site.Kazi Nazrul Islam Airport is about 13 km away from the site.

4.6 SOIL CLASSIFICATION:

Different types of soil are encountered in different topographical biological and

hydrological as well as geological condition within the Burdwan district. In the west

coarse gritty soil blended with rock fragments is formed from the weathering of

pegmatites, quartz veins and conglomeratic sandstones, where as sandy soil

characteristic of granitic rocks and sandstones. This soil is of reddish colour, medium to

coarse in texture, acidic in reaction, low in nitrogen, calcium, phosphate and other plant

nutrients. Water holding capacity of this soil increases with depth as well as with the

increase of clay portions. Towards the east alluvial soil attains an enormous thickness in

the low level plains to the east. This alluvial soil is formed of alluvium brought down by

the Ajay, Damodar, Bhagirathi and numerous other rivers. These soils are sandy, well

drained and slightly acidic in nature.

The soil type of the Core zone of the study area is fine loamy typic endoaquepts in

nature. The prevailing soil types in the study area are mostly belongs to fine loamy typic

ustochrepts. The other soil types found in the study area are loamy skeletaltypic

ustochrepts, coarse loamy fluventic ustochrepts, fine loamy typic haplustalfs, fine loamy

udic ustochrepts, fine loamy udifleventivic ustochrepts

4.7 CLIMATIC DATA FROM SECONDARY SOURCE

The district experiences a warm temperate rainy climate with mild. The cold season

starts from about the middle of November and continues till the end of February. March

to May is dry summer intervened by tropical cyclones and storms. June to September is

wet summer while October and November is autumn.

Secondary information on meteorological conditions has been collected from the nearest

IMD station at Durgapur and IMD Book (1970-2000). Predominant wind direction is SW.

Table 4.3: Summarized Meteorological Data Collected from Durgapur IMD:

Study

Period(Summ

er Season)

Wind Speed

(Km/Hr)

Temperature

(oC)

Relative

Humidity

(%)

Rainfall (mm)

Cloud

Cover

(Oktas)

Mean Max Min Max Min Max Min 24 hr Max Total

March 6.2 0.1 21.9 19.8 66 62 Nil Nil

0

April 6.9 0.3 21.1 18.4 64 60 Nil Nil

0

May 7.1 0.5 17.1 27.1 57 30 Nil Nil

0




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CHAPTER -5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The plant is an integrated steel plant having semi-mechanized operation. It is a labor

intensive project. However, depending on the production schedule, there will be

additional technical labor engaged for operation.

The raw materials shall be transported through covered trucks by road up to the nearest

siding for further transportation by rail. And the finished products will be transported by

both rail and road. The transportation load will not add much to the existing load on the

said road system.

Appropriate plantation program shall be undertaken along with the developmental

program to at least cover the boundary areas with thick and tall plants for containment

of the air borne pollutants within the premises, which is duly reflected in the land use

plan.

There will not be any further infrastructural development other than needed for the

commissioning of the total project component machineries.

5.2 PERIPHERAL DEVELOPMENT PLAN

M/s Spintech Tubes Pvt Limited will make sincere efforts to improve the socio-economic

status of the local habitants. A welfare scheme will be prepared by the company for the

socio economic development of the area. The scheme will envisage promotion of

education in the adjoining villages by giving aid to the local schools, providing drinking

water facility and organizing health check up programs. Local people will be given free

seedlings to develop greeneries all around. The progress of the scheme will be reviewed

periodically and further action will be taken as deeming fit.




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Fig 5.1: MANAGEMENT HEIRARCHY

5.3 LAND USE PLANNING

The total land of 80.93 ha is available for the project. The detailed breakup of the land is

given in the following table:




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Table 5.1: Land Use Pattern for the proposed project

SL

NO

Facilities Total Land in

Ha

1 Facilities 14.0

2

Raw Material Yard &

Finished products 6.42

3

Office & other permanent

structures 0.7

4 Internal Road 0.5

5

Rain Water harvesting

system 4.0

6 Water Reservoir 3.4

7 Green Belt 26.7

8 Vacant Space 25.21

Total 80.93

5.4 ASSESSMENT of INFRASTRUCTURE DEMAND

The proposed project will put negligible amount of load on existing infrastructure in

terms of physical and social. So, demand for additional infrastructure is not anticipated.




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CHAPTER -6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA DISTRIBUTION

80.93 ha of land has already been acquired where the proposed Integrated Plant will be

set up.

6.2 GREENBELT DEVELOPMENT

In order to combat the air pollution, noise pollution and also to improve the aesthetic,

the company proposes to develop greenbelt, landscaping and avenue plantation. 33% of

the total area i.e. about 26.7 ha of land will be demarcated for green belt purpose.

6.3 CONNECTIVITY

The location is well connected by road and Rail. The site is only 0.3 km away from the

NH 60. Ikrah railway station is 2.0 km away. Block Development Office is only 0.4 km

away from the site. Kazi Nazrul Islam Airport is about 13 km away from the site.

6.4 DRINKING WATER MANAGEMENT:

The drinking water will be met from Ajay river after purification. Around 30 KLD will be

used for drinking purposes.

6.5 INDUSTRIAL WASTE MANAGEMENT

6.5.1 WASTE MANAGEMENT

The wastes which will be generated from the process are some used oil and sludge and

slag from Induction Furnace. The induction furnace slag being equivalent to river sand

can be used as land filling. The hazardous waste will be sold to recyclers and dealers.

The waste water from canteen and office toilets will be sent to a soak pit.Canteen waste

water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic

treatment system & gravity sand filter. Sewage from toilets will be treated in septic tank

and discharged to soak pit.

6.5.2 SOLID WASTE GENERATION & MANAGEMENT

Solid waste Quantity in TPA Utilization Measures

Char 57,000 To be burn in FBC to produce steam for

power

Fly Ash-DRI 1,53,000 To be sold to brick/cement

manufacturers

Fly Ash-Power Plant 1,25,000 To be sold to brick/cement

manufacturers

Tailing 4,35,000 Cake Ceramics, Tiles

Fe-Mn Slag 1,60,000 Use in Si-Mn




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6.5.3 POWER REQUIREMENT

Power requirement for the proposed project will be about 132 MW and captive

generation will be 84 MW, hence about 48 MW will be purchased from India Power

Corporation Ltd. Agreement for supply of power has already been done for 50 MVA.

6.6 INDUSTRIAL POLLUTION CONTROL

6.6.1 AIR POLLUTION CONTROL

It is envisaged to install state of the art air pollution control measures in the proposed

project, as given below.

Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES

Sl No Plant/ Area Proposed Pollution Control Measures

1

Raw Material Handling

Raw Material Handling,

Transfer Points, Junction

Houses

- Water sprinkling will be provided at the

transfer points of material at RMHP.

- Bag filter

2 Induction Furnace - Bag Filter

3 DRI - ESP

4 Sinter - ESP

5 EAF - Bag Filter

6 MBF - Venturi scrubber-Emergency flaring

7 Pellet & Beneficiation - Bag Filter

8 SAF - Bag Filter

9 Power Plant - ESP

6.6.2 WATER POLLUTION CONTROL

The waste water from canteen and office toilets will be sent to a soak pit.Canteen waste

water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic

treatment system & gravity sand filter. Sewage from toilets will be treated in septic tank

and discharged to soak pit.

Bottom Ash 83,000 Cement Plant




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6.7 MAN POWER REQUIREMENT

The total man power requirement for plant operation on completion of the proposed

project will be around 2000 and extra 50 nos. for Security. Manpower requirement will

be as follows:

Grade NOs

Managerial 60

Supervisory 40

Skilled 700

Unskilled 1200

Total 2000




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CHAPTER -7

REHABILITATION & RESETTLEMENT

REHABILITATION & RESETTLEMENT

The proposed units will be implemented in the existing plant premises. The existing

lands were already derived as industrial land. As settlement will not be affected so, no

R&R facility is anticipated.




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CHAPTER -8

PROJECT SCHEDULE

8.1 IMPLEMENTATION SCHEDULE

Time schedule for completion of various activities is given below in Table 8.1. The zero

date will commence after getting EC and consent to establish from SPCB.

Table 8.1: Tentative implementation schedule:

Sl.

No.

Activities Duration

1 Engineering

Concept Design 15 days

Basic Engineering 30 days

Detailed Engineering 90 days

2 Civil Work

Land development 15 days

Construction of plant & auxiliary facilities 150 days

3 Statutory Clearance for establishment

State clearance for establishment 20 days

State EC Clearance 90 days

4 Procurement

Place orders for long lead Equipments 90 days

Place orders for commodity items 30 days

Receipt of equipment 230 days

Installation of equipment & items 180 days

5 Erection & Commission

Inspection before commissioning 80 days

Commissioning & production trial run 40 days

Some works will proceed parallel and some in series. Critical Path Method (CPM) and

Project Evaluation & Review Technique (PERT) will be followed for completion of project

work.In short construction job will be completed within two years of time after getting

EC from MoEF&CC.




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8.2 ESTIMATED PROJECT COST

Project Cost

The estimated project cost is 920crore. Cost of the project includes cost towards land

and site development, buildings, plant and machinery, engineering expenses on

drawings and documents, miscellaneous fixed assets, preliminary and pre-operative

expenses, provision for contingencies and margin money for working capital.

This will be as follows.

Sl. No. Cost Head Estimated Cost, in Crore

1 Land development earth

work & civil structure

90.0

2 Plant Machinery &

Pollution control devices

776.0

3 Consultant Expenses 0.80

4 Contingency 3.20

5 Margin for WC 15.00

6 Misc. Fixed Assets 7.00

7 Prel. Expenses 5.0

8 ESC Activities 23.0

Total 920




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CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 FINANCIAL & SOCIAL BENEFITS

The proposed project is expected to bring socio-economic and environmental benefits

both at local and global level as listed below:

9.2 SOCIAL INFRASTRUCTURE

Social awareness programs will be further improved by the local authority such as

sanitation and hygiene, HIV Prevention Program.

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

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

area.

The proposed project will set up training centre for the male and female youth

group by considering their skills and qualification which will support the people for

self employment.

9.3 EMPLOYMENT POTENTIAL

The project is going to create substantial employment and income. Due to this project

activity, some persons in the project area will be recruited as skilled and semi skilled

workers by the company as per its policy. Therefore, substantial amount of employment

and income is likely to be generated for the local people. So, the project will contribute

in a positive manner towards direct employment in the project area. Some employment

potential benefits are given below:

Long term employment of up to 2000 people in the operation phase of the

proposed project.

Generating additional associated jobs due to establishment of the project.

9.4 BENEFITS TO THE REGION AND THE COUNTRY

M/s Spintech Tubes Pvt Limited shall produce TMT rods and coils, SS rods and plates, DI

pipes that are to be utilized in construction activities. The products are in demand and

production shall contribute to the GDP growth of the country.

Techno Economic Feasibility Report of M/s Spintech Tubes Pvt...

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