jeevaka industries private...

JEEVAKA INDUSTRIES PRIVATE LIMITED (Sponge Iron division)

Nasthipur & Mangapur Villages Hatnoora Mandal

Sangareddy District Telangana

Pre-Feasibility Report

(Expansion of Sponge Iron from 300 TPD to 500 TPD and installation of new Induction Furnace - 2 x 500 TPD, Rolling

mill - 1000 TPD , Ferro Alloys- 9 MVA , Pellet Plant – 600 TPD & Power plant - 20 MW (WHRB – 10 MW & FBC – 10 MW)

Pre-feasibility Report


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TABLE OF CONTENTS

Chapter - 1 4

EXECUTIVE SUMMARY 4

Chapter – 2 6

INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 6

2.1 Identification of project and project proponent 6

2.2 Brief description of nature of the project 6

2.3 Need for the project and its importance to the country and or region. 7

2.4 Demand And Supply Gap 8

2.5 Export Possibility 8

2.6 Domestic/Export Markets 8

2.7 Employment Generation (Direct and Indirect) due to the project. 8

Chapter – 3 10

PROJECT DESCRIPTION 10

3.1 Type of project including interlinked and interdependent projects: 10

3.1.1. TYPE OF PROJECT: 10

3.1.2. INTERLINKED PROJECT: 10

3.2 General Location: 10

3.3 Details of alternate sites considered: 16

3.4 Size or magnitude of operation: 16

3.5 Manufacturing Process 17

3.5.1 Manufacturing Process Sponge Iron 17

3.5.2 Manufacturing Process MS Billets 21

3.5.3 Manufacturing Process TMT bars / Structural steels / Wire rod 22

3.5.4 Ferro alloys 24

3.5.5 Pellet unit 29

3.5.6 Power Generation 35

3.6 Raw material requirement, Transport etc.: 36

3.6.1 RAW MATERIAL REQUIREMENT AND ITS SOURCES (AFTER PROPOSED EXPANSION) 36

3.6.2 MODE OF TRANSPORT FOR RAW MATERIALS AND FINISHED PRODUCTS: 37

3.6.3 MARKET OF FINAL PRODUCTS: 38

3.7 Availability of water its source, Energy / power requirement and source: 38

3.7.1 WATER REQUIREMENT AND ITS SOURCES: 38



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3.7.2 SOURCES OF ENERGY/ POWER AND ITS SOURCES: 39

3.8 Generation and disposal of Wastes [Waste Water and Solid Wastes]: 39

3.8.1 WASTE WATER GENERATION: 39

3.8.2 SOLID WASTE GENERATION AND ITS DISPOSAL 40

Chapter – 4 41

SITE ANALYSIS 41

4.1 Connectivity 41

4.2 Land Form, Land use and Land ownership 41

4.2.1 LAND FORM: 41

4.2.2 LAND USE OF THE PROJECT SITE 41

4.3 Topography 41

4.4 Existing land use pattern: 41

4.4.1 LAND USE PATTERN OF THE PROJECT SITE 41

4.4.2 ENVIRONMENTAL SETTING OF THE PROJECT SITE: 42

4.5 Existing Infrastructure 42

4.6 Soil classification 42

4.7 Climatic data from secondary sources 42

Chapter – 5 43

PLANNING BRIEF 43

5.1 Planning Concept: 43

5.2 Population Projection: 43

5.3 Land use planning: 43

5.4 Amenities/Facilities. 44

Chapter – 6 45

PROPOSED INFRASTRUCTURE 45

6.0 Proposed Infrastructure 45

6.1 Industrial Area (Processing Area) 45

6.2 Residential Area (Non Processing Area) 45

6.3 Green Belt. 45

6.4 Social Infrastructure. 46

6.5 Connectivity: 46

6.6 Drinking Water Management: 46

6.7 Sewerage System. 46



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6.8 Industrial Waste Management. 46

6.9 Solid Waste Management 47

6.10 Power requirement & its source 47

Chapter – 7 47

Rehabilitation and Resettlement Scheme 47

Chapter – 8 48

Project Schedule & Cost Estimates 48

8.1 Likely date of start of construction: 48

8.2 Estimated project cost: 48

Chapter – 9 49

Analysis of proposal 49

9.1 Financial and social benefits: 49

9.2 Socio-Economic Developmental Activities 49



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Chapter - 1

EXECUTIVE SUMMARY

1.1 ABOUT PROJECT PROPONENT & PROPOSED PROJECT

Jeevaka Industries Private Limited (Sponge Iron division) is an existing plant Nasthipur &

Mangapur Villages, Hatnoora Mandal, Sangareddy (earlier Medak) District, Telangana,

obtained Environmental Clearance vide order no. J – 11011 / 145 / 2006 – IA II (I) dated 14th

July, 2008. We have obtained extension of validity of EC order vide no. J – 11011 / 145 / 2006 –

IA II (I) dated 11th January, 2016. Following is plant configuration & production capacity and

Implementation status:

S.No. Name of the Product Production capacities as per EC issued vide order no. J – 11011 / 145 / 2006 – IA II (I) dated 14th July, 2008 (valid

up to July, 2018)

Implementation status

1. Sponge Iron (3x100 TPD)

300 TPD

Obtained CFO for 2 x 100 TPD and another kiln will be commissioned before July, 2018

2. M.S. Billets 400 TPD No construction has

been started yet

3. TMT Bars/Structural Steels 400 TPD No construction has been started yet

4. Captive Power plant WHRB – 6 MW

FBC – 6 MW

No construction has been started yet

By July, 2018 we will be able to implement only 300 TPD Sponge Iron unit.

In view of the above, we are herewith submitting Form I & PFR for obtaining Environmental

clearance for enhancement of Sponge iron unit and new Induction Furnace, Rolling mill, Ferro

Alloys Plant, Pellet Plant and Power plant. The proposed expansion project will be taken up

partly in the existing plant premise and partly in the additional land of 30.58 acres acquired.



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The following will be the capacities after proposed expansion project

S.No. Name of the Product

Existing Proposed expansion

After proposed expansion

1. Sponge Iron 300 TPD (3x100 TPD)

200 TPD (2 x 100 TPD)

500 TPD (5 x 100 TPD)

2. Pellet Plant ----- 600 TPD 600 TPD

3. M.S. Billets --- 1000 TPD

( 2 x 40 T Induction

furnace)

1000 TPD

4. TMT

Bars/Structural

Steels

-- 1000 TPD 1000 TPD

Ferro alloys (9 MVA furnace)

5. Ferro

Manganese

-- 100 TPD 100 TPD

6. Silico

Manganese

-- 70 TPD 70 TPD

7. Ferro Chrome -- 70 TPD 70 TPD

8. Ferro silicon -- 42 TPD 42 TPD

Power generation

9. Captive Power

plant

-- WHRB – 10 MW & FBC – 10 MW

WHRB – 10 MW & FBC – 10 MW

Total cost of the proposed expansion project will be Rs. 292.5 Crores.

Water required for existing project is being met from ground water resources. The water

required for the proposed expansion project will also be met from ground water resources.

Water requirement for the existing and proposed expansion will be 630 KLD. Permission from

Ground water department has already been obtained for drawing of 640 KLD of water.



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Chapter – 2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of project and project proponent

M/s. Jeevaka Industries Private Limited is a registered company established in the year of

1996. The company is operating a 2 x 100 TPD Sponge Iron plant and will commission another

100 TPD Sponge Iron Plant at Sponge Iron Division, Nasthipur & Mangapur Villages, Hathnoora

Mandal, Sangareddy District, Telangana & 400 TPD Induction Furnace & 300 TPD Rolling Mill

by Steel Plant Division at Chegunta Village, Chegunta Mandal, Medak District, Telangana. The

company is in this business for the last twenty years. The following are the Board of directors

of the company.

1. Shri. Anil Agarwal, Managing Director

2. Shri. Aashish Agarwal, Director

3. Shri. Abhishek Agarwal, Director

4. Shri. Sudhir Agarwal, Director

The turnover of the company is presently Rs. 400 Crores approximately. Now it has been

proposed to go for forward integration by producing 1000 TPD of MS Billets, 1000 TPD of TMT

Bars and structural steel , Ferro Alloys – 9 MVA, Pellet Plant – 600 TPD and 20 MW electricity

along with 200 TPD sponge iron( Additional). Expansion will be taken up in the existing plant

premises and in the additional land of 30.58 acres acquired.

2.2 Brief description of nature of the project

Jeevaka Industries Private Limited (JIPL) as a part of expansion of the existing steel plant,

envisage to produce the following product through different routes:

Unit : Description

DRI Kiln : Manufacturing of Sponge Iron using Iron ore, Coal and Dolomite

as raw materials

Pellet Plant Manufacturing of Iron Ore Pellets using Iron Ore Fines / Mill

Scales, Bentonite, Lime Stone, Coal as raw materials

Induction Furnace : Manufacturing of MS Billets using Sponge Iron, Scrap, Ferro

Alloys as raw materials.



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Unit : Description

TMT / Structural

steels

: Manufacturing of TMT bars / Structural steels using MS Billets /

Ingots as raw material

Ferro alloys : Ferro alloys will be manufactured using Manganese / Quartz /

Chrome ore as raw material

Power generation : Power generation through WHRB by utilizing hot waste flue gases

from DRI kilns. Power generation through FBC boiler using coal,

Dolochar & Washery Rejects as fuel.

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

India’s economic growth is contingent upon the growth of the Indian steel industry.

Consumption of steel is taken to be an indicator of economic development. While steel

continues to have a stronghold in traditional sectors such as construction, housing and ground

transportation, special steels are increasingly used in engineering industries such as power

generation, petrochemicals and fertilizers. India occupies a central position on the global steel

map, with the establishment of new state-of-the-art steel mills, acquisition of global scale

capacities by players, continuous modernization and up gradation of older plants, improving

energy efficiency and backward integration into global raw material sources. Steel production

in India has increased by a compounded annual growth rate (CAGR) of 8 percent over the

period 2002-03 to 2006-07. Going forward, growth in India is projected to be higher than the

world average, as the per capita consumption of steel in India, at around 52 kg, is well below

the world average (170 kg) and that of developed countries (400 kg). Indian demand is

projected to rise to 300 million tonnes by 2025. Given the strong demand scenario, most

global steel players are in a massive capacity expansion mode, either through brownfield or

Greenfield route. Steel production capacity in India is expected to touch 170 million tonnes

by 2020. While Greenfield projects are slated to add 30 million tonnes, brownfield expansions

are estimated to add 50 million tonnes to the existing capacity of 90 million tonnes. Steel is

manufactured as a globally tradable product with no major trade barriers across national

boundaries to be seen currently. There is also no inherent resource related constraints which

may significantly affect production of the same or its capacity creation to respond to demand

increases in the global market. Even the government policy restrictions have been negligible

worldwide and even if there are any the same to respond to specific conditions in the market

and have always been temporary. Therefore, the industry in general and at a global level is



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unlikely to throw up substantive competition issues in any national policy framework. Further,

there are no natural monopoly characteristics in steel. Therefore, one may not expect complex

competition issues as those witnessed in industries like telecom, electricity, natural gas, oil,

etc.

2.4 Demand And Supply Gap

Demand for steel is high and as soon as they are processed they will be supplied on PAN India

absis to various type of consumers & users.

2.5 Export Possibility

As 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 4th largest producer of crude steel and the largest producer of

sponge iron or DRI in the world. As the demand is more the export possibility of Sponge Iron

will also be more. As the demand is more the export possibility will also be more.

2.6 Domestic/Export Markets

While the demand for steel will continue to grow in traditional sectors such as infrastructure,

construction, housing automotive, steel tubes and pipes, consumer durables, packaging, and

ground transportation, specialized steel will be increasingly used in hi-tech engineering

industries such as power generation, petrochemicals, fertilizers, etc. The new airports and

railway metro projects will require a large amount of steel. Hence the domestic and export

markets for steel sector will rise.

2.7 Employment Generation (Direct and Indirect) due to the project.

The local areas will be benefited by way of generation of employment opportunities, increased

demand for local products and services. There will be an overall improvement in the income

level of the local people.

The project creates employment to about 600 persons once the whole plant comes to the

operational stage of un-implemented units and for 200 persons during construction stage. Top

priority will be given to locals for Semi-Skilled and Unskilled jobs. With the development of this

Plant there will be lot of scope for more ancillary development, which in turn will benefit the

nation.



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There will be a certain enhancement of educational and medical standards of people in the

study area. There will be generally positive and beneficial impacts by way of economic

improvements, transportation, aesthetic environment and business generation. There will be

an overall upliftment of socio-economic status of people in the area with the implementation

of the project.



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Chapter – 3

PROJECT DESCRIPTION

3.1 Type of project including interlinked and interdependent projects:

3.1.1. Type of Project:



Unit : Description


as raw materials

Pellet Plant : Manufacturing of Iron Pellets using Iron Ore Fines / Mill Scale,

Coal, Bentonite, Lime Stone, Coal

Ferro Alloys Manganese Ore, Chrome Ore, Quartz Ore



TMT / Structural

steels





Power generation : Power generation through WHRB by utilizing hot waste flue gases



3.1.2. Interlinked Project:

No interlinked project is envisaged.

3.2 General Location:

Plant is located at Nasthipur Village, Hathnoora Mandal, Sangareddy District, Telangana.

Total land in possession of management is 85.58 acres (existing 55 acres & additional 30.58

acres)

The proposed expansion project will be taken up partly in the existing plant premises and

partly in the additional land acquired.



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The Sy. No.s of the total land are furnished in Annexure – 1

The coordinates of the Project site area

S.No. Latitude Longitude

1. 17°42'59.17" 78°13'54.29"

2. 17°42'58.90" 78°13'54.84"

3. 17°42'57.92" 78°13'58.61"

4. 17°42'56.66" 78°13'59.87"

5. 17°42'56.99" 78°14'2.11"

6. 17°42'59.01" 78°14'2.49"

7. 17°42'57.53" 78°14'7.35"

8. 17°42'57.37" 78°14'4.73"

9. 17°42'55.73" 78°14'7.68"

10. 17°42'54.04" 78°14'8.67"

11. 17°42'52.72" 78°14'8.34"

12. 17°42'53.43" 78°14'3.15"

13. 17°42'51.14" 78°14'3.80"

14. 17°42'49.06" 78°14'6.26"

15. 17°42'43.98" 78°14'2.82"

16. 17°42'45.02" 78°14'8.39"

17. 17°42'38.95" 78°14'4.40"

18. 17°42'39.77" 78°13'59.54"

19. 17°42'44.75" 78°14'00.74"

20. 17°42'47.70" 78°13'59.32"

21. 17°42'47.59" 78°13'55.17"

22. 17°42'49.99" 78°13'54.07"

23. 17°42'50.98" 78°13'50.36"

24. 17°42'54.25" 78°13'49.81"

25. 17°42'56.11" 78°13'53.20"

The entire project area will fall in the Survey of India topo sheet no. 56 K/2

The index map of the project site is shown in Figure - 1



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Figure – 1 : Google Earth Map showing boundary of the project site



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Plant site

Figure – 2 : General Location map



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Figure – 3 : Topographical

Map



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Figure – 4 : Plant Layout



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3.3 Details of alternate sites considered:

No alternative site has been considered, as present proposal will be taken up partly in

the existing plant premises and partly in the additional land of 30.58 acres acquired

adjacent to the site.

3.4 Size or magnitude of operation:

The plant configuration & production capacity of proposed expansion of steel plant is as

follows

S.No. Name of the Product

Existing Proposed expansion

After proposed expansion

1. Sponge Iron 300 TPD (3x100 TPD)

200 TPD (2 x 100 TPD)

500 TPD (5 x 100 TPD)

2. Pellet Plant --- 600 TPD 600 TPD

3. M.S. Billets --- 1000 TPD

( 2 x 40 TPH

Induction furnace)

1000 TPD

4. TMT

Bars/Structural

Steels

-- 1000 TPD 1000 TPD

Ferro alloys (1 x 9 MVA furnace)

5. Ferro

Manganese

-- 100 TPD 100 TPD

6. Silico

Manganese

-- 70 TPD 70 TPD

7. Ferro Chrome -- 70 TPD 70 TPD

8. Ferro silicon -- 42 TPD 42 TPD

Power generation

9. Captive Power

plant

-- WHRB – 10 MW & FBC – 10 MW

WHRB – 10 MW & FBC – 10 MW



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3.5 Manufacturing Process

3.5.1 Manufacturing Process Sponge Iron

DRI KLIN:

Major plant facilities

The major plant facilities for the sponge iron plant envisaged are as follows:

Day bins

Rotary kiln and cooler

Offgas system

Product processing and product storage.

Day bins

There shall be a day bin building to cater to raw material requirement of the kiln. The

day bin building will comprise of six bins, one for iron ore, two for feed coal, one for

limestone/dolomite and two bins for injection coal. These bins will generally have

storage of about one day's requirement of screened iron ore feed (5-20 mm), feed coal

(6-12 mm, 12 – 25 mm), limestone/dolomite (1-4 mm) and injection coal (3-6 mm. 6-

12mm). Weigh feeders will be provided to draw the required quantity of various

materials in proportion from the bins and the same will be conveyed to the kiln feed end

and discharge end.

Rotary kiln and cooler

The rotary kiln of 3.0 m dia. And 42 m length will be provided for reduction of iron ore

into sponge iron using non-coking coal as reductant. The kiln will be lined with abrasion

resistant refractory castable’s throughout its length with damps at feed end and

discharge end.

The rotary kiln will be supported on four piers. A slope of about 2.5% shall be

maintained. Then main drive of the kiln will be by two DC motors with thyristor control.

The speed of the kiln can be varied depending upon the operating conditions. The speed

of the kiln will be in the range of 0.25-0.75 rpm. The auxiliary drive of the kiln will be by

two AC motors.

The other main components of the kiln will be as given below:

Feed end and discharge end transition housing of welded steel construction with

refractory lining including feed chute.



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Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating system

at feed end and discharge end.

On board equipment like fans, manifolds, ports, slip ring, instrumentation etc.

Cooling fans at feed end and discharge end.

Feed end double pendulum valve & dust valves.

The kiln feed from the charging end will consist of sized iron ore (5-20mm), non-coking

coal (6-25 mm) and limestone/dolomite (1-4mm). Air will be supplied to the kiln through

shell mounted air fans. A part of the required coal (3-6mm, 6-12mm) shall be thrown

from kiln discharge end. The slinger coal will be withdrawn from the respective bins in

suitable proportion and pneumatically injected into the kiln. Necessary rotary feeder,

compressor, piping and valves will be provided.

In the kiln, the iron ore will be dried and heated to the reduction temperature of 1000 -

10500C. The iron oxide of the ore will be reduced to metallic iron by carbon monoxide

generated in the kiln from coal. The heat required for the reduction process will also be

supplied by the combustion of coal.

Thermocouples will be installed along the length of the kiln shell for measurement of

thermal profile of the kiln. The temperature will be controlled by regulating the amount

of combustion air admitted into the kiln through no. of ports with the help of fans

mounted on the kiln shell and by controlled coal slinging. The DC main drives provided

to rotate the kiln will have variable speed. Auxiliary drive is provided for slow rotation.

The reduced material from the kiln will be cooled indirectly in a rotary cooler by an

external water spray. The kiln will be provided with one rotary cooler. The rotary cooler

will be of 2.3 m dia. And 22 m length and will be supported on two piers with a slope of

about 2.5 %. The main drive and the auxiliary drive of the cooler will be by one no.

separate AC motor. The speed of the drive will be about 1 rpm. The cooler will be

provided with one plain riding ring and one thrust riding ring and will be provided with

two sets of support rollers at two piers and one set of hydraulic thrust rollers with

antifriction bearings. About 1 m end portion of the cooler acts as a screening section,

which separates all the accretions larger than 50 mm from the reduced material. These

lumps will be discharged separately via. Lump gate. Rest of the material will be

discharged on to the conveyor via double pendulum valve.

The other main components of the cooler will be the following.



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Feed end housing (part of reactor to cooler transition) of welded steel

construction with refractory lining.

Cooler discharge end housing of welded steel construction.

Pneumatic cylinder actuated labyrinth air seal complete with auto lubricating

system at feed end and discharge end.

The cooler will be lined with refractory castable for about 4.0m length from the feed end.

Bypass arrangement will be provided at the discharge end of the cooler for emergency

discharge of materials. The cooled product will be conveyed to the product processing

building by a system of belt conveyors.

The cooling water will be collected in the trough below the cooler and sent to the cooling

tower for cooling. The cooled water will be re-circulated. Closed circuit cooling system

will be followed in the plant.

The rotating parts of the kiln and cooler will be sealed suitably against the stationary

parts at the connecting points to avoid leakage of dust laden gases.

Off gas system

The kiln shall have its separate off gas circuit. Hot waste gases leave the rotary kiln at

about 950 – 1000oC through kiln feed end housing, dust settling chamber and come to an

After Burning Chamber (ABC), where combustibles are burnt completely by supplying

excess air. The gases at about 900 - 950oC will then be led to a air cooled heat exchanger

and then through an Electro-static precipitator (ESP) before letting them out into the

atmosphere through ID fan and a combined stack of 70 m height ( with twin fuels).

Product processing and storage

There shall be one product processing unit for handling the cooler discharge. The

product containing sponge iron, char and spent lime, from the cooler discharge end will

be discharged to a set of conveyors and sent to the product processing building. The kiln-

cooler system shall have a separate surge bin of approx. 200 T capacity. Product from

surge bin can be withdrawn through vibrating feeder and fed to the product processing

building by conveyor. In the product processing building, the product will first be

screened in a double deck screen having 3mm and 20mm screens. +20mm material shall

be dumped as rejects. The screened product i.e., +3-20 mm and -3 mm fraction shall

separately be sent to the product storage separation. Sponge iron lump (3-20 mm) shall

be sent to the product storage building for storing in two no. of bunkers where three



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days storage has been proposed. The sponge iron fines (-3 mm) will be stored in the fines

bunker in the product processing building itself where one day storage capacity will be

provided. The sponge iron lump & sponge iron fines will be further conveyed from the

respective bunkers by truck. The char/non-magnetics shall be stored in separate bins.

Char will be utilized for power generation in the FBC Boiler.



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3.5.2 Manufacturing Process MS Billets

Steel Melt Shop (SMS) is crated to melt the Sponge Iron along with melting scrap and

fluxes to make pure liquid steel and than to mould it in required size billets. The shop

consists of following equipment and subassemblies:

Induction Furnaces: Induction Furnace is a device to melt the charge material using

electrical power. It consists of Crucible lined with water cooled induction coils, Electrical

system to give controlled power to induction coil, Hydraulic tilting system, Heat exchanger

to cool the circulating water, water softener for generating soft water, furnace

transformer, Power Factor improvement system and surge suppressor.

Ladles: Ladles are pots with refractory lining inside to withstand 1600 degC temperature. It

has side arms so that can be lifted with the help of crane. Ladles are used to stores the

liquid steel from Induction Furnace and take it for further processing. Ladles are with

bottom nozzle and pneumatically operated gate for discharge of liquid.

Ladle Refining Furnace (LRF): Ladle furnace is a mini electric arc furnace. It has three

carbon electrodes, roof to cover the ladle, and furnace transformer of suitable capacity.

The operation of electrodes, roof etc are controlled by hydraulic system. Ladle furnace is

used either to keep the liquid steel for sequence casting or for further refining of the

liquid steel to make better quality steel.

Cranes: Electric Over-head(EOT) cranes of various capacities are used to carry the

ladles/materials at different places. Cranes are used in Melting hall to charge melting

scrap, remove the ladles to the LRF, further to place it over the Tundish of the Continuous

Caster, to remove billets from the cooling bed and store at designated places, and also for

other petty use. Accordingly the sizes, capacity and numbers of cranes are decided.

Continuous Casting Machine (CCM) : CCM is used to continuously cast the liquid steel in

required cross section and in length. It consists of Tundish, Mould, Bow with Withdrawal

mechanism, straightening mechanism and cooling bed, hydraulic system for withdrawal

mechanism, water pumps and cooling towers for water spray on the withdrawn section as

well as on the cooling bed. Dummy bar is provided to start the casting. Tundish is a

rectangular vessel, lined with refractory and having discharge nozzle with pneumatically

operated gate. A stand is erected over it where the ladle is stationed for discharging the



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liquid in it. Mould is of copper with water cooled jacked. Its cross-section in the bottom is

of the size of which billet is to be drawn. Initially the dummy for of the same size is kept

inserted. When the liquid steel is poured in the mould the dummy bar is drawn slowly, so

that the liquid steel in partially frozen state comes out of the mould. Water spray nozzles

are installed to spray water over the just drawn billet to cool it further and to harden the

skin of the drawn billet.

There will be 2 x 40 T Induction Furnaces. MS Billets will be produced in Continuous

Casting Machine.

3.5.3 Manufacturing Process TMT bars / Structural steels / Wire rod

Process description

Reheating furnace

A pusher type furnace has been envisaged for the heating of billets. The furnace will be

end charging and side discharging. It will have single row as well as double row charging

facility. The following size of billet will be fed to Billet Re-Heating Furnace.

100 mm x 100mm and 150 mm - 200 mm

The furnace will be heated with FO / Pulverized coal. The furnace combustion system

will comprise of air blowers, FO storage, supply and preheating system and other

associated facilities. The product of combustion will leave the furnace at charging end

and exhausted through underground flue tunnel and passed through a metallic tubular

recuperator before finally let off to a chimney of sufficient height after passing through

Bag filter. A set of instrument will be used for smooth operation of the furnace.

Bar and round mill

A cross country type mill has been envisaged for the plant. The stands have been

grouped into roughing, intermediate and finishing groups. Roughing group will have 4

(four) stands, intermediate group will have 8 (eight) stands and finishing mill will have 8

(eight) stands. Roughing group of stands will be driven by one motor. 4 nos. of

intermediate stands will be driven by two motors and balance 4 nos. will be driven by a

separate motor. Each stand of finishing group will be driven by single motor. Necessary

guides and troughs will be provided at entry and exit of mill stands.



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One wire rod out let has been provided in the mill. The wire rod line will have 4 stand

block driven by a single motor through gear box. Coil forming and handling of coil is

provided.

Automated tilting, drop type tilter and feeding arrangement will be provided in roughing

group of stands. Repeaters have been provided in roughing / intermediate stands as

necessary.

Design provision has been made for introduction of slit rolling facility in future to roll 8

mm, 10 mm & 12 mm rebars in two strands. The rebars discharged from the mill will pass

through a water cooling system comprising cooling pipes with high pressure water

nozzles for rapid water quenching. At the cooling pipes the bar skin temperature will be

reduced to about 600oC. The core of the bar still remains hot. This entrapped heat

tempers the bar. This thermo-mechanical treatment of the bars increases tensile

strength without adversely effecting weldability and elongation properties. This process

eliminates requirement of cold twisting of bars for production of rebars.

A dividing shear, to cut the products to cooling bed length, will be located immediately

after the water cooling system. This shear will divide all products to cooling bed lengths.

Rake type cooling bed has been envisaged to receive the rolled product. Cooling bed will

be provided with incoming and outgoing roller tables. One cold shear has been provided

to cut the bars coming out of cooling bed into commercial length of 6 to 12 m. The bar

products will be formed into bundles and will be strapped by strapping machine

manually.

The finished products will be removed by overhead EOT crane and stored in the storage

area or dispatched through road vehicles. Rolling mill of 1000 TPD capacity is proposed in

the expansion project.



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3.5.4 Ferro alloys

Ferroalloys are alloys of iron with chromium, manganese, silicon, or other

elements. Ferro Alloys will be produced by smelting the ore which contains

one or more of the said elements so as to impart its properties to the alloy.

Ferroalloys are essential additives in steel for imparting desired properties of steel

to suit varied applications.

It can be said that no steel can be made without use of one or more of the several

Ferro Alloys. Within each of these ferroalloy products there are variants whose

classification is based on the extent of carbon present in that alloy. The variants

observed under each of these product categories are explained in this section. Generally

Ferro Alloys are used as de oxidizers and alloy additives in the steel manufacturing.

THE PROCESS:

Ferro Alloys will be smelted at about 1350 – 1500 deg.C Temperature. This will be

achieved by a conventional, Open Submerged Electric Arc Furnace. The three carbon

Electrodes, partially submerged in the charge, are supported on hydraulic cylinders for

upward and down ward movements to maintain the desired electrical conditions.

The body of the furnace is cylindrical in shape, and is lined with firebricks, silicon carbide

bricks and carbon tamping paste. Three tap – holes are provided at 120 degree apart for

drawing out both the molten alloy and Slag. During the repair works one of the tap –

holes the other will function as stand by.

The weighed raw materials will be thoroughly mixed in the proper proportion before

charging into the furnace, through Skip, Telfer hoist and charging chutes. The charge will

be pushed near to electrodes on Furnace top by a Charging Stoker

As the charge enters the smelting zone, the alloy formed by chemical reactions of the

oxides and the reductants, will be heavy, and gradually settles at the bottom. At regular

intervals the furnace will be tapped. The tap hole will be opened by Oxygen lacing pipe

and after tapping is completed, it will be closed by clay plugs.

The liquid alloy and Slag will be collected in a Ladle and Slag will be over flowed to sand

beds. The metal being retained in the ladle having a Nozzle at bottom which allows metal

flows on to C.I. Pans. After solidification the cakes will be broken manually to required

lump size.



26

SILICO MANGANESE & FERRO MANGANESE PROCESS: Manganese ore is in the form of MnO, SiO2, FeO, Al2O3, MgO and other Oxides. MnO is

reduced to Mn and FeO is reduced to Fe taking Carbon from Coke / Coal and the product

is produced as Si Mn /Fe Mn. The other oxides are simultaneously removed as Slag along

with metal. The Slag and Metal are separated by virtue of its self-differential gravities

after collecting in the ladle. The ladle will have a nozzle in the bottom portion through

which the metal flows in to C.I. Pans.

Chemical Composition of Si Mn

Sl. No. Constituent Percentage

1. Mn 60 – 65%

2. Si + 15%

3. C 2% / 0.1% / 0.5%

4. S & P 0.03% Max

Chemical Composition of Fe Mn


1 Mn 70 – 85%

2 Si + 1.5%

3 C 7 - 8% / 1.5% / 0.5%

4 S 0.05%

5 P 0.04%

FERRO SILICON PROCESS:

Ferro Silicon is a Slag less process. Quartz is the main raw material which contains 99% of

SiO2. Charcoal and a small percentage of Coal is used as reductants. Mill Scale / Iron

Ore is added to obtain Ferro Silicon. Fe O is reduced to Fe and Si O2 is reduced to Si

Combining with Carbon and produced as Fe Si.


1 Si 70 – 75%

2 C 7 - 8%

3 S 0.05%

4 P 0.4%



27

FERRO CHROME It is produced by smelting Chrome Ore, reductant (coke) with fluxes in a submerged

electric arc furnace. In this process, Chromium Oxide & Iron Oxides are reduced to

Chromium & Iron and simultaneously combine with carbon to form alloy while other

constituents form slag. The molten alloy & slag are tapped out from time to time through

tap hole and collected in pans or ladles. Alloy is of higher specific gravity material than

slag. Hence, it segregates and remains at the bottom of the pan or the ladle where the

slag rises to top and over flows from it to other pan/ladle/ sand beds. If it is collected in

ladle, again it is to be casted to form cakes. When it is sufficiently cooled, cakes

are broken to required sizes and manually cleaned the slag if it is in surface of the

alloy pieces. Slag is a byproduct and reject material having very limited utility.

Chemical Composition of Fe Cr


1 Cr 60%

2 C 8%

3 Si 3%

4 S 0.04%

5 P 0.04%



28



29

FERRO CHROME RECOVERY PLANT

Ferro chrome recovery process involves the following steps

I. Crushing & screening: In this slag is crushed to smaller size particles as close as

possible

II. Coarse jigging: In this particles having coarse fraction (approximately 32 to -3mm)

is separated through two stage air pulsated jig for recovery of metal.

III. Fine jigging: In this particles of fine fraction (-3mm) is separated through

diaphragm pulsed (through the bed’ jigs for recovery of metal.)

IV. The recovered metal will be reused in the process.



30

3.5.5 Pellet unit

The iron ore pelletization unit comprises of following sections:

1. Drying & Prepn. of Iron Ore Fines

2. Grinding

3. Mixing and Blending

4. Pelletization

5. Screening

6. Travel Grate Furnace

7. Rotary Kiln

8. Cooler

9. Stacking

10. Recovery of Dust and Spillage

a. Drying & Preparation of Iron ore Fines:

Generally Iron Ore Fines, Lime Stone and Dolomite fines available, contain more than

6-7% moisture and require drying before grinding. The drying is carried out in Rotary

Drum Dryer. The moisture content in the dry material is controlled. The low grade Iron

Ore Fines is feed in a screen for separation. Oversize / under size moves to the

primary grinding circuit.

b. Grinding

Iron Ore Fines, Dolomite and Lime Stone are mixed in required proportion and fed into

a Ball Mill. The fineness of the product is controlled as may be necessary for particular

ore and Pellet quality.

c. Mixing and Blending

Iron Ore powder blended with Bentonite and other binding materials in desired

proportion. Small quantity of water is added during blending operation. This raw mix

is ready for Pellet making and store in feed hopper.

d. Pelletization

Controlled quantity of raw mix is fed on disc Pelletizer. Some amount of water is

sprinkled for producing Pellets. These Pellets are passed through oversize and

undersize screens. Sized Pellets are then sent to sintering section.



31

e. Screening

Pellets produce in Pelletization sections are passed through oversize and undersize

screens. Rejects Pellets are sent back to raw mix silos sized Pellets are fed in to

Indurations Furnace.

f. Travel Grate Furnace

A Travel Grate Furnace is used for indurations of Pellets. This is divided into 3 sections

(Drying–Preheating–Heating). Hot Pellets at around 950ºC to 1000ºC from this Travel

Grate are dropped into the Kiln for further strengthening.

g. Rotary Kiln

Rotary Kiln receives Pellets from the travel grate furnace where Pellets have to

withstand at high temperature approx. 1050ºC – 1200ºC. Here the Pellets gain more

hardness due to high temperature. Furnace Oil / Producer gas is charged as a fuel

inside the Kiln. After the Kiln the Pellets are passed to the Grate Cooler.

h. Cooler

Grate Cooler receives hot Pellet with temperature up to 1200ºC coming from Rotary

Kiln. Cooler has its own blowers to blast the air from bottom. The hot air from the first

zone is used as a combustion air in kiln. The hot blast of the second zone is used in the

pre-heating zone-1 of travel grate and the air from the 3rd zone is discharged to the

atmosphere through chimney as its dust concentration is well within the permissible

limits of pollution norms. Volume of cooling air in all the three zones is regulated

automatically through the temperature control loops as per the requirement. Cold

Pellets at about 100ºC are discharged on conveyors and they are quenched by the

cold water for further cooling and then conveyed to the stock pile/ loading hoppers.

i. Stacking

The screened Pellets of required size duly cooled at air cooler and subsequently

natural cooling are transported to Bunkers

j. Recovery of Dust and Spillage

Spillage from drying zone and preheating zone of traveling grate, dust from the wind

box of traveling grate and dust collected through de-duster of technological process



32

shall meet and will be sent to dust bin via belt conveyor, after they are ground

together with iron ore concentrate at grinding mill. Spillage (dry Pellets) produced at

the discharge end of traveling grate will be fed into the kiln from the feed chute of the

kiln feed end by bucket elevation. Almost all the dust and spillage are re-circulated

and recovered.

QUALITY OF PELLETS

Acidic and Basic Pellets: The pellets can be either acidic or basic in chemistry, depending

upon the composition of slag additive. Acid pellets have been used most extensively.

Although basic pellets are known to have advantages over acid pellets in terms of better

reducibility, softening and melting properties, their development has been slower. One

reason for such slow development is that the limestone and dolomite addition employed

requires so much heat for its calcination that the production capacity of the pelletizing

plant is reduced, compared with acidic grade pellets.

Typical analysis of both acidic and basic grade pellets is given in table below:

ANALYSIS OF VARIOUS QUALITIES OF PELLETS

Type Cao/SiO2 Fe, % SiO2, % MgO, %

Compression Strength, Kg/Pellet

Acidic Pellets < 0.15 64-67 2-4.5 <0.2 250-300

Basic Pellets ~0.8-1.0 62-64 2-4.5 1.3 200-250

Proposed Quality of Pellets Blast furnace charge can typically consist of about 20% pellets, 70% sinter and 10% lump

iron ore. Normally, in Indian Blast Furnaces, Pellets with CaO:SiO2 ratio in the range of

0.15 to 0.8 are being used. The targeted analysis of BF grade and DRI Grade pellets

proposed to be produced are given in table below:

QUALITY/ANALYSIS OF PELLET

Sl.No Property BF Grade DRI Grade

A. Chemical Quality

Fe 65% min 66.5% min

SiO2 + Al2O3 5% max 3.00% max

Al2O3 0.60% max 0.60% max

Na2O 0.05% max 0.05% max

K2O 0.05% max 0.05% max

TiO2 0.10% max 0.10% max

Mn 0.10% max 0.10% max



33

Sl.No Property BF Grade DRI Grade

P 0.04% max 0.04% max

S 0.02% max 0.02% max

V 0.05% max

Basicity (CaO+MgO/SiO2 + Al2O3)

0.40 0.50

B. Physical Quality

Size Distribution

+16mm 5% max 5% max

+16mm, +9mm 85% min 85% min

-9mm, +6.35mm 7% max 7% max

-5mm 5% max 5% max

Tumbler Index(+6.35mm) 94% min 94% min

Abrasion Index (+0.6mm) 5 % max 5 % max

C. Metallurgical Properties

Swelling Index 20% max 20% max

Compression Strength 250 Kg/Pellet min 250 Kg/Pellet min

Porosity 25% min 25% min

Reducibility 60% min 60% min

Metallization - 92% min

Fragmentation - 3.5% max

Attainment of these properties will be ensured by providing suitable raw materials/

beneficiated iron ore and also by adopting appropriate process parameters established

through test work before implementation of the project.



34



35

3.5.6 Power Generation

Its is proposed to install 10 MW WHRB & 10 MW AFBC based power plant in the

proposed expansion project to meet the power requirement for various processes of

integrated plant including auxillaries of power plant.

WHRB Power Plant

Production of sponge iron in DRI kiln generates huge quantities of hot flue gases carrying

considerable sensible heat. The energy content of these gases can effectively be used to

generate electric power as well as steam for meeting various process requirements. Thus

a WHRB (Waste Heat Recovery Boiler) power plant would be an ideally suited

proposition to effectively make use of this waste gas. This WHRB Power plant would not

only make the plant independent of external source of electric power to some extent but

would also result in energy conservation and environment protection.

Steam Turbo-generators (STGs) envisaged for the Power plant will be single cylinder,

multistage, extraction – cum – condensing type complete with condenser, air evacuation

system, 2 x 100% condensate extraction pumps, electronic governing system, lubricating

oil system, regenerative feed heating system etc. The turbine will be fed with steam

generated from HRSG in DR kiln. The STGs will be located in the machine hall of the

power plant.

5 x 10 TPH Boilers will be installed for 5 x 100 TPD DRI Kilns to generate 10 MW Power.

AFBC Power Plant

The unit will have One AFBC boiler (1 x 50 TPH Capacity) to generate 1 x 10 MW Power.

The boiler will be designed for continuous operation at Turbine Maximum Continuous

Rating (TMCR). A margin of 10% over TMCR will be taken into account to arrive at Boiler

rated capacity. The boiler will be natural circulation, circulating fluidized bed combustion,

two pass, non reheat, single drum, balanced draft, semi-outdoor type. The boiler will

have continuous evaporation rating of approx. 50 tonnes/hr. (BMCR will not be less than

110% of TMCR) with steam parameters at super heater outlet as 98 Kg/cm2 and 5400C (±

50oC). The feed water temperature at MCR at inlet to economizer is expected to be

around 2300C. Steam parameter are to be fine tuned at Boiler outlet based on actual

plant layout and piping arrangement. The boiler will be complete with ash /solid

separator, economizer, air heater, ducting, FD fans, ID fans and PA fans.

Air cooled condensers envisaged for Power plant to conserve water.



36

3.6 Raw material requirement, Transport etc.:

3.6.1 Raw Material Requirement and its sources (after proposed expansion)

Raw Material Quantity (TPD) Sources Mode of Transport

For DRI Kilns (Sponge Iron) – 500 TPD

Iron ore 800 Bellary

By rail & road (through covered trucks)

Coal Indian 650 Singareni colleries


Imported 500 Indonesia / South Africa / Australia

Through sea route, rail route & by road

Limestone 20 Local area

By road (through covered trucks)

For Pellet Plant – 600 TPD

Iron Ore Fines 600 In plant generation /

NMDC Limited

Through covered trucks by Road

Imported Coal / Indian coal 20 Indonesia / South Africa / Australia / Singareni colleries


Bentonite 6.5 Gujarat


Lime Stone 8 Kadapa / Kurnool


Furnace oil 8 KL Local market Through road

For Induction Furnace (MS Billets) – 1000 TPD

Sponge Iron 900 In plant generation/Local

Market

By Conveyor

Scrap 200 Local area By road (through covered trucks)

Ferro Alloys 10 In plant generation/Local

area


For Rolling Mill (TMT bars & Structural Steel) – 1000 TPD

M.S. Ingots / Steel billets 1,066 In plant generation

through conveyors

Furnace oil 35 HPCL/IOCL depots Tankers

or

Pulverized coal 100 Indian Coal / Imported


Ferro alloys

Manganese ore 366 Imported / indigenous from




37

Karnataka / Orissa / Madhya Pradesh / Andhra Pradesh

Quartz 130 Telangana By road (through covered trucks)

Chrome ore 161 Imported / indigenous from

Karnataka / Orissa / Madhya Pradesh / Andhra Pradesh


Coke 101 Imported / Indigenous /

Singareni Colleries /


Coal 133 Imported / Indigenous /

Singareni Colleries /


Dolomite 68 Andhra pradesh By road (through covered trucks)

EC paste 8 Andhra pradesh By road (through covered trucks)

Ferro manganese slag 28 In plant generation

through covered conveyors

Magnesite 4.2 Andhra Pradesh By road (through covered trucks)

Mill scale 17 In plant Generation


For FBC Boiler [Power Generation 10 MW]

Dolochar 150 In plant generation

From Existing plant


Coal Indian 110 Singareni colleries


Imported 78 Indonesia / South Africa /

Australia

Through sea route / rail route / by road

3.6.2 Mode of Transport for Raw materials and finished products:

The aforesaid raw materials are transported through rail up to the nearest available rail

head and thereafter the same will be transported to the site through tarpaulin covered

trucks.



38

3.6.3 Market of Final Products:

It is proposed to install steel plant with special rolled products facility. As the steel/

power sector had huge demand and supply gap. Hence marketing of the product has no

problem.

3.7 Availability of water its source, Energy / power requirement and source: 3.7.1 Water Requirement and its sources:

Water required for the existing project is 27 KLD and same is being sourced through

Ground water resources

Water required for the expansion project will be 603 KLD and same will be sourced

through Ground water resources

Air cooled condensers will be provided for power plant to reduce the water

requirement

Water permission from State Ground Water Board has already been obtained for 640

KLD

Following is the breakup of water requirement:

S.No. Unit

Quantity in KLD

Existing Plant

Proposed Expansion

Total after Expansion

1. DRI Kilns (Sponge Iron) 15 10 25

2. Induction Furnace (MS Ingot/Billet)

-- 80 80

3. Rolling Mill Hot Rolled TMT / Structural / Cold Rolled Bars/Wire Rod)

-- 80 80

4. Ferro Alloy Plant FeSi / FeMn / SiMn / FeCr

-- 30 30

5. Pellet plant -- 180 180

6. Power Plant -- 215 215

7. Domestic 2 18 20

17 613 630



39

3.7.2 Sources of Energy/ Power and its sources:

Power required for the existing plant is being met from TSSPDCL. Power required for the

proposed expansion project will be met partly from proposed 20 MW power plant and

remaining from TSSPDCL.

The following will be the power consumption break-up for each unit

S.No. Plant Power Requirement

Existing Expansion After

Expansion

1. DRI 0.7 1.05 1.75

2. SMS 0 36 36

3. Rolling Mill 0 10 10

4. Ferro Alloys 0 9 9

5. Pellet plant 0 2.5 2.5

6. Power Plant – WHRB 0 2 2

7. Power plant – AFBC 0 2 2

Total 0.7 62.55 63.25

3.8 Generation and disposal of Wastes [Waste Water and Solid Wastes]:

3.8.1 Waste Water Generation:

There will be no effluent discharge in the DRI, SMS unit, Rolling mill & Pellet unit as

closed circuit cooling system will be adopted.

Effluent from power plant such as boiler blowdown, DM Plant regeneration. Initially the

acidic and alkaline effluent streams coming from cation and anion units of DM plant will

be neutralized in a neutralization tank. Service water will then pass through an Oil

Separator to remove the oil content in the effluent. The pH of Boiler blowdown will be

between 9.5 and 10.5. Hence this effluent stream shall be neutralized in a neutralization

tank before mixing with other effluent streams. All these effluent streams will be mixed

in a Central Monitoring Basin along with cooling tower blowdown. Treated effluent will

be used for ash conditioning, dust suppression and for greenbelt development.

The sanitary wastewater will be treated in septic tank followed by subsurface dispersion

trench. Hence there will not be any chance of contamination of water bodies due to

proposed project.



40

3.8.2 Solid Waste Generation and its disposal

The following will be the solid waste generation and disposal from the existing and

proposed expansion project

S.No Waste Quantity (TPD) Method of disposal

Existing Proposed Total

1. Ash from DRI 90 60 150 Is being given to Brick manufacturers. The same practice will be continued after expansion also.

2. Dolochar 90 60 150 Is being given to brick manufacturers. After proposed expansion it will be used as fuel in AFBC based power plant

3. Kiln Accretion Slag

2.7 1.8 4.5 Is being utilized in road construction and same practice will be continued after the proposed expansion also.

4. Wet Scraper Sludge

13.5 9 22.5 Is being given to brick manufacturer and same practice will be continued after the proposed expansion also.

5. SMS Slag -- 90 90 Slag from SMS will be crushed and iron will be recovered & remaining non –magnetic material being inert nature, will be used as sub base material in road construction / used for brick manufacturing / civil construction works like PCC and wall construction

6. Bag filter dust from SMS

-- 6.5 6.5 Will be being given brick manufacturers

7. Mill scales from Rolling Mill

-- 26 26 Will be used as raw material in pellet plant / SMS unit

8. Slag from SiMn

-- 84 84 Will be utilized in road construction / given to road contractor for road construction

9. Slag from FeMn

-- 80 80 Will be used in manufacture of Silico manganese as it contains high MnO2

10. Slag from FeCr -- 84 84 Will be further processed in Zigging plant for Chrome recovery and the non-chrome contents will be sent for land filling.

11. Ash from Power Plant

-- 155 155 Will be given to Brick manufacturers

12. Iron Ore Fines 15 10 25 Will be used in Pellet Manufacturing



41

Chapter – 4 SITE ANALYSIS

4.1 Connectivity

The Project site is well connected with Rail and Road connectivity. The nearest railway

station is Patancheru RS. The following table gives brief regarding connectivity of the

plant site:

Component Description

Road : SH # 17 (Sangareddy – Narsapur road) adjacent to the site

Rail : Patancheru RS (21.0 Kms)

Air port : Rajiv Gandhi International airport (55 Kms.)

4.2 Land Form, Land use and Land ownership

4.2.1 Land Form:

Present land is industrial land.

4.2.2 Land Use of the Project Site

Present land use is industrial land as existing plant is already under operation.

4.3 Topography

Topography of land is more or less flat terrain without much undulation.

4.4 Existing land use pattern:

4.4.1 Land use pattern of the Project site

Total project area is 85.58 acres (existing – 55 acres & additional – 30.58 acres).



42

4.4.2 Environmental Setting of the Project Site:

Below mentioned table gives brief regarding environmental setting of the project site:

S.No Particulars Distance from the site

1. National Park = Nil

2. Wild life sanctuaries = Nil

3. Reserve Forest = Narsapur RF – 3 Kms

4. Protected Forest = Nil

5. Eco Sensitive Areas = Nil

6. Water bodies = Small ponds exists within 10 Km radius

7. Costal Regulation Zone [CRZ] = Nil

8. Nearest Village = Avancha -0.50 kms.

9. Industrial Area = Nil

4.5 Existing Infrastructure

All required infrastructure is prevailing in the site.

4.6 Soil classification

The soils in the area are generally of clayey and lateritic. 4.7 Climatic data from secondary sources

Sangareddy district climate is classified as tropical. The summers here have a good deal

of rainfall, while the winters have very little. The climate here is classified as Aw by the

Köppen-Geiger system. The average temperature in Sangareddy is 26.3 °C. The average

annual rainfall is 861 mm. Precipitation is the lowest in January, with an average of 1

mm. Most of the precipitation here falls in July, averaging 228 mm.

At an average temperature of 32.2 °C, May is the hottest month of the year. December is

the coldest month, with temperatures averaging 21.9 °C. Between the driest and wettest

months, the difference in precipitation is 227 mm. Throughout the year, temperatures

vary by 10.3 °C.



43

Chapter – 5 PLANNING BRIEF

5.1 Planning Concept:



Unit : Description


as raw materials

Pellet Plant Manufacturing of Iron Ore pellets from Iron Ore fines / Mill

scales, Bentonite, Lime Stone, Coal



TMT / Structural

steels





Power generation : Power geenration through WHRB by utilizing hot waste flue gases



5.2 Population Projection:

There are no major human settlements in the vicinity of the project site. The manpower

requirement will be sourced from the local areas to the extent possible; hence not much

of settlement of outside people in the area. However population concentration may

increase around the project site due to increase in ancillary activities.

5.3 Land use planning:

Plant is located at Nasthipur Village, Hathnoora Mandal, Sangareddy District,

Telangana.

Total land in possession of management is 85.58 acres (existing 55 acres & additional

30.58 acres)



44

The proposed expansion project will be taken up partly in the existing plant premises

and partly in the additional land acquired.

The following is the land use statement

S.No. Item Area in acres

1. Built-up area 30.00

2. Storage area (raw material & solid waste) 6.00

3. Greenbelt area 30.00

4. Internal roads 7.50

5. Parking area 3.00

6. Open area 9.08

Total 85.58

5.4 Amenities/Facilities.

Facilities like canteen, rest room and indoor games facilities will be provided in the

proposed plant as basic facilities to workers. No other additional facilities are proposed.



45

Chapter – 6

PROPOSED INFRASTRUCTURE

6.0 Proposed Infrastructure

Total 85.58 acres of land is in possession of management (existing – 55 acres, additional

– 30.58 acres). Present use of land is Industrial land. The proposed expansion will be

carried out partly in the existing plant premises and partly in the additional land

premises.

6.1 Industrial Area (Processing Area)

The main plant area comprises of Kiln sheds, Furnace sheds, Rolling mill area, raw

material storage and product storage etc.

6.2 Residential Area (Non Processing Area)

No colonization is proposed; however facilities like canteen, rest room and indoor games

facilities have been provided in the existing plant premises.

6.3 Green Belt.

About 1/3rd of total land availability will be developed with greenbelt i.e 30 acres of land

will be allocated (including expansion).

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

10 m wide greenbelt is being maintained all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast

growing, wind firm, deep rooted. A three tier plantation is proposed comprising

of an outer most belt of taller trees which will act as barrier, middle core acting as

air cleaner and the innermost core which may be termed as absorptive layer

consisting of trees which are known to be particularly tolerant to pollutants.



46

6.4 Social Infrastructure.

Social infrastructure will be developed as per need based in the Villages of the vicinity of

the project.

6.5 Connectivity:

The proposed site is well connected with Rail and Road connectivity. The nearest railway

station is Patancheru RS. The following table gives brief regarding connectivity of the

proposed site:

Component Description

Road : SH # 17 (Sangareddy – Narsapur road) adjacent to the site

Rail : Patancheru RS – 21 Kms

Air port : Rajiv Gandhi International airport (55 Kms.)

6.6 Drinking Water Management:

Drinking water supply will be maintained at the proposed project site.

6.7 Sewerage System.

Domestic effluent collected through toilet blocks will be collected through well designed

sewer network and send to Septic tanks followed by sub surface dispersion trenchs.

6.8 Industrial Waste Management.

There will be no effluent discharge in the DRI, SMS, Pellet and Rolling mill units as closed

circuit cooling system will be adopted.

Effluent from power plant such as boiler blowdown, DM Plant regeneration. Initially the

acidic and alkaline effluent streams coming from cation and anion units of DM plant will

be neutralized in a neutralization tank. Service water will then pass through an Oil

Separator to remove the oil content in the effluent. The pH of Boiler blowdown will be

between 9.5 and 10.5. Hence this effluent stream shall be neutralized in a neutralization

tank before mixing with other effluent streams. All these effluent streams will be mixed

in a Central Monitoring Basin along with cooling tower blowdown. Treated effluent will

be used for ash conditioning, dust suppression and for greenbelt development.

The sanitary wastewater will be treated in septic tank followed by sub surface dispersion

trench. Hence there will not be any chance of contamination of water bodies due to

proposed project.



47

6.9 Solid Waste Management

The solid waste from sponge iron will be Dolochar, accretion slag, bagfilter dust, wet

scraper sludge. Dolochar will be used in the FBC power plant and others will be given to

brick manufacturers/ used in road construction

Slag from Induction furnace and Ferro alloys will be utilized in the road construction /

civil works / cement brick manufacturing.

6.10 Power requirement & its source

Power required for proposed expansion project will be sourced from proposed Captive

Power plant and TSSPDCL.

Chapter – 7

Rehabilitation and Resettlement Scheme

No rehabilitation and resettlement is required as there are no habitations in the in the

Project site.



48

Chapter – 8

Project Schedule & Cost Estimates 8.1 Likely date of start of construction:

Construction activity pertaining to unimplemented units will be started within 24 months

from the date of Environment Clearance.

8.2 Estimated project cost:

The estimated project cost for the proposed is about Rs. 292.5 crores. The following is

the break-up

S.No. Unit / Details Estimated Cost

(Rs. In Crores)

1. DRI Kilns [2 x 100 TPD] 24.00

2. SMS [2 x 40 T] 60.00

3. Rolling Mill [1000 TPD] 50.00

4. Ferro Alloys [1 x 9 MVA] 20.00

5. Pellet plant [600 TPD] 30.00

6. Power Plant [10 MW WHRB based & 10 MW FBC

based]

100.00

7. For Occupational Health & Risk Assessment 1.00

8. For Enterprise Social Commitment (ESC)

(2.5 % of the Project Cost)

7.50

Total 292.5



49

Chapter – 9

Analysis of proposal 9.1 Financial and social benefits:

With the implementation of the proposed expansion project, the socio-economic status

of the local people will improve substantially. The land rates in the area will improve in

the nearby areas due to the proposed activity. This will help in upliftment of the social

status of the people in the area. Educational institutions will also come-up and will lead

to improvement of educational status of the people in the area. Primary health centre

will also be developed by us and the medical facilities will certainly improve due to the

proposed project.

9.2 Socio-Economic Developmental Activities

The management is committed to uplift the standards of living of the villagers by

undertaking following activities / responsibilities as the part of Corporate Social

Responsibility.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

HEALTH & HYGINE

Personal and domestic hygiene,

Maintaining clean neighborhood,

Weekly health camps offering free-check up & medicines

Ambulance services

Education & drug de-addiction, aids.

DRINKING WATER

Making drinking water available at centralized locations in the village,

SUPPORTING EDUCATION

Providing books to all poor children,

Conducting annual sports festival in the village schools,



50

Baseline Data Collection (March 2018 to May 2018)

We have commenced Baseline Data Collection from 1st March 2018.

Wind rose plotted as per nearest IMD data (Hyderabad region) for the period (1971 – 1999) for

March, April & May months



51

Ambient Air Quality Monitoring Stations

S.No. STATION DIRECTION DISTANCE

(in Kms.)

CRITERIA FOR SELECTION

1 Plant site --- --- Represent Plant Site (Core area)

2 Awancha E 0.5 Represents nearest habitation

3 Mangapur NW 0.6 Represents downwind direction and

Residential area

4 Ellapur SE 1.5 Represents Upwind direction

5 Ramachandrapuram NE 1.6 Represents Crosswind direction

6 Nastipur SW 1.3 Represents crosswind direction

7 Daulatabad W 1.8 Represents downwind direction

8 Narsapur NE 4.7 Represents highly populated and sensitive

area

jeevaka industries private...

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