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Proposed installation of Integrated Steel Plant (0.4 MTPA) for change in the scope

of EC with revised scope of project by M/s Rashi Steel and Power Limited. PFR

M/s RASHI STEEL AND POWER LIMITED

PRE- FEASIBILITY REPORT & EMP

FOR

PROPOSED INSTALLATION

OF

INTEGRATED STEEL PLANT (0.4 MTPA)

FOR

CHANGE IN THE SCOPE OF EC

WITH REVISED SCOPE OF PROJECT

FOR THE PHASED MANNER,

UNDER CLAUSE 7(II) OF EIA NOTIFICATION, 2006

AS AMENDED

REGISTERED OFFICE : WORKS:

A – 184, 1st Floor, Meera

Bagh, New Delhi - 110087

Village Paraghat and

Beltukri, Tehsil – Masturi,

District- Bilaspur,

Chhattisgarh.



1.0 EXECUTIVE SUMMARY

M/s Rashi Steel and Power Limited propose to install a new project of Integrated Steel

Plant and Captive Power Plant at Survey no. 64 J/8, Village Paraghat and Beltukri, Tehsil

– Masturi, District- Bilaspur, Chhattisgarh.

The revised Proposal envisaged a green-field Integrated Iron Plant having capacity of 0.4

MTPA to manufacture hot DRI through the (RHF DRI/Nugget Plant with Producer Gas

Plant) RHF route using imported Coal for which MOU was available.

There is no National Park, Sanctuary or Forest Land in surrounding 10 Km radius. The

project doesn’t fall under CRZ boundaries.

Total Water requirement for the proposed project (as per revised Scope of the Project)

will be 4000 KLD for the proposed Units and out of which 1902.0 KLD will be recycled

after adequate treatment therefore net water requirement shall be 2098.0 KLD during the

operation phase, which shall be sourced from Surface water (Lilagar River) as well as

Ground water i.e. Bore wells. & mainly used for Process, Utility, Domestic and Green

belt development. Waste water generated will be mainly in form of cooling and blow

down.

As per the revised scope of the project for the phased manner, under clause 7(ii) of EIA

Notification, 2006 as amended, Company proposes to install Beneficiation of Iron Ore

Plant, Coal Washery Plant, DRI Plant - Rotary Hearth Furnace and Producer Gas Plant

(PGP) as fuel source of Plant as a part of proposed project.

Dust, ash, scrap and slag will be mainly generated as solid waste.

Environmental Clearance was granted to us for proposed Plant and Facilities on 199 acres

of land but due to some unavoidable reasons the management of the M/s RSPL has

decided to reduce some proposed Plant and Facilities and approached the MoEF & CC

with a request to allow the construction of reduced Plant and Facilities on 77 acres of

land which was already acquired by RSPL.

Revised Scope:

The unavoidable reason has revised the scope of project. Available land is 77 acres and

requirement of land is 76.27 acres. RSPL has earlier proposed 0.4MTPA integrated

Steel making process with start of Beneficiation of Iron ore via DRI iron making, to

SAF steel /Hot metal process to get 0.3MTPA Ductile iron spun plant. But, it has



altered to 0.4 MTPA high quality iron making process via Rotary Hearth Furnace DRI

unit. RSPL will sale two product till further land get acquired i.e. Beneficiated Iron ore

(Filter cake) & DRI nugget i.e. CDRI.

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

M/s. RSPL is incorporated on 28.08.2009 with Registrar of Company, New Delhi with a

view to venture into Integrated Steel Plant. The promoter of companies is engaged in

various activities such as- Steel Industry, Ferro alloys, Power Generation Unit, Real

Estate & Hotel Business etc. The Group’s annual turnover is about Rs. 500 crore.

Demand for Steel in India is likely to grow at around 12 per cent against the global

average of 5–6 per cent. Steel consumption grew at 3.8 per cent in the January-March

quarter of 2008-09 over the same period last year. Seeing the huge gap in demand and

supply of steel, RSPL proposes to install an Integrated Steel plant with capacity 0.4

MTPA of DRI with 43 MW Captive Power Plant. The environment friendly technologies

are state-of-the-art technologies and new to the country.

The proposed project falls under Activity 3 (a), Category “A” as per the new EIA

Notification dated 14.9.2006 of MoEF amended on 1st December 2009 and 4th April

2011.

Environmental Clearance to set up the proposed Project was granted by the Ministry of

Environment & Forests (IA Division), GOI vide Letter No. /File No. J-11011/466/2010-

IA-II (I) Dated 10th September, 2013.

2.2 COMPANY BACKGROUND

Shri Ashok Kumar Agrawal, Shri Amar Agrawal, Shri Ashok Agrawal, Shri Rakesh

Jindal and Shri Mahesh Gupta are the Directors of M/s Rashi Steel and Power Limited

(RSPL), based in Chhattisgarh, Formally known as M/s Rashi Strips Private Limited.

M/s RSPL had proposed a green-field Integrated Iron & Steel Plant capacity of 1.0

MTPA, based on MIDREX Shaft Furnace and partly on RHF route along with 200 MW

CPP at Village Paraghat and Beltukri, Tehsil- Masturi, District Bilaspur, Chhattisgarh

based on partly indigenous and partly imported Coal.

The case was presented to EAC on 24th September, 2012.



Due to non availability of linkage for indigenous Coal, the Committee informed

that the case can be considered only on receipt of Firm Coal linkage.

Expecting considerable delay in getting Firm Coal linkage for Indigenous Coal,

RSPL had revised the Proposal.

The revised Proposal envisaged a green-field Integrated Iron Plant having capacity

of 0.4 MTPA to manufacture hot DRI through the (RHF DRI/Nugget Plant with

Producer Gas Plant) RHF route using imported Coal for which MOU was

available along with 43 MW CPP.

The Presentations for final Environmental Clearance were held on 5 April,

2013 and 16 May, 2013.

EC Letter was granted on10th

September, 2013.

2.3 IDENTIFICATION OF PROJECT

Sl.No. Particulars Details

1. Project Proponent M/s Rashi Steel and Power Limited

2. Type of project Integrated Steel Plant (0.4 MTPA)

3. Category of Project Category A , Sector 8 , Schedule 3a –

Integrated steel plant

4. Total area 77.0 Acres

5. Location Village Paraghat and Beltukri, Tehsil –

Masturi, District- Bilaspur,

Chhattisgarh.

6. Plant site co-ordinate

(Latitude & Longitude)

82018’46.728’’E 22

003’1.122’’N

82019’36.081’’E 22

003’2.534’’N

82019’39.382’’E 22

002’0.116’’N

82019’03.786’’E 22

002’3.810’’N

7. Plant Site Elevation (MSL) 266 m

8. Climatic Conditions Max. Temp: 410C

Min. Temp: 60C

Annual Avg. Rainfall: 1100 mm

Wind Direction:: Winter - N/NE

: Summer - N/NW

: Monsoon - S/SW



: Post-monsoon - N/NE

9. Nature and extent of land Barren /single cropped Land

10. Nearest Highway NH-200 (8.0 Km in South direction)

11. Nearest Railway Station Jairam Nagar Railway Station – 2.40

Km SW

12. Nearest village Jairam Nagar-2.5 km in SW direction.

Limtara-7.2 km in West direction.

13. Nearest Town Bilaspur is 20 km in WNW direction

14. Critically polluted areas as

per CPCB certification in the

study area of 10 km radius.

Nil

15. Eco- Sensitive area No National Park, Wildlife Sanctuary,

biosphere reserve area within the10 km

radius of project site

2.4 BRIEF DESCRIPTION OF NATURE OF PROJECT

The project fall under category A, section 3 (a) of EIA notification September 2006 and

amendment thereof vide notification no. S.O 3067 (E) dated 1st December 2009. We are

proposing change in the scope of EC with revised scope of project for the phased manner,

under clause 7(ii) of EIA Notification, 2006 as amended.

2.5 NEED OF PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGION

In order to meet the increasing demand of steel product in domestic as well as

international market the company proposes to install an integrated steel plant.

There have been massive capacity addition by all steel majors and several new groups

made foray into primary and secondary steel market in the first phase of liberalization in

early 90s. The major costs of the industry, which is predominantly based on BF-BOF

route, are the costs of iron ore, limestone, coking coal and power. While the country is

rich in iron ore and limestone, its quality of coking coal is poor and power costs are high.

The industry enjoys inherent advantages in terms of availability of raw material and

cheap labor. Considering the above factors, the present project is proposed to fill up the

gap between demand and supply by setting up a state-of-the-art steel plant which is

environmental friendly and not dependent on coking coal. To reduce the dependence on



coking coal, production of Direct Reduced Iron (DRI) by using non-coking coal has

become popular in the world.

The present project is based on rotary hearth furnace plant, which is used to produce DRI.

Due to unavailability of natural gas, this project will gasify non coking coal to form

producer gas in a coal gasified, which will be used in the rotary hearth furnace as a fuel.

The product is a metallic product produced by direct reduction of high-grade iron ore

lumps/ pellets in the solid state. The DRI Plant can be divided into two categories

depending on the fuel used as reductant - coal or gas. Hence, it is called Direct Reduced

Iron (DRI) or Hot Briquetted Iron (HBI) and contains large percentage of metallic iron.

This is a substitute for hot metal produced in blast furnaces for production of steel. DRI/

HBI are used for steel making, mainly in Electric Arc Furnace & Induction Furnace. The

present project will use 1 x 0.4 MTPA Rotary Hearth furnaces for the production to 0.4

MTPA of DRI. The manufactured DRI will be used in Submerged Arc Furnace for

manufacturing of Ductile Iron Spun Pipe (D.I.S.P). Ductile Iron spun pipe proposed plant

is not based on coke, which has high environmental concerns. Thus in the project, coke

which causes high environmental burden is not necessary.

As the proposed plant will be an integrated Iron and Steel Plant, it is proposed to install

Rotary Hearth Furnace with Submerged Arc Furnace and D.I.S.P. plant for production of

0.3 MTPA of ductile iron pipes.

2.6 DEMAND-SUPPLY GAP

Domestic Demand

Generally, a developing economy undertakes large number of infrastructure projects,

which are necessary for building of the nation and ensuring economic growth. China is a

leading example of the economic growth through phenomenal development of

infrastructure.

Strong economic growth rate 8.7% p.a. and present low per capita consumption in India

is expected to drive demand for steel, which is likely to grow @ 7.5% per annum as per

Ministry of Steel, Government of India projections, as detailed in the National Steel

Policy 2005. As per Government estimates, the demand is likely to cross 100 MTPA by

2019-2020.

However, it is considered widely that the above projections are on a conservative side

and the demand is likely to grow at CAGR of about 10% per annum. As per the estimates

of Confederation of Indian Industries (CII), the steel demand in



India is likely to grow to 80-85 MTPA by 2015 itself, thereby registering a growth rate of

about 12.00% per annum.

Export demand

Though India started steel production in 1911, steel exports from India began only in

1964. Exports in the first five years were mainly due to recession in the domestic Iron

and Steel market. Once domestic demand revived, exports declined. India again started

exporting steel only in 1975 touching a figure of 1 Mt of pig iron and 1.4 Mt of steel in

1976-77. Thereafter, exports again declined to pick up only in 1991-92 to 0.39 Mt. In

1995-96, exports of semi-finished and finished steel products were 1.77 Mt while in

2003-04 exports reached 5.2 Mt.

During 2004-05, exports of these products have declined to 4.4 Mt. The exports have

increased by 8.9 per cent in 2006-07 over 2005-06 to touch 4.9 Mt. Exports have declined

in the year 2007-08 by 6.1 per cent to 4.6 Mt – from 8.9 per cent in 2006-07.

Imports of semi-finished and finished steel products mainly HR plates, HR coils/sheets

and CR coils/sheets by India have been in the range of 1.1 Mt and 2 Mt, during the last

ten years.

In view of the above and anticipated higher emphasis on export of steel products in future

as per National Steel Policy-2005 (26 Mt exports of steel products by 2020), export

demand in the range of 10% to 15% of apparent consumption of various products and

150% for GP/GC sheets has been considered.

The country now has a vision to achieve annual steel production, consumption and export

of 110 Mt, 90 Mt and 26 Mt respectively by the year 2019-20. To cater to the recent and

anticipated surge in domestic demand, export and enhancement in the economy of scale,

various existing steel producers and new entrepreneurs have drawn expansion

plans/Greenfield steel projects/acquisitions & mergers.

2.7 IMPORTS VS. INDIGENOUS PRODUCTION

Proposed plant will produce 0.4 MTPA high quality iron making process via Rotary

Hearth Furnace DRI unit. RSPL will sale two product till further land get acquired i.e.

Beneficiated Iron ore (Filter cake) & DRI nugget i.e. CDRI to meet the Indigenous

demand of quality steel and reduce the import requirement of steel.



2.8 EXPORT POSSIBILITY & DOMESTIC / EXPORT MARKETS

There is export potential to other countries, for which detailed market study is to be

conducted. However RSPL intends to manufacture the products for good domestic

markets.

2.9 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE

PROJECT

The total employment generation due to the proposed project is given below:

Type of employment Skilled Un-Skilled

Manpower 150 300

3.0 BRIEF DESCRIPTION OF THE REVISED SCOPE OF THE PROJECT

As the proposed plant will be an integrated Iron and Steel Plant, it is proposed to install

Rotary Hearth Furnace with Submerged Arc Furnace and D.I.S.P. plant for production of

0.3 MTPA of ductile iron pipes.

Since the scope of the proposed Plant & facilities is now altered, therefore the detail

description of the proposed Plant & facilities to be commenced on already acquired land

i.e. 77 Acres is given below:

The report is based on comparison statement, b/w the plant facilities in accorded EC (199

acres land) & Plant facilities in 77 acres (in same 199 acres), with the new scope of

products.

4.0 UNIT CONFIGURATION (AS PER EC ACCORDED)

Sr. No. Particulars Installed Capacity

1. Beneficiation of Iron Ore 1.9 MTPA

2. Pelletization of Iron Ore 1.324 MTPA

3. Coal Washery 0.35 MTPA

4. DRI Plant - Rotary Hearth Furnace 0.4 MTPA

5. Producer Gas Plant (PGP) as fuel source of

Plant.

400 MNM³

6. Ductile Iron Spun Pipe Plant 0.3 MTPA

7. Submerged Arc Furnace 0.243 MTPA

8. Captive Power Plant 43 MW



4.1 UNIT CONFIGURATION (AS PER REVISED SCOPE OF THE PROJECT AT

AVAILABLE LAND)

SR.

No.

Particulars Installed Capacity

1. Beneficiation of Iron Ore Plant 1.9 MTPA

2. Coal Washery Plant 0.35 MTPA

3. DRI Plant - Rotary Hearth Furnace 0.35 MTPA

4. Producer Gas Plant (PGP) as fuel source of Plant. 400 MNM³

5.0 COST OF THE PROJECT

The cost of proposed project of 0.4 MTPA integrated Steel Plant was Rs.540.00 Crores.

Since the scope of our proposed project is now reduced therefore for installation of

proposed facility, the project cost would be Rs. 754.98 Crores approximately due to

rise in the equipment cost.

S.No Particulars Installed Capacity Estimated Project Cost

1 Beneficiation of Iron Ore 1.9 MTPA 75.00

2 Coal Washery 0.35 MTPA 20.98

3 DRI PLANT

Rotary Hearth Furnace

0.40 MTPA 582.00

4 Producer Gas Plant @ 1350

Kcal/NM3 400X10⁶ M³ 77.00

GRAND TOTAL 754.98

6.0 LAND REQUIREMENT:

The entire land required for the proposed project is 199 acres, which will be used for

Beneficiation & Pelletization of Iron-ore, Coal Washery, Nugget RHF Plant, SAF,

Ductile Iron Spun Pipe Plant and Captive Power Plant of 43 MW, Railway siding & other

utilities based on Imported coal. Green belt area developed will be according to MoEF

guidelines. The details are presented in layout.



The Layout Plan is shown in the Annexure I(B). The project Site falls in Zone II of

Seismic Zone which is referred to as Low Damage Risk Zone.

6.1 LAND BREAK-UP OF AWARDED EC FACILITIES

S.No. Unit Area (M2)

1. Wagon Tippler & Unloading 27000

2. Raw Material Handling 59500

3. Truck Tipper & Crusing System 3900

4. Producer Gas Plant 400 10500

5. Ore Beneficiation 28800

6. Pellet Plant 53600

7. Coal Washery 8500

8. Rotary Hearth Furnance/Nugget (HDRI) 38300

9. Submerged Arc Furnace (HM) 34500

10. Ductile Iron Plant & Pipe Storage 54000

11. Power Plant Area 22400

12. Sub-Station 9000

13. Central Workshop 600

14. Central Store & Medical Unit 1200

15. Adm & Others & Canteen 4100

16. Parking & Garage 6000

17. Coal Dumping 4200

18. Slag Dumping 9200

19. Ash Dumping Yards 8000

20. Water Reservoir- I 12100

21. Water Reservoir- Ii 3000

22. Water Harvesting 35400

23. Colony Area 12000

24. Internal Roads Etc 76600

25. Green Cover @ 35% 281300

Grand Total 803700 (M2)

i.e. 199.00 Acres



6.2 LAND REQUIRED FOR REVISED SCOPE (AS PER REVISED SCOPE OF

THE PROJECT)

SR.

No.

Particulars Land and Required (Acres)

1. Beneficiation of Iron Ore Plant 39.86 Acres

2. Coal Washery Plant 13.51 Acres

3. DRI Plant - Rotary Hearth Furnace/Nugget 21.08 Acres

4. Producer Gas Plant (PGP) as fuel source of Plant. 01.82 Acres

Total 76.27 Acres

Possessed land 77.00 Acres

6.3 DETAIL OF LAND REQUIREMENT, ACCORDING TO EACH PLANT

/UNIT

A. BENEFICIATION PLANT

Sl

No.

Description Area proposed in

m2

Area proposed in

Acres

01 BENEFICIATION PLANT 161158 39.86 Acres

a. Plant & Machinery 28800 7.12

b. Raw Material Handling 48040 11.87

c. Water Storage & Treatment 16059 3.97

d. Utility 300 0.07

Plant Area 93199 23.03

e. Green Cover 51271 12.67

f. Colony & Logistic 16688 4.12

Sub Total (01) 161158 39.86 Acres

B. COAL WASHERY PLANT

Sl

No.


m2

Area proposed in

Acres

02 COAL WASHERY PLANT 54693 13.51 Acres

a. Plant & Machinery 8500 2.10



b. Raw Material Handling 13333 3.29

c. Water Storage & Treatment 3232 0.79

d. Waste Handling & Disposal 4200 1.04

Plant Area 29265 7.23

e. Green Cover 17532 4.33

f. Colony & Logistic 7896 1.95

Sub Total (02) 54693 13.51 Acres

C. ROTARY HEARTH FURNACE DRI PLANT

Sl

No.


m2

Area proposed in

Acres

03 ROTARY HEARTH

FURNACE/NUGGET DRI

PLANT

85369 21.08 Acres

a. Plant & Machinery Including Raw

Material Handling

38300 9.46

b. Water Storage & Treatment 4040 0.99

c. Waste Handling & Disposal 2000 0.49

d. Plant Area 44340 10.96

Green Cover 32237 7.97

e. Colony & Logistic 8792 2.17


D. PRODUCER GAS PLANT

Sl

No.


m2

Area proposed in

Acres

04 PRODUCER GAS PLANT 7346 1.82 Acres

a. Plant & Machinery including Raw

Material Handling

3846 0.95

b. Water Storage & Treatment 200 0.05

c. Waste Handling & Disposal 1000 0.25

d. Plant Area 5046 1.25



Green cover 1800 0.44

e. Colony & logistic 500 0.12


6.4 Total requirement of the Land area is summarized below:

Sl.

No.

Description Total proposed area in Acres

(Plant Covered Area ,Total Green Cover ,

Colony & Open Area )

1 Beneficiation Plant 39.86

2 Coal Washery Plant 13.51

3 Rotary Hearth Furnace/Nugget DRI

Plant

21.08

4 Producer Gas Plant 1.82

Total Required Area 76.27

The revised layout plan is shown in the Annexure I (B).

7.0 RAW MATERIAL REQUIREMENT

Imported coal, Iron ore, lime stone and dolomite will be used as raw materials for the

proposed project. The coal shall be procured from M/s ARCTOS Trading (PTY) Ltd.,

South Africa. Iron ore will be procured from NMDC- Orissa. Annual quantity of

procurement and source are given in Table (A & B)

Table (A): Raw Material Requirement

S.NO. MATERIAL REQUIREMENT (TPA)

i) Imported Coal 5,00,000

ii) Iron Ore 20,00,000

iii) Limestone 1,18,470

v) Dolomite 64,836



Table (B): Raw Material & Water Sources

S.No Raw material Source

1 Coal M/s ARCTOS Trading (PTY) Ltd.

Ogies, Witbank, Mpumalanga, South Africa

2 Iron Ore Lumps / fines NMDC Jagdalpur/ Beladula &

Berbil/KATNI/ Keonjhar area of Orrisa

3 Water Lilagar river and ground Water

The specification of imported coal, iron ore, limestone and dolomite will be used in the

plant is given as under:

Table (C): Specification of Imported Coal

Parameter Range (Percentage)

Moisture 4-6

Ash 16-18

Volatile Matter 24-26

Fixed Carbon 56-58

Sulphur 0.6-0.8

Table (D): Specification of Iron Ore


TFe 50-62

SiO2 1.7-2.9

Al2O3 2.8-5.6

Loss on Ignition 2.4-6.8

Phosphorus 0.06-0.08

Table (E): Specification of Limestone


Calcium Oxide (CaO) 49-51

Magnesium Oxide (MgO) 2.4-2.8

Silica (SiO2) 2.6-4.5

Loss on Ignition 38-41

Table (F): Specification of Dolomite




Calcium Oxide (CaO) 27-31

Magnesium Oxide (MgO) 20-21

Silica (SiO2) 1.8-4.7

Loss on Ignition 43-44

8.0 POWER REQUIREMENT:

The Power requirement for the earlier proposed 0.4 MTPA integrated steel plant project

will be 64 MW. From supply side 43 MW will be produced by the coal based captive

power plant plus 18 (13+5) cogeneration from plant through waste heat energy recovery

system(WHRS) and 10 % power from Chhattisgarh power grid, the shortfall made from

Chhattisgarh electricity board.

Table: Total Power Requirement

SI. No POWER REQUIREMENT (MW)

Facility & size As per EC

accorded

As per revised

Scope 1. Beneficiation Plant 5 5

2. DRI Grade Pellet Plant 13.5 NA

3. Coal Washery 1 1

4. Producer Gas Unit 4 4

6. RHF plant 5 5

7. Submerged Arc Furnace for

D.I.S.P

3 x 9 MVA

27.5 NA

8. Power Plant (1X43MW) 4 NA

9. Ductile Iron Pipe Plant 4 NA

TOTAL 64 15

Now, Due to the revised scope of the project Power requirement will be 15.0 MW. M/s

RSPL will meet the requirement and supply side with 5 MW Grid supply, plus 10 MW

through the same WHRS in RHF, which is environment friendly.



9.0 WATER REQUIREMENT & ITS SOURCE (as per previous Scope):

Water requirement for the proposed project will be 7500 m3/day for all the units. Out of

this 800 m3/day water will be required for Captive Power Plant, 1400 m

3/day for

beneficiation plant, 1200 m3/day for ductile iron pipe plant and rest is used in other units.

As most of the flow water is recycled, only the water lost due to evaporation, blow down

(required at specific places for meeting the norm of specific quality), and other minor

losses is to be put in the system as make-up water for maintaining the required flow rates.

Typical water circuits for the plant are shown as under:

Table: Water Requirement for entire Plant

SI.

NO

TOTAL WATER REQUIREMENT

Facility & Size Water requirement (m3/day)

1. Beneficiation Plant 1400

2. DRI grade pellet Plant 1100

3. Coal Washery 400

4. Producer Gas Unit 700

5. RHF briquette Plant

800 6. RHF based DRI Plant

7. Submerged Arc Furnace for pig iron 300

8. Power Plant (1x43 MW) 800

9. Ductile Iron Pipe Plant 1200

10. Miscellaneous 800

TOTAL 7,500

After the completion of the project, the total requirement of water works out to be 7,500

m3 per day and 2.8 MCM in a year. A part of the water requirement will be met through

a separate pond of rain water harvesting and water reservoir, the water storage reservoir

is filled from the surface water and ground water. M/s RSPL have already taken the

permission of 12 MCM per year of surface water from the Lilagar river and 0.826 MCM

per year from ground water. The NOC of ground water withdrawal and permission of

abstraction of water from Lilagar river is attached as water withdrawal permission

Annexure-IVA & B. The water balance diagram is shown in Annexure-III.



9.1 REVISED WATER REQUIREMENT (as per revised Scope of the Project)

SI.

NO

TOTAL WATER REQUIREMENT

Facility & size Water requirement (m3/day)

1. Beneficiation plant 1400

2. Coal Washery 400

3. Producer Gas unit 700

4. RHF/NUGGET based DRI plant 800

5. Miscellaneous 700

TOTAL 4,000

10.0 TECHNOLOGY AND PROCESS DESCRIPTION:

The 0.4 MTPA integrated steel plant is proposed on the basis of imported coal (5,00,000

tonne) which is procured from South Africa. The imported coal is sent to crushing and

screening section where the sizing will be done. Out of 5,00,000 tonne coal, 1,40,000

tonne lump size is sent to air blown gasifier and 3,50,000 tonne fine coal is grind upto the

required size and sent to the coal washery for washing purpose. The washery have the

three product, first one is clean coal which has 12% ash content, having quantity 1,80,000

tonne send to CBSR green ball making plant for mixing with the Beneficiated iron ore for

making cold bonded self reduced pellet and the rest 20,000 tonne clean coal is sent to

submerged arc furnace, 1,32,000 tonne middling coal which has 19% ash content send to

captive power plant and 18,000 tonne reject coal which has high ash content is sold brick

making plant.

19,00,000 tonne Iron ore is beneficiated to produce 13,24,000 tonne filtered cake

(beneficiated), and will be send further iron & steel making process units via

pelletization of filter cake. The two type of pelletization plant has been proposed by the

M/s RSPL. Out of 13,24,000 tons filter iron ore cake,dthe 8,08,000 tonne beneficiated

fine iron ore is to sent to conventional pelletization plant. The product of conventional

pelletization plant is green pellet will be sold. And 5,16,000 tonne beneficiated iron ore

mix with clean coal having quantity 1,80,000 tonne will be sent to CBSR (Cold bounded

self reduce) pelletization plant to produce cold bonded self reduced pellet (Green Balls),

which will further sent to Rotary hearth furnace to produce 4,00,000 tonne of hot direct

reduced iron (HDRI). Of these 1,00,000 tonne CDRI will be sold and 3,00,000 tonne is

sent to the submerged arc furnace from where we get of pig iron is produced which is



then mix with scrap in DISP plant to get 3,00,000 tonne ductile iron spun pipe, as a final

product of the plant.

Revised scope & Technology: Now as scope has revised with very small change in

captive use. The filter cake, to be use as captive use in Conventional pellet plant will be

directly sold to other plants having huge requirement of filtered iron ore cake.

As already mentioned, considering the potential of iron and steel in India and the

experience gained by the group in this sector, M/s RSPL has requested to install the

project with RHF- SAF- D.I.S.P. Plant for producing ductile iron pipes.



10.1. UNITS IN THE PROJECT MASS BALANCE & ELECTRIC BALANCE:

FLOW CHART / MASS BALANCE

WASHED COAL

LUMPS

(3,54,000 Tons)

(1,40,000 T)

(8,08,000 Tons) (5,16,000 Tons) PGP GAS

RAW MATERIAL IRON ORE

(20,00,000 tons)Wet state

I

I

BENEICIATION PLANT (19,00,000 Tons)

I

I CONCENTRATE

IRON FILTER

CAKE

(13,24,000

Tons)

ROTARY HEARTH

FURNACE/NUGGET PLANT

I

I

PRODUCER GAS PLANT

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COAL WASHERY PLANT (4,94,000 Tons)

RAW MATERIAL COAL (5,04,000 Tons)

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IRON NUGGETS FOR SALE &

IN FUTURE IN STEEL

MAKING UNIT PLANTS.

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I SALE (DRI NUGGET) SALE (FILTER

Cake Iron ore)



10.2 ELECTRICITY BALANCE

10.3 TECHNOLOGY DESCRIPTION PLANT-WISE

1) Beneficiation of Iron Ore:

Facilities have been provided to beneficiate iron ore fines because of availability of low

grade of iron ore in india. M/s RSPL will use the iron ore containing 50 to 62% Fe, which

will be further processed in different unit i.e. crushing, grinding, screening, sizing,

classification, jigging and magnetic separation and hydroclone. After passing different

unit operation the lump size of ore will be crushed and screened in smaller size which is

required for the liberation and liberation is required for beneficiation. After beneficiation

the fine iron ore will be approximately 64 to 66 % Fe content and this beneficiated iron

ore will be used in the process which is economically viable. M/s RSPL proposal is to

install beneficiation plant with capacity 1.9 MTPA.

2) Coal Washery:

Electricity

Cap

acit

y M

tpa

Demand Supply Side

MAIN PLANT

UN

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RE

QU

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ME

NT

MW

CU

MU

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RE

QU

IRE

ME

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T M

W

Gri

d P

OW

ER

MW

Co

gen

erat

ion

MW

CA

PT

IVE

GE

NE

RA

TIO

N

MW

TO

TA

L

GE

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MW

Phase 1 (At available Land)

BENEFICIATION PLANT 1.9 5.0 5.0 5

5

ROTARY HEARTH FURNACE

HDRI 0.4 5.0 09.0 10

15

PRODUCER GAS PLANT 400 4.0 14.0

COAL WASHERY 0.35 1.0 15.0

15

Phase 2 (After acquisition of land)

CAPTIVE POWER PLANT 43MW 4.0 19.0

43 61

PELLET PLANT - 1.324 13.5 32.5

61

SUBMERGED ARC FURNACE 0.243 27.5 60.0 3 64

DUCTILE IRON SPUN PIPE

PLANT 0.3 4.0 64.0

64

TOTAL 64.0 64.0 5 16 43 64



Imported coal washing facility has been provided for reduction of ash content in the coal

from 16-18% to less than 12%. Coal having 12% ash content is required for the CBSR

pelletization plant and the submerged arc furnace. The unwashed lump coal is used for

coal gasification, Middling coal 19% ash content will be sent to captive power plant as

sale and in future as captive use and higher ash reject will be sent to ash ponds and sold

to brick maker. The installed capacity of coal washery is 1.2 MTPA but M/s RSPL has

proposed to wash only 0.35 MTPA. The GCV of coal will be from 5600 to 6200 kcal/kg.

Coal washery is basically used for the washing of coal which has high ash content. The

coal will be sized and the lumps are separated from fines. The fine coal will be sent to

washery circuit where it will be further processed in dense media cyclone, floatation cell

and we will get the coal of desired ash content.

3) Rotary Hearth Furnace (RHF):

M/s RSPL has proposed to install iron ore and coal-based direct reduction RHF

technology and adopting regenerative type burner combustion technology. Adoption of

the regenerative type burner combustion technology to be fired with low calorific value

gas can also achieve the reach the high furnace temperature above 1400˚C required for

reduction process and well control the reduction atmosphere inside the furnace, which

breaks through the convention that the overseas direct reduction RHF must use high

calorific value fuel like natural gas, etc. Main characteristics of the process are shown as

follows:

1) The material to be reduced and roasted is the pellet containing carbon ore powder.

The ore powder and coal powder is closely contacted, which provide good

condition for quick reduction. With RHF/Nugget technology ore powder and coal

powder mix in proportionate to get uniform mixed in a mixer, will be send to

balling discs to form green pellets to get reduced.

2) The reduction / roast process is that the thin material layer is heated in high

temperature open flame, which can realize quick reduction; the reduction duration

of burden in the furnace is short.

3) The pellet in RHF will not be pressed during roasting process. There is no relative

movement between burden and furnace lining, therefore, the requirement for the

strength of pellet ore is not high, and the accretion phenomenon that pellet attaches

on the wall will never occur.

4) Coal Gasification



There are three general types of coal gasifiers: fixed bed, entrained flow and

fluidized bed. Here process of M/s RSPL will be based on fluidized bed

gasification will be used.

Basically coal gasification is the process of producing coal gas made by the

incomplete combustion of coal in the presence of insufficient oxygen containing a

variety of calorific gases including hydrogen, carbon monoxide, methane and

volatile hydrocarbons together with small quantities of non-calorific gases such

as carbon dioxide and nitrogen.

An important characteristic of the producer gas process was that no external heat

was applied to the gasifier; the gasifier was heated by the combustion within the

gasifier itself. Once the burning of the fuel inside the gasifier had started, the air

supplied to the producer was carefully controlled. This allowed continuous

combustion in the lower regions of the fuel bed to occur and provide a sufficiently

high temperature to decompose the steam and enable other necessary reactions.

The skill in effectively operating a producer was to ensure that the fuel bed was

neither too shallow or the air supply too great as to allow complete combustion of

the fuel to carbon monoxide, as carbon dioxide has no calorific value. The

producer gas process focused on the incomplete combustion of carbon so that

carbon monoxide produced was maximized.

Air-blown Gasification

Most gasification systems use air instead of oxygen for the gasification reactions

(which is typically used in large-scale industrial and power gasification plants).

Gasifiers that use oxygen require an air separation unit to provide the

gaseous/liquid oxygen; this is usually not cost-effective at the smaller scales used

in gasification plants. Air-blown gasifiers use the oxygen in the air for the

gasification reactions.

In the coal Gasification process, a fuel gas made from coal. Air is passed over the

red hot carbonaceous fuel and carbon monoxide is produced. The reaction is

exothermic and proceeds as follow:

a C + b O2 + c N2 → a CO + c N2 + d CO2 + e CH4

The gasifier operates at a temperature below the ash melting point so the coal ash

is discharged from the gasifier as a solid. Because of this low operating

temperature, the coal gasification process requires significantly lower quantities of

oxygen than the entrained flow gasification processes which melt the ash.

http://en.wikipedia.org/wiki/Coal_gas

http://en.wikipedia.org/wiki/Hydrogen

http://en.wikipedia.org/wiki/Carbon_monoxide

http://en.wikipedia.org/wiki/Methane

http://en.wikipedia.org/wiki/Carbon_dioxide

http://en.wikipedia.org/wiki/Nitrogen



Producer gas: It is the cheapest fuel gas and can substitute furnace oil, LDO,

Kerosene, other fuel and other gases. It is ideally adopted to industrial heating

operation, because of its uniformity, cleanliness and dependability.

Process of gas generation: The producer gas is generated by injecting a blast of

air and steam through a layer of incandescent coal. The carbons of the coal

combine with insufficient air and form a good amount of carbon monoxide, carbon

dioxide and hydrogen. The figure of a coal gasifier is shown in the Fig.

Fig.: Coal Gasifier

Units to be install after in next stage of integrated plant (with prior consent of

MoEF & CC).

Pelletization of Iron Ore:

Pelletization essentially consists of formation of small green balls by rolling a fine iron

bearing material with a critical amount of water and to which an external binder or any

other additive may be added if required. These green balls of nearly 5-20 mm size are

then dried, pre-heated and fired, all under oxidizing conditions, to a temperature around

1250-1350 0C. Bonds of good strength are developed between the particles at such high

temperatures. The sensible heat of the exhaust gases is recovered and is fed back in the

induration operation. The process, therefore produces pellets in a highly oxidized state.



M/s RSPL has proposed to install the two pelletization unit, second one will be the

conventional pelletization plant where the saleable filter cake (beneficiated iron) ore will

be used to form the green pellet which will be sold to the market.

AS first one cold bonded self reduced pelletization plant in RHF, which the beneficiated

iron ore will mixed with 33-35% coal fines, 1-2% binder such as bentonite and molasses,

2-3% additive such as slacked lime and hydrated lime and make the uniform pellet and

indurated at a low temperature and sent to the RHF for making DRI.

RHF-SAF Based DISP Plant

M/s RSPL has proposed to install 0.4 million tonnes per annum (MTPA) DRI capacity

shall be produced through rotary hearth furnace (RHF) and will send to SAF having

capacity 0.3MTPA and finally make the ductile iron spun pipe in DISP plant having

capacity 0.3 MTPA. Keeping in view a low sulphur (<0.03 % approx) and low carbon

hot metal (HM) is essential for making DI pipes, the process employs coal (imported)

based hot direct reduction iron (HDRI).

Spherodisation treatment of hot metal

Melting cum superheating furnace metal will be transferred to melting cum

superheating furnace directly when the composition of hot metal is approximately less

than 0.02% by passing the desulphurisation process.

About 500 tonnes of nodiliser pure magnesium will be injected and 4500 tonnes of

slag will be removed from slag off device. To produce 3,00,000 tonnes of ductile iron

pipe and it is expected that about 4500 tonnes of slag will be removed from slag off

device. The slag generated from this section will be stored within the plant as solid

waste. The constituent of the slag is magnesium sulphate and carbonate.

A stack is attached to this unit which will emit the fumes generated during

desulphurisation process into atmosphere. The gas temperature will be in the range of

55 to 65 0C and the volume of the air is to be handled from this section is about 20,000

Nm3/hr. The major constituents of the gas are SPM, and hot fumes. .

Centrifugal casting machines

Water-cooled metal mould process has been envisaged for centrifugal casting

machines for production of DI pipes. After the spheroidsation process, the SG grade

iron is directed to centrifugal pouring cum casting machine. Molten SG grade is

transferred to quadrant type ladle and from the bottom of a quadrant-type ladle into a

rotating pipe mould in the water jacket inside the centrifugal casting machine. A head



core made of resin-coated sand serves to seal the socket end of the mould and form the

inside of the socket end of the pipe.

As the mould rotates evenly, centrifugal force distributes the metal evenly, forming the

pipe wall. Centrifugal casting machine containing the mould is mounted on set of

wheels, which ride on a track. Molten metal is poured into spinning mould by means

of pouring trough. As spinning mould is retracted from pouring trough, a uniform

layer of metal is deposited on the mould. Hydraulically operated extraction devices

will be provided for easy removal of the moulded pipe. Water jacket will be provided

for circulating water continuously around the mould thus cooling it uniformly. The

number centrifugal casting machines envisaged for this project is furnished below.

At the discharge side, pipe impression testing machine will be provided for testing the

spheroidisation and annealing quality of ductile iron pipe. Pipe impression tester is

special equipment for testing the spheriodization and annealing quality of the ductile

cast pipe after annealing.One number of pipe impression tester will be provided for

DISP plant. Zinc spraying machine will be used to treat pipes to increase corrosion-

resistance and service life of the pipes. The metallic zinc coating shall be applied by a

spraying process in which metallic zinc oxide will be heated to a molten state and will

be sprayed by spray guns onto outer surface of the pipes.

The equipment required for cement lining of pipe shall consist of cement batching,

mixing and material transfer equipment, cement and sand silos, cement lining machine

along with traversing equipment, etc. Internally lined DI pipes will be cured in the

curing oven. The curing oven is a chamber with controlled temperature and humidity.

Generation of Power:

It is proposed to install a coal based captive power plant using fluidized bed combustion

technology (FBC) to generate 43MW power, which shall be used for running

beneficiation plant of coal and iron, Pelletization plant, Rotary hearth furnace,

Submerged Arc Furnace, Ductile Iron Spun Pipe plant and lighting purposes. The FBC

will use the washery middling coal.

M/s RSPL is proposed to install a capacity of 0.3MTPA of ductile iron spun pipe plant

for the production of ductile iron pipe. The DRI produced from the RHF is taken to

submerged arc furnace for melting the iron and then it is taken to ductile iron spun pipe

plant.



M/s RSPL’s new scope has revised power requirement upto 18 MW, which shall be meet

up with State power board. Also RSPL has pledge to recover maximum waste heat

energy to leave minimum carbon foot record. Remaining 13 MW power recovery will be

covered under Waste Heat Recovery System steam generator, incorporated in Rotary

Hearth Furnace Chineese/German technology. E.g Kobe steel.

11.0 DESCRIPTION OF MITIGATION MEASURES

The project is provided with pollution control systems with standard treatment systems.

Storm water drainage shall be kept separate from plant effluent drainage system so that

they do not mix with each other. The pollution control systems adopted are shown below:

11.1 WASTE WATER TREATMENT:

Total waste water generation will be 16.0 m3/day with the revised scope of the Project as

compare to earlier quantity of 26.5 m3/day. After adequate treatment, it will be used for

gardening and dust suppression at road side & material handling areas. No liquid effluent

will be discharged outside the premises. The Unit shall achieve zero discharge. Domestic

effluent shall be subjected to the septic tank/soak pits.

11.2 Water Pollution Control

Sl. No. Item Description Pollution Control

1 Coal Washery Backwash

Water

From the

pressure

filter

cleaning

process

To be treated at thickner and

recirculation through process water

tank. Overflow of the thickner to

blow down tank for reuse in plant

for dust suppression, dust

suppression and road spraying.

Storm water to be collected in

separately and to be taken in rain

water harvesting pit and oil trap.

Overflow from RWH recharge pit

to RWH tank for reuse in plant.

Filter Presses will be install to

recover maximum water to be use

in process again.

2 Ore

Beneficiation

Backwash

Water

From the

pressure

filter

cleaning

process




3 Coal gasifier

(PGP)

Cooling water to be cooled in CT,

blow down to blow down tank for

reuse in plant for dust suppression,

road spraying, gardening and raw

material spraying. Storm water to

be collected separately and to be

taken to rain water harvesting pits

after oil trap. Overflow from RWH

recharge pits to RWH tank for

reuse in plant.

4

Rotary Hearth

Furnace/Nugget

plant

Cooling water to be cooled in CT,

blow down to blow down tank for

reuse in plant for dust suppression,

road spraying, gardening and raw

material spraying. Storm water to

be collected separately and to be

taken to rain water harvesting pits

after oil trap. Overflow from RWH

recharge pits to RWH tank for

reuse in plant.

11.3 AIR POLLUTION CONTROL MEASURE:

S. No. Item Description Pollution Control

1

Raw material handling

area, Material Transfer

Points

Non Process

Dust suppression system and

de-dusting systems comprising

of bag filters.

2 Coal Washery Non Process

Control of fugitive dust

emission by Dust suppression

system.

3 Ore Beneficiation Non Process



system in the material handling



S. No. Item Description Pollution Control

area.

4 Producer Gas

Plant/Coal gasifier

Non Process +

Process



system in coal handling area &

de-dusting plant using bag

filter.

5 Rotary Hearth

Furnace/Nugget Plant

Process + Non

process


emission by water spraying and

de-dusting system using bag

filter.A burner at the bottom of

the stack burns any

combustibles remaining in the

flue gas. For that dilution air is

injected prior to the stack.A

portion of the flue gas sensible

heat is used to preheat

combustion air.

11.4 SOLID / HAZARDOUS WASTE MANAGEMENT:

Solid waste i.e. fly ash generation (26000 MTPA), which will be sold to the brick

manufacturer.


1. Coal washery Rejects

It is proposed to blend 20 % of imported

raw coal with Washery rejects; the mix

becomes a useful fuel with improved

calorific value of around 5.0 MWh

(thermal) per tonne. This is recycled &

sold to captive power plant near the

plant.e.g M/s KSK Plant.



Quantity of Solid Waste Generated

Sl. No. Item Description Norm(Loss) Quantity Quantity Pollution

2. Ore Beneficiation Slime

Tailing filter presses will be install for

collection in Twin ponds, one in use and

the other being emptied- filter cake is being

formed and sold to cement plant nearby.

3. Coal gasifier

Ash Ash collection system. Disposal through

Brick making

Dust in

outgoing

gases

Dust collection from outgoing flue gases.

Sold as Coal Dust

Tar

It will be stored in hazardous waste storage

tank. Disposal through selling it to

reprocessing industry.

4.

Rotary hearth

furnace/Nugget

Plant

Process dust To be recycled in the same unit.



TPA TPD Control

1 Coal

washery Rejects 5% 18000 55

Twin ponds

for collection

,one in use

and the other

being

emptied- filter

cake is being

formed and

sold

2 Ore

Beneficiation Slime 30% 633284 1863

Twin ponds

for collection

,one in use

and the other

being

emptied- filter

cake is being

formed and

sold

3 Coal gasifier

Ash 17% 24750 75

Ash collection

system.

Disposal

through

selling it to

Brick maker.

Dust in

outgoing

gases

0.50% 1800 5

Dust

collection

from outgoing

flue gases.

Disposal

through

selling it to

Brick maker.

4

Rotary

hearth

furnace

Dust from

the grinding

units and

20 Kg/t 8000 24

To be

recycled in

the system



Sl. No. Item Description Norm(Loss) Quantity

TPA

Quantity

TPD

Pollution

Control briquetting

plant and

screening

material.

Cyclone

type Dust

collector

system for

outgoing

flue gases

Solid Waste Generated and Their Control Measures


TPA

Quantity

TPD

Pollution

Control

1 Coal

washery Rejects 5% 18000 55

Twin ponds

for

collection

,one in use

and the

other being

emptied-

filter cake is

being

formed and

sold

2 Ore

Beneficiation Slime 30% 576000 1700

Twin ponds

for

collection

,one in use

and the

other being

emptied-

filter cake is




TPA

Quantity

TPD

Pollution

Control being

formed and

sold

3 Coal gasifier

Ash 17% 24750 75

Ash

collection

system.

Disposal

through

selling it to

Brick

maker.

Dust in

outgoing

gases

0.50% 1800 5

Dust

collection

from

outgoing

flue gases.

Disposal

through

selling it to

Brick

maker.

4

Rotary

hearth

furnace

Dust from the

grinding units

and

briquetting

plant and

screening

material.

Cyclone type

Dust collector

system for

outgoing flue

gases

20 Kg/t 8000 24

To be

recycled in

the system



12.0 GREEN- BELT DEVELOPMENT:

Locally available Tree Species and other Aromatic Plants are sown in linear parallel

fashion all along the periphery at 1.5 M c/c spacing. Green belt also developed along with

the Roads as well as the Fence and all the open land available at premises. Green belt will

be developed on 33% of the total land area as per MoEF & being strengthened regularly.

In view of the above we once again emphasize that kindly allow us construction activities

on the possession land i.e. 77 Acers for proposed plant & facilities based on revised

scope of the Project. Project was already accorded Environment Clearance after a

detailed Environment Impact Assessment study and subsequent Public Hearing and due

to reduction in the scope of Project, Impact of this project will also be reduced eventually

so further base line data generation and public hearing are not required. Therefore, we

request your kind self to exempt the base line data generation and public hearing and

revise the scope of Environment Clearance accorded to us on 10.09.2013.

13.0 RAINWATER HARVESTING SYSTEM

Rainwater harvesting in the present scenario holds vast potential in controlling runoff and

resulting water logging problems besides assuring an alternative source of water and a

supplement to existing natural resources in a wide variety of circumstances.

A rainwater harvesting system comprises components of various stages namely-

Transporting rainwater through pipes or drains.

Filtration

Storage in tanks for reuse or recharge.



\

Fig.- Design of Typical Recharge Pit

Rashi Steel and power limited is planning to have a system of rainwater harvesting at

village Paraghat and Beltukri, district Bilaspur, Chhattisgarh. Rainwater harvesting is

primarily dependent on various site characteristics such as soil property, catchments

characteristics; rainfall characteristics, and ground water tables etc.

There are artificial as well as natural rainwater harvesting systems. The collecting system

can be implemented for i) Individual units and ii) Centralized collection system

Scheme I: Collection of rainwater harvesting from individual building units. Rainwater

falling on other open area is to be collected, through constructed drainage system and

discharge system and discharge to surface out-fall (by passed for rainwater harvesting)

Scheme II: Construction of rainwater filter bed at centralized place where water from

individual unit as well as storm water from open area shall be diverted

The reference is hydrological data of Bilaspur from the IMD. The maximum rainfall in July

in the year of 2012-13 is 370 mm. The yearly rainfall is 1010 mm in 2012-13 and 996 mm



is the average rainfall in the last five year from 2007 to 2011. 1,16,700 m3 maximum water

will be collected from the rain fall in the rain water harvesting pond in a month.

Approximately 4,04,949 m3 water will be collected from the rain fall in the rain water

harvesting pond, which will fulfill the 47 days requirement of the plant.

Fig. Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the unpaved

areas and allowed to get absorbed. Also there would be proper storm water drainage

network to collect the excess storm water runoff.

14.0 SAFETY MEASURES

Company will provide full proof fire hydrant system & all kinds of fire extinguishers to

ensure the safe working environment. The workers shall be provided with face-mask,

hand gloves, moreover the production halls shall be fitted with exhaust fans etc.

The organization will establish, implement & maintain documented Occupational health

& safety objectives, at relevant functions & levels within the organization and training /

awareness program will be conducted on regular basis.

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