M/s. KASHVI INTERNATIONAL PVT. LTD.

Transcription

1 PRE-FEASIBILITY REPORT On Proposed 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. ( 4 W + 1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each. OF M/s. KASHVI INTERNATIONAL PVT. LTD. At-Champadihi, Keonjhar District,Odisha Prepared by:- SEPTEMBER-2014 VISIONTEK CONSULTANCY SERVICES PVT. LTD (An Enviro Engineering Consulting Cell) Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Phone No. : , , Fax: visiontekin@yahoo.co.in, visiontekin@gmail.com Visit us at -

2 TABLE OF CONTENTS Sl. No. Particulars Page No. CHAPTER-1 1 Executive Summary Introduction Project Description Site Analysis Land Use Planning Proposed Infrastructure Rehabilitation & Resettlements (R & R) Plan Project Schedule & Cost Estimates Analysis of Proposal 7 CHAPTER-2 INTRODUCTION 2.1 Introduction Identification of Project & Project Proponent Description of Nature of the Project Need of the Project & its importance to the Country and/or Region Demand-Supply gap Export Possibility Employment Generation(Direct & Indirect) due to the Project 13 CHAPTER-3 PROJECT DESCRIPTION 3.1 Type of Project Location & Accessibility Site Selection Size of Magnitude of Operation Project Description Plant & machinery Source Raw Materials Requirements Water & Power Requirement Pollution Control Measures Schematic representations of the feasibility drawing which give information of eia purpose. 42

3 CHAPTER-4 SITE ANALYSIS 4.1 General Connectivity Topography Existing Land Use Pattern Existing Infrastructure Climate Data 44 CHAPTER-5 PLANNING BRIEF 5.1 Planning Brief Population Projection Land Use Planning Amenities & Facilities 47 CHAPTER-6 PRPOSED INFRASTRUCTURE 6.1 Industrial Area Residential Area Green Belt Social Infrastructure Connectivity Drinking water Management Sewerage System Industrial Waste Management Solid Waste management Power Requirement & Supply/ Source 52 CHAPTER-7 REHABILITATION & RESETTLEMENT(R & R) PLAN 7.1 Policy to be adopted for R & R w.r.t Project 53 CHAPTER-8 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule Project Cost 56 CHAPTER-9 ANALYSIS OF PROPOSAL 9.1 Financial & Social Benefits Other Benefits 58

4 LIST OF TABLES Sr.No PARTICULARS PAGE No. 1.0 Product Profile Requirement of Raw Materials Waste Water Generation & Reuse Solid Waste Generation & Management Project Profile Project demand of Indian Iron Ore Pellets Demand,Availability & resultant gap(-)/surplus(+) for Pellets(MTPA) Avg. domestic demand of Pellets(SF+DR grade) World DRI Production by year Projected demand of Indian Iron Ore Pellets Domestic/Export Markets Category wise breakup of Manpower Production capacity of the Company Typical Analysis of input raw materials Consumption Norms of Raw Materials Comparison of qualities of BF & DR Grade pellets Storage Details of Major Materials Requirement of Raw Materials Water Requirement Source of air pollution & control Measures Waste Water Generation & Reuse Solid Waste Generation & Management Domestic Solid Wastes Hazardous Wastes Weather Analysis Report Land Use Break-Up Solid Waste Generation & Management Project Cost Break- Up 57

5 LIST OF FIGURES Fig. No. Particulars Page no. 3.0 Plant Location TOPO Map(10 Km Radius) Process Flow Chart for 0.6 MTPA Pellet Plant Schematic Diagram Plant Layout Water Balance Schematic Representation 43

6 CHAPTER - I EXECUTIVE SUMMARY 1 Name of the project Proposed an Iron Ore Pellet Plant of Capacity 0.6 MTPA & 5 Nos. (4w+1s) Producer Gas Plant of Capacity 5000 Nm³/hr each. 2 Sl. No. in the schedule 3(a) 3 Registered Office Plot No.1234(P), Govind Prasad,Bomokhal,CuttackPuri,Bhubaneswar Name of the promoters Er. Debabrata Behera Plot No.1234(P), Govind Prasad, Bomokhal, CuttackPuri, Bhubaneswar Present Business Power & Steel 6 Area of Plant Acres 7 Topo Sheet No. 73G/5 & 73G/9 8 Latitude N Longitude E Proposed Capacity 0.6 MTPA Pellet Plant & 5 Nos(4 w+1s) Producer Gas 9 Plant of 5000 Nm³/hr each. 10 Cost of Project Lakhs 11 Manpower Requirement 93 People 12 Power Requirement Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Sub-station of OPTCL at Palaspanga Nearest Railway Station/airport along Nayagarh Railway Station-6 km. with distance in kms. Bhubaneswar Airport-185 km. Nearest town, City, District Head Jhumpura km. quarters along with distance in kms. 15 Village Panchayats, had,municipal Zilla Paris corporation, Local telephone nos. to be given) body (complete postal addresses with telephone no.s to be given) At- Champadihi Block & Tehsil- Jhumupra Village Panchayat-Kutugaon Zilla Parishad-Keonjhar District- Keonjhar, Odisha Page 1

7 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. 1.0 Introduction 1.1 Identification of Project and Project Proponent M/s Kashvi International Pvt. Ltd. has proposed to setup an iron ore pellet plant of capacity 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each At-Champadihi, Keonjhar District, Odisha. The Kashvi International Pvt. Ltd (hereinafter referred to as KIPL ) is and having its Registered office At-Plot No.1234(P), Govind Prasad, Bomikhal, Cuttack-Puri Road, Bhubaneswar. M/s Kashvi International Pvt. Ltd. is part of the Kashvi Group of Keonjhar, Odisha having decades of experience in Iron Ore Fines trading, Iron Ore Lumps crushing & screening, Road Logistic & Mineral Export Business. The goal of the group is to promote & get stream lined in state's mission of prosperity through Industrialization by employing its own work force. In the past business of the company, it has basically employed mostly local professional & work men. It has specifically emphasized to even employ State's specialized organization for its Projects. The other associated companies of the promoter are: M/s Kashvi Power & Steel (P) Ltd. M/s D.B. Minerals (P) Ltd, (Iron Ore Crushing & Screening Unit). M/s D.B. Road ways (Road logistic Company). M/S Hotel Kashvi International (Star category Hotel). Promoters The promoters of the project are Mr.Debabrata Behera, who is the Managing Director of the Company & he has wide experience in multiple business activities, co-promoter of the project is Mrs. Sushmita Behera who is very apt in relationship business & manages the Hotel & Restaurant business of the group. The promoter is a dynamic and resourceful person. He is a Civil Engineer having wide experience in Construction, Road logistics, Hotel business, Real estate business. Previously he was also doing trading of Sponge Iron manufactured by Orissa Sponge Iron & Steel Ltd. to different parties in Odisha and outside Odisha also. He is also a member of All India Sponge Iron Manufacturer Association (SIMA) & Odisha Sponge Iron Manufacturer Association (OSIMA). The promoter belongs to a well established business family of Keonjhar. Mr Debabrata Behera is now a day managing four minerals related Companies through export activities. Apart from the above mentioned business promoter is having one star category hotel & restaurant at Keonjhar namely M/S Hotel Kashvi International which is running successfully for last three years. Mr. Debabrata Behera belongs to Keonjhar and has rich contacts over here due to operation in the similar business since last fifteen years. He can arrange procurement of raw materials smoothly. M/S D.B. Roadways is a partnership firm whose main business is Page 2

8 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. transportation in which Mr. Debabrata Behera is also a partner & hence raw material can be easily transported to any site in the country. 1.2 Employment Generation It is estimated that the total employment generation due to the proposed project will be Project Description 2.1 Location The proposed Project will be located at Champadihi Village, Keonjhar District of Odisha State (Ref: Topo sheet 73G/5 & 73G/9). The Latitude and Longitude of the proposed site N and E respectively. 2.2 Site Selection Site is located at Champadihi, District- Keonjhar in the state of Odisha. The site has following facilities: 2.3 Proximity to the sources of base raw material, Availability of common Infrastructure facilities / utilities (water / power etc.), Technology Selection Technology selection involves an analysis of past achievements, present status and future prospects of each technology under consideration keeping in view the following criteria. Availability of project plant capacity/module. Suiting to selected product mix & raw materials Conservation of scarce inputs such as power & water. Considerations of capital cost & maintenance cost. Plant is going to utilize Iron ore fines to produce iron ore pellet using combination of producer gas and furnace oil as fuel in the pellet plant. All units shall be based on Advanced Process technology. 2.4 Product Profile M/s Kashvi International Pvt. Ltd. intends to set up an iron ore pellet plant to produce iron ore pellet of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1S) Producer Gas Plant of Capacity 5000 Nm³/hr each at Champadihi, Keonjhar District, Odisha. Page 3

9 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Table 1.0 Product Profile SI. No. Units Product Configuration Capacity 1 Iron ore Pelletization Plant Iron Ore Pellet 1x0.6MTPA 6,00,000 TPA 2 Producer gas Plant Producer gas(gcal) 5 Nos. (4W+1 S) 5000 Nm³/hr each 2.5 Raw Material Requirement Table 1.1 Requirement of Raw Materials Sl No. Description Quantity Source Mode of Transport 6,48,000 Odisha(KJS Ahluwalia, RP Sao, MESCO Steel, Kalinga Mining) Road/Rail A. Pellet Plant 1 Iron Ore Fines 2 Bentonite 6,000 Rajasthan Road/Rail 3 Coke 18,000 Rourkela Steel Plant, Rourkela Road/Rail 4 Limestone 18,000 Sundergarh, Odisha Road/Rail MCL, Odisha & ECL, Jharkhand Road/Rail B. Producer Gas Plant 1 Steam Coal Total 60,000 7,50,000 Water and Power Requirement For the project the water requirement is about 15 m3/hr (4 m3/hr from Baitarani River & 11 m3/hr from ground water). This will be sufficient for the present requirement. Further the River Baitarani is passing very close to the site. Further the promoters have plan to harvest the rain water for efficient use of it. Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Substation of OPTCL at Palaspanga. Further the promoter will have the DG sets to meet the emergency power requirement. 2.6 Waste Generation and Management Waste water generated from pellet plant and others is depicted below. Table 1.2 Waste Water Generations and Reuse Process Unit Pellet Waste water qty (m3/day) Source No waste water Cooling generation. Cooling water will be completely recycled. Waste water characteristics High Temp Waste water management Complete recirculation Page 4

10 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Raw water 9.5 treatment system 14.5 Backwash TSS from filtration unit TSS Underflow of clarifier Will be treated in settling tank and taken to guard pond for reuse Domestic Domestic use TSS, BOD, Oil & from plant Grease Will be treated in STP and reused for greenbelt Gas Cleaning Phenol, Ammonia, Section Cyanide, BOD,COD Will be treated in ETP and treated water used in dust suppression, greenbelt Producer Gas 2.50 Plant Table 1.3 Solid Waste Generation and Management Units Solid Wastes Pellet plant Dust from APC devices 350 Broken Pellet 660 Raw water treatment plant Sludge Producer Gas Plant Bottom Ash 3.0 Site Analysis 3.1 Connectivity Qty In TPA 6 10,000 Disposal practice Reused making in Will be used landscaping pellet for Will be used in filling low laying areas. The site is well connected with road. The project site is only 12 km from Kotolposhi and 4 km away from the village Nahabada. Kotolposhi is on NH-215. NH 215 is from Panikoili (on NH5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance from Kortolpshi to Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is very close to the site. Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi. The railway facility is also available near to the site. The nearest Railway station is Nayagarh in Joda area and is only 6 km away from the project site. Nearest airport is at Bhubaneswar, 185 Km from proposed project site in its Southern side. 3.2 Topography and Existing Land use Pattern The topography of the land is generally flat and well suited for development of industrial projects. Project / Plant is coming under the non- forest category land. Page 5

11 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. 3.3 Climate Data The climate of the Keonjhar district is characterized by hot summer with low humidity. During the summer maximum temperature is C. The temperature in the month of December is lowest i.e C. Sometimes it even drops down to 70 C. The average annual rainfall is mm. 4.0 Land Use Planning Total land requirement for the proposed unit is about acres which is already identified and acquired. 5.0 Proposed Infrastructure 5.1 Industrial Area The setting up of the Main Plant Facilities, Raw Material Storage, Ash Storage, Raw Water Storage Reservoir & Treatment, Auxiliary facilities, viz. Administrative Building, Technical Building, Workshop, QC Lab, Switch Yard, etc. & Green belt required is 6.49 Acres land out of which acres. Company uses nearest road for goods transportation and equipped with all other required facilities. 5.2 Green Belt A greenbelt development plan will be prepared and implemented along with the project. Total green belt area shall be 33% (6.49 Ac) of total area (i.e Ac). The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas Others A garland drain around the plant along boundary is envisaged to collect surface run-off during rainy season. Additional drinking water facilities will be provided for employees as well as nearby villagers. Rehabilitation & Resettlements (R & R) Plan The proposed project is going to setting up on acres area. Total land has already been identified and acquired. There is no existence of displaced habitants in the identified land. Land is also devoid of any vegetation. Local people will be engaged for construction and operation activities and the local area have all the infrastructure facilities. Here no housing colony/township is envisaged. 7.0 Project Schedule & Cost Estimates 7.1 Project Schedule The total project implementation schedule is 18 months from zero date, land development. The external agencies such as consultant, machinery suppliers, contractors of civil construction and Page 6

12 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. equipment will be selected carefully well in advance. 7.2 Project Cost An indicative estimated capital cost of the proposed Plant is Rs Lacs, including the preoperative expenses, contingency and interest during construction. 8.0 Analysis of Proposal The socio-economic benefits of the proposed project are as follows: Improvement and construction of road network in the nearby villages. Extension & renovation of Local School buildings with playgrounds. Social awareness programme will further improve the quality of life and standard of living such as sanitation and hygiene, HIV Prevention Programme etc. Implementation of adult education and female education programmes in the villages surrounding the project area. Financial assistance to talented and poor students for higher studies.(management/engineering/medical science) Expected to employment are 93 persons. Page 7

13 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. CHAPTER 02 INTRODUCTION 2.1 Introduction M/s Kashvi International Pvt. Ltd. has proposed to setup an iron ore pellet plant of capacity 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each At-Champadihi, Keonjhar District, Odisha. The Kashvi International Pvt. Ltd is having its registered office At-Plot No.1234 (P), Govind Prasad, Bomikhal, Cuttack-Puri Road, Bhubaneswar. 2.2 Identification of Project and Project Proponent M/s Kashvi International Pvt. Ltd. is part of the Kashvi Group of Keonjhar, Odisha having decades of experience in Iron Ore Fines trading, Iron Ore Lumps crushing & screening, Road Logistic & Mineral Export Business. The goal of the group is to promote & get stream lined in state's mission of prosperity through Industrialization by employing its own work force. In the past business of the company, it has basically employed mostly local professional & work men. It has specifically emphasized to even employ State's specialized organization for its Projects. The other associated companies of the promoter are: M/s Kashvi Power & Steel (P) Ltd. M/s D.B. Minerals (P) Ltd, (Iron Ore Crushing & Screening Unit). M/s D.B. Road ways (Road logistic Company). M/S Hotel Kashvi International (Star category Hotel). Promoters The promoters of the project are Mr.Debabrata Behera, who is the Managing Director of the Company & he has rich experience in multiple business activities, co promoter of the project is Mrs.Sushmita Behera who is very apt in relationship business & manages the Hotel & Restaurant business of the group. The promoter is a dynamic and resourceful person. He is a Civil Engineer having wide experience in Construction, Road logistics, Hotel business, Real estate business. Previously he was also doing trading of Sponge Iron manufactured by Orissa Sponge Iron & Steel Ltd. to different parties in Odisha and outside Odisha also. He is also a member of All India Sponge Iron Manufacturer Association (SIMA) & Odisha Sponge Iron Manufacturer Association (OSIMA). The promoter belongs to a well established business family of Keonjhar. Mr Debabrata Behera is now a day managing four minerals related Companies through export activities. Apart from the above mentioned business promoter is having one star category hotel & restaurant at Keonjhar namely M/S Hotel Kashvi International which is running successfully for last three years. Mr. Debabrata Behera belongs to Keonjhar and has rich contacts over here due to operation in the similar business since last fifteen years. He can arrange procurement of raw Page 8

14 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. materials smoothly. M/S D.B. Roadways is a partnership firm whose main business is transportation in which Mr. Debabrata Behera is also a partner & hence raw material can be easily transported to any site in the country. 2.3 Description of Nature of the project is going to install 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each. At-Champadihi, Keonjhar District, Odisha. Table 2.0 Project Profile SI. No. 1 2 Units Product Configuration Capacity Iron ore Pelletization Plant Producer gas Plant Iron Ore Pellet 1x0.6MTPA 6,00,000 TPA Producer gas(gcal) 5 Nos. (4W+1 S) 5000 Nm³/hr each The object of the process is to transform the finer size iron ore into hardened pellets that can be used as blast furnace feed or direct reduction kiln feed. The transformation is achieved by the Grate Kiln. The Grate transfers the green pellets through a series of controlled temperature zones to produce a preheated pellet at temperature C, which is then feed into the Rotary Kiln. The Rotary Kiln finishes the Induration Process and operates at C. The Indurated Pellets then fed to an Annular Cooler, where the pellets are cooled to a suitable temperature for transporting on a belt to load out facilities. The gases from the Annular Cooler are recycled to the Kiln and the Grate, resulting in the Grate-Kiln-Cooler technology being the most energy efficient system for producing Indurated Pellets. 2.4 Need of the Project and its Importance to the Country and/or Region Visualizing the demand of iron and steel in the country and to promote maximum value addition within the state, the state government of Odisha has signed number of MoU for establishment of steel plants in Odisha. The present reserves of high grade iron ore within the state suitable for manufacture of Iron and steel is very much limited and will be consumed within coming 20 to 25 years, if all the steel projects will be established as per MoU signed. Therefore, there is an urgent need for utilization of iron ore fines lying in huge quantity in all the iron ore mines located in Barbil-Joda sector of Keonjhar district. This iron ore fines is the raw material for the Pellet Plant. The abundance of iron ore fines in Joda Barbil area led the Management to establish the Iron Ore Pellet Plant at village Champadihi, Kotolposi,Joda, Keonjhar District, Odisha which will be ultimately used for steel making through blast furnace/dri route. Page 9

15 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. In the light of above the availability of iron ore will continue to be in big concern in future. The country has abundant reserves of iron ore fines and dumps which can be beneficiated and used in the production of sponge iron & steel making. Therefore, there is huge scope of iron ore pellet plant to convert iron ore fines for steel making which will not only be helpful in enhancement of reserves inventories of desired iron ore grade but also will be helpful to recover the valuable land, which has been covered under iron ore fines dumping. Steel finds wide applications in our day to day life. Various key industries like construction, transport, communication, agriculture and energy cannot sustain without steel. The manufacturing process from iron ore to finished product involves production of a large number of intermediate products. All the intermediate products have a domestic as well as a global market. 2.5 Demand Supply Gap Global capacity and production The Pellet market consists of a group of sellers controlling a majority of Pellet capacity worldwide. Long term contracts for supply of Pellets are the norm in the industry. Some of the largest Pellet manufacturers are from Latin America & Sweden. The market leader in the industry is CVRD (Brazil) whose prices are generally considered as benchmark price for pellets. In the export market, the present and future DRI/HBI producers in Southeast Asia, Middle East and North Africa have given them a definite advantage over the suppliers from Brazil, North America and Sweden. The Pellet deficiency in the target market is being currently met from South America (CVRD, Samarco) and Europe. In view of potential market in South East Asia region and export of iron ore Pellets by India in the past, a provision of 40% of total anticipated domestic demand of Pellets is kept for export demand for iron Pellet has been worked out and given in Table. Table 2.1 Project demand of Indian Iron ore Pellets: Demand Year Domestic Export Total * Extrapolated from Demand of Metallic & Compilations from various data sources. Page 10

16 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Resultant demand-supply scenario Based on the demand and availability discussed in the previous paragraphs, the resultant gaps/surpluses of Pellets have been worked out and presented in the following table: Table 2.2 Demand, Availability and resultant gap (-)/surplus (+) for pellets (MTPA) Years Demand Domestic Total Export ) Availability Gaps(-)/surpluses (+) Domestic Export 4800 (+)4800 (-) (-)5700 (-) From the above table, it may be observed that country is likely to face a shortage of about 5.7 Mt of pellets by With export demand, the gap may further widen. Under the circumstances, addition of Pellet plant capacity in the country is necessary. As discussed above Pellet is considered to be a superior feed stock for any primary Iron making process. While Smelting Reduction Processes and Direct Reduction Processes is currently utilizing Pelletized ore, Blast Furnace based process still prefers to use sinter as it is produced in-house. However sinter plants are not very environment friendly, as such it is predicted that slowly Blast Furnace will start using a part of its burden as Pellet. With increasing trends of Pellet usage in Blast Furnaces there shall be great demand from steel in next few years. The steel demand and its growth is as given below: Steel Demand Forecast by Gross Domestic Products (GDP) Domestic demand for steel can be related to GDP. Analysis of data for the last several years shows a very high level of correlation between GDP and steel demand. On conservative basis, assuming present growth rate of 8% to be constant (as projected by Finance Ministry) the projected demand with respect to this growth rate is as shown below. (Sensitivity with Table: Steel Demand Forecast Respect to constant GDP to constant GDP Growth Rate) Year Project Demand of Finished Steel (In Million Tones) Projections are based on base year apparent consumption i.e. 38MT In India 90% of steel is consumed by 15% of the population while the balance 10% goes to remaining 85% population. India being a developing country, it is definite that moderate urbanization of some rural area is to take place in the near future, thereby boosting the Page 11

17 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. consumption of steel to a considerable extend. In view of this authors opine that the projected demand of steel by year 2012 would be around 60 million tones. Also out of 60 million tonnes of steel it has been estimated that around 45 million tonnes of steel shall be produced through Blast Furnace route. With a moderate use of iron ore pellet (20% in burden) the demand for pellet would be around 20 million tones. Pellet Demand Considering the projected production of DRI and share of iron ore pellets in iron bearing feed materials in coal based DRI units, demand of iron ore pellets works out to 0.64 Mt in and 2.6 Mt. in Anticipated total demand of DR Grade for gas based units as well as coal based units works out to 7.6 Mt in and 11 Mt. in Aggregate domestic demand of iron ore pellets is furnished in Table: Table 2.3 Average domestic demand of Pellets (SF + DR grade)('000 Tons) Year SF Grade DRI Grade Total The world sponge iron production has increased from 0.79 million Mt in 1970 to over 43.2 million Mt in Worldwide the sponge iron production increased by 2.5% to 43.2 million tones in 2000 despite a slump in steel market. The increase was due to a number of large DRI plants started in late 1997 & early 1998 and heavy demand from steel manufacturers. The high quality of this product is the main factor affecting growth in production of sponge iron. Table 2.4 World DRI Production by year. Year Quantity (in Million Tonne.) Year Quantity (in Million Tonne.) The sponge iron requirement & its production are increasing day by day due to increase in metallic requirement for steel making. India became the third largest producer of sponge iron with the production of 5.40 million Mt in 2000 and the largest producer in the year 2001 with a production of 5.7 million Mt. Venezuela has been the largest producer of sponge iron in 2000 Page 12

18 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. with production of 6.41 million Mt. Mexico has placed second with 5.90 million Mt production, India was third with 5.40 million Mt production and Iran was fourth with 4.54 million Mt production. These four countries are sharing almost 53% of the world's total sponge iron production. 2.6 Export Possibility Export Market for Iron Ore Pellets. In view of potential market in South East Asian region and exports of Iron Ore Pellets by India in the past, a provision of 40% of total anticipated domestic demand of pellets is kept for export for the present study. Accordingly, the export demand for iron is pellet has been worked out and given in Table: Table 2.5 Projected demand of Indian Iron Ore Pellets (Million Tonnes) Demand Year Domestic Export Total Export Possibility. Competition in exports is mainly from CVRD (Brazil), LKAB (Sweden), GIIC (Bahrain) and Savage River (Australia). In view of the present situation, FISPL will have two main competitive advantages viz. Proximity to China and other Asian Markets Customer needs to maintain less inventory Lower freight costs Further, supply from Indian Pellet producers will be advantageous to the Customer of lower lead-time for supplies, lower voyage time and lesser inventory holding costs. Table 2.6 Domestic/Export Markets Years Demand Total Availability Gaps(-)/Surpluses( +) Domestic With Exports Domestic Exports (+) 4800 (-) (-) 5700 (-) Employment Generation (Direct and Indirect) Due to the Project Basis of manpower estimate The manpower estimates have been made taking into consideration the following aspects: Page 13

19 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. a. The proposed organization structure, production processes involved, layout, equipment with its degree of automation and mode of operation. b. Additional manpower over and above the daily requirement at the rate of twenty-five (25) per cent is provided to cater weekly off, holidays, leave, absenteeism etc. for departments/sections working seven days a week. c. The operation staff will be required to carry out routine checking of their own plant and equipment as well as minor repairs and adjustments in addition to plant operation. Moreover, during equipment shutdown for maintenance, the operation personnel will assist the maintenance personnel in carrying out the maintenance tasks to maximize the utilization of manpower. d. The maintenance personnel will have multi-disciplinary skills; for example, mechanic will be able to perform simple machining, welding and gas cutting. Implementation of such concept will optimize the utilization of human resources and thereby will increase labour productivity of the plant which, in turn, will reduce the cost of production. e. Implementation of computer systems including local area network (LAN) with standard user friendly software's in the field of financial management, human resource management, personnel management, materials management, order scheduling, sales and marketing management, management information systems (MIS), production planning and control, maintenance and spares planning, etc. has been considered to increase work efficiency and to reduce manpower requirement. f. For security services, canteen and catering services, horticulture and landscaping services, sanitary services, personnel transport, heavy maintenance and capital repairs, plant civil maintenance, general cleaning and up-keep of the plant, loading and unloading of materials, product handling, stores handling, and other miscellaneous semi-skilled and unskilled job, appropriate external agencies will be employed under management supervision. Total manpower requirement Based on the above, it is estimated that the manpower requirement for the proposed plant will be about 93 persons, comprising 67 persons for pellet plant and 26 persons for producer gas plant. The details of manpower estimate for administration and works departments are presented in Table 2.7 Page 14

20 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Category-wise breakup of manpower Category of personnel required in each job position for all departments is indicated in Table 2.7. The category-wise breakdown of manpower for administration and works departments of the plant is given in Table 2.7. TABLE 2.7 Category-Wise Breakup of Manpower Sl. No. Category Pellet Plant Producer Gas Plant Total 1 Manager Supervisor Skilled Workers Un-skilled Workers TOTAL Training It is presumed that the personnel in the administration departments having requisite qualification and experience will be available from the local market and they do not normally require any specific training. It is expected that their recruitment will be progressive depending upon the requirement during the construction period and will be completed before commissioning of the plant. For works departments, most of the key positions in operation and maintenance of the proposed plant at different categories will be manned by the qualified persons having experience in the similar field in metallurgical industries and attitude to learn new technologies. However, depending on the type of equipment/facilities along with the degree of automation contemplated, the operation and maintenance personnel of the plant so recruited will require specific need based training which is proposed to be carried out on-site by the respective equipment supplier during equipment erection, start up and commissioning of different plant units. Page 15

21 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. CHAPTER - 3 PROJECT DESCRIPTION M/s Kashvi International Pvt. Ltd. Intends to set up an iron ore pellet plant to produce iron ore pellet of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W + 1S) Producer Gas Plant of Capacity 5000 Nm³/hr each At-Chamapdihi, Keonjhar, Odisha 3.1 Type of Project The proposed project is a Greenfield independent project envisaged to produce BF and DRI grade iron ore pellet through iron ore pellet plant. Plant shall be based on Advanced Process technology. The plant will also be equipped with the most efficient auxiliary sub systems, material handling facilities and pollution control equipment. 3.2 Location & Accessibility The proposed Project will be located at Champadihi Village in Keonjhar District of Odisha State (Ref: Topo sheet No. 73G/5 & 73G/9. The Latitude and Longitude of the proposed site N and E respectively. a. Road Connectivity: The site is well connected with road. The project site is only 12 km from Kotolposhi and 4 km away from the village Nahabada. Kotolposhi is on NH-215. NH 215 is from Panikoili (on NH-5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance from Kortolpshi to Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is very close to the site. Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi. b. Rail Connectivity: The railway facility is also available near to the site. The nearest Railway station is Nayagarh in Joda area and is only 6 km away from the project site. c. Airport: Nearest airport to the project site is Bhubaneswar at a distance of 185 kms. d. Seaport: Nearest Seaport at Paradip is located at a distance of about 216 km from the project site. Page 16

22 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Fig 3.0 Plant Location Page 17

23 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Fig 3.1 TOPO MAP (10 Km Radius) Page 18

24 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. 3.3 Site Selection The selection of project site/location has been based on the following considerations. Proximity to the sources of raw material (iron ore fines), Availability of Infrastructure like power. Land for proposed project does not involve any displacement of habitation or any diversion of forest / vegetation. The site is well connected with road. The project site is only 12 km from Kotolposhi and 4 km away from the village Nahabada. Kotolposhi is on NH-215. NH 215 is from Panikoili (on NH-5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance from Kortolpshi to Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is very close to the site. Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi. Access to high growth domestic steel markets and future industrial and infrastructure development has been planned. Availability of water from Baitrani River. 3.4 Size or Magnitude of Operation Table 3.0 Production capacity of the company SI. No. 1 2 Units Product Configuration Capacity Iron ore Pelletization Plant Producer gas Plant Iron Ore Pellet (1x0.6MTPA) 6,00,000 TPA Producer gas(gcal) 5 Nos. (4W+1 S) 5000Nm³/hr each 3.5 Project Description Process Description Pelletization Plant Design basis: System design of a Pelletizing Plant is carried out on the basis of desired capacity, quality of raw materials, desired product quality as well as the process parameters established through appropriate test work. Such test work is yet to be undertaken for the proposed Pelletizing Plant. Accordingly, suitable assumptions have been made for design of the system including equipment selection, based on Consulting Engineers' experience in similar projects and in-house information on the subject. Plant capacity: The pellet plant will be designed to produce 0.6 MTPA pellet & 5 Nos. (4 w+ 1 s) Producer Gas Plant of capacity of each unit 5000 Nm³/hr each. Annual pellet production capacity, million tons : 0.6 MTPA Producer Gas Plant : 5 Nos. (4 W +1 S) Capacity of each unit-5000 Nm³/hr each No. of working days per year : 330 days Working hours per day in 3-shift operation : 24 Page 19

25 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Based on the above assumptions, the effective annual working hours amount to 7,920 hours and pellet production rate works out to about 76 tons per hour. All equipment shall be selected by keeping a 15 per cent design margin. Also the sizing of equipment shall take care of other process fluctuations Quality of raw materials The typical analysis of input raw materials envisaged for the production of pellets are given in Table below Table 3.1 Typical Analysis of Input Raw Materials Raw Fe SiO2 Al2O3 CaO MgO LOI Calorific Value Materials % % % % % % (Kcal/kg) Bentonite Limestone Coke >5700 Iron ore fines Oxide Feed Stock Pellets can be made from both hematite and magnetite concentrate. Magnetite concentrate, if available, is the preferred oxide feed, as use of the same reduces the external energy input requirement and results in higher productivity. However, the proposed Pelletizing plant is planned to be based on hematite iron ore mainly available in the region. Source of Iron Ore concentrate/fines will be from Serajuddin & Co, R.P. Sao, T.P.Sao, KJS Ahluwalia Mines etc. from Joda and Barbil sector. Binders For the formation of green ball of adequate strength and fired pellets of specific quality, it is necessary to add a suitable binder. Bentonite is the most popular binder in use. Bentonite is a latticed layered-structure clay material, capable of absorbing large quantity of water. When water is added, it swells and forms a gel-like mass. This property is the most important characteristic for its bonding capability. Coke breeze Coke/Coal is added to improve the Furnace productivity and overall fuel economy. Additives Additives are often used to modify the chemistry of Pellets, specially the slag forming constituents. Additive generally used is limestone, for basically adjustment as well as for other likely benefits, such as improvement in pellet strength and porosity. Page 20

26 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha Fuel Fuel will be required in Pelletizing plant for heat hardening of green pellets in the Grate and Rotary Kiln. In this regard, natural gas and heavy oil have high calorific value, are clean burning, provide operational flexibility and are convenient for use as fuel. However, natural gas is not available in the region and heavy oil is costly. A likely alternative fuel is Coal. There are instances of large plants being run successfully with coal fired Gasifier. It is also reported that fuel cost could be economized to the extent of about 50 percent by replacing heavy oil with Producers gas for firing the Grate and Rotary Kiln. For Producers gas based Grate and Rotary Kiln, about 25 per cent of total thermal energy may be required to be supplied by oil for starting as well as for maintaining requisite temperature profile in the preheating zone. However, use of coal makes the Grate, Rotary Kiln and the product vulnerable to ash deposition. Therefore, it is necessary to be selective about the characteristics of the coal intended to be used as fuel in a Grate and Rotary Kiln. The desired coal characteristics should generally conform to the E and F grade having FC little above 45. Specific requirement of thermal energy for production of one ton of pellet is about 250,000 Kcal. An advantage of Grate Kiln Technology is that 75% of thermal energy can be provided from low ash coal for maintaining flame of burner of kiln and the balance 25% from fuel oil for maintaining the temperature gradient within the Grate. Low Sulphur High Stock (LSHS) oil with calorific value about 10,000 Kcal per Kg is envisaged for this purpose. Some amount of LSHS oil will also be required for preheating purpose. 16 liters of oil will be consumed to produce 1T of iron ore pellet Consumption of input materials The consumption of raw materials will vary depending upon the grade and basic requirements. These will have to be computed on the basis of test results. In the absence of test work, suitable assumptions in respect of consumption rates have been made for the purpose of the report and the same are given in Table below: Table 3.2 CONSUMPTION NORMS OF RAW MATERIALS Sl No. Description Quantity Source Mode of Transport A. Pellet Plant 1 Iron Ore Fines 6,48,000 Odisha(KJS Ahluwalia,RP Sao,Mesco Steel,Kalinga Mining) Rail/Road Page 21

27 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. 2 Bentonite 6,000 Rajasthan Rail/Road 3 Coke 18,000 Rourkela Rail/Road 4 Limestone 18,000 Sundergarh, Odisha Rail/Road Steam Coal 60,000 MCL, Odisha & ECL, Jharkhand Rail/Road Total 7,50,000 B. Producer Gas Plant 1 NOTES: (1) Quantity on dry basis (2) Quantity excluding moisture and handling losses (3) To be added depending upon the end use Process Flow Description Page 22

28 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Fig 3.2 Process Flow Chart for 0.6 MTPA Pellet Plant Page 23

29 Major equipment and facilities: The Pelletizing Plant will mainly consist of the following sections: A. Iron ore fines storage and handling Grinding B. Filter press C. Storage & handling of Filter cake, Binder and Additive D. Proportioning and Mixing E. Balling, Induration and Cooling F. Finished Product Storage Iron ore fines storage In coming Iron ore fines will be stored in storage yard. Grinding Section At the storage yard the Iron Ore Fines are charged into a hopper which transfers the material to the ball mill through a conveyor. In the ball mill the incoming iron ore fines which is of -6mm is grinded (with water) to 45 micron. This material goes to a screen, where 45 micron goes to the Thickener & +45 micron material goes back to the ball mill. The capacity of the Ball Mill is 100 TPH. The material from the Thickener goes to the Filter Press through an Agitator. Filter Press In the Filter Press the moisture is taken out and cakes are formed. The cakes formed can be directly taken to the Proportioning bins or can be stored in the storage shed. Proportioning System There are five bins in the Proportioning building. Two bins for Iron Ore concentrate, one bin for Bentonite, one bin is for coke and one bin for limestone. Under the bins are belt conveyors and belt weighers. From these bins required quantity of materials are transferred to the mixture machine & in Mixture machine iron ore cake, Bentonite & limestone are properly mixed. Pelletizing Section The blended materials shall be carried by a belt conveyor to the upper portion of the Pelletizing building and discharged into two blending bins separately. The blending bin is equipped with a 1.0 meter wide conveyor along with belt weigher from where the material is fed to the Pelletizing disc, whose speed and tilting angle are both adjustable. Green balls are then produced & are collected by a belt conveyor and transferred to the system of green ball screening and distribution. Page 24

30 Green Ball Screening & Distribution System It consists of Oversize Roller Screen, Wide belt conveyor, Roll distributor and Belt conveyor returning fines. The Green balls passes through Over size Roll Screen where the over size (+16 mm) Green balls are separated & collected by a belt conveyor to be conveyed back for reuse. The under sized (-16 mm) is conveyed by a Wide belt conveyor to the Roller conveyor. In the Roller conveyor -6 mm are separated & +6 mm to -16 mm is passed on to the Indurating Kiln & the under sized Green balls (-6 mm) is collected by a belt conveyor & conveyed back to the Disc Pelletizer. Induration The Pellet Induration system mainly consists of three major equipments: Traveling Grate, Rotary Kiln and Annular Cooler. Traveling Grate It consists of Drying and Pre-heating. The main heating source in the drying zone is the waste gas from the cooling zone and partially from the hot gas from the pre-heating section. The main heating source in the pre-heating zone is the waste gas from the Feed End of the Rotary Kiln with temperature of 11000C. Temperature in the Grate for Drying is maximum 9500C to10500c. Rotary Kiln: After Pre-heating, the Pellets are discharged to the Rotary kiln where the roasting is done. Pellets receive heat in the Rotary kiln evenly as Pellets are roasted while rotating. The temperature in the Rotary kiln is maintained at 1100 to C. Rotation speed of the kiln can be regulated in accordance with different material so as to determine its retention time and to determine the quality of Pellet. Discharge end of the kiln is equipped with specially designed Burner. The Burner can use either Liquid fuel or Producer gas for thermal energy. Annular Cooler Hot Pellets with temperature of around 12500C are discharged to the Annular Cooler. Normal cooling time in the Cooler is 45 to 50 minutes. Cooling of the hot Pellets is done by air from number of Blowers. Hot gases from the Cooler are recycled back to the Rotary kiln and the Traveling grate for use. Finished product handling and storage The hardened and cooled Pellets will be screened for removal of any -6 mm Pellets generated during transfer. Undersize material from the screen will be recycled to the plant. The +16 mm Pellets obtained as oversize fraction of the screen will be conveyed and stacked in a ground Page 25

31 stockpile. The same would be reclaimed and dispatched along with the sized product by conveyor system by conveyor system to the Pellet silos for loading into trucks. Core Equipment Brief Description Ball Mill There are two sets of φ 3.6 X 7.5 mtr Ball mills. Iron ore fines are conveyed into the Ball mill by belt conveyer. In the Primary Ball mill Iron Ore fines is ground off to 45 micron If required a secondary Ball mill may be considered for grinding up to 45 micron. Filter Press In Filter Press building, there are number of Filter Press Machines. Iron ore slurry materials are injected to the filter press by Slurry pumps. Iron ore fines are separated from water & Iron ore fines cakes are formed. Size of the Filter Press is 250M2 discharge 17 T & cycle time is 30 minutes. Proportioning There are five bins in proportioning building. One for Bentonite (Capacity: 100 T), one for lime stone (Capacity: 5 0T), one for coke (Capacity: 100TPH) and two for iron ore (Capacity: 100 T). Under iron concentrate bins there are belt conveyers and belt weighers. The Bentonite bin is equipped with a sensor detecting bin level and commanding the operation of material supply system and therefore the proportion ratio to be set, controlled and regulated automatically. Bentonite to be transferred into the bin pneumatically, once it is full then transferring pump will stop. Under bentonite bin there is a variable speed screw feeder and adding dosage of bentonite is 2% of the concentrate. Mixer machine In the Mixer machine Iron ore concentrate, Bentonite, Coke & Limestone are properly mixed. The capacity for mixer machine is 100 TPH. Pelletizing Disc The blended materials shall be carried by a belt conveyer onto the upper part of the pelletizing building and discharged into 3 blending bins separately, the effective capacity of which is 55M 3 for each and under which there are 3 X φ6.0mtr. Disc Pelletizers with capacity of 50 TPH each. The blending bin is equipped with a 1.0mtr. wide conveyer along with belt weigher from where the blended materials to be fed onto pelletizing disc, whose speed and tilting angle are both adjustable. Page 26

32 Water shall be added during Pelletizing process to ensure the optimal moisture in the mixture. Green balls formed in the Pelletizing disc are collected by a belt conveyer and transferred to the system of green ball screening and distribution. Over size / under size roller Screen Green balls are collected on a conveyor and transferred to green ball screening and distribution system. It consists of Over/Under size Roller Screen, Wide belt conveyor, Roller distributor and Belt conveyor returning fines. The gap of the roller screen is adjustable. The over size (>16 mm) green balls are collected by a belt conveyor and conveyed back to be reused for balling while the undersized (<16 mm) are conveyed by the wide conveyor to the roller screen. The speed of the wide conveyor is -regulated by a frequency modulator. The Roll Screen separates the small balls of <6mm and at the same time distributes the balls of +6 to -16 mm on to the traveling grate. The undersized green balls (<6mm) are collected by a belt conveyor and conveyed back to Disc Pelletizer. Traveling Grate It consists of Drying and Pre-heating. The main heating source in the drying zone is the waste gas from the cooling zone and partially from the hot gas from the pre-heating section. The main heating source in the pre-heating zone is the waste gas from the Feed End of the Rotary Kiln with temperature of11000c. Rotary Kiln After Pre-heating, the Pellets are discharged to the Rotary kiln where the roasting is done. Pellets receive heat in the Rotary kiln evenly as Pellets are roasted while rotating. The temperature in the Rotary kiln is maintained at 1100 to C. Rotation speed of the kiln can be regulated in accordance with different material so as to determine its retention time and to determine the quality of Pellet. Discharge end of the kiln is equipped with specially designed Burner. The Burner can use either Liquid fuel or Producer gas for energy. Annular Cooler Hot Pellets with temperature of around 12500C are discharged to the Annular Cooler. Normal cooling time in the cooler is 45 to 50 minutes. Cooling of the hot Pellets is done by air from number of Blowers. Hot gases from the Cooler are recycled back to the Rotary kiln and the Traveling grate for use. Dust abatement facilities The Pelletizing plant comprising various process units, accessories and handling facilities will be provided with adequate dust suppression and dust extraction facilities to restrict the particulate emission level within acceptable limits i.e. 50 mg per N cum. The systems will consist of water Page 27

33 spraying facilities, mechanical gas cleaning equipment, dust recycle arrangement and exhaust stack. Exhaust gas from drying and grinding system will be cleaned using fans, dustings, suction hoods, cyclones, bag filters, ESPs etc. as applicable. The indurating furnace gas will be made to pass through electrostatic precipitator (ESP) before being released to the atmosphere. Dust content in the work zone shall be limited to 5mg/Nm3 over and above the prevailing dust level. Filtered air supply system has been envisaged for MCC rooms and basements to supply adequate fresh air to stagnant air zones. The control rooms will be air-conditioned. The system will be designed in such a way that no solid waste will be discharged outside the system, the solid waste that is the dust generated in the system will be recycled back to the system itself Output of product pellet The chemical analysis of the pellet computed on the basis of qualities of raw materials and additives as well as the specific consumption indicated above, works out as given in following Table: Expected Chemical Analysis of Pellet Fe : 64.0% SiO2 : 3.3 to 3.4% Al2 O3 : 2.2 to 2.25% The desired physical and metallurgical characteristics of the pellet to be produced in the plant are given in following table Some of the Desired Characteristics of Product Pellet Property Value Size distribution +16 mm : 5% max mm : 92%min -6 mm : 3% max Compressive strength : 230 kg/pellet Tumbling index +6 to -16mm : 92% It is suggested that attainment of the above properties should be ensured by adopting appropriate process parameters established through necessary test work before implementation of the project. Page 28

34 Table 3.3 COMPARISON OF QUALITIES OF BF & DR GRADE PELLETS PARAMETER Fe(t) SiO2 + Al2O3 Na2O K2O TiO2 Mn P S V Basicity (CaO/SiO2) Moisture (free moisture loss at 105 ºC) CHEMICAL PROPERTIES BF GRADE SPECIFICATION Below 65% 5% Max 0.05% Max 0.05% Max 0.10% Max 0.10% Max 0.04% Max 0.02% Max 0.05% Max % max (fair season), 6% max (monsoon) PHYSICAL PROPERTIES BF GRADE Screen Analysis Specification -16mm +9mm 85% Min -9mm,+6.35mm 7% Max -5mm 3% Max Tumbler text (ASTM) Tumble Index (+6.35mm) 94% Min Abrasion Index (+0.6mm) 5% Max DR GRADE 66.5% 3.10% Max 0.05% Max 0.05% Max 0.10% Max 0.10% Max 0.04% Max 0.02% Max % max (fair season), 6% max (monsoon) DR GRADE Screen Analysis Specification +19mm 5% Max -16mm,+9mm 85% Min -9mm,+5mm 5% Min -5mm 3% Max Tumbler text (ASTM) Tumble Index (+6.3 5mm) 94% Min METALLURGICAL PROPERTIES Specification Parameter BF GRADE DR GRADE Swelling (JIS) 18-20% Max 20% Max Compression strength 250 kg/pellet 250 kg/pellet Min Porosity 25% Min 18-25% Min Reducibility (JIS) 70% Min 70% Min Note: Above is indicative specification only Receipt, unloading & storage of materials It is envisaged that the Iron Ore fines from storage yards will be carried out by front-end-loader (FEL) and then the same will be delivered by tippers/trucks of appropriate size for onward discharge into the plant head receiving hopper. This operation is planned to be taken care by KIPL or their outsourced agency separately. The battery limit of proposed plant has been considered from the said receiving hopper onwards. For limestone, the requirement being in the tune of tons per annum, the annual procurement has been considered in several consignments according to the available storage facility in the Pellet plant. However the said volume will be procured by road logistic from Joda- Page 29

35 Barbil sector of Keonjhar district of Odisha by trucks & shall be stacked in desired stock pile height of 2.5 mtr. The other raw material for Pellet plant viz. Bentonite will be transported from their respective sources and will be received at the Pellet plant by road and stored in the stockpile area earmarked in the yard (in the pellet plant) in desired stockpile height of 2.5 m through outsourcing by KIPL. The storage details of major raw materials are given in Table below: Table 3.4 Storage Details of Major Materials Sl. No Materials Ore fines Bentonite Limestone Coke Pellet Stocking area L(m) x W(m) x H(m) 130 x 130 x 5 20x10x x 10 x x10x x50x2 Stock quantity No. of days Reclaiming and subsequent dispatch of raw materials to consuming units: Pellet plant From Mines, iron ore fines will be carried to plant by tippers. The iron ore fines will stored in a covered shed & the same shall be loaded by front-end-loaders and transported through tippers (front-end-loaders and tippers outsourced) to the designated stockpile located inside plant boundary and having around 15 days' storage capacity. The scheme stated above will be taken up separately by KIPL and an outside agency will be engaged to carry out the same. Front-end loader shall be used for reclaiming ore fines from the stockpile and discharge the same to a reclaim hopper and finally transport to the pellet plant through a conveyor. Lime stone unloaded manually by outside agency at the side of the designated railway track. From railway siding, the same shall be loaded by front-end-loaders and transported through tippers (frontend-loaders and tippers outsourced) to the designated stockpile located inside plant boundary and having around 15 days' storage capacity. The scheme stated above will be taken up separately by KIPL and an outside agency will be engaged to carry out the same. Front-end loader shall be used for reclaiming limestone from the stockpile and discharge the same to a reclaim hopper and finally transport to the pellet plant through a conveyor. Bentonite shall be reclaimed from the stockpiles by loader and discharge onto the reclaim hopper for onward transportation to the pellet plant by a conveyor. Product pellet Page 30

36 The product pellet shall be stored through a set of conveyor belts and a non-slewable luffable stacker. The product pellet shall be reclaimed by a reclaimer and transported to the Wagon Loading House for loading the same to the wagons. In the Wagon Loading House a set of conveyors and bins are there for loading product pellet on to the wagons. BOXN types of wagons have been considered for Pellet dispatch due to space constrain. Review shall be required for use of wagons other than BOXN type for product Pellet dispatch. It has been envisaged that total cycle time for loading of a rake of product Pellet shall be five (5) hours. Weighing has been envisaged through belt scale mounted on the conveyor in the Wagon Loading House. Metal detectors, DE/ DS system and belt scales will be provided in the system as per requirements. Hoist will be provided at Junction houses PRODUCER GAS PLANT PROCESS GASIFICATION Gasification is a major & unique element in the development of advance, improved, renewable energy systems. It is a thermo-chemical process that converts solid coal/bio-coal to a low heat valve (LHV) gaseous fuel called producer Gas. This producer gas is fuel for many different applications of shaft power or electricity in the equipment like, IC engines, furnaces, kilns dryers, rolling mills and heat treatment equipment GASIFICATION PROCESS The different zones inside the reactor (Gasifier) are clearly shown in the below diagram: Fig 3.3 Section Diagram of Gasfier Page 31

37 ADVANTAGES OF PYROLYTIC GASIFIER WITH EXTENTED SHAFT OVER CONVENTIONAL FIXED SHAFT The produced gas generated in Pyro-Gasifier has higher Calorific Value in the range of K.Cal/NM3 which is suitable for getting high flame temperature in the range of C as required by most of the thermal processes. The efficiency of the Pyro-Gasifier is higher by 10-20% than the conventional Gasifier, so to result in reduction of coal consumption Tar Content in the gas by pyro-gasification is minimal as the gas temperature C, thus delivering gas of higher calorific value to result in higher gasification efficiency and lower coal consumption rate. Due to cleaner gas, the chocking and cleaning of the burner and duct pipes is low, which results in lower down time and increase in productivity and lesser interruptions in the Process. Due to consistency of gas quality lesser gas control actions are necessary. Wide varieties of the coal can be used FEATURES & ADVANTAGES The Coal Gasifier system is capable of gasifying several types of solid fuel such as Charcoal, Imported Steam coal, Briquettes at high efficiency. Minor traces of SC /NOX formation due to low gasification & low flame temperature. There is no effluent output in the process. The washing of gas is done with hot (70-80 C) recirculated phenol water which separates out the Tar in liquid form like FO which can be burnt in the furnace for giving extra energy to combustion. Extremely Low Particulates and smoke emission due to the complete direct firing of Producer Gas & much lesser than prescribed by the PCB. Much lesser heat losses in flue gases as compare to solid /liquid fuels firing, Worldwide accepted environment friendly Renewable Energy technology, Very low Payback period. Worldwide accepted environment friendly Renewable Energy technology. Very low Payback period TECHNICAL SPECIFICATION Complete up-draft Gasifier system for your thermal application; COAL GASIFIER SYSTEM (Gas Volume: 5000 Nm3 /hr) Model : RREDA-P-8000 Installed capacity (Thermal) : 8000 Kilowatts Thermal Output : 7,425,000 KCal/Hr. Liquid Fuel Replacement capacity : Liters/Hr. Page 32

38 Note: For this project total requirement of Nm3/Hr of Gas, 4+1 nos.of 5,000 Nm3/Hr. moduies of Producer's Gas Plant is selected. SOLID FUEL CONSUMPTION RATIO (Approx) Steam Coal - B Grade : 3.00 Kg/Litter Liquid Fuels Steam Coal - C & D Grade : 3.50 Kg/Litter Liquid Fuels Steam Coal - Imported : 2.50 Kg/Litter Liquid Fuels Bio-coal / Briquette : 4.00 Kg/Litter Liquid Fuels Wood Coal/Charcoal : 1.75 Kg/Litter Liquid Fuels Wood : 4.00 Kg/Litter Liquid Fuels SOLID FUEL DATA Solid Fuel Size Moisture content : < 15 % Ash content : mm : Up-to 25% CHEMICAL COMPOSITION OF PRODUCER GAS (Approx.) The Gasifier can convert any type of coal into Producer Gas. The chemical composition of Producer Gas is as under; CO (Carbon Monoxide) : 20 ±2% CH4 (Methane) :03±l%, H2 (Hydrogen) :18±2% CO2 (Carbon Dioxide) : 10±2% N2 (Nitrogen) : Rest Characteristic of Producer Gas (Approx.) Calorific value of Producer gas Plant Layout The layout of the plant will be developed taking into following considerations: Process departments will be consolidated into comprehensive production units requiring short conveying distances; The major utilities and service facilities will be centrally located in respect to points of high consumption; Sufficient space will be provided for ease of operation and maintenance; The lengths of power cables will be minimized by suitably locating load distribution centres in respect of process departments; Outward movements of materials from customers/suppliers will be segregated from internal plant traffic Page 33

39 Sufficient space for storage of raw materials and finished products. Green belt will be provided. Rainwater harvesting pond will be provided at lowest elevation to collect surface run-off to maximum possible extent. Adequate area will earmark for tailings and ash disposal. Weigh Bridge and administrative block will be located at the entrance. Page 34

40 Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha. Fig3.4 Plant Layout Page 35

41 3.6 Plant and Machinery Source All plant and machinery will be sourced through globally reputed and proven suppliers having vast experience of supply of various equipments required for the steel Industry. All equipment will incorporate the latest state of the art design and technology, eco friendly and will conform to global standards of workmanship. Taking into account, reliability of equipment and matching capacities between the different sections of the plant, the type of equipment/ installation system and the departmental capacities at the plant, have been arrived at. 3.7 Raw Materials Requirements Table 3.5 Requirement of Raw Materials Sl No. Description Quantity Source Mode of Transport A. Pellet Plant 1 Iron Ore Fines 2 Bentonite 3 4 6,48,000 Odisha (KJS Ahluwalia, RP Sao, Mesco Steel, Kalinga Mining) Road/Rail 6,000 Rajasthan Road/Rail Coke 18,000 Rourkela Road/Rail Limestone 18,000 Sundergarh, Odisha Road/Rail MCL, Odisha & ECL, Jharkhand Road/Rail B. Producer Gas Plant 1 Steam Coal Total 60,000 7,50,000 NOTE: Based on the following operating days/year: 330 days and 24 hrs/day for pellet plant Fuel oil will also be required to start-up the rotary kiln and for emergency requirements in the kiln, flushing of LSHS pipelines etc. Light diesel oil (LDO) conforming to IS: 1460 has been considered for this purpose. The estimated requirement of LDO during start-up of the kiln and others will be about 5 KL per day. For meeting the above requirements, suitable capacity bulk oil storage tanks and day oil tanks are proposed along with unloading and distribution pumps. 3.8 Water and Power Requirement Water Requirement Water is required in Pelletizing plant for various equipments cooling as well as wet grinding. In addition, it is required for drinking and sanitary purposes of working personnel, laboratory, workshop, office etc. and also for fire fighting and other miscellaneous purposes. Water is also required for dust suppression of stockpiles of raw materials and also at junction houses to abate dust nuisance. On study of the various systems, supporting facilities and the corresponding flow Page 36

42 figures, it is estimated that the total make-up water requirement for the proposed iron ore and pellet plant will be around 15M3 per hour. Estimated break up of makeup water quantities is given in following table. Table 3.6 Water Requirement Description Make up water (m3/hr) Pellet Plant process make-up 4.9 Producer Gas Plant 1.6 Cooling Tower make-up 3.5 Dust Suppression 1.5 Drinking water and Sanitation water for Plant 1.0 Landscaping, greeneries, environmental requirements 1.0 Raw water treatment & conveyance losses 1.0 Fire Fighting 0.5 TOTAL 15.0 The above water requirement will be made from an intake of 4 m3/hr River Baitrani and remaining 11 m3/hr from ground water source on continuous basis, located at about 0.2 km away from the proposed site. The static level difference between Plant site and River Baitrani is approximately 200 mtr. Page 37

43 Fig 3.5 WATER BALANCE Power Requirement The estimated power requirements of the plant including utilities and auxiliary facilities are as follows: Annual energy consumption : 40 million kwh 15-minute maximum demand : 5 MW (Considering 0.8 Power Factor) 1-Minute peak demand : 5 MW Characteristics of plant loads The loads of the proposed plant will be more or less steady in nature with little variation in load factor depending on the process requirement. Source of power Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Substation of OPTCL at Palaspanga. For that promoter has already approached OPTCL and NESCO authorities. Further the promoter will have the DG sets to meet the emergency power requirement. Page 38

44 3.9 Pollution Control Measures Air Environment Mitigation Measures Suitable extraction & cleaning system are required to be provided to maintain work zone dust as well as stack emission to the desired level as follows: Stack emission Work zone :100 mg/nm3 (Max) :Dust content in the work zone shall be limited to 5 mg/nm3over and above the prevailing dust level. The scheme proposed for dedusting and prevention of air pollution are as follows: i) Extraction of waste gases from the indurations plant after necessary utilization/recovery of heat in the preheat zone and discharging them to the atmosphere through stack after cleaning: Dry type electrostatic precipitators have been envisaged for this system as a part of the respective plant package. The dust laden air shall be sucked through ductwork and then cleaned in an Electrostatic Precipitator (ESP) before discharging to the atmosphere through a fan and self supporting stack. ii) Extraction of dust for raw material processing area viz. drying, ore grinding, pulverizing units and other dust generating units as required. Suitable type and capacities of bag filters have been envisaged for this dedusting system as a part of the respective packages. The dust laden air shall be sucked through hoods and ductwork and then cleaned in a bag filter before discharging to the atmosphere through a fan and exhaust duct/stack. Electrostatic precipitator and bag filters will be selected based on dust content, moisture content in gas and gas analysis at the inlets normally encountered for the respective units. The selection will also consider the dust resistance, dust chemistry, volume of gas to be cleaned and its temperature and suction flows in the network (normal and maximum). Page 39

45 Table 3.7 Source of air pollution and control measures Section Pellet plant Source of Pollution Air pollution control Measures Capacity of APC Device (M3/hr) Stack Height (M) Raw material Handling (Normally transfer for bunker) Bag Filter Coke grinding Bag Filter Proportioning system Bag Filter Induration furnace & Traveling Grate kiln ESP Finished product Handling Bag Filter Water Environment Mitigation Measures In the pellet plant there will be no effluent generation from the process. Water will be used in to maintain moisture in pellets. Further major water will be used for equipments which will be completely recycled with make-up water. From scrubber waste water will be taken to setting tank and recycled with makeup water in a closed circuit. Waste water generated from pellet plant is depicted below. Table 3.8 Waste Water Generation and Reuse Process Unit Pellet Waste water qty (m3/day) No waste water generation. Cooling water will be completely recycled. Raw water 9.5 treatment system 14.5 Domestic 19 Producer Gas plant 2.50 Source Cooling Waste water characteristics High Temp Backwash from filtration unit Underflow of clarifier TSS Domestic use from plant Gas cleaning section TSS, BOD, Oil & Grease TSS Phenol,Ammonia,Cya nide,bod,cod Waste water management Complete recirculation Will be treated in settling tank and taken to guard pond for reuse Will be treated in STP and reused for greenbelt Will be treated is ETP and treated water used in dust suppression and greenbelt. Page 40

46 Raw Water Treatment The raw water from the river will be suitably treated in water treatment units like clarifier & filtration unit as per the requirement for cooling process & other requirements. Waste water treatment Waste water from RWTP in form of Back Wash will be treated in settling pond and reused in dust suppression. STP is proposed to treat the domestic waste water. The treated water will be used for green belt development, dust suppression etc. the STP sludge will be used as manure for green belt development. The project will have its inbuilt system for reuse and recycle of water in the process. Thus, water requirement from the river will be minimum Solid Waste Management Proposed Plant will generate the following solid wastes from different production processes and the respective management plans are mentioned against each heads. Table 3.9 Solid Waste Generation and Management Sl. No Units Solid Wastes Pellet plant Dust from devices Broken Pellet Raw water treatment Sludge plant Producer Gas Plant Bottom Ash APC Qty In TPA Disposal practice Reused in pellet making Will be used for landscaping Will be used in filling low lying areas. Table 3.10 Domestic Solid Wastes Units STP Solid Wastes STP Sludge Canteen Garbage waste and Qty In TPA 2 food 12 Disposal practice Will be used as manure for landscaping Organic and inorganic portion of waste will be separated, organic waste will be vermin composted and used for greenbelt development. Inorganic portion will be given to scrap dealer. Page 41

47 Table 3.11 Hazardous Wastes Hazardous Wastes Quantity Hazardous Wastes Management Used Oil and Lube Oils 1.0 KL/Annum Collected used oil will be stored on close drums and will be disposed to authorized re-processors. Used Oil Filters Nos./Annum The used oil-filters are considered a hazardous waste. The same will be disposed as per hazardous waste management and handling Rules, 1989 and amendment thereof. Oily sludge 1.0 TPA Disposed as per hazardous waste management and handling Rules, 1989 and amendment thereof Noise Levels The major noise prone equipment s are product screening through crushing, milling, separators, compressors etc. The noise control will be done in four ways, namely by selecting low noise prone equipment which would have led level below 75 db (A) at 1 meter distance; By selecting low noise generating equipment, which would have below 75 dba at 1m distance. This is taken care at the equipment design stage. By isolating the noise unit from the working personnel s continuous exposure by providing acoustic aids for plant personnel. By administrative & safety measures, providing noise level monitoring, remedial measures, providing noise safety appliances. The noise impact on the surrounding environment during the construction phase will be within acceptable limits. The operation of high noise generating equipment shall be restricted during the night time. Various measures proposed to reduce noise pollution include reduction of noise at source, provision of acoustic lagging for the equipment and suction side silencers, selection of low noise equipment and isolation of noisy equipment. The plant personnel in noisy area will be provided with high noise reduction aid such as ear muffler & also the duration of exposure of the personnel will be limited as per the norms. Thick green belt development is planned for the attenuation of noise pollution and to maintain ambient noise quality within the statutory limit. Page 42

48 3.9.5 Green Belt Development A greenbelt development plan will be prepared and implemented along with the project. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the noise generated in the plant apart from improving the aesthetics of the plant site. The Greenbelt provided will be 33% (6.49 Ac) of total area Ac and will have a suitable density so as to mitigate the effects of emissions from the plant. The treated effluents from the plants will be utilized for the greenbelt development. The landscaping of the plant will be carried out. Roads for vehicular movement will be paved and adequate mitigation measures will be provided to prevent fugitive emissions SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OF EIA PURPOSE. Fig 3.6 Schematic Representation Page 43

49 CHAPTER-04 SITE ANALYSIS 4.1 General The proposed site is located at Vill-Champadihi in Keonjhar district of Odisha. The site is at about 35 km away from nearest town Keonjhar. The national highway NH-215 (in eastern side) is runs at 9.5 km from the site respectively. Nearest airport is at Bhubaneswar, 185 Km from proposed project site in its Southern side. Nearest river, Baitrani, is 0.2 Km away from the site. About acres of land is available in this area of proposed site. 4.2 Connectivity Road The site is well connected with road. The project site is only 12 km from Kotolposhi and 4 km away from the village Nahabada. Kotolposhi is on NH-215. NH 215 is from Panikoili (on NH5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance from Kortolpshi to Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is very close to the site. Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi. Rail Linkage The railway facility is also available near to the site. The nearest Railway station is Nayagarh in Joda area and is only 6 km away from the project site. Port The Paradeep port is the nearest port for this plant site, which is about 216 km away. Nearest airport, Bhubaneswar, is at 185 Km away from the site. 4.3 Topography The topography of the proposed land is generally flat and well suited for development of industrial projects. 4.4 Existing Land Use Pattern Land of the proposed project is devoid of any vegetation. Plant is not coming under the dense forest category land. This area does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve. 4.5 Existing Infrastructure Land Total land requirement for the proposed unit is about acres. Utilities Page 44

50 A. Power Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Substation of OPTCL at Palaspanga. Further the promoter will have DG sets to meet the emergency power requirement. B. Water For the project the water requirement is about 15 m3/hr (4 m3/hr from Baitarani River & 11 m3/hr from ground water. This will be sufficient for the present requirement. Further the River Baitarani is passing very close to the site. Further the promoters have the plan to harvest the rain water for efficient use of it. Transport The plant site is well connected by road NH-215 is at 9.5 km from the proposal plant site. Nayagarh in Joda area is the nearest board gauge (BG) railway station at about 6 km away from the proposed plant site. Communication Communication facilities such as telephone, tale fax and internet are available in Keonjhar (Sadar), which is the block headquarter situated near the plant site. Habitation Nearest habitation is in village Champadihi, 0.8 Km from the site. The area is sparsely populated. All basis amenities such as school, hospital, market, etc. are available in 10 Km area. 4.6 Climate Data Temperature The climate of the district is characterized by hot summer with low humidity. Summer generally commences in the month of March. Temperature begins to rise rapidly attaining the maximum in the month of May. During the summer maximum temperature is C. The weather becomes more pleasant with the advent of the monsoon in June and remains as such up to the end of October. The temperature in the month of December is lowest i.e C. Sometimes it even drops down to 70 C. The average annual rainfall is mms. Rainfall More than 76 percent of the annual rainfall occurs during monsoon in the period from June to October. Average annual rainfall is mms. Page 45

51 Table 4.0 Weather Analysis Report WEATHER ANALYSIS REPORT Relative Humidity Mean daily Mean daily max temp in C min. temp in C January February March April May June July August September October November December Annual Month ( in IST ) Page 46

52 CHAPTER 05 PLANNING BRIEF 5.1 Planning Concept M/s Kashvi International Private Ltd proposes to setup an Iron ore pellet plant of capacity 0.6 Million ton/annum & 5 Nos. (4w + 1s) Producer Gas Plant of capacity 5000 Nm³/hr each. High grade iron ore fines will be used in 0.6 MTPA of Pellet making. Iron ore pellet produce will be sold to integrated steel plant for utilization in blast furnace and DRI for production of pig iron and sponge iron. As the nearest railhead is within 10 kms and NH-215 is within 10km from the site, the transportation of both raw material as well as product will depend on the roads and rail. As the site is almost at the confluence of two major national highways, road transportation will not cause much problem. Existing road connection from the plant site to the NH will be utilized for material transportation. Plant should be provided with following facilities: 5.2 Transportation facility shall be provided to the executives. An ambulance shall be provided for the emergency. Qualified doctor shall be engaged for the regular health check up. Drinking water and electricity facilities shall be provided. Greenbelt shall be developed in and around the plant. Canteen shall be provided with all facilities. Separate sanitary facilities shall be provided. Population Projection With the set up of proposed project infrastructure and social development will simultaneously takes place. Project will contribute for raising the population of the locality as it creates job opportunities and economic upliftment of the area. The company is providing employment to persons during construction phase and 93 persons during the operation period of the proposed project Plant activities will also boost the ancillary industries, business and market establishments. The whole set will invite both skilled and unskilled from outside. This will result in increase in the population density due to industry. 5.3 Land Use Planning Following is the break-up of the land use of the project site/area: Page 47

53 Table 5.0 LAND USE BREAK-UP Sl. No. 5.4 Description Area in acre 1. Plant Built-up Auxiliary facilities Admn. Building, Offices, Lab, Canteen & First Aid Roads Solid waste Disposal Area Raw material & Product Storage Yard Water Storage & Rain water harvesting pond Greenbelt 6.49 Total Amenities & Facilities To render the necessary repair & maintenance, inventory, quality control related and administrative services for the proposed pellet plant with slime and associated facilities, following auxiliary facilities have been considered inside the plant boundary. Laboratory: Taking into account the quality assurance of iron ore slimes and pellets, it is proposed to install a laboratory. The role of the laboratory is to carry out physical and chemical testing of samples. A laboratory will be set up in a building along with the plant control room located in close vicinity of the plant. Tests will be carried out in the laboratory to determine physical and chemical properties of the samples as a part of the quality control activities. The laboratory will be equipped with the sample preparation facilities and testing devices. Repair and maintenance shop: It is proposed to set up a local repair shop equipped with facilities for machining, fabrication, assembly, electrical repairs, instrument calibration/repair etc. A mobile crane of 10 ton capacity will also be provided for dismantling and mounting of component assemblies and sub-assemblies of equipment. Stores: A single-bay building will keep equipment spares, hardware, wearing parts and consumables. A strong room for keeping valuable item, offices for inventory control, material receipt section, toilet etc will be suitably provided. Plant office: An office building will be constructed inside plant premises. The office building will be complete with separate toilet, conference rooms, computer room, separate executive's room and other facilities like record maintenance, printing, scanning etc. Ancillary buildings: Besides the auxiliary facilities other ancillary buildings with necessary facilities such as canteen, time office & security offices etc. will also be provided. Page 48

54 Canteen: A canteen building will be set up near the plant office and a suitable external agency is proposed to be engaged to service snacks and refreshments to the workers, supervisory and office staff working in the different plants/facilities and other working area. Page 49

55 CHAPTER 06 PROPOSED INFRASTRUCTURE 6.1 Industrial Area The setting up of the Main Plant Facilities, Raw Material Storage, Raw Water Storage Reservoir & Treatment, Auxilliary facilities, viz. Admn. Bldg., Tech. Bldg, Workshop, QC Lab, Switch Yard, etc. & Green belt (33%) required 6.49 Acres land. Company will use nearest road and rail facility for goods transportation and equipped with all other required facilities. 6.2 Residential Area The area around the site is under development with reasonably good communication facilities. Around 93 people will be engaged in the plant and Keonjhar town is very close to the project site and the area around the site is under development with reasonably good communication facilities. Other social infrastructure like housing, schooling and medical facilities has been developed and in some area it is underdeveloped. Hence, no residential colony/township is envisaged for employees. 6.3 Green Belt A greenbelt development plan will be prepared and implemented along with the project. Total green belt area shall be 33% (6.49 Ac) of total area (i.e Ac). The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. Comprehensive greenbelt/plantation program will be undertaken in and around the project. The species selection will depend upon crown shape, surface of bark and leaves, flower, color, capacity of growth in the wide variations of ecological conditions etc. A mixture of soil should be prepared by mixing commercial fertilizer, cow dung, BHC powder in the topsoil. 6.4 Social Infrastructure KIPL will commence a lot of infrastructure developmental works in the periphery area. Some glimpses of the developmental activities are presented below: Improving and building road network in the adjoining villages. Strengthening School buildings with playgrounds. Social awareness programme will further improve by the local authority such as sanitation and hygiene, HIV Prevention Program. Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding area. The proposed project will set up training centre or tie up with Industrial Technical Institutes to educate local youth as skilled labour. Page 50

56 6.5 Connectivity Proposed project is well connected to NH-215 and also connected to the Nayagarh Railway station. However the existing road network will be strengthened and new road network will be built in the adjoining villages. 6.6 Drinking Water Management Drinking water facilities will be provided for employees as well as nearby villagers. A fresh water tank will be constructed for this drinking purpose. A water treatment plant is envisaged for providing potable water to the colony and employees. After ensuring the drinking water standards prescribed by CPCB water will be supplied for drinking purpose Waste water treatment system The unit will adopt zero discharge concept as per water balance given above except rainy season. There will be no effluent generated from the pellet plant. Water will be used in the process to maintain the moisture content of 8-10% in the raw material. Cooling water will be completely recycled in a closed loop. Effluent generated from backwash of filtration plant and clarifier underflow will be treated in settling tank and will be taken to common monitoring basin. From common monitoring basin treated effluent will be reused for ash handling, dust suppression and greenbelt development. 6.7 Sewerage System A garland drain around the plant is envisaged to collect surface run-off during rainy season. Separate Internal drainage system will be constructed to collect domestic and industrial effluent. A common basin will be constructed for the treatment of effluents the plant. The sewage from the various plant buildings will be taken to a common STP through trenches. The treated water from the STP will be used for greenbelt development. As the sewage is taken in trenches the soil will not get contaminated. Sludge from STP will be used as manure for greenbelt development Waste water treatment system Domestic effluent from canteen and plant will be treated in STP of capacity 20 m3/day consist of following units: 1) Bar screen and grit chamber 2) O & G Trap 3) Aeration tank (diffused air aeration system) 4) Secondary settling tank Page 51

57 5) Multi grade filter 6) Chlorination 7) Sludge drying bed (2 nos.) Domestic effluent after treatment will be reused for landscaping and green belt Run-Off Management The rain water collected from the roof of buildings will be channelized through drains around the buildings and will be recharged into the ground by providing recharging pits. Overflow, if any, will be discharged to the nearby plant drainage. Also one rain water collection pond has been considered in the layout. All the plant storm water drains will be routed to the rain water collection pond and overflow, if any, from the pond will be discharged to any existing natural outfall outside the plant area. The rain water collection pond will be unlined. A Rain Water Harvesting Pond has been contemplated to act as collection basin for rainwater. The collected water will be 100% reused in the raw water reservoir in dry season. The pond will be located at the lowest area of the plant so that it can effectively collect all the rainwater by gravity. The Tank shall be earthen. The pond will be lined at the bottom and sides with two layers of HDPE lining of appropriate thickness to prevent percolation of the harvested rainwater in to the ground. Figure below depicts schematically the proposed rainwater harvesting scheme for the proposed plant. The Rain Water Harvesting Pond is depicted below: Garland drain will be provided around raw material stock pile area. The run-off collected from these areas will be treated in adequate settling pond and will be taken to rain water harvesting pond. Suitable pump house will be installed adjacent to the rain water collection pond so that the settled water from the collection pond can be pumped and supplied to the plant for meeting some of the daily requirement. Page 52

58 6.8 Industrial Waste Management Hazardous Wastes Majority of the wastes (spend oils, lubricants and oily sludges etc.) will be preferably sold to the potential users with necessary authorization for reprocess/reuse. The non-hazardous (solid) wastes at proposed project site are sludges from raw water treatment plant, biological sludge from STP; and the domestic solid waste from plant area. The non-hazardous solid waste, i.e. after sludge thicker/centrifuge and sludge drying beds, could be used as landfill material/manure in greenbelt area or even for reclamation of low lying areas, however they will be ultimately disposed as per MoEF guidelines in consultation with OPCB. 6.9 Solid Waste Management The solid wastes include dust from pellet plant. Dust from pellet plant will be recycled and reused for pellet production. Table 6.0 Solid Waste Generation and Management Units Solid Wastes Pellet plant Dust from APC devices 350 Broken Pellet 660 Raw water treatment plant Sludge Producer Gas Plant Bottom Ash 6.10 Qty In TPA Disposal practice Reused in pellet making 6 Will be used for landscaping 10,000 Will be used in filling low lying areas. Power Requirement & Supply/Source Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Sub-station of OPTCL at Palaspanga. Further the promoter will have the DG sets to meet the emergency power requirement. Page 53

59 CHAPTER 07 REHABILITATION AND RESETTLEMENT (R & R) PLAN 7.1 Policy to Be Adopted For R & R Plan w.r.t Project The proposed project is going to come up on acres area. Total land has already been acquired. There is no existence of displaced habitants in the area. Land is also devoid of any vegetation. Local people will be engaged for construction and operation activities and the local area have all the infrastructure facilities. Joda Town is just 15 Km away from the site and is well connected with NH-215, thus, no housing colony/township is envisaged. Page 54

60 CHAPTER 08 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule In this industry, any one of the following three alternate modes of project execution is adopted: Turnkey Semi Turnkey Packaged procurement mode Planning Of Activities Careful planning of all the activities is one of the pre-requisite for timely completion of the project. Following activities will be given special attention. Pre Project Activities Management Approvals. Selection of location Land acquisitions Statutory Clearances Financial Approvals and Tie ups. Selection of Consultants Conceptual Design Preparation of main machinery tender Evaluation of tenders Project Activities (Implementation Stage) Firm up basic design Main Machinery Order placement Detailed engineering of the project Statutory approvals of Building Plans. Preparation of Tender, Evaluation of tenders received and Order placement for balance machinery Completion of procurement activities on time Release of civil drawing for civil construction Page 55

61 Civil construction Supply of mechanical & electrical equipment Inspection of major machinery at supplier s works Erection of all plant & machinery Commissioning of the plant Statutory Clearances The proposed project will require various statutory approvals and clearances from various authorities of the Government. Clearances required for the proposed project shall be identified in due course and necessary action will be taken to obtain the same. Project Schedule The schedule has been developed on the basis of the estimated quantum of work, expected delivery and installation periods of plant and equipment and the need to commission the plant facilities in the shortest possible time. The schedule envisages a total project implementation period of 18 months from the date of 'Go-ahead'. Schedule commissioning of the plant can only be achieved if construction, delivery and erection periods as shown in the bar chart can be met by respective suppliers and contractors. The 'Go-ahead' date for the project implementation has been considered as a date of 'Goahead' given to the Consulting Engineers for detailed engineering. The schedule has been prepared based on the assumption that the following activities will be completed prior to the date of 'Go-ahead'. i. Freezing of adequate project details to enable preparatory site activities to commence on ' Go-ahead', ii. Finalizing the arrangement for requisite finance as per projections matching with implementation schedule, iii. Acquiring all relevant statutory Govt. clearance (environmental, forest, rehab illation etc) Strategies for Timely Execution of the Project The following strategies would be adopted for smooth functioning as well as timely execution of the project: The task of implementing the project in time shall be achieved by ensuring a well coordinated project implementation task force in-house and from external agencies Page 56

62 A well chosen team of experienced personnel for project execution shall coordinate the implementation of the project from in-house Experienced engineering consultants with proven track records shall be selected for detailed engineering of the project. Reputed and experienced contractors with adequate resources of finance, men, material and tools and tackles, will be engaged for execution of the construction and erection work. Effective project monitoring including project planning schedule and monitoring shall be employed in this project. Timely execution and resources will be monitored using computer based project monitoring tools. In case of deviations in project progress, all possible corrective actions such as crashing of network etc. will be carried out. 8.2 Project Cost An indicative estimated capital cost of the proposed Plant is Rs Crores, including the preoperative expenses, contingency and interest during construction. A broad break-up of the indicative estimate of the Project capital cost is provided below: Table 8.0 Project Cost Break-Up Sl. No Particulars Land & Land Development Cost Building & Infrastructural Facilities Steel Structural & Civil Work for Plant & Equipments Plant & Equipments Miscellaneous Fixed Assets Provision for Contingencies Consultancy Charges Pre- Operative Expenses Preliminary Expenses Margin For Working Capital TOTAL Amount in Crores Page 57

63 CHAPTER 09 ANALYSIS OF PROPOSAL 9.1 Financial and Social Benefits In order to meet the growing demand of iron ore pellets required as raw material in steel plants, M/s Kashvi International Private Ltd. proposes to produce iron ore pellets by setting up a pellet plant of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each At-Champadihi, Keonjhar District, Odisha. In view of the increasing demand for Iron ore pellets, both indigenious and export, the project will be financially profitable and viable. It will also help in conservation of high grade ores for the future and mitigate the pithead environmental pollution. Besides there will be immense social benefits of the project, to the backward region Improvements in the Physical Infrastructure KIPL has envisaged a lot of infrastructure developmental works in the periphery area. Improving and building road network in the adjoining villages. Strengthening School buildings with playgrounds. Providing the Drinking Water Facilities Improvements in the Social Infrastructure Employment, direct and indirect for the local predominantly tribal people. Social awareness programme will further improve by the local authority such as sanitation and hygiene, health, immunization etc. Through this project, adult education and female education will be provided to the illiterate adults and backward females of the villages in the project surrounding area. Sponsor the education to Poor Students of the Proposed Area. The proposed project will set up training centre or tie up with Industrial Technical Institutes to educate local youth as skilled labour. Provide & conduct the Free Eye & Health Check up Programmes Employment It is estimated that the total requirement of manpower for the whole organization will be 93. There will be much larger indirect employment in transport, ancillary, support facilities and growth in local trades and business. Expected to employ a peak workforce of about 200 persons (peak demand) and 100 persons (average demand) during construction phase. Page 58

64 9.2 Other Benefits Development of the local area in terms of an enlarged market. Besides above, indirect benefits have also occurred to the region by way of increase in industrial production. Thus, the proposed project will usher in the social and economic upliftment of the persons living in the vicinity of the Project i.e. of society at large. Page 59

65 Visiontek Consultancy Services Pvt. Ltd (An Enviro Engineering Consulting Cell) Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: , , Fax : visiontekin@gmail.com, visiontekin@yahoo.co.in, Visit us at : Committed For Better Environment