M/s. WELSPUN ORISSA STEEL PVT. LTD.

Transcription

1 PRE-FEASIBILITY REPORT On Proposed 4.4 MTPA Iron Ore Pellet Plant At-Dhamra, Bhadrak District, Odisha OF M/s.. Prepared by:- October-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-01 EXECUTIVE SUMMARY 1 Brief Summary Introduction Project Description Site Analysis Landu Use Planning Proposed Infrastructure Rehabilitation & Resettlements(R & R) Plan Project Schedule & Cost Estimates Analysis of Proposal 6 CHAPTER-02 INTRODUCTION 2.1 Introduction Identification of Project & Project Proponent 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 Basis of Manpower estimate 13 CHAPTER-03 PROJECT DESCRIPTION 3.1 Type of Project Location & Accessibility Site Selection Size or Magnitude of Operation Process description Plant & Machinery Source Raw Materials Requirements Water & Power Requirement Pollution Control Measures Schematic Representation of the feasibility drawing which give information of EIA 43

3 purpose CHAPTER-04 SITE ANALYSIS 4.1 General Connectivity Topography Existing Land Use Pattern Existing Infrastructure Climate data 45 CHAPTER-05 PLANNING BRIEF 5.1 Planning Concept Population Projection Land Use Planning Amenities & Facilities 47 CHAPTER-06 PROPOSED 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-07 REHABILITATION & RESETTLEMENTS(R & R) PLAN 7.1 Policy to be adopted for R & R Plan w.r.t project 53 CHAPTER-08 PROJECT SCHEDULE & COST ESTIMATES 8.1 Project Schedule Project Cost 56 CHAPTER-09 ANALYSIS OF PROPOSAL 9.1 Financial & Social Benefits Other Benefits 59

4 LIST OF TABLES Sl.No Particulars Page No 1.0 Product Profile Raw Material Requirement & Source Waste water generation & Reuse Solid waste generation & Managemennt Project Profile Project demand of Indian iron ore pellets Demand, Availability and resultant gap (-)/surplus (+) for pellets (MTPA) Average domestic demand of Pellets (SF + DR grade) ('000 Tons) World DRI Production by year Projected demand of Indian iron ore pellets(mt) Domestic/Export Markets Category wise breakup of manpower Product capacity of the project Raw material Analysis Consumption norms of raw materials Types of draught fan with capacity Major equipment & facilities Comparisons of qualities of BF & DR grade pellets Storage details of major materials Requirement of raw materials & source Water requirement Source of air pollution & control measures Waste water generation & reuse Solid waste generation & management Domestic solid waste Hazardous wastes Land use breakup Solid waste generation & management Summary of pollution control equipments Total project cost details 57

5 LIST OF FIGURES Sl. No. Particulars Page No. 3.0 Plant Location TOPO Map(10 km Radius) Process flow & description Plant Layout Information of EIA Purpose 43

6 CHAPTER - I EXECUTIVE SUMMARY 1 Name of the Project Proposed 4.4 MTPA Pellet Plant of M/s Welspun 2 S.No. in the Schedule 3(a) Orissa Steel Pvt. Ltd. 3 Registered Office M/s Welspun Orissa Steel Pvt. Ltd. 3,HIG,BDA Housing Complex, Kapil Prasad, Bhimtangi, Bhubaneswar ,Odisha 4 Name of the Promoters Mr. Madhusudan Sharma Welspun House,3 rd Floor, Kamala City, Senapati Bapat Marg, Lower Parel, Mumbai. 5 Present Business Iron & Steel 6 Area of Plant Acre 7 Topo Shet no. NF 73 L/13 & 73 L/14 8 Latitude Longitude 20ᵒ N 86ᵒ E 9 Proposed Capacity 4.4 MTPA Pellet Plant 10 Cost of the Project 1,05, Lac 11 Man Power Requirement 190 People 12 Water Requirement 60.3 M³/hr, will be sourced from Matai River 13 Power Requirement 45 MW, will be sourced from NESCO grid 14 Nearest Railway Station/ Airport along with distance in Kms. 15 Nearest Town, City, District Head quarters along with distance in Kms 16 Village Panchayats, Zilla Parishad,Municipal corporation, Local telephone nos. to be given) body (complete postal addresses with telephone no.s to be given) Bhadrak Railway Station-56.5 Km Bhubaneswar Airport- 135 Km Bhadrak-56 km At- Doshinga Block -Chandbali Village Panchayat- Doshinga and Chinipahi Zilla Parishad- Bhadrak District- Bhadrak Odisha. Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 1

7 1.0 INTRODUCTION 1.1 Identification of Project and Project Proponent M/s Welspun Orissa Steel Pvt. Ltd. has proposed to setup a pellet plant of Capacity 4.4 MTPA at Dhamra, in the District of Bhadrak, Odisha. WELSPUN is one of the top three home textile manufacturers in the world with a distribution network in 32 countries. The company has state-of-the-art manufacturing facilities in India and Portugal. Being the largest exporters of home textile products from India, the company caters to the likes of Wal-Mart, J C Penny, and Macy s to name a few. The Company is listed in Bombay Stock Exchange (BSE), India and National Stock Exchange (NSE), India. Welspun Corp Ltd (WCL) - Formerly known as Welspun Gujarat Stahl Rohren Ltd., is ranked as the 2nd Largest (Large Diameter) Pipe Company in the World (Financial Times, UK, 2008), and recognized as the Emerging Company of the Year (Economic Times Corporate Excellence Awards 2008). With its ability to make steel pipes from ½ to 100 in diameter, the pipes division of the Company has supplied pipes to the world s deepest off-shore applications in Gulf of Mexico, U.S.A. The company is the first from India to produce the highest recognized line pipe grade of X80 and it has a creditable list of clients that is unmatched in the Industry. With an installed capacity of 2.20 Million tpa (1.55 Million TPA in India, 0.35 million TPA in USA and 0.30 Million TPA in Dammam, Saudi Arabia), the Company is currently the largest large diameter pipe manufacturer in the World. Welspun Corp Ltd. is listed in Bombay Stock Exchange (BSE) India and National Stock Exchange (NSE) India. WCL is also a trusted name amongst domestic and international lenders and Investors which include Apollo, Temasek (Government of Singapore), ICICI Venture, 3i (UK) Genesis (UK), and others. 1.2 Employment Generation It is estimated that the total employment generation (direct & indirect) due to the proposed project will be 190 Nos. 2.0 PROJECT DESCRIPTION 2.1 Location The proposed project site is located at Dhamra in Bhadrak District of Odisha State (Ref: Topo sheet F45 N/14. The Latitude and Longitude of the proposed project site N and E respectively. Bhubaneswar Page 2

8 2.2 Site Selection Criteria Site is located at Dhamra, District- Bhadrak in the state of Odisha. The site has following facilities: Iron ore: Fines to be beneficiated near the mines at proposed beneficiation plant (Nayagarh) and transported through slurry pipe line to Dhamra having port facility Iron ore / Coal mines: Govt. to give Priority for allocation Railway: Adjacent to DPCL rail yard. Road: Connected to the National Highway Port: Well connected by road and rail Power: Available from the state grid / captive power plant Water: Available from perennial river Airport: Bhubaneswar airport is about 130 km from Dhamra 2.3 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 concentrate 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 Welspun Orissa Steel Pvt. Ltd. intends to set up a pellet plant to produce iron ore pellet of 4.4 MTPA at-dhamra District- Bhadrak, Odisha. Table No.-1.0 Product Profile SI. Units Product Configuration Capacity No. 1 Pellet Plant Iron Ore Pellet 1x4.4MTPA 44,00,000 TPA Bhubaneswar Page 3

9 2.5 Raw Material Requirement Table No.-1.1 Raw material Requirement & source Raw Materials Requirement Source Mode of Transportation Annually (T) Iron Ore 4,752,000 Iron Ore Fines <63 % Fe, By Road/Rail Concentrate from local iron ore mines, Open market and Govt. mines. Bentonite 44,000 Gujarat By Road/Rail Dolomite/ 88,000 Open Market By Road/Rail Limestone Coal/Coke 88,000 Nearby mine By Road/Rail breeze Fuel Oil 61,600 IOCL By Road/Rail 2.6 Water and Power Requirement The water required for the pellet plant is 60.3 m 3 /hr. Welspun Orissa Steel Pvt. Ltd. has been permitted to draw 122 m 3 /hr. water from Matai River. The power shall be sourced from the NESCO grid at 132 kv. The demand is expected to be about 45 MW. 2.7 Waste Water Generation and Management Process Waste water qty Unit (m 3 /hr) Pellet No waste water generation. Cooling water will be completely recycled. Raw water treatment system Table No.-1.2 Waste Water Generation and Reuse 2.50 Backwash from filtration unit Source Waste water Waste water characteristics management Cooling High Temp Complete recirculation TDS TSS Will be treated in settling tank reused in greenbelt development and dust suppression Domestic 2.50 Domestic TSS, BOD, Oil & Will be treated in STP and use from Grease reused for greenbelt plant Total Complete recycle/ reuse to achieve zero discharge Bhubaneswar Page 4

10 Table No.-1.3 Solid Waste Generation and Management Units Solid Wastes Qty In TPA Disposal practice Pellet plant Dust from APC devices 5200 Reused in pellet making Broken Pellet 4200 Raw water treatment plant Sludge 10 Will be used for landscaping Domestic waste from Canteen & staff Colony Garbage and food waste 20 Organic waste will be vermin-composted and used for greenbelt development. Inorganic portion will be given to scrap dealer. 3.0 SITE ANALYSIS 3.1 Connectivity The site is at about 56 km away from nearest town Bhadrak. The national highway NH-5 and SH- 9 are runs at 56 km and 21 km away from the site respectively. Bhadrak railway station will be the serving station for the proposed plant. The railway station located at a distance of about 56.5 km and DPCL Connectivity. Nearest airport is at Bhubaneswar 135 Km from proposed project site in its West east 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. 3.3 Climate Data The climate of the Bhadrak district is characterized by an oppressively hot summer with high humidity. During the summer maximum temperature is 42 0 C. The temperature in the month of December is lowest i.e C. Sometimes it even drops down to 7 0 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, Raw Water Storage Reservoir & Treatment, Auxiliary facilities, viz. Administrative Building, Technical Building, Workshop, QC Bhubaneswar Page 5

11 Lab, Switch Yard, etc. & Green belt required is Acres land. 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% (53 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. 5.3 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. 6.0 REHABILITATION & RESETTLEMENTS (R & R) PLAN The proposed project is going to come 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 equipment will be selected carefully well in advance. 7.2 Project Cost An indicative estimated capital cost of the proposed Plant is Rs. 1, 05,937 Lakhs, including the pre-operative 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. Bhubaneswar Page 6

12 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 190 persons. Bhubaneswar Page 7

13 CHAPTER 02 INTRODUCTION 2.1 Introduction M/s Welspun Orissa Steel Pvt. Ltd. has proposed to setup an pellet plant of capacity 4.4 MTPA at Dhamra in the District of Bhadrak, Odisha. 2.2 Identification of Project and Project Proponent M/s Welspun Orissa Steel Pvt. Ltd. has proposed to setup a pellet plant of capacity 4.4 MTPA at Dhamra, in the District of Bhadrak, Odisha. Welspun India Ltd. is one of the top three home textile manufacturers in the world with a distribution network in 32 countries. The company has state-of-the-art manufacturing facilities in India and Portugal. Being the largest exporters of home textile products from India, the company caters to the likes of Wal-Mart, J C Penny, and Macy s to name a few. The Company is listed in Bombay Stock Exchange (BSE), India and National Stock Exchange (NSE), India. Promoters Welspun Group is a USD 3 billion conglomerate with abundance of expertise, resources, opportunities and engineering excellence. With global leadership position in Line Pipe and Home Textiles, its marquee client list includes most of the Fortune 100 Companies operating in Oil & Gas and retail sectors like Chevron, TCPL, Exxon Mobil, Wal-Mart, Target etc. amongst others. With strong foothold in over 50 countries, over 24,000 employees and 100,000+ shareholders, Welspun is one of India's fastest growing conglomerates. Welspun believes in its crucial role of a responsible Corporate Citizen and sincerely practices empowerment of the underprivileged and sustenance of the environment. 2.3 Nature of the project M/s Welspun Orissa Steel Pvt. Ltd. is going to install 4.4 MTPA Pellet Plant to produce iron ore pellet At-Dhamra, District- Bhadrak in the state of Odisha. Table 2.0 Project Profile SI. No. Units Product Configuration Capacity 1 Pellet Plant Iron Ore Pellet 1x4.4MTPA 44,00,000 TPA The process of pelletisation will be based on straight grate or travelling grate technology. In this process iron ore will be mixed with flux (ground limestone), solid fuel 9ground coke) and Bhubaneswar Page 8

14 additive (ground bentonite) along with process water. The final mixture with moisture below 9% will be used to make green balls of size 9-16 mm. Green balls be fed to the indurating machine, where it will be first dried, then heat hardening by gradually raising the temperature to 1300 ºc and finally cooled down to 100ºc. The cooled pellets will be transported to the screening building, where indurated pellets with size range of above 6 mm are screened out as product. Some part of fired pellets of size mm are separated and recycled back to process to be used as Hearth Layer 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. 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 use 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. Bhubaneswar Page 9

15 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. 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 Total Availability Gaps(-)/surpluses (+) Domestic Export Domestic Export ) (+)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 are as given below: Bhubaneswar Page 10

16 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 pr ojected 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 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 Bhubaneswar Page 11

17 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. Year Table-2.4 World DRI Production by 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 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 Bhubaneswar Page 12

18 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: 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 shut down 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 Bhubaneswar Page 13

19 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 190 persons, comprising 38 persons for administration and 152 persons for works. The details of manpower estimate for administration and works departments are presented in Table 2.7 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 CATEGORY-WISE BREAKUP OF MANPOWER Main unit Sub unit Manager Supervisor Skilled Unskilled Total Pellet Pellet Plant Plant Laboratory II Maintenance II Finance 2 2 Administrative 2 2 Security Total Bhubaneswar Page 14

20 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. Bhubaneswar Page 15

21 CHAPTER - 3 PROJECT DESCRIPTION M/s Welspun Orissa Steel Pvt. Ltd. intends to set up a pellet plant to produce iron ore pellet of 4.4 MTPA at-dharma District- Bhadrak in the state of 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 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 site is located at Dhamra in Bhadrak District of Odisha State. The Latitude and Longitude of the proposed site N and E respectively. a. Road Connectivity: The project site is well connected by rail and road network. The site is located at a distance of 56 Km from NH-5 and 21 km from SH-9. b. Rail Connectivity: The nearest railway station is Bhadrak at 56.5 km and from the proposed project site. c. Airport: Nearest airport to the project site is Bhubaneswar at a distance of 135 kms. d. Seaport: Nearest Seaport at Dhamra is adjacent to the project site. Bhubaneswar Page 16

22 Fig:- 3.0 Plant Location Bhubaneswar Page 17

23 Fig-3.1 TOPO MAP Bhubaneswar Page 18

24 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 nor any diversion of forest/ vegetation, Availability of land, with common approach road connected to NH 5 (56 km) and SH-9 (21 km). Access to high growth domestic steel markets and future industrial and infrastructure development has been planned. Availability of water from Matai river till the slurry pipe line is commissioned 3.4 Size or Magnitude of Operation Table 3.0 Production capacity of the company SI. No. Units Product Configuration Capacity 1 Pellet Plant Iron Ore Pellet 4.4MTPA 44,00,000 TPA 3.5. Process Description Pellet 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 4.4 MTPA pellet. Annual pellet production capacity, million tons : 4.4 No. of working days per year : 330 Working hours per day in 3-shift operation : 24 Based on the above assumptions, the effective annual working hours amount to 7,920 hours and pellet production rate works out to about 555 tons per hour. Bhubaneswar Page 19

25 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 Materials Fe % SiO 2 % Al 2 O 3 % CaO % MgO % LOI % Calorific Value (Kcal/kg) Iron ore fines Bentonite Limestone Coke >5700 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 100 % hematite iron ore mainly available in the region. The iron ore concentrate should be 75 % less than 45 micron, with a Blaine of cm 2 /g and total Fe content not less than 64%. Binders For the formation of green ball of adequate strength and fired pellets of specific quality, it is necessary to add a suitable binder. Sodium type 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. it should be 95 % less than 74 micron, with and moisture content less than 12 %. Coal Coke/Coal is added to improve the Furnace productivity and overall fuel economy. Coal with calorific value (low grad) > 28.5 MJ / kg, (6,800 kcal / kg) volatile matter > 8 %, ash content < 14 %, ash fusion point (temperature) > 1400 deg. C, sulphur content < 0.5 %, incoming size < 80 mm, moisture content < 10 % shall be used. Bhubaneswar Page 20

26 Additives Additives are often used to modify the chemistry of Pellets, specially the slag forming constituents. Additive generally used is BF grade limestone, for basically adjustment as well as for other likely benefits, such as improvement in pellet strength and porosity. BF Grade lime stone of the order of 22 kg / t is used in the pellet mix. sticking of balls and reduces sulphur level. Addition of lime stone prevents 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. Therefore, furnace oil has been considered as fuel to fire the pellet plant until natural gas is available.. 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: Raw Materials Table-3.2 CONSUMPTION NORMS OF RAW MATERIALS Requirement Annually (T) Source Mode of Transportation Iron Concentrate Ore 4,752,000 Iron Ore Fines <63 % Fe, from local iron ore mines, Open market and Govt. mines. By Road/Rail Bentonite 44,000 Gujarat By Road/Rail Dolomite/ 88,000 Open Market By Road/Rail Limestone Coal/Coke breeze 88,000 Nearby mine By Road/Rail Fuel Oil 61,600 IOCL By Road/Rail NOTES: (1) Quantity on dry basis Bhubaneswar Page 21

27 (2) Quantity excluding moisture and handling losses (3) To be added depending upon the end use Main Section of Pellet Plant I. Raw Material handling II. Balling / Pelletising area III. Induration area IV. Pellet product handling (output) area The pelletising process flow scheme is shown in figure below Bhubaneswar Page 22

28 Process Flow & Description (Fig-3.2) Bhubaneswar Page 23

29 I. Raw material-handling Iron ore fines having an average Fe of 63% will be transported from iron ore mines by Rail/Road and stored in storage yard. Coal / coke breeze, bentonite and lime stone will be received by trucks and stored separately in store yards. Handling of additives & fluxes Bentonite is used in the pellet plant as binder to improve the physical properties of the green pellets in order to give them enough strength for transport and during drying on the traveling grate. Flux (like dolomite or limestone) is used to adapt the specified basicity of the product pellets. Solid fuel (like anthracite or coke) is added to the pellet mix and reduces the total fuel consumption of the process significantly. Bentonite, flux and other additives such as coke which require grinding to the fineness necessary for pelletizing. For that reason a separate grinding plant for bentonite, flux as well as for coke would be required. Limestone and breeze are ground together in a ball mill and bentonite is ground in vertical roller mill. Ground bentonite is pneumatically transported directly to day bin in mixing area. Ground mix of limestone and coke breeze is pneumatically transported to storage silo and from there to day bin mixing area. Mixing In the mixing area ground ore is mixed with a variety of additives in order to; form green pellets with sufficient mechanical strength to withstand the subsequent transportation, screening and heat treatment process, and to adjust the chemistry of the pellets to favour the production of mechanically resistant product pellets with a high compression strength and low abrasion indices, and to adjust the chemistry of the product pellets to favour their reducibility during subsequent reduction processes (in blast furnaces or direct reduction plants) With the controlled addition of process water and slurry from the thickener, which mainly consists of water and iron bearing dust from the dedusting systems, the moisture content of the material is raised to approx. 9-10%. Mixing is performed in one high intensive bowl type mixer. The first of this type mixers was successfully installed by OT / Lurgi in the palletizing plant for Essar. The mixed material Bhubaneswar Page 24

30 will be transported by a belt conveyor to the balling unit. II. Balling The mixed material from the mixing unit is conveyed and distributed to 7 mixed material bins with a storage capacity of 50 m 3 each, installed directly above the corresponding balling disc. A horizontal conveyor, equipped with pneumatically operated ploughs will distribute the mixed material and green ball returns into the mix material bins. Any spillage passing under these ploughs will be discharged at the head end of the conveyor and recirculated with roller screen rejects. Belt weigh feeders will be provided at the outlet of each bin to draw out required quantity of material. The mixed material will be continuously discharged from the bins and fed to seven 7.5 m diameter balling discs. (six working and 1 standby) with rim height of 800 mm by means of fluffers. The fluffer has two functions, namely, the disintegration of any compacted material as well as the distribution of the mixed material on the balling disc. Control quantity of water shall be added to the balling discs to adjust the final moisture content of the green balls. The inclination and the rpm of the discs are variable. Optimum inclination (approx. between 45 and 50 deg.) is determined during start up, according to the mixed material properties, desired green ball diameter and feed rate. It is possible to regulate the disc rpm between 5 to 12 during operation. The green balls produced are discharged onto a reversible belt conveyor. In case of irregular operations and during start up of the balling disc, the green balls do not possess the required properties ( diameter, green ball strength etc.), therefore the disc discharge can thus be recycled or discharged to an emergency stockpile. During normal operation, the reversible belt conveyor transfers the green balls to the green pellet collecting conveyor. This flat belt conveyor ensures smooth handling of the green balls. A belt scale is installed in this belt for weighing the total amount of green balls discharged from the balling discs, which is one of the parameters for the indurating machine speed control. III. Induration area For distributing the green balls from the balling unit smoothly and evenly onto the 4 m wide indurating machine, a reciprocating conveyor will be installed which feeds the green balls uniformly onto a 4 m wide belt conveyor. The 4 m wide belt conveyor, in turn, discharges the green balls onto a double deck roller screen which consists of an upper and a lower deck of Bhubaneswar Page 25

31 stainless steel rollers; the rollers on each deck being driven through a chain by a variable speed drive / individually driven rollers. Oversize and undersize green pellets will be recycled by belt conveyors back to the mixed material stream between the mixers and the balling feed bins. The required green balls in the size range of 9 mm to 16 mm will be fed to the indurating machine for their induration. Traveling grate process The traveling grate process is selected for the induration of pellets.green balls (green pel lets) will be indurated on a traveling grate having a reaction area of 504 m 2 (4 m wide and 126 m long). The traveling grate indurating machine consists of an endless chain of pellet cars (192 nos.) moving on tracks. The height of the green balls on the grate is an important factor in determining the productivity of the machine. Accordingly, the bed height of the indurating machine is envisaged to be 500 mm (75 mm for hearth layer plus a green ball layer of 425 mm). One of the process pre-requisites for obtaining a uniform product quality is a uniform bed height which is ensured by automatic control of the great speed as a function of the green pellets feed rate bay a series of ultrasonic level sensors. A grate bar cleaning device is located near the lowering station on the return track of the traveling grate. The pellets and the grate bars are of special and well proven design for the induration process thus enabling long service life with low maintenance. To avoid thermal shocks to grate bars, green pellets are charged over a layer of indurated pellets, called hearth layer. from excessive heat, with indurated pellets called side layers. Pellet side walls (both sides) are also protected A storage bin (175 m 3 ) for hearth and side layers having three outlet chutes is provided at the feed of the traveling grate. The height of the hearth layer on the pellets can be adjusted by a motor driven gate. The hearth and side layers bin will be equipped with an emergency chute which permits additional filling of fired pellets with hearth layer in case of failure in the green pellet feeding system and thus protecting the pellet cars and grate bars from overheating. The three feed components are charged onto the pellet cars in the following order:- First, hearth layer is fed onto the indurating machine followed by simultaneous feeding of side layers ( both sides) and green balls onto the pellet car that has already been loaded with Bhubaneswar Page 26

32 hearth layer earlier. Green pellets are subject to the following thermal zones during the process of induration. The indicative length of individual zone is mentioned below :- Sl. No. Zone Length in m. 1 Updraught drying zone (UDDZ) 12 2 Downdraught drying zone (DDDZ) 12 3 Preheating zone 21 4 Firing (Induration) zone 33 5 After firing zone 6 6 Updraught Cooling Zone I (UCZ-1) 33 7 Updraught Cooling Zone II (UCZ-II) 9 Total 126 Following drying of green pellets in the updraught and downdraught drying zones, the dried pellets will be preheated to a progressively higher temperature to initiate magnetite oxidation and sulphur burning due to coke breeze present in the mix. The pellets will then be fired at approx C to provide the recrystallization and slag bonding which will impart adequate strength to the pellets. An unifired short selection designated as after firing allows the eliminating sudden quenching of pellets and consequent deterioration of properties. Cooling of indurated pellets shall be accomplished by updraughting ambient air through the pellet bed supplied by a cooling air fan. The cooled pellets will leave the indurating machine at C or less. Process gas flow General The induration process is characterized by max. recovery of heat from the cooling zone as well as firing zone of the traveling grate machine. This calls for recirculation of hot gases through ducts to different process zones using five fans. A total of five process fans have been envisaged as follows:- Table 3.3 Types of Draught Fan with Capacity SL.NO. TYPES OF DRAUGHT FAN CAPACITY 1 Cooling Air Fan 15,500 m³/min 2 Updraft drying fan 5,500 m³/min 3 Wind box recuperation fan 7,700 m³/min 4 Hood Exhaust Fan 6,600 m³/min 5 Wind box Exhaust fan 12,500 m³/min Length of various zones of indurating machine and the capacity of above process fans are Bhubaneswar Page 27

33 indicative and will be finalized by the selected bidder after detailed pot testing of raw materials. For the purpose of recovery of heat, the grate will be provided with a refractory lined hood above the machine all along the length. Seal boxes are used in different zones to seal this indurating hood against the moving pellets to avert heat loss. The hood will be provided with water cooled side and transverse lintels. The following is a brief account of the process gas flow:- The cooling air, supplied by the cooling air fan, picks up heat from the hot pellet bed and is collected in the first and second cooling zones. The heated air is recycled to the process as a heat carrier. Recirculation from up draught cooling zone I to preheating / firing zone In the first cooling zone, hot air leaving the top of the bed containing a large quantity of sensible heat will be ducted through a direct recuperation header, (without the use of a hot fan) to the side wall mounted gas burners of the preheating and firing zones of the indurating machine. The air will be heated in the chamber according to a temperature profile controlled by the operator. The arrangement and sizing of the burners ensures a uniform hog gas temperature over the width of the pellet bed. Since the burners are divided into several control zones, an optimum temperature profile can be achieved thus permitting an optimum heat treatment of the pellets. The temperatures in the individual zones of the preheating and firing zones are measured with thermocouples for automatic control of gas flow to the individual zones. Recirculation from preheating / firing zone to down draught drying zone The hot process gases from the firing and partly forms the after firing zones serve as the drying gases in the down draught drying zone of the grate. They are sucked through the pellet bed in the firing zone by the wind box recuperation fan and then forced via gas duct into the hood above the downdraft drying zone. In order to protect the wind box recuperation fan from overheating, control dampers are provided at the suction side of the fan. The hot air passing through the down draught drying zone will be collected by the wind box exhaust fan located between a ESP and the common waste gas stack. The wind boxes of the down draught drying zone and the preheating zone are all connected to the wind box Bhubaneswar Page 28

34 exhaust fan. Clean air from this stream will be exhausted to the atmosphere up the waste gas stack. Recirculation from up draught cooling zone II to up draught drying zone Hot air from the second cooling zone (UCZ II) will be blown by the up draught drying fan and forced through a duct into the wind boxes of the updraft drying zone of the grate. In order to stabilize the temperature of this air for optimum green pellet drying, ambient air may be sucked in ahead of the up draught drying fan through a bleed in. The air will be forced through the bed after which it is cleaned in an ESP, collected by the hood exhaust fan (located be tween a second ESP and the stack) and discharged into the atmosphere through the common waste gas stack. Excess air not required for up draught drying and causing excessive pressure in the wind boxes of the up draught drying zone is by passed via a bleed off gas duct. Pellets Segregation and Hearth Layer Separation Hearth and side layers will be used to protect the grate bars and the side walls of the pellet car from excess heat. No screen has been envisaged in the pellet plant for separation of the hearth layer and for removal of fines. Large pellets roll to the edges of a pile due to their greater potential energy. This effect will be used to separate hearth layer by natural segregation. Pellets discharged from the indurations machine will be transported to a segregation bin. Larger pellets will be separated to the sides of the bin and will be allowed to overflow to a side chute to return as hearth layer. The product pellets will be discharged from the bottom of the bins for onward transportation to blast furnace / ground stock piles by means of belt conveyors. A variable speed product belt will determine the rate of overflow, which in turn is controlled by the level of the hearth and side layers bin. Hearth layer from pellet segregation unit will be fed to a hearth and side layers bin by conveyors. A hopper is provided for emergency filling of the hearth layer system. From the hopper the upper size pellets will be fed to indurating machine to form side and bottom layers. Equipment list for major technological equipment is placed at Table given below. Bhubaneswar Page 29

35 Table 3.4Major equipment and facilities: The Pelletizing Plant will mainly consist of the following sections: S.No. Equipment Description 1 Steel Storage hopper with supporting structure fpor bentonite 2 Steel Storage hopper with supporting structure for fine coal/ coke 3 Bag filter for storage hopper 4 Storage gopper for iron ore concentrate and drier 5 Grinding of additives 6 Bowl type mixers 7 Collecting conveyor below mixer 8 Plough over belt conveyor 9 Belt Conveyor 10 Belt Conveyor to collect roller screen rejects and balling disc rejects 11 Belt Conveyor 12 Gates below mixed material bins 13 Belt Weigh Feeder 14 Balling Discas. Dia 7.5 m,rim height 800 mm. RPM 5 to 12, disc slope deg- 7 nos. 15 Fluffers-& Nos. 16 Conveyor for green pellet collection, B/w 1800,Cap. 600 tph 17 Reciprocating type belt conveyor, B/w 1800, Cap. 600 tph 18 Wide Belt Conveyor, B/w 4.5 m, Cap. 600 tph 19 Double deck roller screen width 4.0 m, Cap. 600 tph, size 9-16 mm 20 Oversize belt conveyor, B/w 650, cap-100 tph 21 Belt Conveyor for over and under size green pellets, B/w 650, cap.300 tph. 22 Belt conveyor for collecting under size green pellets from lower deck,belt width 2.2 m 23 Indurating machine, active area 504 m²,width 4.0 m, total reaction length 126 m, zone wise length UDD-12 m DDD -21 m Firing-33 m After firing-6 m Cooling-I-33 m Cooling-II-9 m 24 Cooling air fan,cap m³/min 25 Updraught drying fan, cap.5500 m³/min 26 Hood exhaust fan,cap.6600 m³/min 27 Recuperation fan,cap m³/min 28 Wind box exhaust fan, cap m³/ min 29 Electrostatic precipator, cap m³/min 30 Electrostatic precipator, cap m³/min 31 Indurating machine discharge station,vol. 65 m³,cap. 500 tph 32 Vibro feeder be;ow indurating machine discharge station 33 Belt Conveyor for hearth layer, cap.300 tph,/w Hearth layer bin over induration machine, vol.175 m³/min 35 Wet Scrubber over hearth layer bin 36 Fan for wet scrubber, cap.600 m³/ min 37 Belt conveyor for carrying machine discharge, b/w 1000, cap. 500 tph 38 Segregation bin cap. 500 tph Bhubaneswar Page 30

36 Feed size 9-16 mm Overflow 9-16 mm Product upto 16 mm 39 Wet scrubber over segregation bin 40 Fan for wet scrubber F103, cap.900 m³/min 41 Belt conveyor,b/w 1000, cap. 500 tph 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% SiO 2 : 3.3 to 3.4% Al 2 O 3 : 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 Size distribution Value +16 mm : 5% max mm : 92%min -6 mm : 3% max Compressive strength Tumbling index +6 to -16mm : 92% : 230kg/pellet 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. Table 3.5 COMPARISONS OF QUALITIES OF BF & DR GRADE PELLETS CHEMICAL PROPERTIES BF GRADE DR GRADE PARAMETER SPECIFICATION Fe(t) Below 65% 66.5% SiO 2 + Al 2 O 3 5% Max 3.10% Max Na 2 O 0.05% Max 0.05% Max K 2 O 0.05% Max 0.05% Max Bhubaneswar Page 31

37 TiO % Max 0.10% Max Mn 0.10% Max 0.10% Max P 0.04% Max 0.04% Max S 0.02% Max 0.02% Max V 0.05% Max -- Basicity (CaO/SiO 2 ) Moisture (free moisture loss at 105 ºC) PHYSICAL PROPERTIES 4% max (fair season), 6% max (monsoon) BF GRADE DR GRADE Screen Analysis Specification Screen Analysis Specification -16mm +9mm 85% Min +19mm 5% Max -9mm,+6.35mm 7% Max -16mm,+9mm 85% Min -5mm 3% Max -9mm,+5mm 5% Min Tumbler text (ASTM) -5mm 3% Max Tumble Index (+6.35mm) 94% Min Tumbler text (ASTM) Abrasion Index (+0.6mm) 5% Max Tumble Index (+6.3 5mm) METALLURGICAL PROPERTIES Parameter Specification BF GRADE DR GRADE Swelling (JIS) 18-20% Max 20% Max 4% max (fair season), 6% max (monsoon) 94% Min 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 concentrate from storage yards will be carried out by front-endloader (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 Welspun Orissa Steel Pvt. Ltd. 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 88,000 tons per annum, the annual procurement has been considered in several consignments according to the available storage facility in the Pellet plant. 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 Bhubaneswar Page 32

38 earmarked in the yard (in the pellet plant) i n desired stockpile height of 2.5 m through outsourcing by Welspun Orissa Steel Pvt. Ltd. The storage details of major raw materials are given in Table below: Table 3.6 STORAGE DETAILS OF MAJOR MATERIALS Sl. No. Materials Stocking area L(m) x W(m) x H(m) Stock quantity No. of days 1. Ore fines 130 x 130 x Bentonite 20x10x Limestone 20 x 10 x Coke 20x10x Pellet 100x50x2 10 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 Welspun Orissa Steel Pvt. Ltd. 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 (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 Welspun Orissa Steel Pvt.Ltd. 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 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 Bhubaneswar Page 33

39 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 Plant Layout The layout of the plant will be developed taking into following considerations: 1. Process departments will be consolidated into comprehensive production units requiring short conveying distances; 2. The major utilities and service facilities will be centrally located in respect to points of high consumption; 3. Sufficient space will be provided for ease of operation and maintenance; 4. The lengths of power cables will be minimized by suitably locating load distribution centres in respect of process departments; 5. Outward movements of materials from customers/suppliers will be segregated from internal plant traffic 6. Sufficient space for storage of raw materials and finished products. 7. Green belt will be provided. 8. Rainwater harvesting pond will be provided at lowest elevation to collect surface run-off to maximum possible extent. 9. Adequate area will earmarked for tailings and ash disposal. 10. Weigh Bridge and administrative block will be located at the entrance. Bhubaneswar Page 34

40 Fig-3.3 PLANT LAYOUT Bhubaneswar 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 3.7 Requirement of Raw Materials Raw Materials Requirement Annually Source Mode of (T) Transportation Mode of Transportation Iron Ore Concentrate 4,752,000 Iron Ore Fines <63 % Fe, By Road/Rail from local iron ore mines, Open market and Govt. mines. Bentonite 44,000 Gujarat By Road/Rail Dolomite/ Limestone 88,000 Open Market By Road/Rail Coal/Coke breeze 88,000 Nearby mine By Road/Rail Fuel Oil 61,600 IOCL By Road/Rail NOTE: Based on the following operating days/year: 330 days and 24 hrs/day for pellet plant Furnace oil (FO) has been envisaged to be used as fuel for the pellet plant. Daily requirement shall be around 205 kl (approx.) & hourly consumption shall be 9 kl storage facilities have been envisaged to meet the consumption for 7 days requirement. Proposed facilities Fuel oil storage tanks For storage of fuel oil, it has been envisaged to provide 2 nos. fabricated cylindrical vertical mild steel tanks each of capacity 1000 kl. The tanks will be designed as per IS : Each tank will be provided with all standard accessories and fittings, thermal insulation, electrically heated suction heater etc. The outflow suction heater will be adequately designed to meet the temperature requirement of heavy furnace oil at desired conditions. Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 36

42 Fuel oil decanting / unloading facilities FO shall be brought in road tankers and the same shall be unloaded into the storage tanks through unloading header. 2 nos. pumps (1 working + 1 standby) each of 50 m 3 / hr. capacity shall be provided for unloading. Provision shall be made for unloading of 2 nos. road tankers simultaneously. FO unloading pipelines including valves shall be electrically traced with electrical heat tracers and lagged with mineral wool blanket and aluminium cladding. Fuel oil supply to the consuming units 2 nos. delivery pumps each of 15 m 3 / hr capacity (1 working + 1 standby) shall be installed for supply of FO from storage tanks to the ring main circuit. From the storage tanks, oil is supplied through a ring main to oil burners of the indurating machine at required pressure & temperature. A day oil tank of adequate capacity is provided near the additive grinding unit for supplying fuel oil to the hot gas generator. The entire FO delivery system including storage tanks, pumps, pipelines, valves & the ring main shall be electrically heat traced & lagged with mineral wool blanket and aluminium cladding for maintaining flowability of oil. Duplex filters at suction side of each unloading pumps & delivery pumps shall be provided. Adequate provision shall be made in the design of piping system which shall be laid overhead and supported on shop columns. The oil delivery pressure shall suit the burner requirement of the pellet plant. All standard instrumentation and control facilities as required for safe, smooth and trouble free operation of the FO system shall be provided. LDO Storage & handling facilities A 100 kl storage tank for light diesel oil (LDO) shall be installed for flushing the FO pipelines. LDO shall be brought in road tankers and the same shall be unloaded into the storage tank by means of 2 nos. (1 w + 1 s) unloading pumps. The capacity of the LDO unloading pumps is to be 10m 3 / hr. each. For supply of LDO to the consumers, 2 nos. delivery pumps (1w+1s) provided above for FO service shall be utilized. Necessary, unloading header, hoses, piping, valves and fittings shall be provided for the completeness of the LDO system. 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 Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 37

43 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 figures, it is estimated that the total make-up water requirement for the proposed iron ore and pellet plant will be around 60.3M 3 per hour. Estimated break up of makeup water quantities is given in following table. Table 3.8 Water Requirement Sl. No. Unit Makeup m³/hr. 1 Process Requirement(Mixer & 30.0 Balling discs) 2 Indurating Machine Secondary Colling Evaporation & Cooling Washing Others Drinking water for plant & 2.0 Personnel Sub Total Make up Water 60.3 Remarks Industrial water consumed in the process and other areas Thus fresh water project site.. will be drawn from the nearest River Matai which is 7.0 km away from the Fig 3.4 WATER BALANCE Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 38

44 3.8.2 Power Requirement The estimated maximum demand and annual energy consumption for the proposed pellet plant project are given below:- Pellet plant Max. demand : 45 MW Annual energy consumption : 339 x 10 6 kwh 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 Power is proposed to be received in the main receiving and step down substation (MRSS) of the Pellet plant at 132kV level from grid substation NESCO over single circuit overhead transmission line. 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/nm 3 (Max) : Dust content in the work zone shall be limited to 5 mg/nm 3 over 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 cleaning: the preheat zone and discharging them to the atmosphere through stack after 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. Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 39

45 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). Table 3.9 Source of air pollution and control measures Section Iron Ore Pellet plant Source of Pollution Raw material Handling (Normally transfer for bunker) Air pollution control Measures Capacity ofstack Height APC Device(M) (M 3 /hr) Bag Filter Limestone & Coke grinding Bag Filter Bentonite 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 3.10 Waste Water Generation and Reuse Process Waste water qty Unit (m 3 /hr) Pellet No waste water generation. Cooling water will be completely recycled. Source Waste water Waste water characteristics management Cooling High Temp Complete recirculation Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 40

46 Raw water treatment system 2.50 Backwash from filtration unit TDS TSS Will be treated in settling tank reused in greenbelt development and dust suppression Domestic 2.50 Domestic TSS, BOD, Oil & Will be treated in STP and use from Grease reused for greenbelt plant Total Complete recycle/ reuse to achieve zero discharge 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 3.11 Solid Waste Generation and Management Units Solid Wastes Qty In TPA Disposal practice Pellet plant Dust from APC devices 5200 Reused in pellet making Broken Pellet 4200 Raw water Sludge 10 Will be used for landscaping treatment plant Table 3.12 Domestic Solid Wastes Units Solid Wastes Qty In TPA Disposal practice Canteen Garbage and food waste 20 Organic and inorganic portion of waste will be separated, organic waste will be vermicom posted and used for greenbelt development. Inorganic portion will be given to scrap dealer. Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 41

47 Table 3.13 Hazardous Wastes Hazardous Wastes Quantity Hazardous Wastes Management Used Oil and Lube Oils 4.2 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 2.5 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 db A 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. Visiontek Consultancy Services Pvt. Ltd, Bhubneswar 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% (53Ac) 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 3.4 Information of EIA Purpose Visiontek Consultancy Services Pvt. Ltd, Bhubneswar Page 43