PRE-FEASIBILITY REPORT

Transcription

1 PRE-FEASIBILITY REPORT By Agrawal Iron & Industries (Unit # 2) [Regularisation of Pellet plant 90,000 MTPA along with Coal Gasifier 5000 Nm3/Hr] at Kh.No.219, 220, 221, P.H.No.54, Village Billory, Tehsil Jagdalpur, District Baster, Chhattisgarh

2 TABLE OF CONTENTS CHAPTER 1: EXECUTIVE SUMMARY ABOUT THE PROPOSED PROJECT... 1 CHAPTER 2: INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION IDENTIFICATION OF PROJECT AND PROJECT PROPONENT... 2 BRIEF DESCRIPTION OF NATURE OF PRODUCT NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION DEMAND SUPPLY GAP EMPLOYMENT GENERATION (DIRECT & INDIRECT)... 5 CHAPTER 3 : PROJECT DESCRIPTION TYPE OF THE PROJECT... 6 LOCATION OF THE PROJECT DETAILS OF THE ALTERNATE SITES SIZE OR MAGNITUDE OF OPERATION MANUFACTURING PROCESS - PELLETISATION UNIT RAW MATERIAL REQUIREMENT WATER REQUIREMENT AND ITS SOURCE WASTEWATER MANAGEMENT SOLID WASTE GENERATION AND ITS DISPOSAL CHAPTER 4 : SITE ANALYSIS CONNECTIVITY LANDUSE AND LAND OWENERSHIP TOPOGRAPHY EXISTING LAND USE PATTERN EXISTING INFRASTRUCTURE CLIMATIC DATA FROM SECONDARY SOURCES CHAPTER 5 : PLANNING BRIEF PLANNING CONCEPT POPULATION PROJECTION LAND USE PLANNING ASSESSMENT OF INFRASTRUCTURE DEMANT (PHYSICAL & SOCIAL) AMENTIES / FACILITIES CHAPTER 6 : PROPOSED INFRASTRUCTURE INDUSTRIAL AREA (PROCESSING AREA) MAIN BUILDING & BUILDING STRUCTURE RESIDENTIAL AREA (NON PROCESSING AREA) GREEN BELT SOCIAL INFRASTRUCTURE CONNECTIVITY DRINKING WATER MANAGEMENT SEWERAGE SYSTEM INDUSTRIAL WASTE MANAGEMENT POWER REQUIREMENT & ITS SOURCE... 17

3 CHAPTER 7 : REHABILITATION & RESETTLEMENT (R & R) PLAN CHAPTER 8 : PROJECT SCHEDULE & COST ESTIMATES PROJECT SCHEDULE PROJECT COST CHAPTER 9 : ANALYSIS OF PROPOSAL FINANCIAL AND SOCIAL BENEFITS SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES... 20

4 Chapter 1: EXECUTIVE SUMMARY 1.1 ABOUT THE PROPOSED PROJECT Agrawal Iron & Industries (Unit # 2) is a Partners hip Firm. Agrawal Iron & Industries (Unit # 2) envisages establishing 90,000 TPA capacity Pellet plant along with 5000 Nm 3 /hr capacity Coal Gasifier at Billori Village, Jagdalpur Tehsil, Bastar District, Chhattisgarh. They have obtained Consent for Establ ishment from CECB for the above plant vide no. letter no. 3911/TS/CECB/2013 dt. 2 nd Nov As per NGT order vide no. 5/2014 dt. 27 th May 2014, all Pellets plant needs to obtain Environmental Clearance as per EIA notification Accordingly CECB has issued a letter for obtaining Environmental Clearance for the proposed Pellet plant acres of land is in possession of management and same is converted for Industrial Purpose. 1

5 Chapter 2: INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION 2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Agrawal Iron & Industries (Unit # 2) is a Partnership Firm. They are mainly involved in iron ore industries. Promoters The proposed project of the Pellet Plant would be undertaken & implemented by the management of AII. The promoters have made a thorough study of entire project, planning as well as implementation schedule. The names and designations of the Promoters are as under: S.No Name Designations 1. Shri Anil Agrawal Partner 2. Shri Suresh Kumar Ja in Partner 3. Shri Neeraj Agrawal Partner 4. Shri Ankit Agrawal Partner 2.2 BRIEF DESCRIPTION OF NATURE OF PRODUCT Proven technology for large capacity Pelletization Plants is available from western world and few plants with such technology are operating in India. But for medium and small - scale projects much development work has been done in China. In China, due to availability of low-grade Iron Ore deposits, beneficiation, sintering and pelletisation process are absolutely necessary. Thus lot of work h as been done from large scale to small-scale plants on all these processes. The raw material from them is mostly beneficiate magnetite iron ore concentrate, normally standardized to quality of > 67% Fe, < 200 micron size & 12% moisture. Beneficiation process is part of the activity of mining companies. Also due to availability of good quality coking coal, the main route of iron making is Blast furnace route. From Blast Furnace, substantial quality of excess blast furnace gas is available which can be best utilized for sintering & pelletising. Therefore both sintering and pelletization plants are part of the Blast Furnace Plant complex for preparation of feed materials and use Blast Furnace gas as Fuel. 2

6 India s situation is much different in following respects: - 1. The necessity is recently realized. 2. Wide variation in the quality of iron ore pellets plant. 3. Most of the Pellet plants will be green field / independent projects. So different fuels to be selected as per situation. 4. Small pellet plants are planned to prepare feed for self-use in sponge iron kilns. Thus Indian Pellet Plants cannot be a copy of Chinese Plant. Necessary changes as per the situation are essential and been considered to make this plant efficient and productive. The company after assessing the market potential of the steel industry thoroughly decided to go in for iron-ore pellets. The highly encouraging response received on market survey also ruled favorably for the said project. Promoters are well experienced entrepreneurs and are well supported by technical personnel experience to run such unit. Presently, most of the coal based sponge iron plants in India uses iron ore lumps. The requirement is generally 1.8 t/ t of sponge iron. This high requirement is mainly due to the fines generated in handling the purchased ore from the source to the plant. This reduces the kiln campaign length and increases ore fines lost. Use of pellets with better physical and metallurgical properties for sponge iron production reduces the accretion formation in the kiln and the pellets consumption is about 1.6 t/t. Further, the production from the kiln is expected to increase by 25% to 30%. 2.3 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION Utilization of Iron ore fines has to play an important role. In India partly due to the sponge iron sector; the overall percentage of lumps usage in steel making (47%) is higher than most other countries. As hard ore reserves is depleting day by day, lump generation suitable for blast furnace operation is coming down resulti ng in production of large amount of surplus fines. Alternative iron making processes for production of steel may lead to changing pattern of use material inputs and feed stock causing significant shift in respective share of lumps and agglomerated iron ore (pellets) and will also enable the use of ores which could not be utilized earlier. As fines forms considerable part of iron ore resources, value addition to the iron ore fines through various activities such as Pelletization is the need of the hour. 3

7 2.4 DEMAND SUPPLY GAP With the rapid development of Infrastructure and manufacturing sector, the Iron and steel industry is poised for an accelerated growth. Steel demand in the country is increasing at an average rate of 10% and is likely to rema in in 10-12% range at least for the next decade. In order to meet the steadily growing steel demand in the country, domestic steel producing capacity is required to be higher than 110 mtpa within ne xt three years and, 150 mtpa by the year Indian economy is growing at more than 10% rate, steel demand and supply will grow in the same way. As good quality iron ore deposits are depleting fast Pelletisation technologies will have to be adopted to meet iron ore demand. Agglomeration technologies such as Pelletization will have to be added to DRI Plant / Steel Plant so that concentrates can be used as feed material. Using Iron ore fines in pelletization process as feed material will result in better Return on Investment as compared to using Iron ore as feed material. With superior reducibility behavior of pellets compared to lump ore efficiency of DRI production improves. In the Indian context, by the year 2020, India s production of steel is expected to touch110 Million Tonnes and it is imperative that the fines generated in the mining of iron ore be utilized for the production of steel. The Indian steel industry which predominantly uses expensive lump ore is gradually moving towards usage of iron ore pellets. The present Indian raw material scenario offers an opportunistic disposition towards pellet making owing to the availability of large quantities of sub grade fines, slimes and blue dust etc. at different mine heads. These materials are not suitable for sinter making. Pelletization is the only possible route for salvaging these, otherwise waste but valuable materials. Recent techno-economic studies indicated favorable indices for installation of pellet plants, both small and large scale. The demand supply analysis also underlines the need for Pelletiza tion. 4

8 2.5 EMPLOYMENT GENERATION (DIRECT & INDIRECT) PHYSICAL INFRASTRUCTURE Once the proposed activity is commissioned, the socio-economic status of the local people will improve and there by infrastructure facilities like communication systems will improve. Most of the villages at present do not have protected water supply. After the implementation of the project, the affordability of the public to spend on water treatment, supply & distribution will more along with the aid from the state government. EMPLOYMENT POTENTIAL The proposed project creates employment to 100 people during construction and 50 people during operation of the proposed project. SKILLED Total skilled employment in the proposed plant will be around 15. SEMI-SKILLED Total Semi-skilled employment in the proposed project will be around 15. Priority will be given to local people for semi -skilled jobs. UNSKILLED Total Unskilled employment in the proposed project will be around 20. Top priority will be given to local people for unskilled jobs. 5

9 Chapter 3: PROJECT DESCRIPTION 3.1 TYPE OF THE PROJECT Proposed project is Regularization Pellet plant for which Consent of Establishment (CFE) has been obtained from CECB vide letter no. 3911/TS/CECB/2013 dt. 2nd Nov Following is configuration for which CFE has been obtained i. Pellet Plant 90,000 TPA ii. Coal Gasifier 5000 Nm3/hr 3.2 LOCATION OF THE PROJECT Agrawal Iron & Industries (Unit #2) is proposed to establish 90,000 TPA capacity Pellet plant along with 5000 Nm 3 /hr capacity Coal Gasifier at Kh.No.219, 220, 221, P.H.No.54, Billori Village, Jagdalpur Tehsil, Bastar District, Chhattisgarh acres of land is in possession of management and same is converted for industrial purpose. Project Site 6

10 3.3 DETAILS OF THE ALTERNATE SITES No alternative site has been considered, as the proposed project is regularization of Pellet plant for which Consent of Establishment (CFE) has been obtained from CECB vide letter no. 3911/TS/CECB/2013 dt. 2 nd Nov SIZE OR MAGNITUDE OF OPERATION Proposed to establish 90,000 TPA capacity Pellet plant along with 5000 Nm 3 /hr capacity Coal Gasifier. 3.5 MANUFACTURING PROCESS - PELLETISATION UNIT The iron ore pelletization unit comprises of following sections: 1. Drying & Prepn. of Iron Ore Fines 2. Grinding 3. Mixing and Blending 4. Pelletization 5. Screening 6. Travel Grate Furnace 7. Rotary Kiln 8. Cooler 9. Stacking 10. Recovery of Dust and Spillage a. Drying & Preparation of Iron ore Fines: Generally Iron Ore Fines, Li me Stone and Dolomite fines available, contain more than 6-7% moisture and require drying before grinding. The drying is carried out in Rotary Drum Dryer. The moisture content in the dry material is controlled. The low grade Iron Ore Fines is feed in a screen for separation. Oversize/ under size moves to the primary grinding circuit. b. Grinding Iron Ore Fines, Dolomite and Lime Stone are mixed in required proportion and fed into a Ball Mill. The fineness of the product is controlled as may be necessary for particular ore and Pellet quality. 7

11 c. Mixing and Blending Iron Ore powder blended with Bentonite and other binding materials in desired proportion. Small quantity of water is added during blending operation. This raw mix is ready for Pellet making and store in feed hopper. d. Pelletization Controlled quantity of raw mix is fed on disc Pelletizer. Some amount of water is sprinkled for producing Pellets. These Pellets are passed through oversize and undersize screens. Sized Pellets are then sent to sintering section. e. Screening Pellets produce in Pelletization sections are passed through oversize and undersize screens. Rejects Pellets are sent back to raw mix silos sized Pellets are fed in to Indurations Furnace. f. Travel Grate Furnace A Travel Grate Furnace is used for indurations of Pellets. This is divided into 3 sections (Drying Preheating Heating). Hot Pellets at around 950ºC to 1000ºC from this Travel Grate are dropped into the Kiln for further strengthening. g. Rotary Kiln Rotary Kiln receives Pellets from the Indurations Furnace where Pellets have to withstand at high temperature approx. 1050ºC 1200ºC. Here the Pellets gain more hardness due to high temperature. Furnace Oil / Producer Gas is used as a fuel inside the Kiln. After the Kiln the Pellets are passed to the Grate Cooler. h. Cooler Grate Cooler receives hot Pellet with temperature up to 1200ºC coming from Rotary Kiln. Cooler has its own blowers to blast the air from bottom. The hot air from the first zone is used as a combustion air in kiln. The hot blast of the second zone is used i n the pre-heating zone-1 of travel grate and the air from the 3 rd zone is discharged to the atmosphere through chimney as its dust concentration is well within the permissible limits of pollution norms. Volume of cooling air in all the three zones is regul ated automatically through the temperature control loops as per the requirement. Cold 8

12 Pellets at about 100ºC are discharged on conveyors and they are quenched by the cold water for further cooling and then conveyed to the stock pile/ loading hoppers. i. Stacking The screened Pellets of required size duly cooled at air cooler and subsequently natural cooling are transported to Bunkers j. Recovery of Dust and Spillage Spillage from drying zone and preheating zone of traveling grate, dust from the wind box of tra veling grate and dust collected through de-duster of technological process shall meet and will be sent to dust bin via belt conveyor, after they are ground together with iron ore concentrate at grinding mill. Spillage (dry Pellets) produced at the discharge end of traveling grate will be fed into the kiln from the feed chute of the kiln feed end by bucket elevation. Almost all the dust and spillage are re -circulated and recovered. 9

13 3.6 RAW MATERIAL REQUIREMENT Raw material required are as followed: For Pelletisation unit S.No. Raw Material Quantity (TPA) Source Mode of Transport 1. Beneficiated Iron ore fines Local / Orissa Sector By Rail & Road through covered trucks 2. Coal fines 450 Chhattisgarh/Vizag. Rail route / by road 3. Limestone 900 Chhattisgarh / Madhya Pradesh By Rail & Road through covered trucks 4. Bentonite 1350 Gujarat By Rail & Road through covered trucks For Coal Gasifier S.No. Raw Material Quantity (TPA) Source Mode of Transport 1. Coal 7200 SECL / Imported Through sea route / rail route / by road 3.7 WATER REQUIREMENT AND ITS SOURCE Water required for the proposed project will be 42 KLD. Water required will be sourced by Ground water sources. 3.8 WASTEWATER MANAGEMENT Closed circuit system will be adapted in the prop osed project. Hence zero effluent discharge will be maintained. Only waste water generated will be sanitary waste water, which will be treated in septic tank followed by sub-surface dispersion trench. 3.9 SOLID WASTE GENERATION AND ITS DISPOSAL S.No Type of Solid waste Quantity Disposal Proposed (in TPD) 1. Ash / Dust generated 8 Will be recycled back into the process. 10

14 Chapter 4 : SITE ANALYSIS 4.1 CONNECTIVITY The project site can be approached by Jagdalpur by NH # 43. Nearest Railway Station is at Semra at distance of 1.8 Kms. from the project site. The location has a big advantage in its closed proximate to its market. Traditionally, iron manufacturing units have tendered to cluster in the eastern zone of India namely in the state of Jharkhand, Orissa a nd Chhattisgarh because of easy availability of major raw input iron-ore and coal. Infrastructural and other utility services are easily available. Skilled and un-skilled laborers are also available easily. 4.2 LANDUSE AND LAND OWENERSHIP Total land envisaged for the proposed project is 3.43 acres. Same is in possession of management. Land is converted for Industrial purpose. 4.3 TOPOGRAPHY The topography of the land is flat without undulations. 4.4 EXISTING LAND USE PATTERN 3.43 acres of land is envisaged for the proposed project. The land is converted to Industrial use. There are no ecologically sensitive places like national park, sanctuary, biosphere reserve, etc. around 10 Kms. radius of the site. Few Reserve forest exists within the study area. There is no route of migratory animals within the project site. 4.5 EXISTING INFRASTRUCTURE Water supply in most of the vi llages is available. Inter-village transport facility is available only for the selected villages. While educational facilities & health facilities are not encouraging in most of the villages. There is well established road connection. 11

15 4.6 CLIMATIC DATA FROM SECONDARY SOURCES Jagdalpur has a tropical savanna climate (Köppen climate classification Aw) with th ree main seasons: summer, monsoon, and winter. Summers last from March to May and are hot, with the average maximum for May reaching 38.1 C (100.6 F). The weather cools off somewhat for the monsoon season from June to September, which features very heavy rainfall. Winters are warm and dry. 12

16 Chapter 5 : PLANNING BRIEF 5.1 PLANNING CONCEPT Agrawal Iron & Industries (AII) envisages establishing 90,000 TPA capacity Pellet plant along with 5000 Nm 3 /hr capacity Coal Gasifier at Billori Village, Jagdalpur Tehsil, Bastar District, Chhattisgarh. They have obtained Consent for Establishment from CECB for the above plant vide no. letter no. 3911/TS/CECB/2013 dt. 2 nd Nov As per NGT order vide no. 5/2014 dt. 27 th May 2014, all Pellets plant needs to obtain Environmental Clearance as per EIA notification Accordingly CECB has issued a letter for obtaining Environmental Clearance for the proposed Pellet plant. 5.2 POPULATION PROJECTION The project will be providing direct employment to nearly 100 workers. The local persons will be given preference in employment as per the qualification and technical competencies. Necessary training will be given to train the unemployed youths of the nearby villages as per the qualification and technical competencies. Indirect employment opportunities will be created in the periphery of the project automatically as the project started operation in the region. In order to operate and maintain the plant facilities, including its technical general administration needs, the manpower for the proposed will be 100. The above manpower covers the top management, middle and junior level executives and other supporting staff including workforce. 5.3 LAND USE PLANNING Total land envisaged for the proposed project is 3.43 acres. Same is in possession of management. Land is converted for Industrial purpose. 13

17 5.4 ASSESSMENT OF INFRASTRUCTURE DEMANT (PHYSICAL & SOCIAL) The road facility is already available which shall be used and maintained. Infrastructure facilities like road transport, Post & Telegraph, Telephone, Banks etc. are basics for each and every area. The company management will take various steps for upliftment of the basic amenities of the area by providing drinking water, pucca road, communication facilities etc. The area is not very well developed as far as job opportunities and living standard of the population is concerned. With the start of the proposed Plant, various employment opportunities will be generated. Several persons will be benefited with contract works, employment through contractor, running of jeep and buses, canteens, different kind of shops and transport related business avenues. This will improve the economic condition of the persons. 5.5 AMENTIES / FACILITIES A well planned office will be provided having sufficient space to accommodate executives and staff. It will be equipped with telephones and Internet facilities. Facilities like canteen, rest room and indoor games facilities will be provided in the proposed plant as basic facilities to workers. 14

18 Chapter 6 : PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREA (PROCESSING AREA) The main plant area comprises of iron ore handling area, storage area etc. The major equipment and facilities envisaged for the pelletizing plant are described below The pelletizing plant will mainly consist of the following sections: Storage and handling of iron ore fines Storage, handling and preparation of binder and additive Iron ore improvement Proportioning and mixing Balling, in duration and cooling Finished product storage MAIN BUILDING & BUILDING STRUCTURE Industrial Building 1. Ore Grinding 2. Additive Grinding 3. Ore Up gradation 4. Proportioning & mixing 5. Palletization 6. Transfer Tower 7. Indurations Furnace 8. Electrical Sub-station 9. Main Control Room Structure Building 1. Belt Corridor 2. Hopper and Bins 3. Foundation for dryer, grinding, mills, fan 4. Straight great furnace. 5. Multi cyclone 6. Chimney 15

19 6.2 RESIDENTIAL AREA (NON PROCESSING AREA) No colonization is proposed in the proposed project. However Fa cilities like canteen, rest room and indoor games facilities will be provided in the proposed plant as basic facilities to workers. 6.3 GREEN BELT More than 1/3 rd of total land availability is reserved for plantation i.e. greenery. Greenbelt development plan Local DFO will be consulted in developing the green belt. Greenbelt of 33% of the area will be developed in the plant premises as per CPCB guidelines. 5 m wide greenbelt is being maintained all around the plant. The tree species to be selected for the plantation are pollutant tolerant, fast growing, wind firm, deep rooted. A three tier plantation is proposed comprising of an outer most belt of taller trees which will act as barrier, middle core acting as air cleaner and the innermost core which may be termed as absorptive layer consisting of trees which are known to be particularly tolerant to pollutants. 6.4 SOCIAL INFRASTRUCTURE With the start of Construction phase, various employment opportunities will be generated. Several persons will be benefited with contract works, employment through contractor, running of jeep and buses, canteens, different kind of shops and transport related business avenues. Peoples will be provided with either direct employment or indirect employment such as contract work, development work like road etc. 6.5 CONNECTIVITY The project site can be approached by Jagdalpur by NH # 43. Nearest Railway Station is at Semra at distance of 1.8 Kms. from the project site. 16

20 The location has a big advantage in its closed proximate to its market. Traditionally, iron manufacturing units have tendered to cluster in the eastern zone of India namely in the state of Jharkhand, Orissa and Chhattisgarh because of easy availability of major raw input iron-ore and coal. Infrastructural and other utility services are easily available. Skilled and un-skilled laborers are also available easily. 6.6 DRINKING WATER MANAGEMENT Drinking water for the proposed project will be sourced ground water sources. It is estimated about 1 KLD will be required for domestic and drinking purpose during operation of the proposed plant. 6.7 SEWERAGE SYSTEM Domestic effluent collected through toilet blocks and other areas will be collected through well designed sewer network and send to Septic tanks followed by soak pits. No effluent will be left-out after Soak pits. 6.8 INDUSTRIAL WASTE MANAGEMENT Closed circuit system will be adopted in the proposed project. Hence zero effluent discharge will be maintained. Only waste water generated will be sanitary waste water, which will be treated in septic tank followed by sub-surface dispersion trench. 6.9 POWER REQUIREMENT & ITS SOURCE Power required for the proposed project will be sourced from nearby grid. 17

21 Chapter 7 : REHABILITATION & RESETTLEMENT (R & R) PLAN No rehabilitation and resettlement is required as there are no habitations in the in the Project site. 18

22 Chapter 8 : PROJECT SCHEDULE & COST ESTIMATES 8.1 PROJECT SCHEDULE The plant has already been implemented. Awaiting for Environmental Clearance from the Hon ble MoEF & NOC from CECB. 8.1 PROJECT COST The estimated cost for the proposed project will be Rs Crores. Particulars Amount (Rs. In Crore) Lease Hold (Land) & Site Development Factory Building Plant & Machinery 9.50 Electrical Installation Other Equipment Total

23 Chapter 9 : ANALYSIS OF PROPOSAL 9.1 FINANCIAL AND SOCIAL BENEFITS With the implementation of the proposed project, the socio-economic status of the local people will improve substantially. The land rates in the area will improve in the nearby areas due to the proposed activity. This will help in upliftment of the social status of the people in the area. Educational institutions will also come -up and will lead to improvement of educational status of the people in the area. Primary health centre will also be developed by us and the medical facilities will certainly improve due to the proposed project. 9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES The management is committed to uplift the s tandards of living of the villagers by undertaking following activities / responsibilities as the part of Corporate Social Responsibility. Health & hygiene Drinking water Education for poor Village roads Lighting HEALTH & HYGINE Personal and domestic hygiene, Maintaining clean neighborhood, Weekly health camps offering free -check up & medicines Ambulance services Education & drug de -addiction, aids. DRINKING WATER Making drinking water available at centralized locations in the village, 20

24 SUPPORTING EDUCATION Providing books to all poor children, Conducting annual sports festival in the village schools, Providing amenities like fans, lavatories, Maintain play ground etc. 21