Annexure Prefeasibility Report - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/17_Apr_2018... · Boudouard reaction 4. CO 2 + C = 2CO The material

Goa Sponge & Power Ltd. Sy.no. 58/59/60, Santona Village,

Sanguem, Goa - 403706

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Annexure – Prefeasibility Report

1. Executive summary The Goa Sponge & Power Ltd. was established in April, 1995. The industry manufactures Sponge Iron, Steel Billets and Fly-ash bricks on its plot located on Sy.no. 58/59/60 of Santana Village, Taluka Sanguem, State Goa. The industry had obtained Consent to Establish from Goa State Pollution Control Board for establishing Sponge Iron Plant (250 TPD), Power Plant (12 MW), Rolling Mill and Induction Furnace (12 T X 2 nos. = 90,000 TPA) vide letter no. 5/2240/02-PCB/1790 dated 4th February, 2003. The Industry had consent to operate under Section 21 of The Air (P&CP) Act 1981 (Consent to Operate granted by Goa State Pollution Control Board vide letter no. 6/890/05-PCB/3355 dated 24/02/2005 valid till 30/11/2006) and Section 25 of The Water (P&CP) Act 1974 (Consent to Operate granted by Goa State Pollution Control Board vide letter no. 5/2240/02-PCB/3343 dated 24/02/2005 valid till 30/11/2006) - for manufacture of sponge iron of 250 TPD, captive power plant producing total power of 12 MW (8 MW from WHRB and 4 MW from FBC) and for operation of induction furnace of capacity 90,000 TPA (12 T X 2 nos.) use for making steel billets. The power generated is used for operation of induction furnace. The sponge iron manufacturing of 250 TPD was revised to 90,000 TPA by Goa State Pollution Control Board in the year 2009 during the renewal of Consent to Operate. The industry has valid Consent to Operate from Goa State Pollution Control Board vide letter no. 4/2240/02-PCB/CI-3946 dated 15/03/2018. The Consent to Operate is granted for

Sr.no. Description Quantity

1. Sponge Iron 90,000 TPA (250 TPD)

2. Coal Char 40 TPD

3. Fly ash 28-30 TPD

4. WHRB 8 MW

5. FBC 4 MW

6. Steel billets using induction furnace (12 T X 2nos.) 300 TPD

Since the industry and its activities were initiated prior to 16th September, 2006 the sponge iron manufacturing caped at 90,000 TPA and Induction Furnaces of total 90,000 TPA capacity were not under purview of EIA notification 2006 and hence does not require prior Environmental Clearance. Though the proposed activity involves expansion of existing facility, it is applied as “NEW APPPLICATION” since the online application required to upload previous Environmental Clearance details. Without this the application was not being accepted.



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The present proposal is for expansion of present capacity as mentioned below –

Unit Existing Capacity Proposed Capacity Enhancement

Final capacity

Existing

Sponge Iron Manufacturing

90,000 TPA 35,000 TPA 1,25,000 TPA

Induction furnace and Billet caster

12 T X 2nos = 300 TPD (90,000 TPA)

15 T X 1 no. by replacing one of the

12 T Induction furnace = 125 TPD

425 TPD (12 T & 15 T

Induction furnace)

Captive power plant 8MW: WHRB + 4MW: FBC = 12 MW

0.5 MW 12.5 MW

Proposed expansion

Direct charging hot rolling mill

-- 425 TPD 425 TPD

The capacity enhancement of sponge iron manufacturing will be achieved by

1. Replacing low grade coal (with fixed carbon content less than 40-42%) with high grade coal (with fixed carbon up to 59%) imported from South Africa.

2. Replacing low grade iron ore (with Fe content less than 58%) with high grade iron ore (with Fe content up to 68%) imported from South Africa.

The replacing the low grade raw material with high grade, total volume of raw material feed to the rotary kiln will be reduced. This will increase higher feed rate to attain higher production. The capacity enhancement of induction furnace will be done by

1. Increasing the number of melts per day through increase in power wattage from avg. 9 MW to additional 1 MW. Therefore, the total power wattage to the induction furnace will be avg. 10 MW.

Additionally, a direct charging hot rolling mill will be installed. The plant has installed following Air Pollution Control Devices

Sr.No. Description of Stack Stack Height

1 Electric static precipitation for Rotary Kiln 75 mtrs

2 Dust extraction system for product (bag filter) 43 mtrs

2. Introduction of the project/Background information

i) Identification of project and project proponent. The proposed expansion project may be categorized under schedule 3(a) of EIA notification 2006. Out of the total project activities, the activities under the purview of EIA notification 2006 are as below 1. Sponge Iron manufacturing from: Existing 90000 TPA + additional 35000 TPA =

125000 TPA 2. Induction furnace (IF): 300 TPD (using 12 T X 2 nos. of IF) + 125 (replacing one of 12 T

IF with 15 T IF) = 425 TPD (12 T and 15 T induction furnace) Project Proponent: Goa Sponge & Power Ltd. (Represented by Mr. Manish Goel)



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ii) Brief description of nature of project


Final capacity

Existing


90,000 TPA 35,000 TPA 1,25,000 TPA


12 T X 2nos = 300 TPD (90,000 TPA)



425 TPD (12 T & 15 T

Induction furnace)

Captive power plant

8MW: WHRB + 4MW: FBC = 12 MW

0.5 MW 12.5 MW

Proposed expansion


-- 425 TPD 425 TPD

iii) Need of the project

With shutdown of mining operations in Goa the iron ore has been started to be imported along with coal. These raw materials are higher grade compared to Indian material. Therefore, the production yield by using these material is more.

iv) Demand-supply gap Not envisaged.

v) Import vs. indigenous production Not envisaged.

vi) Export possibility Not envisaged.

vii) Domestic/export markets Not envisaged

viii) Employment generation (Direct and Indirect) due to the project 50 nos.

3. Project Description

i) Type of project including interlinked and interdependent projects if any Expansion project. Though the proposed activity involves expansion of existing facility, it is applied as “NEW APPPLICATION” since the online application required to upload previous Environmental Clearance details. Without this the application was not being accepted.

ii) Location (map showing the general location, specific location and project boundary & project site layout) with coordinates

Project coordinates: Lat: 15.278305°, Long: 74.149004°



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General location of project



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Specific location of project

Project boundary



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Project site layout Is attached as Annexure 1.

iii) Details of alternate sites considered and the basis of selecting the proposed site, particulary the environmental considerations gone into should be highlighted. No alternative site has been considered.

iv) Size and Magnitude of operation


Final capacity

Existing


90,000 TPA 35,000 TPA 1,25,000 TPA


12 T X 2nos = 300 TPD (90,000 TPA)



425 TPD (12 T & 15 T

Induction furnace)

Captive power plant

8MW: WHRB + 4MW: FBC = 12 MW

0.5 MW 12.5 MW

Proposed expansion


-- 425 TPD 425 TPD

v) Project description with process details (a schematic diagram/ flow chart showing the

project layout, components of the project etc. should be given)

MANUFACTURING PROCESS OF SPONGE IRON

The main Raw Material required for making the Sponge Iron are: 1 IRON ORE 2 NON-COKING COAL 3 LIME STONE/ DOLOMITE The sizes are IRON ORE : 5 – 20 mm/ Pellets 9-16mm COAL : 0 – 20 mm. DOLOMITE : 4– 8 mm. The Iron Ore is imported from South Africa, 6 – 30mm size which is crushed and screened to get required size of 4 – 20mm. In case of non-availability of iron ore, pellets are procured from Karnataka region. Roll crushers are used to crush the coal, crushed coal is screened and sent to respective bins. From the sized material bins the mix of Iron Ore, Coal & Dolomite is sent to the feed end and fed into Kiln by means of conveyors.

Inside the Kiln, the temperature is maintained upto 11000 C. At this temperature, Fe203

is converted to Fe, in solid state. Inside the Kiln different temperatures are maintained in different zones. The rotary kiln direct reduction seems to be a simple



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process. However, it is a combination of many physical and chemical sub-processes, such as: a) Heating up of raw materials. b) Evaporation of moisture from ore and coal. c) Degasification of Coal. d) Degradation and decrepitation of iron and coal. e) Physical mixing and tumbling of raw materials. f) Combustion of various gaseous components. g) Reduction of Iron ore. h) Boudouard reaction.

These sub processes take place simultaneously along the length of the kiln and they have a lot of influence on each other. The chemical reaction that takes place inside the kiln are as follows.

1. 3Fe2O3 + CO = 2Fe3O4 + CO2 2. Fe3O4 + CO = 3FeO + CO2 3. FeO + CO = Fe + CO2 Boudouard reaction 4. CO2 + C = 2CO

The material coming out of the Kiln is at 10000 C and indirect cooling cools this material inside the cooler. The mix of Sponge Iron & char is taken to separation building. The Magnetic material (Sponge Iron) is stored in silos & Non – Magnetic material is stored in Char bin. The waste gases leaving the kiln at 950o C are taken to WHRB for generating steam. See the flow diagram. Coal is used as reducing agent and heat source for kiln operations. The gases generated in the sponge iron production are used in WHRB.

Power Generation Process

Power generation depends on two boilers installed in the premises of M/s. Goa Sponge & Power Ltd. A) WHRB Boiler: The waste heat gases from Kiln ABC outlet of DRI plant are utilized for the steam generation and inturn for power generation. The waste gases at temperature of 800 - 1000oC generates the steam of 22 – 32 TPH depending on quantity and temperature of waste gases leaving the kiln. B) FBC Boiler: In order to utilize waste coal fines & char coal generated in Sponge Iron Kiln, a 22 Tons Per hour steam generating boiler based on well-established aerated fluidizing bed combustion boiler (AFBC) principle was set up at M/s. Goa Sponge & Power Ltd. This is also in line with recent guidelines issued by Central Pollution Control Board to take care of char, a waste by product from sponge iron rotary kiln. The process involves storing coal fines & char in feed bunkers of FBC after necessary sizing and quality improvement. Sized char & coal fines are then pneumatically blown into boiler to generate the steam of required quality & quantity. Fully burnt char & coal fines which lead to formation to fly ash along with flue gases are sent to a 3 field ESP. The fly ash is separated and clean gases are let out to atmosphere. A deducting unit is installed in fuel handling circuit to take care of fugitive dust generation during material transfer from one point to another.



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GSPL has Power generation capacity of 12.0 MW of which 10.0 MW is consumed inhouse for steel making and Sponge iron unit and the balance power of 1 -2 MW is exported to Goa Electricity Grid.

Flow Chart

MANUFACTURING PROCESS OF BILLETS

Sponge Iron upto 80 – 90%, Pig Iron and Scrap 10% - 20% is melted in Induction furnace and liquid hot metal is transferred to pouring ladle. From pouring ladle the liquid metal is transferred to concast machine. After the hot metal gets solidified, the billets are continuously withdrawn and cut into required length and are automatically transferred to cooling area. The billets after cooling are shifted to dispatch bay. The size of billets is 110mm sq., 125mm sq.

PROCESS FLOW CHART



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vi) Raw material required along with estimated quantity, likely source, marketing area of final products/s, mode of transport of raw material and finished product.

Finished product: Sponge Iron Manufacturing

Material Existing quantity required

Quantity estimated after proposed expansion

Mode of transportation

Iron Ore 500 TPD 550 TPD By road. It is proposed to import iron ore for furture manufacturing through sea to Mormugao Port Trust and then by road to the site

Coal 250 TPD 300 TPD By road. It is proposed to import iron ore for furture manufacturing through sea to Mormugao Port Trust and then by road to the site

Dolomite 12.5 TPD 18 TPD By road

Finished product: Steel Billets Manufacturing

Sponge iron As per the ratio of carbon required for manufacture of steel billets

Available within the plot premises. Pig iron is brought by trucks

Scrap

Pig iron

Finished product: Hot rolling mill

Steel billets Nil As per the requirement of product

Available within the plot premises.

vii) Resource optimization/recycling and reuse envisaged in the project, if any, should be

briefly outlined. The waste heat gases from Kiln ABC outlet of DRI plant are utilized for the steam generation and in-turn for power generation. Waste coal fines and char coal generated in Sponge Iron Kiln is used in Aerated fluidizing bed combustion boiler (AFBC). Fly-ash from WHRB is used for making fly-ash bricks within the plot premises.

viii) Availability of water, its source, Energy/power requirement and source should be given Water Availability of water: Borewell, Rain water Harvesting, Quarry and mining pit in the vicinity of plant premises. Current water demand is 1450 KLD. With increase in expansion the water requirement will increase by 20 KLD.

Power No additional power is required. Source of power is Captive Power Plant of 12 MW and Goa Electricity Dept. The current demand for power is 11 MW. With expansion the additional power requirement will be 12 MW. Additional 1 MW will be sourced from Captive Power Plant.



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ix) Quantity of wastes to be generated (Liquid and solid) and scheme for their

management/disposal Liquid waste: Only sewage will be generated. Sewage is disposed through septic tank followed by soak pit within plant premises. Solid waste Hazardous waste

Sr.no

Description of waste

Existing quantity of generation

Proposed quantity of generation

Final quantity

Mode of disposal

1 Used Oil 250 Ltrs/annum Nil 250 Ltrs/annum

To recycler registered with CPCB and having valid authorization of SPCB

Non Hazardous Waste

Sr.no



Estimated Proposed

quantity of generation

Final quantity

Mode of disposal

1 Fly Ash 30 TPD 5 TPD 35TPD Brick manufacturing within plant premises

2 Dolochar 40 TPD 15 TPD 55 TPD Brick manufacturing within plant premises

3 Slag 15 TPD 6 21 Used for landfilling / Road construction through approved agencies



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x) Schematic representations of the feasibility drawing which give information of EIA purpose.

4. Site Analysis

i) Connectivity

Nearest Town, City, District Headquarters

Sanvordem (approx. 5.3 Km)

Nearest Railway Station and Airport

Railway station – Sanvordem-Curchorem Railway Station (approx. 8.1 km) Airport – Dabolim Airport (approx. 49 Km)

ii) Land form, Land use and Land Ownership Within 10 km radius - There is no reserved forest - There is no Biosphere reserve - There is no national park - There is no wildlife sanctuary The expansion project is proposed within existing premises, the land is already used for industrial purpose. It is owned by the Goa Sponge & Power Ltd. Project site is already under ownership of Goa Sponge & Power Ltd.



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iii) Topography (along with map)

iv) Existing land use pattern (agriculture, non agriculture, foret, water bodies (including area unde CRZ), shortest distance from periphery of project to periphery of the forests, national park, eco sensitive areas, water bodies (distance from HFL of the river), CRZ. Incase of notified industrial area, a copy of the Gazette notification should be given The proposed project activity is within the existing plant premises. No additional land is required. There will be no change in existing land-use pattern.

v) Existing infrastructure Land for the proposed expansion is available within the existing premises. All necessary infrastructure are available within premises. The site is approachable through road.

vi) Soil classification Not envisaged

vii) Climatic data from secondary sources.

Not envisaged.

viii) Social infrastructure Not envisaged.



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5. Planning brief

i) Planning concept (Type of industries, facilities, transportation etc.) Town and country planning/development authority classification

The project layout is enclosed as Annexure 1.

ii) Population projection During construction phase 50 nos. of construction workers will be employed. During operation phase it is estimated that project will have about 220 nos. of occupants at full occupancy including guest and staff.

iii) Land use planning (break up along with green belt area etc.)

Area Unit (m2)

Total Plot Area 50,000

Total covered area 14689.65

Existing Coverage 29%

Proposed coverage for rolling mill

1500

Green Belt area 7000

iv) Assessment of infrastructure demand (physical & Social)

The only major infrastucture demand is water of additional 20 KLD. The additional demand will be met through adjacent abundant quarry in the plant premises.

v) Facilities/Amenities Hot Rolling Mill will be added to manufacture TMT/MS bars.

6. Proposed infrastructure

i) Industrial area (processing area) An area of 11705 sq.mtrs will be used. The proposed coverage is available within the plant premises.

ii) Residential area (nonprocessing area)

Not applicable

iii) Green belt An area of 7000 sq.mtrs is maitained as green belt area.

iv) Social infrastructure

50 nos. (direct and indirect) workers.



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v) Connectivity (Traffic and Transportation Road/Rail/Metro/Water ways etc.)

Nearest Railway Station and Airport

Railway station – Sanvordem-Curchorem Railway Station (approx. 8.1 km) Airport – Dabolim Airport (approx. 49 Km)

The site is excessible by road from the nearest town – Sanvordem.

vi) Drinking water management (Source and supply of water)

Borewells are used for as a source of drinking water after due filtration system.

vii) Sewarage system Sewage will be disposed off through septic tank followed by soak pit within plant premises.

viii) Industrial waste management

Hazardous waste

Sr.no



Proposed quantity of generation

Final quantity

Mode of disposal

1 Used Oil 250 Ltrs/annum

Nil 250 Ltrs/annum

To recycler registered with

CPCB and having valid

authorization of SPCB



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ix) Solid waste management Non Hazardous Waste

Sr.no



Estimated Proposed

quantity of generation

Final quantity

Mode of disposal

1 Fly Ash 30 TPD 5 TPD 35TPD Brick manufacturing within plant premises

2 Dolochar 40 TPD 15 TPD 55 TPD Brick manufacturing within plant premises

3 Slag 15 TPD 6 21 Used for landfilling / Road construction through approved agencies

x) Power requirement and supply/source Operation phase An additional of 1 MW of electricity is required. It will be sourced from Captive power plant. Source: Captive power plant and Govt. Electricity Dept. Back up: D.G sets- 1250 KVA X 2 nos.

7. Rehabilitation and Resettlement (R&R) plan As there is no requirement of additional land for the proposed expansion project. The plant is running project which is under operation, so there is no need of any new Rehabilitation and Resettlement (R&R) Plan. 8. Project schedule and cost estimates.

i) Likely date of start of construction and likely date of completion (time schedule for the project to be given) Sponge iron manufacturing can be increased immediately once Environmental Clearance for expansion is granted. Start of construction: year 2018 for installation of rolling mill. Likely date of completion: within one year for installation of rolling mill.

ii) Estimated project cost along with analysis in terms of economic viability of the project Estimated cost for proposed expansion: 30 Cr



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9. Analysis of proposal (Final recommendation) The proposed expansion of sponge iron is achieved only by replacing the low grade raw materials with high grade imported raw material. No new machinery is required to installed. The hot rolling mill will installed within the plant premises to manufacture TMT/MS bars. The induction furnace capacity will be increase but without additional demand from Govt. Source. The captive power plant installed within the premises will cater the entire load of operation of industry. The fly ash generated is also used within the plot premises to manufacture fly ash bricks. No new type or volume of Hazardous Waste will be generated. New employment opportunities may be generated due to proposed modernization and expansion activities.

Annexure Prefeasibility Report - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/17_Apr_2018... · Boudouard reaction 4. CO 2 + C = 2CO The material

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