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JEEVAKA INDUSTRIES PRIVATE LIMITED (Sponge Iron division)
Nasthipur & Mangapur Villages Hatnoora Mandal
Sangareddy District Telangana
Pre-Feasibility Report
(Expansion of Sponge Iron from 300 TPD to 500 TPD and installation of new Induction Furnace - 2 x 500 TPD, Rolling
Dolomite 68 Andhra pradesh By road (through covered trucks)
EC paste 8 Andhra pradesh By road (through covered trucks)
Ferro manganese slag 28 In plant generation
through covered conveyors
Magnesite 4.2 Andhra Pradesh By road (through covered trucks)
Mill scale 17 In plant Generation
through covered conveyors
For FBC Boiler [Power Generation 10 MW]
Dolochar 150 In plant generation
From Existing plant
through covered conveyors
Coal Indian 110 Singareni colleries
By rail & road (through covered trucks)
Imported 78 Indonesia / South Africa /
Australia
Through sea route / rail route / by road
3.6.2 Mode of Transport for Raw materials and finished products:
The aforesaid raw materials are transported through rail up to the nearest available rail
head and thereafter the same will be transported to the site through tarpaulin covered
trucks.
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3.6.3 Market of Final Products:
It is proposed to install steel plant with special rolled products facility. As the steel/
power sector had huge demand and supply gap. Hence marketing of the product has no
problem.
3.7 Availability of water its source, Energy / power requirement and source: 3.7.1 Water Requirement and its sources:
Water required for the existing project is 27 KLD and same is being sourced through
Ground water resources
Water required for the expansion project will be 603 KLD and same will be sourced
through Ground water resources
Air cooled condensers will be provided for power plant to reduce the water
requirement
Water permission from State Ground Water Board has already been obtained for 640
KLD
Following is the breakup of water requirement:
S.No. Unit
Quantity in KLD
Existing Plant
Proposed Expansion
Total after Expansion
1. DRI Kilns (Sponge Iron) 15 10 25
2. Induction Furnace (MS Ingot/Billet)
-- 80 80
3. Rolling Mill Hot Rolled TMT / Structural / Cold Rolled Bars/Wire Rod)
-- 80 80
4. Ferro Alloy Plant FeSi / FeMn / SiMn / FeCr
-- 30 30
5. Pellet plant -- 180 180
6. Power Plant -- 215 215
7. Domestic 2 18 20
17 613 630
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3.7.2 Sources of Energy/ Power and its sources:
Power required for the existing plant is being met from TSSPDCL. Power required for the
proposed expansion project will be met partly from proposed 20 MW power plant and
remaining from TSSPDCL.
The following will be the power consumption break-up for each unit
S.No. Plant Power Requirement
Existing Expansion After
Expansion
1. DRI 0.7 1.05 1.75
2. SMS 0 36 36
3. Rolling Mill 0 10 10
4. Ferro Alloys 0 9 9
5. Pellet plant 0 2.5 2.5
6. Power Plant – WHRB 0 2 2
7. Power plant – AFBC 0 2 2
Total 0.7 62.55 63.25
3.8 Generation and disposal of Wastes [Waste Water and Solid Wastes]:
3.8.1 Waste Water Generation:
There will be no effluent discharge in the DRI, SMS unit, Rolling mill & Pellet unit as
closed circuit cooling system will be adopted.
Effluent from power plant such as boiler blowdown, DM Plant regeneration. Initially the
acidic and alkaline effluent streams coming from cation and anion units of DM plant will
be neutralized in a neutralization tank. Service water will then pass through an Oil
Separator to remove the oil content in the effluent. The pH of Boiler blowdown will be
between 9.5 and 10.5. Hence this effluent stream shall be neutralized in a neutralization
tank before mixing with other effluent streams. All these effluent streams will be mixed
in a Central Monitoring Basin along with cooling tower blowdown. Treated effluent will
be used for ash conditioning, dust suppression and for greenbelt development.
The sanitary wastewater will be treated in septic tank followed by subsurface dispersion
trench. Hence there will not be any chance of contamination of water bodies due to
proposed project.
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3.8.2 Solid Waste Generation and its disposal
The following will be the solid waste generation and disposal from the existing and
proposed expansion project
S.No Waste Quantity (TPD) Method of disposal
Existing Proposed Total
1. Ash from DRI 90 60 150 Is being given to Brick manufacturers. The same practice will be continued after expansion also.
2. Dolochar 90 60 150 Is being given to brick manufacturers. After proposed expansion it will be used as fuel in AFBC based power plant
3. Kiln Accretion Slag
2.7 1.8 4.5 Is being utilized in road construction and same practice will be continued after the proposed expansion also.
4. Wet Scraper Sludge
13.5 9 22.5 Is being given to brick manufacturer and same practice will be continued after the proposed expansion also.
5. SMS Slag -- 90 90 Slag from SMS will be crushed and iron will be recovered & remaining non –magnetic material being inert nature, will be used as sub base material in road construction / used for brick manufacturing / civil construction works like PCC and wall construction
6. Bag filter dust from SMS
-- 6.5 6.5 Will be being given brick manufacturers
7. Mill scales from Rolling Mill
-- 26 26 Will be used as raw material in pellet plant / SMS unit
8. Slag from SiMn
-- 84 84 Will be utilized in road construction / given to road contractor for road construction
9. Slag from FeMn
-- 80 80 Will be used in manufacture of Silico manganese as it contains high MnO2
10. Slag from FeCr -- 84 84 Will be further processed in Zigging plant for Chrome recovery and the non-chrome contents will be sent for land filling.
11. Ash from Power Plant
-- 155 155 Will be given to Brick manufacturers
12. Iron Ore Fines 15 10 25 Will be used in Pellet Manufacturing
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Chapter – 4 SITE ANALYSIS
4.1 Connectivity
The Project site is well connected with Rail and Road connectivity. The nearest railway
station is Patancheru RS. The following table gives brief regarding connectivity of the
plant site:
Component Description
Road : SH # 17 (Sangareddy – Narsapur road) adjacent to the site
Rail : Patancheru RS (21.0 Kms)
Air port : Rajiv Gandhi International airport (55 Kms.)
4.2 Land Form, Land use and Land ownership
4.2.1 Land Form:
Present land is industrial land.
4.2.2 Land Use of the Project Site
Present land use is industrial land as existing plant is already under operation.
4.3 Topography
Topography of land is more or less flat terrain without much undulation.
4.4 Existing land use pattern:
4.4.1 Land use pattern of the Project site
Total project area is 85.58 acres (existing – 55 acres & additional – 30.58 acres).
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4.4.2 Environmental Setting of the Project Site:
Below mentioned table gives brief regarding environmental setting of the project site:
S.No Particulars Distance from the site
1. National Park = Nil
2. Wild life sanctuaries = Nil
3. Reserve Forest = Narsapur RF – 3 Kms
4. Protected Forest = Nil
5. Eco Sensitive Areas = Nil
6. Water bodies = Small ponds exists within 10 Km radius
7. Costal Regulation Zone [CRZ] = Nil
8. Nearest Village = Avancha -0.50 kms.
9. Industrial Area = Nil
4.5 Existing Infrastructure
All required infrastructure is prevailing in the site.
4.6 Soil classification
The soils in the area are generally of clayey and lateritic. 4.7 Climatic data from secondary sources
Sangareddy district climate is classified as tropical. The summers here have a good deal
of rainfall, while the winters have very little. The climate here is classified as Aw by the
Köppen-Geiger system. The average temperature in Sangareddy is 26.3 °C. The average
annual rainfall is 861 mm. Precipitation is the lowest in January, with an average of 1
mm. Most of the precipitation here falls in July, averaging 228 mm.
At an average temperature of 32.2 °C, May is the hottest month of the year. December is
the coldest month, with temperatures averaging 21.9 °C. Between the driest and wettest
months, the difference in precipitation is 227 mm. Throughout the year, temperatures
vary by 10.3 °C.
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Chapter – 5 PLANNING BRIEF
5.1 Planning Concept:
Jeevaka Industries Private Limited (JIPL) as a part of expansion of the existing steel plant,
envisage to produce the following product through different routes:
Unit : Description
DRI Kiln : Manufacturing of Sponge Iron using Iron ore, Coal and Dolomite
as raw materials
Pellet Plant Manufacturing of Iron Ore pellets from Iron Ore fines / Mill
scales, Bentonite, Lime Stone, Coal
Induction Furnace : Manufacturing of MS Billets using Sponge Iron, Scrap, Ferro
Alloys as raw materials.
TMT / Structural
steels
: Manufacturing of TMT bars / Structural steels using MS Billets /
Ingots as raw material
Ferro alloys : Ferro alloys will be manufactured using Manganese / Quartz /
Chrome ore as raw material
Power generation : Power geenration through WHRB by utilizing hot waste flue gases
from DRI kilns. Power generation through FBC boiler using coal,
Dolochar & Washery Rejects as fuel.
5.2 Population Projection:
There are no major human settlements in the vicinity of the project site. The manpower
requirement will be sourced from the local areas to the extent possible; hence not much
of settlement of outside people in the area. However population concentration may
increase around the project site due to increase in ancillary activities.
5.3 Land use planning:
Plant is located at Nasthipur Village, Hathnoora Mandal, Sangareddy District,
Telangana.
Total land in possession of management is 85.58 acres (existing 55 acres & additional
30.58 acres)
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The proposed expansion project will be taken up partly in the existing plant premises
and partly in the additional land acquired.
The following is the land use statement
S.No. Item Area in acres
1. Built-up area 30.00
2. Storage area (raw material & solid waste) 6.00
3. Greenbelt area 30.00
4. Internal roads 7.50
5. Parking area 3.00
6. Open area 9.08
Total 85.58
5.4 Amenities/Facilities.
Facilities like canteen, rest room and indoor games facilities will be provided in the
proposed plant as basic facilities to workers. No other additional facilities are proposed.
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Chapter – 6
PROPOSED INFRASTRUCTURE
6.0 Proposed Infrastructure
Total 85.58 acres of land is in possession of management (existing – 55 acres, additional
– 30.58 acres). Present use of land is Industrial land. The proposed expansion will be
carried out partly in the existing plant premises and partly in the additional land
premises.
6.1 Industrial Area (Processing Area)
The main plant area comprises of Kiln sheds, Furnace sheds, Rolling mill area, raw
material storage and product storage etc.
6.2 Residential Area (Non Processing Area)
No colonization is proposed; however facilities like canteen, rest room and indoor games
facilities have been provided in the existing plant premises.
6.3 Green Belt.
About 1/3rd of total land availability will be developed with greenbelt i.e 30 acres of land
will be allocated (including expansion).
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.
10 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.
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6.4 Social Infrastructure.
Social infrastructure will be developed as per need based in the Villages of the vicinity of
the project.
6.5 Connectivity:
The proposed site is well connected with Rail and Road connectivity. The nearest railway
station is Patancheru RS. The following table gives brief regarding connectivity of the
proposed site:
Component Description
Road : SH # 17 (Sangareddy – Narsapur road) adjacent to the site
Rail : Patancheru RS – 21 Kms
Air port : Rajiv Gandhi International airport (55 Kms.)
6.6 Drinking Water Management:
Drinking water supply will be maintained at the proposed project site.
6.7 Sewerage System.
Domestic effluent collected through toilet blocks will be collected through well designed
sewer network and send to Septic tanks followed by sub surface dispersion trenchs.
6.8 Industrial Waste Management.
There will be no effluent discharge in the DRI, SMS, Pellet and Rolling mill units as closed
circuit cooling system will be adopted.
Effluent from power plant such as boiler blowdown, DM Plant regeneration. Initially the
acidic and alkaline effluent streams coming from cation and anion units of DM plant will
be neutralized in a neutralization tank. Service water will then pass through an Oil
Separator to remove the oil content in the effluent. The pH of Boiler blowdown will be
between 9.5 and 10.5. Hence this effluent stream shall be neutralized in a neutralization
tank before mixing with other effluent streams. All these effluent streams will be mixed
in a Central Monitoring Basin along with cooling tower blowdown. Treated effluent will
be used for ash conditioning, dust suppression and for greenbelt development.
The sanitary wastewater will be treated in septic tank followed by sub surface dispersion
trench. Hence there will not be any chance of contamination of water bodies due to
proposed project.
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JEEVAKA INDUSTRIES PRIVATE LIMITED (Sponge Iron division)
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6.9 Solid Waste Management
The solid waste from sponge iron will be Dolochar, accretion slag, bagfilter dust, wet
scraper sludge. Dolochar will be used in the FBC power plant and others will be given to
brick manufacturers/ used in road construction
Slag from Induction furnace and Ferro alloys will be utilized in the road construction /
civil works / cement brick manufacturing.
6.10 Power requirement & its source
Power required for proposed expansion project will be sourced from proposed Captive
Power plant and TSSPDCL.
Chapter – 7
Rehabilitation and Resettlement Scheme
No rehabilitation and resettlement is required as there are no habitations in the in the
Project site.
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Chapter – 8
Project Schedule & Cost Estimates 8.1 Likely date of start of construction:
Construction activity pertaining to unimplemented units will be started within 24 months
from the date of Environment Clearance.
8.2 Estimated project cost:
The estimated project cost for the proposed is about Rs. 292.5 crores. The following is
the break-up
S.No. Unit / Details Estimated Cost
(Rs. In Crores)
1. DRI Kilns [2 x 100 TPD] 24.00
2. SMS [2 x 40 T] 60.00
3. Rolling Mill [1000 TPD] 50.00
4. Ferro Alloys [1 x 9 MVA] 20.00
5. Pellet plant [600 TPD] 30.00
6. Power Plant [10 MW WHRB based & 10 MW FBC
based]
100.00
7. For Occupational Health & Risk Assessment 1.00
8. For Enterprise Social Commitment (ESC)
(2.5 % of the Project Cost)
7.50
Total 292.5
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Chapter – 9
Analysis of proposal 9.1 Financial and social benefits:
With the implementation of the proposed expansion 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 standards 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,
SUPPORTING EDUCATION
Providing books to all poor children,
Conducting annual sports festival in the village schools,
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Baseline Data Collection (March 2018 to May 2018)
We have commenced Baseline Data Collection from 1st March 2018.
Wind rose plotted as per nearest IMD data (Hyderabad region) for the period (1971 – 1999) for
March, April & May months
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Ambient Air Quality Monitoring Stations
S.No. STATION DIRECTION DISTANCE
(in Kms.)
CRITERIA FOR SELECTION
1 Plant site --- --- Represent Plant Site (Core area)
2 Awancha E 0.5 Represents nearest habitation
3 Mangapur NW 0.6 Represents downwind direction and
Residential area
4 Ellapur SE 1.5 Represents Upwind direction
5 Ramachandrapuram NE 1.6 Represents Crosswind direction
6 Nastipur SW 1.3 Represents crosswind direction
7 Daulatabad W 1.8 Represents downwind direction
8 Narsapur NE 4.7 Represents highly populated and sensitive