Pre Feasibility Project Report - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/30_Aug_2016... · Pre Feasibility Project Report PROPOSED INSTALLATION

Sarda Energy & Minerals Ltd

1

Pre Feasibility Project Report

PROPOSED INSTALLATION of 10 NOS. OF COAL GASIFIERS - 27046 Nm3/hr.

(Fuel Replacement for Operational 0.6 MTPA Pellet Plant)

MODERNIZATION OF 0.7 MTPA IRON ORE GRINDING UNIT TO 1.0 MTPA

IRON ORE GRINDING & BENEFICIATION PLANT

of

SARDA ENERGY & MINERALS LIMITED

PHASE-I OF SILTARA INDUSTRIAL GROWTH CENTRE, MANDHAR,

DISTRICT – RAIPUR (C.G.)

Ph: 0771- 2214210


2

Chapter – 1

Executive Summary

1.1 EXECUTIVE SUMMARY

1.1.1 Report objective

M/s. Sarda Energy & Minerals Ltd. (Formerly M/s Chhattisgarh Electricity Company)

had established a 0.6 MTPA Pelletization plant at Phase – I of Siltara Industrial Growth

Center at village Mandhar, Raipur which is under operation since 07.10.2009.

Sarda Energy & Minerals Limited has envisaged for establishment of following projects

as backward integration to its existing operational 0.6 MTPA Pellet Plant:

1. Expansion of 7,00,000 TPA Iron ore Grinding Unit to 10,00,000 TPA Iron Ore Grinding & Beneficiation Plant

2. Installation of 27046 Nm3/Hr. Coal Gasifiers (10 Nos) (Fuel Replacement of

Operational 0.6 MTPA Iron Ore Pellet Plant)

The report is being prepared describing the details of operation process, plant and machinery, Material balance, Water Balance Cost of Project, Land requirement and Man

Power Requirement etc.

1.1.2 Report Summary:

The basis of selection of major equipment including a review of technologies and their

evaluation is indicated in the report. The chapter in the report also deals with the annual

requirement of raw material.

The project report also covers the plant facilities and plant description for coal Gasifier

and Iron Ore Grinding and Beneficiation plant.

The detailed process description of all the system has been covered in the project report.

The chapter in the project report deals with the facilities provided for the plant water

system and other utilities such as fuel etc. The pollution control measures proposed for

Coal Gasifier and Iron Ore Grinding & Beneficiation plant are also described in the

chapter of the report.

The chapter of the report also includes the organization and manpower for the proposed

10 Nos Coal Gasifier with total capacity of 27,046 Nm3/Hr. and 10,00,000 TPA Iron Ore

Grinding & Beneficiation plant.

The estimates of capital cost, annual manufacturing expenses and the financial analysis of

the project are presented in the report.


3

1.2 PROJECT AT A GLANCE

1.2.1 COMPANY DETAILS

Company’s name : Sarda Energy & minerals Ltd.

Address

Telephone No.

Fax No.

E-mail Address

Phase-I, Industrial Growth Center, Siltara,

: Village - Mandhar

Raipur (Chhattisgarh) 493 111

: (0771) 403925 to 29

: (0771) 403924 / 33

: [email protected]

1.2.2 BOARD OF DIRECTORS

Board of directors : Mr. K.K. Sarda, (B.E.)

Smt. Uma Sarda

Mr. Pankaj Sarda, (B.E, MS-USA)

Mr. P. K. Jain

Mr. Prabhakar Ram Tripathi

Mr. Rakesh Mehra

Mr. Asit Kumar Basu

Mr. G.S.Sahani Mr.Jitender Balakrishnan

1.2.3 SITE DETAILS

Project Location : Phase-I of Siltara Industrial Growth Centre,

Village - Mandhar, Raipur (C.G.)

Nearest Railway Station : Mandhar – 1.5 Kms.

Nearest Airport : Raipur – 30 Kms.

Road Access : National Highway No.200 - 5 Km.

Nearest Sea Port : Visakhapatnam –500Kms.

Altitude : 289.5 Meters

Latitude : 21o 22’ 22” – North

Longitude : 81o 41’ 31” East

Wind data : Max. 60 Kms. Per hour

Rainfall : 40” – 60” (June – September)

Temperature

-Minimum : 7oC

-Maximum : 46oC


4

1.2.4 PROJECT DETAILS

SEML has established and is operating a 6,00,000 TPA Pelletization Plant at Phase-I,

Siltara Industrial Growth Center, Mandhar which was commissioned in the year 2009.

The company has envisaged establishing the following projects as a part of backward

integration for the 0.6 MTPA Pellet Plant:

A. Expansion of 7,00,000 TPA Iron ore Drying and Grinding to 10,00,000 TPA

Iron Ore Grinding & Beneficiation Plant

B. Installation of Coal Gasifiers (10 Nos) 27046 Nm3/Hr. (Fuel Replacement of


Expected date of Commercial Production

Proposed Expansion

1. 10 Nos Gasifier Plant January 2018

2. 7,00,000 TPA Iron Ore Grinding Unit to

10,00,000TPA Iron Ore Grinding &

Beneficiation Plant

January 2018


5

Chapter – 2

2.1 Company Background

Sarda Energy & Minerals Ltd. (Formerly Chhattisgarh Electricity Company Ltd.),

Incorporated on 23rd January 1998, is a Public Limited Company. The company has a

Pellet plant of capacity 0.6 MTPA. The Company had installed 20 MW coal based

thermal power plant, which commenced operations in the year 2001, gradually the

capacity of power plant has been increased to 81.5 MW. The Company also installed five

9 MVA Submerged Arc Ferro alloys furnaces in phases to use captive power from power

Plant and to have maximum realization for the power generated presently total capacity

of plant is 45 MVA, which makes company the second largest producer of manganese

based Ferro Alloys in the country. The facilities are installed at Industrial Growth Centre,

Siltara, Raipur over an area of about 70 acres. Chhattisgarh Electricity Company Ltd. has

got merged with Raipur Alloys & Steel Limited as per the orders of Hon’ble High Court

of Chhattisgarh, Bilaspur dated 11th May, 2007 & the name of Raipur Alloys & Steel

Limited has also been changed to “Sarda Energy & Minerals Limited” (SEML) as per

Fresh Certification of Incorporation dated 2nd August 2007. Liberalization of economy

by the Government, throwing open for manufacturing of Iron and Steel including mining

of iron ore, coal and other related minerals to private entrepreneurs, provided an avenue

for further growth in this segment to SEML. Company is a industrial house to set up a

modern integrated steel plant at Siltara Industrial Estate, Raipur. The steel plant uses non-

coking coal for sponge iron production of 79,200 TPA, further it has expanded to

4,60,000 TPA sponge iron production. Initially for meeting its requirement for 79,200

TPA sponge iron, SEML obtained a mining lease for iron ore situated at Dongarbor in the

Rajnandgaon District, to produce 2.0 lakhs TPA. After expansion of sponge iron plant to

meet its requirement of iron ore, the company has increased production capacity of

Dongarbor Iron Ore Mine from 2.0 lakhs TPA to 15.0 lakhs TPA for extraction of iron

ore in the year 2007. Company has been allotted a captive coal block at Karwahi near

Tamnar, District-Raigarh, and Chhattisgarh State to produce 1.2 Million TPA coal.

Company is having underway project for installation of 1.1 Million TPA Integrated Steel

Plant and 60 MW WHRB Power Plant at Siltara Industrial Growth Centre, Mandhar, and

Raipur.


6

PRESENT MANUFACTURING FACILITIES

The present manufacturing facility of the Company is situated at Phase-I, Siltara

Industrial Growth Centre, Siltara, Raipur and other districts in Chhattisgarh and

comprises of the following:

S.N. Facility Capacity

1 Sponge Iron 4,60,000 TPA (with WHR facility)

2 Steel Melting 3,60,000 TPA

3 Ferro Alloys 5 X 9 MVA Furnaces

( 90,000 TPA)

4 Power Plant 81.5 MW

5 Rolling Mill 1,80,000 TPA

6 Pellet Plant at Mandhar 6,00,000 TPA

7 Iron Ore Mine at Rajnandgaon 1.5 Million TPA

PATENT

The Company is marketing TMT bars under its registered trademark “Hytech” which

has got tremendous response from the corporate sector due to its quality. The company

has also got Patent for its Special Design Steel Bar that is registered in class 25-99 at

design no. 198260. The patent is valid for an initial period of 10 years and may be

extend for a further period of five years.

CAPITAL STRUCTURE

The Authorized capital of the Company is Rs. 50 Crores and the present issued and paid up capital is Rs. 35.95 Crores.

BANKERS

The Company is banking with Union Bank of India, Bank of Baroda, UCO Bank

and UTI Bank under consortium.

LISTING

The Company is currently listed on the Bombay Stock Exchange and is traded under

scrip id. SARDAEN.

CREDIT RATING

Short Term Rating given by CARE is “PR+1”, the highest rating. Long Term Rating given by CARE is “AA-“.


7

SHAREHOLDING PATTERN

The promoters of the Company hold around 69% shares and the remaining is held by

FII’s, Banks, Corporate Bodies and public.

2.2 MANAGEMENT

BOARD OF DIRECTORS

Kamal Kishore Sarda, aged 57 years, B.E.(Mech.) is Chairman & Managing Director of

the Company. He has more than 32 years industrial experience and has a brilliant track

record. He stood 1st in SSC Merit in M.P. and 2

nd in B.E. (Mech.) Merit. He has also

completed course on Strategic Management from IIM, Ahmadabad. He has traveled

extensively across the world to study & observe new developments & trends in the

industry. He is the Ex-Chairman of CII, Chhattisgarh Chapter.

Pankaj Sarda, aged 30 years is an Industrial Engineer from Nagpur University and has

also completed Masters’ Degree in Science in Industrial Administration from Purdue

University. He has an experience of 7 years in the field of Corporate Affairs and

Management. He has been appointed as Whole time Director W.e.f. 1st November, 2007.

Mr. P.K. Jain CA, CS aged 49 years is Chief Financial Officer with Sarda Energy &

Minerals Ltd. He is having more than 25 years of experience of accounts and banking and

is associated with SEML for last more than 15 years. He is in-charge for company’s

accounting, financial, secretarial and taxation matters

Prabhakar Ram Tripathi, aged 65 years, is an authority on mine management and

mineral Grinding. He earned honors in Bachelors of Science in Mining Engineering from

Indian School of Mines, Dhanbad, Jharkhand, India. He also earned his First Class Mines

Manager's Certificate under coal mines regulation. Former Chairman & Managing Director

of National Mineral Development Corporation (NMDC), he has more than 47 years

experience in the field of mining and related activities. He is recognized as a leading

management practitioner in India and has also contributed to development of management

excellence through association with All India Management Association and National HRD

Network.

Rakesh Mehra, aged 56 years, FCWA, is Ex-General Manager of MPAVN. He is a

Financial Consultant and serves as a Professional director on the Board of many

Companies.

Asit Kumar Basu, aged 59 years is B.M.E. with rich experience in the field of finance.

He is Ex-CGM, IDBI.


8

G.S. Sahani, aged 62 year is a Former Director General of Shipping, Govt. of India and

Former Secy. (Coordination), Cabinet Secretariat, Govt. of India.

2.3 Need for the project and its importance to the country and/ or region

The need for Iron Ore Beneficiation Plant as a part of the iron making facility requires to

be carefully evaluated particularly due to the runaway increase in iron ore prices and

shortage of Iron ore in the recent year in India.

Coal - The fuel utilized in the Pelletization Plant is High Grade Imported Coal/Coke. By

utilizing the domestic coal in pellet plant through Gasification. The companies will not

only deficit the BOP of the country and also reduce the Sulphur emission generated from

combustion of High Grade Imported Coal/Coke.

Iron Ore Fines – Utilization of unusable abundantly available low grade iron ore fines in

the process of steel making.

In view of the above, M/s Sarda Energy & Minerals Limited has proposed Installation of

Coal Gasifiers and Iron Ore grinding & beneficiation plant.

2.4 Demand -Supply Gap

Steel Industry in India is on an upswing because of the strong global and domestic

demand. India’s rapid economic growth and soaring demand by sectors like

infrastructure, real estate and automobiles, at home and abroad, has put Indian steel

industry on the global map. According to the latest report by International Iron and Steel

Institute (IISI), India is the seventh largest steel producer in the world. The current status

of iron ore and its future prospects have direct relationship mainly with steel production

in India. The total iron ore resources in India are approximately 25,249 Million tons (out

of which Hematite constitutes 14,630 MT and Magnetite constitutes 10,619 MT). Out of

the total production, 56% of iron ore production comes out as fines and 44% as boulders

which have to be sized to 10-30 mm for blast furnaces and 6-18 mm for sponge iron

plants. Iron ore in a finely ground state is not easily transported or readily processed.

Thus it is necessary to agglomerate the fine ground ore into pellet using binders.

2.5 Cost of Project:

Since the report includes a project which is already under operation the Cost of Project.

Thus, for the established unit the Gross Capital Made has been considered as Cost of

project and for the other two it is estimated based on enquiries floated, quotations


9

received. The financing and pre-operative cost has been considered based on the

proposed financial package.

The estimated cost thus evaluated to be is Rs 12.789 Crores including pre-operative

expenses and margin money for working capital requirements

Cost of Capital

All Fig Lac Rs

Sl No Particular Amount

1 Iron Ore Grinding & Beneficiation Plant 8202

2 10 NO Coal Gasifier 4587

# Total 12789

2.6 Employment Generation (Direct and Indirect) due to Project

The major benefit due to the proposed expansion project will be in the sphere of

generating direct employment for about 252 persons in that area. The proposed project

will benefit local population. The manpower requirements for the operational phase of

the proposed Plant will be about 252 people. In addition, there will be an indirect

employment for skilled/ semi skilled people during project life. All attempts will be made

to employ suitable, locally available, skilled personnel from the nearby area. In case of

non-availability of skilled persons, people will be employed from outside area.

Manpower Estimate

It is estimated that the total requirement of manpower for the whole organization will be

approximate 252. Department-wise /division-wise manpower is given as under. The manpower has been divided into the following categories:

- Managerial

- Executive

- Supervisory - Skilled (SK)

Department Total

Administration 5

Works Office 10

Raw Material Handling System 30

Gasifies 37

Grinding & Beneficiation 65

Stores 15

Utilities & Services 20

Maintenance 70

Total 252


10

Chapter – 3

3.1 Type of project

Existing and Proposed Projects at Mandhar Village

SEML had obtained consent for installation of existing 6,00,000 TPA Pelletization

Plant from CECB and plant was commissioned in the year 2009.

The company is applying for Grant of Environment Clearance for Flowing:

A. Expansion of 7,00,000 TPA Iron ore Drying and Grinding to 10,00,000 TPA Iron Ore

Grinding & Beneficiation Plant

B. Installation of Coal Gasifiers (10 Nos) 27046 Nm3/Hr. (Fuel Replacement of


3.2 Location (map showing general location, specific location, and project boundary and

project site layout) with coordinates

Company has been allotted 204.452 Hectares of land at village Mandhar, Phase-I of Siltara

Industrial Growth Centre, Raipur for installation of 1.1 MTPA Integrated Steel Plant and

60MW WHRB power plant. The site is located within 21o 22’ 22” – North Latitude, and 81

o

41’ 31”- East Longitude. It is located centrally vis-à-vis source of raw material as well as

Sponge Iron consuming industry. The map showing general Location of the proposed

Project and Project site layout plan is shown below.


11


Project

Site

Location

Fig. - Map Showing General Location


12

STP

10,00,000 TPA IRON ORE GRINDING & BENEFICIATION

PLANT

AREA FOR FUTURE EXPANSION33

L E G E N D:-

PROPOSED EXPANSION

1

R OAD

Pl an ts

Stack Pelletizing E.S.P

Co al

Proportioning Bins

Sto rage

6

900015900 180001320015000132009800 8000 10500 11000 12000 12000

9 000

Pul v eri zi ng

O IL TANK

32

GAS OUTLET

TO GR

ATE-OVEN

3

19

3

RAJENDRA S

TEEL

OPEN A

REA

RAJENDRA STEEL

(IN SIDE BOUNDRY WALL)

Diverted

Appro

ach R

oad

Line

SEM

L LAND

BOU

ND

ARY

Property

Line

HT

TOWER

HT

TOWER

HT

TOWER

EXIS

TIN

G H

T L

INE

Property

POND

EX

G.

CA

NA

L

21

27

15

2

DM & SW

Plant

Dn400 MW

Dn 200

Dn 200

Dn65 CWDn65 DW

Dn 300

11

302.5

Dn40 DW

Reducer

Canal

Raw Water Reservoir

GREEN BELT AREA

Raw Water Reservoir

9m

MRSS

Raw Water Reservoir

Rain Water Harvesting Pond

Adm Building

Officer's Canteen

LBSS-1

AUXILIARY FACILITIES:

13

12

11

10

9

8

7

Stores14

Diesel Tank15

Weigh Bridge16

Raw Material Laboratory17

EXISTING PLANT & FACILITIES

L E G E N D:

Pellet Plant - 600000 TPA1

Flux & Coke Crushing18

Railway Yard

Raw Material Stockyard3

2

L E G E N D:

UNDERWAY PROJECTS:

Rolling Mill - 350000

Steelmelt Shop 4

5

1- Electric Arc Furnace - (2x 40 Ton) 500000 TPA

2- CCM (2x3 Strand) 470000Chimney19

Chimney19

Air Vent20

Coke Oven (Non Recovery) - 520000 21

Blast Furnace (2x450Cu.M) - 790000

Sinter Plant (2x60 m )- 1300000

1- Electric Arc Furnace (1x90 TON) - 600000

22

23

2 - CCM (1 x 4 Strand) - 600000

Power Plant (WHRB)- 2x30MW Coke Oven & B.F.

Rolling Mill - 60000025

26

Oxygen Plant - 2 x 150 TPD27

Steelmelt Shop24

20

20

4

25

19

19

19

20

1919

2

19 19 19

SARDA ENERGY & MINERALS LIMITED

28.05.14

SEML/MAN/PR/06

Unloading platform28

Raw Material Yard of SEML29

Office Complex For The Mills30

Central Ware House31

7,00,000 TPA IRON ORE DRYING & GRINDING TO 6

EXISTING COMMON FACILITIES:

10 NOS. COAL GASIFIER - 27046 Nm /hr.32

11

BORE WELL34

3411m

330m

GREEN BELT

9

SOLAR PLANT

3333

33


13

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environmental considerations

As it is an expansion project no alternative sites were considered.

The following are the factors in favor of selection of site at village Mandhar:

- Easily availability of raw material

- Availability of power

- Availability of adequate water

- Availability of adequate land for locating the plant with approach roads

- Suitability of land from topography and geological aspects

- Proximity of National Highways & Transport of heavy equipments

The environmental consideration of the site is tabulated below:

Sr. No. Particulars Details

1. Latitude Between N 210 20’09.74” – N21

020’42.57”

2. Longitude Between E81041’10.57” - E81

0 42’02.48”

3. Altitude 282 m above MSL 4. Toposheet 64 G/11 5. Seismicity Area falls under least affected

earthquakes zone II as per IS 1893 - 1984

6. Climatic condition

(Annual Average)

Ambient Air temp 7oC to 46

oC

Avg. annual rainfall 1200 mm

7. Nearest village Mandhar

8. Nearest town Raipur

9. Nearest railway station Mandhar (1.5 KM)

10. Nearest airport Raipur (25 KM)

11. Streams / Rivers Kharoon

12. Sanctuaries /National Parks/

Biospheres, etc.

Nil

13. Topography Gently sloping

14. Defense Installations Nil

15. Historical Places Nil

16. Road Access NH 200 (5 KM)


14

3.4 Project Area description

Plant Site

Company has been allotted 204.452 Hectares of land at village Phase-I of Siltara

Industrial Growth Centre, Mandhar, Raipur for installation of 1.1 MTPA Integrated Steel

Plant and 60MW WHRB power plant. Company has been allotted 204.452 Hectares of

land at village Mandhar, Phase-I of Siltara Industrial Growth Centre, Raipur for

installation of 1.1 MTPA Integrated Steel Plant and 60MW WHRB power plant. It is

located centrally vis-à-vis source of raw material as well as Sponge Iron consuming

industry.

STATEMENT OF AREA

SEML has in possession of 204.452 hectares of Land in Phase-I, Siltara Industrial

Growth Centre, Mandhar, for installation of 1.1 Million TPA Integrated Steel Plant along

with 2x30MW WHRB based Power Plant. The details of land area for existing, underway

and proposed expansion projects are shown in table given below:-

Composite Area Statement (in M2)

S.

No

Facility Existing Proposed

expansion

Total

1 Pellet Plant 15727 - 15,727

2 Iron Ore Grinding & Beneficiation Plant - 7971 7,971

3 Coal Gasifiers for Pellet Plant - 10150 10,150

3 Steel Melting Shop (EAF , LRF & CCM) 69500 - 69,500

4 Coke Oven 70000 - 70,000

5 Coal / Flux Crushing & Iron Ore

Handling

19000 - 19,000

6 Flux / Coke Crushing 15000 - 15,000

7 Sinter Plant 44250 - 44,250

8 Blast Furnace 69123 - 69,123

9 Rolling Mills 78000 - 78,000

10 Power Plant 50000 - 50,000

11 MRSS 20000 - 20,000

12 Oxygen Plant 14000 - 14,000

13 Administrative Building 8000 - 8,000

14 Store & Maintenance Building 8000 - 8,000


15

15 Plant Water Reservoir 29650 - 29,650

16 Roads 80000 - 80,000

17 Raw Material Yard 88000 - 88,000

18 Railway Yard 58460 - 58,460

19 Greenbelt 600962 73730 674,692

20 Other 485274 28552 513,826

21 Area En marked for future Expansion - 101171 101,171

TOTAL 1822946 221574 2,044,520

TOTAL (HA) 204.452

3.5 Mechanical Equipments and Process Flow Diagram

3.5.1 Brief Process Description (Manufacturing Process):

Manufacturing Process of Proposed Coal Gasifier Plant

These Extended Shaft Gasifier are of distinctly improved design over the conventional 19th

Century old design single stage Gasifier with respect to quality and consistency of gas,

smooth and trouble free operation without interruptions, higher calorific value, adaptability

to lower grades of coal, safety and operation friendliness, ecology and pollution control,

easily controllable and flexibility of operation etc.

The object of the New Technology is to produce a clean consistent quality Producer Gas of

high Calorific Value from majority of grades of Indian Coal from ‘A’ to ‘G’ grade and with

faster rate of gasification or more coal through-put per unit grate area. With this objective

in view a deep coal bed was introduced with extension of shaft over the conventional

generator proper of the single stage design and the product gas has been fully diverted to

the top to come out from the top of the Gasifier. The advantages accrued from such

modifications are thus:

The Extended Shaft is so precisely calculated that the fuel coal while moving downwards get

stripped off its Volatile Matter to a great extent and the coal itself gets converted to ‘Near-

Coke’ state with an acquired advantage of greater reactivity for a faster gasification almost

similar to coke gasification. The product gas, on the other hand, while moving upwards,

counter-current to the incoming feed coal gets auto enriched with the stripped and distilled

volatile matter of coal to a higher calorific value. This novel feature had greatly improved the

kinetics of gasification, specific mass flow of gas per unit empty cross section of the Gasifier,


16

gas make per MT of coal, calorific value, and consistency of gas quality and more stream

days of operation without interruption.

At the same time, coal bed of Extended Shaft helps to adsorb dusts soot etc of the product

gas and no extensive cleaning facilities are required for better and consistent quality of gas.

The Process is continuous and as controllable and maneuverable as oil firing.

The Process is Eco-friendly; the equipment is operation friendly and conforms to all PCB

norms.

GENERAL PROCESS DESCRIPTION WITH VARIOUS PROCESS STEPS AND

REACTIONS

Process steps and Reaction are:

Coal from ground buffer stock is lifted and delivered to the over head bunker by means of

an inclined Conveyor/bucket elevator and through a Vibrating Screen.

From the Bunker, Coal is fed to the extended shaft Gasifier through leak-proof

pneumatically operated double bell feeding system as per the specified exit temperature of

outlet PG not exceeding 140°C

After entering the Extended Shaft the feed coal passes through following steps and

gasification reactions:

Pre-heating, Drying and Distillation Zone.

Feed coal travels downwards and gets dried and preheated to the distillation temperature of

400°C to 500°C as per the modified temperature-profile. Due to prolonged stage of better

physical contact with coal interfaces, substantial heat transfer from gas to coal takes place

and at the same time high volatile matters of coal get stripped off and enter the gas phase,

in turn auto-carbureting the later.

After distillation zone, coal enters the Secondary Reduction Zone where it faces

oxidation and primary reducing gases and thereby Secondary Reduction reactions take

place as per the following equations:

C+CO2 =2CO

CO+H2O = CO2+ H2

Primary Reduction Zone:

The reactions are:


17

C + H2O = CO + H2

C + 2H2O = CO2 + 2H2

C + CO2 = 2CO.

Oxidation Zone:

Coal oxidation or burning takes place in this zone with the standard oxidation of

carbon with generation of CO2

C + O2 = CO2

The reaction is highly exothermic and it provides heat to the reduction reaction which is endothermic. Steam, air and CO2 are carrier of heat for successive reactions in the

Reduction zones.

Ash zone:

Just below the oxidation zone there is ash zone. Air and steam at specified quantity,

which is described at later chapter, enter through the bottom skirt and pass through grate

rings and ash, where these gases pick up heat from the ash and thereby cool the ash which

thus protects the grate from intense heat of oxidation (about 1200° C). Air and steam on

the other hand get pre-heated for a faster and better oxidation. It is obvious that too much

extraction of Ash will damage the grate stool and too much accumulation of Ash will

shift the whole temperature profile upwards with reduction in distillation zone and upper

zone. The results are lower C.V Producer gas, more un-decomposed steam and more

quantity of dusts and soot in the product gas.

Hence maintaining the correct temperature-profile with a maximum outlet gas temperature

within 140° C is most important. The two gas streams with full quantity of Producer gas

coming out from the two gas off-takes run parallel up to the Mixing cum washing chamber

where this is washed with re-circulated water at 60° C to 70° C. The height of the chamber

and rate of circulation are such that the gas cannot be cooled down below the above

temperature and water vapor content remains much below the saturation quantity to avoid

more condensation of water vapor and volatile matters. From the washing chamber the

gas is connected to the common-header. The heavy tar and water collected at the bottom

of the washing chamber flows to the water circulation tank from where this is again

circulated to the washing chamber as described above. The heavy tar which gets settled at

the bottom of the settling tank to be drained to tar tank for further disposal.

For further removal of dust particulate matter the above gas is treated in Lim Washer and

for minimum tar content the gas is treated in electrostatic tar precipitator.


18

Ecological Features of Gasifier

The basic Ecological features of Extended Shaft Gasifier are:

Gasifiers are operation friendly

The New Generation Producers are easy to operate and with proper instrumentation, the

control of various parameters like change in Coal through-put, addition of air for a

controlled Blast Saturation Temperature (BST), maintaining the mobility of coal – bed

and ash discharge system, regulating the coal through – put directly as per heat demand

through BST controller which is cascaded with air flow are all very simple. With proper

automation and instrumentation, less labor will be involved for the operations.

Safety Aspects

The Gasifiers are extremely safe to operate. With proper sealing arrangement of the coal

feeding system, poke-holes and ash-bowl, there is absolutely no gas-leakage to the

surroundings nor any emissions of particulate matters.

Against any over-pressure of the Gasifier, water seals are provided at desired locations.

High and low level alarms are provided on the jacket –boiler steam-drum.

Gasifiers are Eco-friendly

Extended Shaft Gasifier is fairly pollution-free. There are no gaseous or liquid effluents.

Heat radiation / loss is well guarded with the help of Cooling Jacket and glass wool

insulation on the bottom shell and refractory insulation in the Extended Shaft. So far as

liquid effluent is concerned, 0.5 to 1.5 MT of light tar per day is collected in the mixing

cum washing chamber. This is in a highly fluid state due to ingress of stripped volatile

matter of coal and its viscosity is almost similar to Furnace oil.

As such, it can be used after removing moisture as CTF in the oil-burner along with furnace

oil or can be disposed gainfully at a high price. The only solid discharge is ash-granules,

which is non-toxic. This can be used in Cement Plants or for Road Repairs or filling of low

lying areas. Other PCB aspects like Noise-level (below 60 db), Chemical Substance

control, physical hazards and other agronomical aspects are well taken care of to the

ultimate satisfaction of Pollution Control Board and the Work force.


19

CONTROL PHILOSOPHY OF PRODUCER GAS PALNT

The control of Producer Gas Plant will be most operation friendly and full-proof against

hazard and human error through proper automatic and PLC based instrumentation system

wherever necessary. The details of PLC Based automations are given below:-

The areas of automation:

i) Control of Coal feed as per demand.

ii) Control of Producer Gas output as per consumption pattern.

iii) Control of B. S. T. (Blast Saturation Temperature) or addition of steam for

optimum output and composition of gas.)

iv) Control of air introduction as per heat demand in down –stream section.

v) Temperature and Pressure Control of gas.

vi) Control of ash discharge.

vii) The control of soft water input for jacket cooling and steam rises.

viii) Air addition to individual Gasifier.

ix) The flow of make-up water to sump of Washing Chamber.

x) Storage and Control of Soft water.

The details of Automation:

Control of Coal feed as per demand:

The gas will come out though two L.T.C. pipes LTC -1 & LTC-2of each Gasifier at a

temperature of about 120°C to 140°C. As coal –bed comes down; the temperature of

L.T.C. pipes tends to come up. Thermocouples TE-1 & TE-2 based temperature indicator is

set at a temperature of 140°C. As L.T.C. temperature touches 140°C. the switch actuates

three air pressure operated power cylinders PC-1, 2 & 3 at sector gate (SG) and two bell

cones BC-1&2 respectively which open sequentially – 1st the sector gate (SG) (for 30

seconds or as adjusted) and then 1st bell –cone BC-1 after sector is closed and lastly 2nd

bell cone BC-2 after 1st bell cone is closed. Thus Coal is fed into the producer. If after 5

min of coal charging, the temp does not fall below the set value, the coal feeding will be

repeated.

Control of Producer Gas output as per heat demand.

A pressure transmitter will be fitted at the outlet gas header before gas booster, which will

generate signal to monitor and control the gas pressure. Air is the primary variable for

increasing or decreasing gas output. As consumption of gas increases, the header pressure


20

decreases and with decrease of the header pressure from a set value, the PLC send signal to

the Variable Frequency Drive (VFD) to increase the Frequency of the Motors (M) of the

Air Blowers AB-1&2 and thereby speed of the blower increases to increase in air-output.

More air increases the reaction rate and gas output increases to maintain outlet gas pressure

at the set value. Reverse sequence of operation will occur if the heat demands, i.e.

consumption of gas decreases. In this case, therefore, there will be no need of bleeding the

generated gas through the chimney (CH-1) valve but the generation will itself decrease to

save fuel and energy cost.

Control of B.S.T. and addition of steam and Air.

Similar to addition of air, which Controls the output, addition of steam is also important

for regulated Gasification with optimum steam carbon reactions, temperature Control and

prevention of clinker formation etc. Optimum steam addition is required for highest CO

and H2 content in the gas. For optimum CO and Hydrogen formation, a Blast Saturation

temperature of 63°C will be ideal for ‘F’ grade. Steam addition is automatically

controlled by B.S.T control valve with variation in air flow to maintain the BST. If there

is tendency of clinker formation, a little more steam is added by increasing BST, and not

by increasing air which is primary variable and is controlled as per heat demand, all are

controlled through PLC. B.S.T. is set at desired level by Thermocouples through PLC

which actuates the BST control Valve.

Control of Air addition as per heat – demand.

This has already been explained at (i) above. Flow of air is automatically regulated with

VFD of air blower which again changes with consumption of gas in downstream sections.

Automatic Control of Gas pressure and temperature.

This has already been explained at Para No (ii), (iv) and (i) above. However, at the time

of coal charging, the gas -pressure tends to come down by about 20mm to 30 mm. This

will be checked by addition of steam by a solenoid valve SV-4, which will open at the

time of opening of lower Bell cone BC-2 through PLC.


21

Control of Ash – Discharge.

This system is auto-manual. Rotation of ash bowl and grate helps removal of ash from the

system. As reaction proceeds, coal bed moves down and ash layer over the grate also

moves down wards and comes out through the water seal of the ash-bowl.

There are two speeds of the grate - one is slow speed and continuous and completes one

round in four hours. This helps homogeneous settling of coal bed for perfect draught

condition, breaking of clinkers and easy movement of ash. The other speed is high and

intermittent and generally takes place at an interval of 2 Hrs, which is again adjusted as

per ash discharge. At this speed, the grate with Bowl make a complete round in about 40

to 45 minutes. Both these motions are affected by Hydraulic Power Pack. Over and above

these automatic motions the quick rotation can be done by means of manual local

switches if the ash level comes up abnormally due to clinker formation. Level of ash can

be known at the time of poking. Ash bed must cover the grate to save if from the intense

heat of oxidation. Addition of air + steam mixture cools the ash and it gets pre-heated.

Ash thus removed falls on a belt conveyor, which carries it for loading a tractor trailer

though an overhead chute.

Control of Soft-water input for Jacket cools and steam rising.

The soft-water will be supplied from existing source which will be stored in a Soft-water

Tank SWT-2and the level of the tank will be maintained by a mechanical float valve and

Float – Switch From this tank, water will be continuously pumped to an overhead tank

SWT – 1 of 6 KL capacity and is of spill-return type. From this tank, water will flow to

the vapor drum VD-1of each Gasifier through a control valve LCV which will

automatically maintain the level of vapor drum at about 50%. There will be thermos

phonic natural circulation of water through the jacket cooler and the depletion of level by

steam generation will be automatically made up by the control valve.

Air addition to individual Gasifier

It is important to distribute equal amount of air in each Gasifier which is about 1400

Nm3/Hr on an average at normal condition of the Gasifier or slightly higher depending on

the flow ability and mobility of ash. The air flow to individual Gasifier is automatically

adjusted through PLC by pneumatically operated damper PCV in each air inlet line to


22

individual Gasifier to maintain a set pressure in the pressure transmitter before the producer

air inlet. However, each damper is ‘fail-close’ type, that is, will fully close at the time of

power failure by solenoid valve SV-7, while at the same time, steam valve of the B.S.T.

controller is ‘fail-open’ type, that is, will open at power failure.

The flow of makeup water to the sump of the washing chamber

The position of the normal water outlet valve SSV-2 with automatically closes in case of

power failure. The makeup water, however, is added to the sump through a solenoid

operated valve SV-8 of ‘fail-open’ type which will immediately open full to let in

makeup process water into the sump for sealing the outlet gas line to the gas header. This

make up water will flow in from an overhead tank EOT-1 which is kept full at any time

to ensure availability of water at the time of power failure.

The storage and control of soft water

As indicated earlier, a mechanical float valve is maintaining water level in the soft water

tank SWT-2. From this tank, water is pumped to a common overhead Tank SWT-1 of

spill return type. From this tank water flows by gravity to two drums of two Gasifier. The

level of drum is maintained at about 50% by means of a controller in the water inlet lime

to the drum.

IRON ORE GRINDING AND BENEFICIATION METHODS AND PRACTICES:

With over 25 billion tons of ore reserves India is one of the leading producers and

exporters of iron ore in the world. Although Indian iron ore is rich in iron, but it contains

high alumina which is not favorable for efficient operation of Blast Furnace. In order to

meet the requirement of low alumina content of iron ore and also taking care of

environment pollution problem and the need of resource conservation, total processing of

Iron ore covering, lump, fines and slime is proposed.

Inferior grade iron ore cannot be used in metallurgical plant so it need to be upgraded to

increase Iron content and reduce gangue content. The process adopted to upgrade the ore

is called Grinding and Beneficiation.


23

Depending upon the origin and mineralogical characteristics of the ore, the Grinding and

Beneficiation methods vary from simple crushing and screening to complex

concentration process.

Furnished below are some of the established facts on use of grinded and beneficiated iron

ores in iron making:

Iron content: A 1% increase in Fe content in the burden increases productivity by 2%

and decreases the coke rate by 3% in view of reduced slag.

Silica content: A decrease of 1.5 % silica content in the burden will reduce the slag

volume by 65 kg/MT of pig iron and hence less fuel consumption.

Alumina content: Every 1% reduction in alumina in the burden, the coke and the flux

rate decrease by 40 to 60 kg/MT of pig iron and consequently increase the productivity

by 2 to 2.5%.

Iron Ore Fines: A 1% decrease in fines of less than 6 mm leads to a decrease in coke

rate of 1 kg/MT.

Typical Unit Processes in Major Iron Ore Grinding and Beneficiation Plant

• Scrubbing - Screw Classifier

• Size classification by wet screening

• Cyclones

• Primary Grinding–Size reduction for liberation

• Gravity concentration –Spirals

• Magnetic separation – HGMS/WHIMS

• Secondary grinding – for grinding concentrate to pellet fineness (0.045mm)

• Slurry Thickening– Thickeners

• Filtration- Pressure and Ceramic Filters

However, the generalized process of Grinding and Beneficiation includes following:

Screen: It is used to segregate the ROM to + 50mm and -50 mm iron ore.


24

Crusher: The oversize from the Screen will be fed to Crusher to crush the iron ore to –

50 mm.

Power screen (Wet Screen): It will separate – 50mm crushed ore after washing into three

sizes viz. 20 – 50 mm for Blast Furnace, 10 – 20 mm for DRI Kiln, part of 1-10 mm for

Sinter and balance – 10 mm for Grinding and Beneficiation. During washing the

Grinding and Beneficiation of Ore also takes place due to washing.

Primary Ball Mill: The primary stage ball mill will be installed for the crushing, will

reduce the ore to 500 microns and the reduced slurry will pumped to De-sliming cyclone.

Over size will be transferred to secondary Grinding circuit for the further reduction.

De-sliming cyclone: In this process the material under goes to cyclic effect due to this

low specific gravity material i.e. Gangue/Tailing goes to the HGMS by over flowing.

Those materials having high specific gravity i.e. concentrate goes to Grinding circuit

cyclone through under flow.

HGMS (High Gradient Magnetic Separator): The Overflow i.e. tailing of De sliming

cyclone is fed to HGMS for further recovery of Iron Ore. In this process Tailing goes to

Tailing Thickener and Concentrate goes to the Grinding circuit cyclone.

Grinding circuit cyclone: In this, material is fed from HGMS and De-sliming cyclone

under flow i.e. Concentrate. In this process the over flow cut- off size 325mesh (-

45microns) i.e. Concentrate goes to the Concentrate Thickener and under flow (+45

microns) goes to the Secondary Ball Mill for re-grinding.

Secondary Ball Mill: In this material is fed from Grinding circuit cyclone under flow. In

this ball mill, wet grinded and over flow goes to again Grinding circuit cyclone. This is a

close circuit Grinding. Grinding circuit cyclone (GCC) again gives 2 products. Under

flow (+45microns) of GCC comes to secondary ball mill and over flow goes to the

concentrate thickener.

Concentrate thickener: In this material is fed from over flow Grinding circuit cyclone

i.e. concentrate. The material fed to concentrate thickener having 70% water and 30%

solid. After thickening process the under flow will have 70% solid and 30% water, which


25

goes to the concentrate holding tank from where it will be pumped to Pressure

Filter/ceramic filter.

Pressure Filter/Ceramic Filter: In this process the moisture content of Concentrate will

be removed by pressuring and squeezing the concentrate. The de-watered concentrate

containing 8.5% moisture will be used for making pellets.

The Input and output quality of Iron Ore will beneficiate from Input of 58 Fe Grade

to 63.5 Fe Grade output.


26

3.5.2 Process Flow Charts

Coal Gasification


27

Process Flow Diagram: Iron ore Beneficiation – Proposed


28

Raw material Requirement

The gross annual requirement of various raw materials of the plant with probable source and Material

Balance are given in table below.

Annual requirement of major raw materials

After Expansion

Raw Material

Annual

Consumption Sources of

Supply

Mode of

Transportation Plant

(including

Moisture)

Iron Ore Fines 10,00,000 TPA

Captive

Dongerbor Iron

Ore Mine,

Rajnandgaon

/NMDC, Barbil,

Orissa

Rail/Road.

10,00,000 TPA

Beneficiation

Plant/6,00,000

TPA Pelletization

Plant

Coal 94,500 TPA E-auction Road.

10 Nos Coal

Gasifiers/[6,00,000

TPA Pelletization

Plant]

Material balance for 1MTPA Beneficiation Plant

10,00,000 TPA Beneficiation Plant (All Fig in Ton)

Input Qty Output Qty

Iron Ore

Fines

(Fe~58)

1000000

Beneficiated

Concentrate

(Fe~63.5)

700000

Tailing 300000

Total 1000000 Total 1000000

Per Ton of Product

Input Qty Output Qty

Iron Ore

Fines

(Fe~58)

1.43

Beneficiated

Concentrate

(Fe~63.5)

1.00

Tailing 0.43

Total 1.43 Total 1.43


29

Material balance for 10 Nos Coal Gasifiers

10 Nos Coal Gasifiers

Input Qty in

TPA Output Qty in TPA

Coal 94500 Producer Gas 43000 (194.731

MNm3)

Ash (as Cinder) 48900

Tar 2600

Total 94500 Total 94500

1 Nm3 of product (Producer Gas)

Input Quantity

in Gram Output

Quantity in

Gram

Coal 485 Producer Gas 221 (1Nm3)

Ash (as Cinder) 250

Tar 14

Total 485 Total 485

3.5.3 Plant & Machinery (List of Equipments)

LIST OF EQUIPMENT & MACHINERY: - MAJOR EQUIPMENTS- COAL

GASIFIERS PLANT

A. RAW MATERIAL HANDLING SYSTEM, B. GASSIFIER MODULES – 3.2MTR DIA – 10NO'S

C. MIXING CUM WASHING CHAMBER,

D. LM WASHER,

E. ELECTROSTATIC TAR PRECIPETATOR,

F. BOOSTER

G. CENTRAL BURNER FOR KILN,

H. TG BURNERS

I. ASH HANDLING SYSTEM,

J. TAR HANDLING SYSTEM,

K. SOFTNING PLANT

L. GAS TRANSMISSION PIPELINE

M. ELECTRICAL PANEL, INSTRUMENTATION & AUTOMATION

N. LIQUID WASTE INCINERATOR


30

Coal Gasifier Analysis

Total Gasifier 10

Total Coal Required 94500 TPA (485 g/ Nm3)

Make Up Water Required 301m3/Hr

Heat Required 360,000 Kcal/tonne

GCV of the Fuel 1100 Kcal / NM3

Gas Requirement 27,046 Nm3 / Hour

Pellet Output 83.33 T/Hour

Ash Generation 48900 TPA (250 g/ Nm3)

Tar 2600 TPA (14 g/ Nm3)

Water Requirement:

Water is required in the plant is mainly for the purpose of process mixing and equipment

cooling. Water is also required for drinking, sanitary, and fire fighting purposes. In order

to conserve water and minimize the makeup water requirement, it is proposed to adopt

re-circulating systems for equipment cooling. In re-circulating system same water

re-circulates again and again and some make up water is added for evaporation losses.

Requirement

Water

Requirement

(m3/Day)

System

loss

Wastewater

Generation(m3/Day)

Treatment /

Disposal

Methodology

Coal Gasifier Plant:

jacket cooling

and steam

rising

70 50 20

Will be utilized for

Spraining and Dust

Suppression

Ash Pan &

Seal Pots) 167 167 0 --

Gas Gleaning

(Mixing

Chamber &

ETP)

63 61 2 to be incinerated in

an incinerator

Domestic 1 0.5 0.5 Taken to Septic tank


31

3.10 Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal

3.10.1 Solid Waste Management

The tar Generated from Coal Gasifiers will be sold in the market to Authorized Vendors,

whereas the generated ash will be utilized in brick plant. Tailing generated from Iron Ore

Grinding and Beneficiation plant will making bricks Blocks, Tiles, Pavers, etc and also

sold to Cement Plant.

Tailing will be used for making Blocks, Tiles, Pavers, etc and sold to cement plant. The

quantity of solid waste generation and their utilization shall be as mentioned below in the

table:

S. No. Solid Waste

Source Quantity TPA Utilization

1. Ash Coal Gasifier 48900 (6.17 T/Hr. )

Will be raw material for brick manufacturing plant

2. Tar Coal Gasifier 2600 (0.33 T/Hr. )

Will be Sold to the market to

Authorized Vendors

3. Tailings

Iron Ore

Beneficiation plant

300000 (37.87

T/Hr. )

Will be usedfor making bricks

Blocks, Tiles, Pavers, etc and

sold to Cement Plant.

attached with soak

pit. In addition to

this STP will be

provided.

Sub Total B 301 278.5 22.5

Iron Ore Beneficiation plant:

Process 1061 1061 0

Domestic 5 1 4

Taken to Septic tank

attached with soak

pit. In addition to

this STP will be

provided.

Sub Total C 1066 1062 4

Total A+B+C 1367 1340.5 26.5


32

3.10.2 Air Pollution

The major source of air pollution in the plant, fugitive emission from various dry material

handling & transfer points.

The de-dusting system will be provided at various points, including raw material de-

dusting, dryer de-dusting, annular cooler discharging and product storage and

transportation de-dusting. The entire junction / transfer points of material will be

provided with adequate capacity of de-dusting system (Bag filters and cyclones), Fogging

system (Dust Suppression System) to control the fugitive emission.

Various Air Pollution Control System for the proposed expansion projects is as

under:

Process Air Pollution

Control System

Stack Height

Proposed

Expansion

Iron Ore Grinding and

Beneficiation plant

Not applicable Nil

Coal Gasifier Not Applicable 30 Mtrs

(Incinerator)

3.10.3 Water Pollution

Water is required in the plant mainly for the purpose of process mixing and equipment

cooling in Iron Ore Beneficiation purpose. Water is also required for drinking, sanitary,

and fire fighting purposes. In order to conserve water and minimize the makeup water

requirement, it is proposed to adopt re-circulating systems for equipment cooling. In re-

circulating system same water re-circulates again and again and some make up water is

added for evaporation losses. The outflow from toilets of the plant buildings shall be led

to various septic tanks in respective areas through separate drains and the run-off from

them will be connected to soak pits/ dispersion trenches.

3.10.4 Noise Abatement

Noise from compressor, fans, centrifugal pumps, electrical motors etc. will be kept in

control so that the ambient noise level shall not exceed 75 dB (A) during day time & 70

dB (A) during night time. Noise pollution control measures will be provided in respective

departments by way of providing silencers, soundproof cubicle / covers & proper

selection of less noise prone machinery and by development of green belt.


33

3.10.5 Plantation/Greenbelt Development

• Total Plant Area is 204.452 ha.

• Approx. 67.4692 ha with 1500 trees/ha is earmarked as greenbelt development

• SEML has already planted 45560 trees in its plant area.

Presently, total plantation at the premises is spread over an area of 30.37 Ha.


34

CHAPTER-4

Site Analysis

4.1 Connectivity

The proposed coal Gasifier and of Iron ore Grinding unit to Iron Ore Grinding &

Beneficiation Plant is located at village: Mandhar, Tahsil: Dharsiwa, Dist: Raipur ,

Chhattisgarh State. The nearest city from the site is Raipur which is around 12 KM. The

nearest railway station is Mandhar on Mumbai – Howrah main line which is around 1.5

KM. Nearest air port is at Raipur which is 25 KM from site. The nearby sea port is Vizag

– 500 KM. The site is connected to National Highway-200 which is 5 KM from Site.

4.2 Land Form, Land use and Land ownership

SEML is having 204.452 Ha of industrial land at village Mandhar allotted by

Chhattisgarh State Industrial Development Corporation (CSIDC), Raipur for installation

of 0.6 MTPA pellet plant and 1.1 MTPA Integrated Steel plant (underway Project). The

proposed expansion is within the same premises.

4.3 Topography - with map

The project site is fairly flat with trees/shrubs present at some places. There will not be

much cutting and filling required for the proposed expansion project.

The Topographical map of 10 km radius of the proposed plant site is attached below:


35

81°45'

81°40'

81°40'

81°45'

21°25'

21°20'

21°15' 21°15'

21°20'

21°25'

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

INDEX

RAILWAY LINEPREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES

10 KM. STUDY AREA

Phase-1, Siltara Industrial Growth Center, Village - Mandhar

M/s Sarda Energy & Minerals Limited.

A-7

Tanda

SiltaraSondraChikhli

Nimora

Sankra

Dhaneli

Birgaon

Achholi

Nawadih

PadharidihKanhera

Kumhari

BahesarLata

Devsara

Mundrethi

Dharsihwa

Tiwria

KurnaKapasda

Parastarai

AkoliGidhauri

Barbandha

Mandhar

Newardih

Bhurkoni

Semaria

Baroda

Saddu

Sevni daldalBhanpuri

Urkura

Ranwabhata

GiraudMandhar

Matia

Tarra Jarauda

Pauni

PatthriTaresar

Khurmuri

Mangsa

Kurud

Nagargaon

Mohdi

Tor

Dande Kalan

Dande Khurd

Nardaha

Amasevni

Tekari

Sarora

Gandwara

Gurhiari

RajtalaoLabhandih

Pirda

Tulsi

Dhansuli

Akoldih

Pacnera

Khamtarai

Khamardih Kachna

KHARUN RIVER

KU

LH

AN

NA

LA

CHHOKRA NALA

Chhopora

Khurmuri

Fig-Topographical Map


36

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including

area under CRZ)), shortest distances from the periphery of the project to periphery of

the forests, national park, wild life sanctuary, eco sensitive areas, water bodies

(distance from the HFL of the river), CRZ.

Company is having 204.452 Ha land at Mandhar which is industrial land. The physical

changes in respect of topography and land use, though permanent, shall be compensated by

developing green belt around the project site.

There is no National Park, Wildlife Sanctuaries, and Forests in 10 KM radius from our

existing pellet and ISP site.

Nearby Eco-sensitive zones- Nil

Nearby Elephant/Tiger Reserves-Nil

Migratory Routes- No

4.5 Existing Infrastructure

Good infrastructure is available in the vicinity of Plant; some of the key features are listed

below:

1. Availability of NH-200 which is 5 KM away from proposed expansion project site.

Same can be used for transportation of all kind of Plant Equipment, Raw material etc.

2. SEML is having its own Railway Siding in the existing premises of 1.1 MTPA

Integrated Steel Plant (underway project).

3. Availability of adequate Water Resources.

4. 132 kV/ 33 kV switch yard already exists in the proposed plant premises for taking

electricity supply from CSPDCL. SEML also have facility to take power supply from

our power plant.

4.6 Soil classification

Physical characteristics of soil are delineated through specific parameters viz. particle size

distribution, bulk density, porosity, water holding capacity and texture. The bulk density of

the soil in the site ranged between 1.32 to 1.47 g/cc which indicates favorable physical

condition for plant growth. The porosity and water holding capacity of the soils are in the

range of 26.21 % to 33.27 % and 24.88% to 31.65% respectively. The soil in the impact zone

has clayey structure with moderate water holding capacity.


37

4.7 Climatic data from secondary sources

Climatological data collected from Secondary source i.e. IMD Raipur. The details of data are tabulated below:-

Month

Temperature (oc) Relative Humidity

(%)

Rain-fall

Min Max Min Max Mean

January 27.7 13.5 62 39 12.2

February 30.3 16.2 55 31 20.4

March 34.7 20.5 41 24 23.3

April 39.2 25.1 36 21 15.1

May 42.3 28.9 35 22 16.8

June 37.5 26.8 61 49 193.6

July 30.3 24.1 85 73 391.8

August 30.1 24.1 86 73 393.6

September 31.0 24.1 82 74 249.4

October 31.2 21.5 73 60 62.4

November 29.1 16.0 63 46 7.8

December 27.5 13.2 62 43 1.8

The maximum wind speed of the area is 60 km/hr.

4.8 Social Infrastructure available

Mandhar is the nearest village to plant. General social infrastructure like Samudayik

Bhawan, School, hospital etc. is available in the village.


38

CHAPTER- 5

Planning Brief

5.1 Planning concept

Type of industry: Pellet Plant along with coal gasifier and Iron Ore Grinding & Beneficiation

Plant.

Transportation Facilities: National Highway-200 for transportation which is about 5 KM

from Plant site connected by internal roads. Mandhar railway station is about 1.5 KM from

proposed plant site. The Company is having its own Railway Siding in the proposed

expansion premises.

Town and Country planning/Development authority: Gram Panchayat

5.2 Population Projection

Total Population in 10 KM radius of site is estimated as 95022.

5.3 Land use planning (breakup along with green belt etc.)

Company has been allotted 204.452 Hectares of land at village Phase-I of Siltara Industrial

Growth Centre, Mandhar, Raipur for installation of 1.1 MTPA Integrated Steel Plant and

60MW WHRB power plant. Company has been allotted 204.452 Hectares of land at village

Mandhar, Phase-I of Siltara Industrial Growth Centre, Raipur for installation of 1.1 MTPA

Integrated Steel Plant and 60MW WHRB power plant. Out of which 12.04 Ha of land has

been utilized by Pellet Plant along with the proposed expansion of Coal Gasifier and

modernization into Iron Ore Grinding & Beneficiation Plant. About 10.12 out of the above

204.452 Ha has also been earmarked for future expansions. It is located centrally vis-à-vis

source of raw material as well as Sponge Iron consuming industry.

STATEMENT OF AREA

SEML has in possession of 204.452 hectares of Land in Phase-I, Siltara Industrial Growth

Centre, Mandhar, for installation of 1.1 Million TPA Integrated Steel Plant along with

2x30MW WHRB based Power Plant. The details of land area for existing, underway and

proposed expansion projects are shown in table given below:-


39

Composite Area Statement (in M2)

S.

No

Facility Existing Proposed

expansion

Total

1 Pellet Plant 15727 - 15,727

2 Iron Ore Grinding & Beneficiation Plant - 7971 7,971

3 Coal Gasifiers for Pellet Plant - 10150 10,150

3 Steel Melting Shop (EAF , LRF & CCM) 69500 - 69,500

4 Coke Oven 70000 - 70,000

5 Coal / Flux Crushing & Iron Ore

Handling

19000 - 19,000

6 Flux / Coke Crushing 15000 - 15,000

7 Sinter Plant 44250 - 44,250

8 Blast Furnace 69123 - 69,123

9 Rolling Mills 78000 - 78,000

10 Power Plant 50000 - 50,000

11 MRSS 20000 - 20,000

12 Oxygen Plant 14000 - 14,000

13 Administrative Building 8000 - 8,000

14 Store & Maintenance Building 8000 - 8,000

15 Plant Water Reservoir 29650 - 29,650

16 Roads 80000 - 80,000

17 Raw Material Yard 88000 - 88,000

18 Railway Yard 58460 - 58,460

19 Greenbelt 600962 73730 674,692

20 Other 485274 28552 513,826

21 Area En marked for future Expansion - 101171 101,171

TOTAL 1822946 221574 2,044,520

TOTAL (HA) 204.452

The plantation and green belt development will also be taken care in the plant and the

space reserved for plantation will be more than 33% of the total plant area. SEML will

take-up massive green belt development by planting about 800 trees per acre. In view of

above, SEML proposed to develop 15-20 meters wide green belt along the boundary wall


40

inside the factory premises. Adequate plantation will substantially abate the dust

pollution, filter the polluted air, reduce the noise and ameliorate the plant environment.

5.4 Assessment of Infrastructure Demand (physical & social).

Basic infrastructure demand for nearby area would be first to have internal roads,

availability of clean and pure drinking water, availability of good schools, availability of

Hospitals, community halls, Sulabh Shauchalaya , easy and faster means of transportation

and connectivity to nearby town and city, availability of uninterrupted electricity etc. are

the present assessed demands for sustained and healthy growth of nearby area of site.

Most of the infrastructure demand mentioned above comes automatically when industry

of this magnitude comes in such area, systematic efforts shall be made to bring such

facility in the surrounding area for all round physical and social development.

5.5 Amenities / Facilities

For the social development in the area the company has planned to construct community

halls, roads, provide drinking water etc. Company will provide mobile medical van for

the free treatment for nearby villagers. Time to time the company will also organize free

eye check up, cataract camp, free distribution of spectacles etc.


41

CHAPTER-6

Proposed Infrastructure

6.1 Industrial Area

Our existing premises of 6,00,000 pellet plant and 1.1 MTPA ISP (Underway) which is

located at phase-I of Siltara Industrial Growth centre, Village- Mandhar, District- Raipur.

The proposed expansion of 10 Nos Coal Gasifiers along with Modernization of Iron Ore

Grinding Unit to Iron Ore Grinding and Beneficiation Plant is also proposed to be

established in the same premises.

6.2 Green Belt

The plantation and green belt development will also be taken care in the plant and the

space reserved for plantation will be more than 33% of the total plant area. SEML will

take-up massive green belt development by planting about 800 trees per acre. In view of

above, SEML proposed to develop 15-20 meters wide green belt along the boundary wall

inside the factory premises. Adequate plantation will substantially abate the dust

pollution, filter the polluted air, reduce the noise and ameliorate the plant environment.

6.3 Social Infrastructure

For the social development company will provide the arrangement of community hall,

road, water, electricity etc. in the nearby villages. For the economical development the

company will provide the employment as per requirement and individual’s qualification

& eligibility.

6.4 Drinking Water Management

Water for the plant will be supplied from Kharoon River located about 11KM from the

site through water pump, or from rain water harvesting pond of the plant site. The water

system will cater to the drinking and sanitary requirements of plant personnel as well as

laboratory and contingent users. The required water will be withdrawn from the storage

reservoir by two pumps (including one stand-by). The treated water will be chlorinated

and stored in the overhead tank for distribution as drinking water.


42

6.5 Sewerage system

It is proposed to collect fecal sewerage through sewerage network from the plant and lead

it to the sewerage treatment plant. The treatment plant shall consist of screen grit

separator, primary sedimentation tank, activated sludge plant, secondary clarifier, sludge

recirculation pump house etc. The treated effluent quality shall confirm to the Indian

Standard for discharge to surface water.

6.6 Industrial Waste Management

Management procedure of all kind of wastes from Plant like Ash & Effluent Water etc is

already discussed in details under point no. 3.10.3 of this report.

Power requirement for 10,00,000 Iron Ore Grinding & Beneficiation Plant & Coal

Gasifier

The total power requirement after expansion for Iron Ore Grinding &

Beneficiation Plant and Coal Gasifiers will be about 5108 KW.


43

CHAPTER- 7

Rehabilitation and Resettlement (R & R) Plan

The total land allotted by CSIDC to SEML for the installation of 1.1 MTPA Integrated Steel

Plant (underway) is 204.452 ha. which is industrial land. There was no displacement of people.

Thus R & R issues are not applicable.


44

CHAPTER-8

Project Schedule and Cost Estimates

8.1 Likely date of start of construction and likely date of completion:

Expected date of Commercial Production

Proposed expansion 10 Nos Coal

Gasifiers Plant

January 2018

Proposed expansion Iron Ore Grinding

Unit to Iron Ore Grinding &

Beneficiation Plant

January 2018

Project Implementation Concept

In order to ensure coordinated implementation within the short construction period

envisaged for the project, it will be necessary to evolve an optimal compromise between

the fully disaggregated mode and the turnkey package implementation mode. In

principle, it will be prudent to tie up the technology requirements and the key equipment

in the production units to reliable and high quality vendors. In the case of the major

production packages, it will be necessary for the Principal supplier (responsible for the

basic engineering, equipment engineering, technology, critical equipment supply, and

performance guarantees). The local procurement can cover the balance non-critical

equipment, auxiliaries and systems. The major auxiliary packages in the power system,

water system and the yard utilities will be formed into discrete packages.

The proposed model has been adopted in a number of projects with considerable success

and fast ramp up. The construction schedule for the project has been drawn up

accordingly.

Construction Schedule

The schedule has been developed considering mostly the supply of plant and equipment,

as well as volume of work for Construction /Erection of the plant and other local

conditions at site. According to the schedule, worked out, the coal gasifier & iron ore

grinding & beneficiation plant has been planned, to be commissioned within 12 months

from the date of placement of order for the main plant.


45

ADVANCE ACTIONS

The project due to its large investment stands to gain substantially if the actual

construction and implementation period is kept to the minimum. For this purpose it is

necessary that the planning and preparatory work on the project be done in a thorough

manner, which will ensure that the project construction and implementation once started

can proceed uninterrupted and without any delays. The start date (Zero date) for the

construction schedule is reckoned as the completion of these advance actions. The

advance actions on the project which will provide the appropriate foundation for cost

effective and timely implementation are:

i) Environmental clearance for implementation of the project

ii) Finalization of the financing arrangements for the project and the creation of a

project organization

iii) Finalization of the adequate details of the project to enable site activities to

commence from the date of ‘go-ahead’.

iv) Issue of inquiries for the major packages and finalization of the orders for the

same.

vii) Actions for linkages of power, water and other infrastructure.

SITE DEVELOPMENT & CONSTRUCTIONS FACILITIES

Site development activities include contour survey, soil investigation, site preparation,

site drainage, construction water, construction power, construction storage yards etc.

Activities related to site acquisition surveys and soil investigations will envisage to be

accomplished by the time the ‘go-ahead’ for project commences. Establishment of

construction power, water site preparation and other activities will be completed in three

(3) months from ‘go-ahead’.

Special efforts will have to be made during implementation to keep the earthwork and the

site preparation to the minimum both for cost savings as well as reduction in construction

time.

CIVIL & STRUCTURAL WORK

The schedule for carrying out the civil work and structural steel work is based on the

volume of work and interlink between the completions of some of these activities to


46

enable the subsequent activities to proceed. Structural steelwork covers all the building

structures. In order to meet the overall time-frame envisaged in the schedule, the

completion of civil and structural work in a time-bound manner is a pre-requisite for the

project completion for the schedule.

EQUIPMENT MANUFACTURE & DELIVERY

As indicated earlier, as an advance action, enquiries will have to be issued for the various

plant and equipment, on a global basis, tenders evaluated and orders finalized. Major

packages will cover material handling system, Beneficiation Plant, Gasifiers and these will

need to be tendered out. Placement of order for such packages is envisaged within two (2)

months to seven (7) months from the date of go ahead for project construction. It is

assumed that advance work on the preparation of specifications, evaluation of tenders and

readiness for placement of orders will be taken parallely with the land acquisition process

and the project preliminaries. The duration generally accepted internationally for

manufacture and delivery of various equipments have been taken into account while

evolving the implementation schedule.

EQUIPMENT ERECTION

Erection of equipment will have to commence after availability of fronts on completion

of the civil and structural work as well as delivery of equipment at the plant site. It is

expected that the duration for erection of equipment for the various plant facilities will

vary between Six (6) months to Eight (8) months from the date of commencement of

equipment erection.

EXTERNAL FACILITIES

The various off site facilities such as external water supply, external power supply and

rail transportation links, road links etc are already available in our existing premises

where the expansion of project is proposed.

TRIAL RUNS & COMMISSIONING

Commissioning work will be done after completion of Erection work. A period of 6

months has been envisaged for carrying out commissioning work and trial runs.


47

Project Monitoring

At the project implementation stage, all project activities from design and engineering to

construction, equipment supply, erection, testing and commissioning of the plant and

equipment will be monitored on the basis of a computerized network monitoring system.

Various reports as relevant for different aspects of project monitoring will be generated

through the computerized system.

Action points will be identified agency-wise and actions taken for timely implementation

the milestones to be achieved for meeting this schedule will be identified and monitored for

their achievement. Critical activities of the project as they arise will also be identified and

monitored and followed up to ensure timely completion.

8.2 Estimated project cost along with analysis in terms of economic viability of the

project

Since the report includes a project which is already under operation the Cost of Project.

Thus, for the established unit the Gross Capital Made has been considered as Cost of

project and for the other two it is estimated based on enquiries floated, quotations

received. The financing and pre-operative cost has been considered based on the

proposed financial package.

The estimated cost thus evaluated to be is Rs 12.789 Crores including pre-operative

expenses and margin money for working capital requirements

Cost of Capital

All Fig Lac Rs

Sl No Particular Amount

1 Iron Ore Grinding & Beneficiation Plant 8202

2 10 NO Coal Gasifier 4587

# Total 12789


48

CHAPTER-9

Analysis of proposal (Final Recommendations)

9.1 Financial and social benefits with special emphasis on the benefits to the local people

including tribal population

The pellet plant already exists, However, the proposed expansion project will result in

improvement of infrastructure as well as upliftment of social structure in the area. The people

residing in the nearby areas will be benefited directly and indirectly. It is anticipated that the

proposed plant will provide benefits for the local people in two phases i.e. during

construction phase as well as during operational stage of the plant.

• Construction Phase

Employment

The major benefit due to the proposed expansion project will be in the sphere of

generating employment for people of that area. The proposed expansion project will

benefit local population.

• Operational Phase

Community Services

SEML will employ local people to the extent possible for avoiding creation of additional

infrastructure. SEML will develop medical facilities for catering to the needs of the

project personnel. These facilities will also be extended to the local community in due

course.

Education

SEML will initiate action for social upliftment in the area like female education,

vocational training. Financial support will also be extended to strength education

infrastructure in the region.

Transportation

There will also be small increase in the vehicular traffic due to passenger transport. This

increase in traffic will not have any consequence to warrant special mention. One should

expect that the increased passenger load in the sector would prompt the state


49

government/ private movers to start new and frequent public transport services to this

area, bringing upliftment to the whole locality.

Other Benefits

SEML is equally conscious for the all round socio-economic development and is

committed to raise the quality of life and social well being of communities where it

operates. Its CSR initiatives have been prioritized on local needs, which focus on Health,

Education, Infrastructure Development and Environment Conservation.

Pre Feasibility Project Report - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/30_Aug_2016... · Pre Feasibility Project Report PROPOSED INSTALLATION

Documents