PRE FEASIBILITY REPORT FOR THE PROPOSED 1.0 MTPA HOT METAL PLANT FOR PRODUCTION OF 0.7 MTPA PIG IRON AND 0.3 MTPA DUCTILE IRON PIPE WITH 60 MW WHRB POWER PLANT NEAR DIMBULI VILLAGE, CIRCLE MANOHARPUR, WEST SINGHBUM DISTRICT, JHARKHAND STATE Submitted to: Ministry of Environment and Forest and Climate Change New Delhi Submitted by: M/s. Vedanta Limited (Formerly Sesa Sterlite Ltd) Goa February, 2017
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PRE FEASIBILITY REPORT FOR
THE PROPOSED 1.0 MTPA HOT METAL PLANT FOR PRODUCTION OF 0.7 MTPA PIG IRON AND 0.3 MTPA DUCTILE IRON PIPE
WITH 60 MW WHRB POWER PLANT NEAR
DIMBULI VILLAGE, CIRCLE MANOHARPUR, WEST SINGHBUM DISTRICT, JHARKHAND STATE
Submitted to:
Ministry of Environment and Forest and Climate Change New Delhi
Submitted by:
M/s. Vedanta Limited
(Formerly Sesa Sterlite Ltd)
Goa
February, 2017
TABLE OF CONTENTS
Sr. No. Contents
1 Executive Summary
2 Introduction of the project
3 Project Description
4 Site Analysis
5 Project Brief
6 Rehabilitation and Resettlement (R & R) Plan
7 Project Schedule & Cost Estimates
Figures
Figures -1 Index Map
Figures -2 Study Area Map
Figures -3 Process Flow Sheet
1.0 Executive Summary
Sr. No Description Details
1 Name of the Project Vedanta Limited (Vedanta) proposes to
establish a green field 1.0 MTPA hot metal
plant for production of 0.7MTPA pig iron and
0.3 MTPA ductile iron pipe.
2 Location of the Plant Vedanta Limited is planning to set up a
greenfield project at Dimbuli Village, Circle
Manoharpur, West Singhbum District,
Jharkhand State.
The Latitude and Longitude of the site are:
Latitude : 22°21’41.9” to 22°22’32.56”N
Longitude : 85°12’57.84” to 85°13’59.93”E
3 Total land requirement
for the project
428.01 acres
4 Total Water requirement
& Source
The total requirement of water is ~6500 m3
per hour while 303 m3 per hour will be used
as make up water. Total make-up water
required is app. 8000 m3 of fresh water per
day. The fresh water make-up water required
for the proposed plant shall be met in
required quantity and quality from
neighboring river Koyal.
5 Rehabilitation and
Resettlement
No R & R issues are involved.
6 Manpower Direct: 300
Indricect:700
7 Estimated Cost of the
Project
About Rs. 1971.894Crores
8 Total Power requirement
& Source
A 60 MW (approx) Waste Heat Recovery
Power plant is proposed
2.0 Introduction of the Project/ Background Information
2.1 Identification of Project and Project Proponent
Vedanta Limited, formerly known as SesaSterlite Limited (SSL)/Sesa Goa LTD, a
Vedanta Group company is one of the world’s largest global diversified natural
resource majors, with operations in zinc-lead-silver, oil & gas, iron ore, copper,
aluminium and commercial power.
2.2 Brief Description of Nature of the Project
Nature of the Project
The proposed capacity expansion project falls under Category-A, under section 3(A)
as per the prevailing EIA Notification, dated 14th September 2006.
Size of the Project
The project cost for the proposed greenfield project is about Rs. 1971.849Crores and
EMP cost is about Rs. 100 Crores. The proposed greenfield project required 428.01
acres for installation of Blast Furnace, Sinter Plant, coke oven Heat Recovery and
Waste Heat Recovery Power Plant.
Vedanta Limited (Vedanta) is contemplating to establish a green field 1.0 MTPA hot
metal plant for production of 0.7MTPA pig iron and 0.3 MTPA ductile iron pipe. The
process for production of hot metal is based on blast furnace, sinter plant and coke
oven plant. Vedanta is already having 0.832 MTPA pig iron manufacturing unit at
Goa along with 1MTPA sinter plant , 0.6MTPA heat recovery coke plant & 60 MW
waste heat recovery plant.
Location of the Project
The proposed project area is located at Dimbuli Village, Circle Manoharpur, West
Singhbum District, Jharkhand State.
2.3 Need for the Project and its Importance to the Country and Region
Demand-Supply Gap/Export Possibility
The total production for sale of pig iron was 9.70 MT in 2014-15 as compared to 1.59
MT in 1991-92. Earlier, pig iron was produced primarily by theintegrated public
sector steel plants, SAIL and RINL. In contrast, the private sector accounted for 91%
of total production for sale of pig iron in thecountry in 2014-15. Production for sale of
pig iron is given in Table-1.
TABLE-1
PRODUCTION SALE OF PIG IRON
Year Main Producer Major & Other Producers Grand Total
1991-1992 1.490 0.100 1.590
1992-1993 1.679 0.165 1.844
1993-1994 1.977 0.273 2.250
1994-1995 2.005 0.780 2.785
1995-1996 1.813 1.060 2.873
1996-1997 1.733 1.570 3.303
1997-1998 1.711 1.687 3.398
1998-1999 1.354 1.644 2.998
1999-2000 1.226 1.955 3.181
2000-2001 0.964 2.434 3.398
2001-2002 1.016 3.055 4.071
2002-2003 1.107 4.178 5.285
2003-2004 0.966 3.980 4.946
2004-2005 0.625 2.603 3.228
2005-2006 1.007 3.683 4.690
2006-2007 0.860 4.093 4.953
2007-2008 0.936 4.348 5.284
2008-2009 0.589 5.618 6.207
2009-2010 0.731 5.153 5.884
2010-2011 0.579 5.104 5.683
2011-2012 0.502 4.869 5.371
2012-2013 0.674 0.674 6.870
2013-2014 0.552 7.398 7.950
Source: Steel Authority of India
The demand of pig iron during 2011-12 emerges as about 6.0 MT, which is likely to
increase to 6.9 MT by 2016-17 is given in Table-2.
TABLE-2
PROJECTED DEMAND FOR PIG IRON
Year Demand
2011-12 5968
2016-17 6857
Demand Analysis for DI Pipes
The demand drivers for pipes in general and DI pipes in particular are:
Economic growth;
Demand for water;
Urbanization ;
Improvement in water supply and sanitation coverage;
Awareness on safety and hygiene;
Investment by the Central and State Governments in Water and Sanitation
schemes;
Assistance from external agencies;
Inter-linking of rivers; and
Export potential.
Economic Growth
Indian economy is likely to grow in the range of 5.4 to 5.9 per cent in 2014-15 and
the outlook is very positive. The average consumer spending has increased
significantly which has fuelled demand for quality infrastructure services like roads,
electric power, transportation, water supply, sanitation, communication, etc.
Demand for Water
Water is a precious resource in India because the country accounts for 16% of the
world population as against just 4% of global water resources. The water use
efficiency is low in the country compared to international standards. As in the
previous years, agriculture will continue to be the major demand segment for water
in India. However, the demand from industries is expected to grow faster than the
demand from agriculture and domestic sectors. It is understood that the use of water
in Indian industries is high due to a combination of factors such as obsolete process
technology, poor recycling and reuse practices, and poor wastewater treatment. Use
of water in industries is closely linked to the economy of a country. The major water
guzzling industries are pulp and paper units, thermal power plants, fertilizer units,
iron and steel plants, sugar plants, and textile units.
Estimates vary with respect to the requirement of water for industries. According to
the MoWR, the requirement will increase from 30 billion cubic metre in 2000 to 120
billion cubic metre by 2025. According to the World Bank, the water demand for
industrial uses and energy production will touch 228 billion cubic meter by 2025. As
per the Tenth Plan, the stipulated norms are 40 litres per capita per day (lpcd) of
safe drinking water within a walking distance of 1.6 km and at least 1 hand pump for
every 250 persons. The norm will be relaxed to 55 lpcd in states where the 40-lpcd
norm has been achieved already. The above-mentioned norms are quite reasonable
because it is reported that in many large cities, water withdrawal amounts to 300 to
600 lpcd.
In contrast, the consumption in the developed countries of Europe and North
America had already touched 500-1000 lpcd by the turn of the last century. Water
demand projection varies from agency to agency. Consumption of water by 2020 in
different sectors as projected by Water Resources Division, Planning Commission is
given below:
Projected Water Consumption in 2020 (Billion cubic metres)
End Use Normal Pessimistic
Irrigation 640 602
Manufacturing 56 51
Domestic 57 57
Power 28 27
Total 781 737
According to a WHO-UNICEF Sponsored Study (India Assessment 2002-Water Supply
& Sanitation), the total water requirement by 2050 will be 1,422 billion cubic metre.
Tata Energy Research Institute (TERI) has estimated that the overall water demand
will virtually double from 564 billion cubic metres in 1997 to 1,048 billion cubic metre
in 2047.
MoWR has assessed the water requirement at 694 cubic km in 2010, 784 cubic km in
2025, and 973 cubic km in 2050. As against the projected demand, the availability of
water in 2050 is estimated at 996 cubic km.
At the national level, it will be a difficult to increase the availability to the projected
levels as most of the water resources are concentrated in a few river basins.
Transporting huge quantity of water from like rivers, lakes, wells, and treatment
plants to millions of homes would require a reliable pipeline system that will serve for
years without leaks and contamination. The increase in demand for water will call for
enormous efforts to capture, preserve, and distribute available water equitably.
Urbanization
It is estimated that by the end of the 12th Plan in 2017, approximately 40% of the
country’s population will live in cities and towns. This fast pace of urbanization will
increase the demand for piped water supply. Thus, the increase in population
accompanied by the fast pace of urbanization will together contribute for the growth
in demand for pipes.
Improvement in Water and Sanitation Coverage of Government to provide drinking
water & sanitation to 100% of the population:
Thrust of government to provide drinking water & sanitation to 100% of the
population Government’s focus to improve the urban infrastructure has increased
significantly during the last 10 years. The investment allocation to water supply &
sanitation during five year plan is INR 423 Bn.
• The year wise fund allocation growth rate in this five year plan is 21% which is
higher than the year wise growth rate of 15% during last five year plan
• The JNNURM scheme commenced during the five year plan is the main driver for
urban infrastructure development. JNNURM scheme is focused towards
strengthening the infrastructure in 63 cities, the other schemes UIDSSMT &
AUWSP focuses on other cities/towns
• Water PPP’s have emerged during the last 10 years & are fairly successful in
India; the central Government has planned to increase the number of PPP
projects in-order to support state water authorities in improving the system
efficiency
• The depletion of fresh water sources is driving the need of desalination projects &
these projects are expected to drive the growth of urban water infrastructure in
the coming years. The desalination projects are being planned & ongoing in
certain coastal cities
The investment allocation to water supply & sanitation during the 12th five year plan
is INR 255319 crores. Based on prior experience, it is estimated that 13% of this
expenditure to be on DI pipes.
Considering domestic demand and the requirement from the export market, Pipes
demand is expected to reach 1.99 MT by 2016–17.
Year 2014-15 2015-16 2016-17
Demand 1.47 MT 1.70 MT 1.99 MT
Production 1.37 MT 1.51 MT 1.70 MT
Gap 0.10 MT 0.19 MT 0.29 MT
With the demand growing and the supply scenario showing incremental growth, the
demand supply gap is set to increase to 0.29 MT.
The investment in water supply and sanitation sector by the Central and State
governments registered a compound annual growth rate of 18.5% from the end of
the 8th Five Year Plan to the end of the 11th Five Year Plan.
Supply constraints in the past have inhibited market expansion and the industry is
yet to pick up momentum. DI pipes being at the beginning of its product life cycle, it
is expected that the growth trajectory will be very buoyant at least in the next
decade or so after which it may mature to a stable level.
Import V/s Indigenous production
Although India started exporting steel way back in 1964, exports were not regulated
and depended largely on domestic surpluses. However, in theyears following
economic liberalization, export of steel recorded a quantum jump. Subsequently, the
rapid growth of domestic steel demand has ledto a decline in the rate of growth of
steel exports from India to ensure that domestic requirements are adequately met.
Import of iron steel is given in Table-3.
TABLE-3
IMPORT OF IRON STEEL
Year Pig Iron Total Finished Steel Total Value
1991-1992 152 970 1441.32
1992-1993 73 1143 1676.00
1993-1994 21 1119 1613.00
1994-1995 1 1775 2536.00
1995-1996 8 1617 3181.00
1996-1997 15 1632 3053.00
1997-1998 3 1648 2904
1998-1999 2 1194 N.A.
1999-2000 3 1678 N.A.
2000-2001 2 1491 2659
2001-2002 2 1373 2560
2002-2003 1 1663 3051
2003-2004 2 1753 3728
2004-2005 8 2293 6244
2005-2006 3 4305 11585
2006-2007 3 4927 15747
2007-2008 11 7029 24977
2008-2009 8 5841 30509
2009-2010 11 7382 25983
2010-2011 9 6664 26996
2011-2012 8 6863 27017
2012-2013 21 7925 39347
2013-2014 34 5450 30525
2014-2015 23 9320 44994
Source: Steel Authority of India
Employment generation (Direct and Indirect) due to the project
The proposed project will generate direct employment of approx. 300 manpower
including contract labour. It will provide new opportunities for local people also
resulting in indirect employment for more than 700 manpower. Training programs
will be set up for the development of local community as per the work requirement.
3.0 Project Description
Type of project including interlinked and interdependent projects, if any
It is envisaged toestablish a green field 1.0 MTPA hot metal plant for production of
0.7MTPA pig iron, 0.3 MTPA ductile iron pipe and 60 MW waste heat recovery power
plant at Dimbuli Village, Circle Manoharpur, West Singhbum District, Jharkhand
State.There is no interlinked project.
Location (map showing general location, specific location and project
boundary & project layout) with coordinates.
The index map of the project site is shown in Figure-1 and a map showing 10 km
around the project site is shown in Figure-2.
Details of alternative sites considered and the basis of selecting the
proposed site, particularly the environmental considerations gone into
should highlighted.
The three sites were examined. Important features of these sites are given below:
Parameters Site – I Manoharpur
Site - II Kharsawan
Site - III Dipa
Latitude 22°21’41.9” to 22°22’32.56”N
22046'48" N 22026'50.8" N
Longitude 85°12’57.84” to 85°13’59.93”E
85050'18" E 85011'49.2"E
Village in the Vicinity Dimbuli village (0.7 km, ENE)
Kharsawan (0.2 km, NNW) Bandiram Village (0.5 km, S) Didhsah Village Adjacent to plant
Dipa village (0.4 km, S) Baradungri (0.2 km, N)
Distance from nearest city/ town Rourkela (40 km, WSW) Chaibasa (61.0 km, NE)
City:Chaibasa (23.0 km, S) Town: Saraikela (12.6
km, SE)
Rourkela (41.0 km, SW)
Elevation of the site, above MSL 220 MSL 200 MSL 240 MSL
Land availability (in acres) 428.01 700.0 612.3
Private /
Government
Private and Government Private Private
Agriculture land within 1km Yes Yes Yes
Barren
Single crop
Double crop
Forest land
Single Double crop Single
Water body / Transmission line Koina River adjacent to West
Koel River (1.8 km, W)
Sanjoy River (6.0 km, S) Sona Nala (0.2 km, N) Khar Khai River (11.6
Koel River (0.1 km, NW) Koina River (5.6 km, S)
Karo River (4.4 km, NNE)
Parameters Site – I Manoharpur
Site - II Kharsawan
Site - III Dipa
Karo River (10.6 km, E) km, SE) Sapu nala (0.9 km, NW)
Road connectivity SH-4 Adjacent to site NH-149 (12.6 km, SE) SH-4 (1.4 km, W)
Rail connectivity Manoharpur (2.0 km, W) Rajkharsawan (5.0 km, SSW)
Posotia (5.1 km, E) Manoharapur (5.5 km, S)
Forests within 15 km There are 15 PF and 10 RF
Chandil-Gamharia Forest There are 16 PF and 8 RF
National parks & Wildlife sanctuaries Nil Nil Elephant Corridor
FIGURE-1
INDEX MAP SHOWING THE PROJECT SITE
PROPOSED HOT METAL PLANT
FIGURE-2
STUDY AREA MAP
Size or magnitude of operation
Production of 0.7MTPA pig iron and 0.3 MTPA ductile iron pipe at Dimbuli Village,
Circle Manoharpur, West Singhbum District, Jharkhand State.
Project description with process details
Blast Furnace and Related Facilities
The following has been considered for 10,00,000 TPA Blast Furnace and related
facilities:
A. 1000,000 TPA Blast Furnace
B. Sinter plants to produce 2 Mill tons of sinters required for the new Blast Furnace.
C. Waste Heat Recovery Coke plant (0.6MTPA) and Power Plant (~ 60 MW based on
waste heat of Coke plant and Blast Furnace gas)
D. Ductile Iron Pipe plant of 0.3MTPA capacity
A. 1000,000 TPA Blast Furnace:
It is proposed to install a Blast Furnace of 1000,000 TPA capacity in Manoharpur
village Jharkhand.
This furnace will be a modern Blast Furnace equipped with Hot Blast Stoves, Bell
less top, and Pulverized Coal Injection including O2 enrichment.
B. Sinter Plant:
The availability of the calibrated iron ore lumps is becoming scarce; hence it is
proposed to install sintering machines of adequate capacity along with the Blast
furnace.
The advantages with the use of Sinter is that, it improves the productivity of the
Blast Furnace, lowers the coke rate, allows usage of low iron bearing material
and low value coke breeze in the production.
C. Waste Heat Recovery Coke plant and Power Plant (based on waste heat of Coke
plant and Blast Furnace gas):
To cater to the coke requirement of Blast Furnace it is proposed to add Coke
making capacity of 600,000 TPA with Sesa’s technology of Heat Recovery, which
conforms to the most stringent environment norms worldwide.
The proposed power plant will have capacity of 60 MW and will utilize the waste
heat from Coke Ovens and the excess gas available from the proposed 1000,000
TPA Blast furnace.
D. Ductile Iron Plant
To add value to pig iron part of hot metal produced will be converted to ductile
iron pipe having capacity of 300000 TPA.
The Flow sheet showing Blast Furnace and related facilities is given in Figure-3.
FIGURE-3
BLAST FURNACE AND RELATED FACILITIES
Technological considerations and plant facilities:
The Blast Furnace shall operate with sized iron ore, Sinter; self-produced coke,
fluxes, and additives.
The blast furnace shall have the following major units:
A. Raw material storage yard, stock house, fines handling and main blast furnace
charging conveyor
B. Blast furnace proper and cast house
C. Hot blast Stoves and Waste gas chimney
D. Hot blast supply system including hot blast main, expansion joints,
E. Bustle main &tuyere stock assembly
F. Dust catcher and dust discharge equipment.
G. Gas cleaning plant including its water system and sludge tanks and flare stack
system
H. Cast house slag granulation plant with its water system
I. Dry slag pit
J. Water cooling system for Blast Furnace and stove valves.
K. Stock house de-dusting system, ventilation, & air-conditioning system.
L. Ladle repair shop
M. Pig casting machine
N. Instrumentation, automation and process control system
O. Blower house and cold blast supply system
P. Compressor and compressed air piping
Q. Shop electrics & Illumination
/ Ductile iron pipe plant
R. Hoisting and handling facilities
S. Effluent & waste handling
T. Drainage & sewerage
U. Interplant and pipelines for steam, BF gas, compressed air, Oxygen, Oxygen and
Pulverized Coal Injection.
V. BF control room
W. Auxiliary facilities like laboratory, stores etc.
Sinter Plant
Sintering is a process for agglomerating iron ore fines to convert it into lump form
suitable for use in blast furnaces. However sintering has an additional advantage,
that it can recycle all Ferrous bearing waste material generated in the plant.
The use of sinter is also beneficial as it reduces the coke rate and improves the
productivity of blast furnace. However in the current context apart from the cost
saving a sintering plant also has strategic value since it is expected that with the
current growth rate of domestic steel production the availability of lump ore is likely
to be constrained.
Thus the sintering plant would ensure a sustained availability of raw materials for
blast furnace operations.
Iron ore fines cannot be charged into the Blast furnaces since it will reduce the
permeability of the burden material and will not allow the reducing gases to pass
through the charge material inside the furnace. Blast Furnaces need lump feed
(preferably in a close size range) only so as to facilitate easy flow of gases through
the charge material inside the furnace.
So the iron ore fines need to be agglomerated either in the form of Sinter or Pellets
before charging into the Blast furnace.
The main advantages of sintering are:
Lower coke rate due to the saving in the heat requirement in the Blast Furnace since
the calcinations of the fluxes take place in the sintering process outside the Blast
Furnace and better reducibility of the charge material.
Higher productivity due to the improved burden permeability from the reduction in
the height of cohesive zone.
Ability to recycle the iron bearing waste from the plant, e.g., dust catcher fines,
“return ore fines”, and low value coke breeze etc.
Raw material required along with estimated quantity likely source,
marketing area of final products, mode of transport of raw material and
finished product.
Raw material details are given below:
Sr.
No
Raw Material
Requirement
At Sinter
Feed
(90%) in
MT
Source Mode of
Transport
1 Iron ore fines 14,60,000 Own Truck
2 High grade lumps 1,80,000 Mine Truck
3 Lime stone 1,37,220 Jharkhand/Orissa/Chhattisgarh Truck