Techno Economic Feasibility Report of M/s Maithan steel ...

Techno Economic Feasibi l i ty Report of M/s Maithan steel & Power Ltd At

PO: Bonra, P S- Neturia, Dist- Purl ia, W B

1 Global Tech Enviro Experts Pvt. Ltd.




TABLE OF CONTENTS

CHAPTER-1 ......................................................................................................... 5

EXECUTIVE SUMMARY ........................................................................................ 5

CHAPTER-2 ......................................................................................................... 7

INTRODUCTION OF THE PROJECT ...................................................................... 7

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT .................................. 7

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ....................................... 8

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION...................... 8

2.3.1 Domestic Scenario ................................................................................. 10

2.3.2 Global Steel Scenario ........................................................................ 12

2.4 EMPLOYMENT GENERATION DUE TO PROJECT ............................................ 12

2.5 METHODOLOGY OF THE STUDY................................................................. 12

2.6 ENVIRONMENTAL MANAGEMENT PLAN: ..................................................... 14

2.7 LITIGATION/COURT CASE AGAINST THE COMPANY ..................................... 15

2.8 AUTHORIZATION .................................................................................... 15

2.9 ACKNOWLEDGEMENT: ............................................................................. 16

CHAPTER-3 ....................................................................................................... 17

PROCESS DESCRIPTION ................................................................................... 17

3.1 LOCATION OF THE PROJECT ..................................................................... 17

Fig 3.1 Toposheet of Maithan Steel & Power Ltd, Bonra, showing project site ... 18

Fig 3.2 Satellite Imagery of MSPL ................................................................. 19

3.2 DETAILS OF ALTERNATE SITES ................................................................. 19

3.3 SIZE OR MAGNITUDE OF OPERATION ........................................................ 19

3.4 LAYOUT OF THE AREA ............................................................................. 19

3.5 PROCESS DESCRIPTION .......................................................................... 20

3.5.1 DRI KILN ......................................................................................... 20

3.5.2 FERRO ALLOYS: ................................................................................ 21

3.6 PROJECT CONFIGURATION & PRODUCT MIX ............................................... 22

3.7 RAW MATERIAL INVENTORY .................................................................... 23

Table 3.1 Major Annual Raw material inventory ............................................ 23

3.8 WATER REQUIREMENT ............................................................................ 23

Table 3.2 Water Requirement of the project .................................................. 24

3.9 POWER REQUIREMENT ............................................................................ 24

Table 3.3 Power requirement ..................................................................... 24

3.10 SOLID WASTE ........................................................................................ 25




Table 3.4 Solid waste generation and its management .................................. 25

3.11 PROJECT COST& TIME OF COMPLETION ..................................................... 25

Table 3.5 Breakup of the total project Cost .................................................... 25

CHAPTER -4 ...................................................................................................... 26

SITE ANALYSIS ................................................................................................ 26

4.1 CONNECTIVITY ....................................................................................... 26

4.2 LAND FORM, LAND OWNERSHIP ............................................................... 26

Table 4.1: Land Use Pattern after Expansion ................................................ 26

4.3 TOPOGRAPHY ......................................................................................... 26

4.4 LAND USE PATTERN ................................................................................ 26

Table 4.2 Land distribution Pattern of the Buffer Zone ..................................... 27

4.5 EXISTING INFRASTRUCTURE .................................................................... 27

4.6 SOIL CLASSIFICATION: ........................................................................... 27

4.7 CLIMATIC DATA FROM SECONDARY SOURCE .............................................. 27

CHAPTER -5 ...................................................................................................... 28

PLANNING BRIEF ............................................................................................. 28

5.1 PLANNING CONCEPT ............................................................................... 28

5.2 PERIPHERAL DEVELOPMENT PLAN ............................................................. 28

5.3 LAND USE PLANNING .............................................................................. 28

Table 5.1: Land Use Pattern after Modernization & Expansion* ....................... 28

5.4 ASSESSMENT of INFRASTRUCTURE DEMAND .............................................. 29

CHAPTER -6 ...................................................................................................... 30

PROPOSED INFRASTRUCTURE .......................................................................... 30

6.1 INDUSTRIAL AREA DISTRIBUTION ............................................................. 30

6.2 GREENBELT DEVELOPMENT FACILITY ........................................................ 30

6.3 CONNECTIVITY ....................................................................................... 30

6.4 DRINKING WATER MANAGEMENT: ............................................................. 30

6.5 INDUSTRIAL WASTE MANAGEMENT ........................................................... 30

6.5.1 Waste Management ........................................................................... 30

6.5.2 Solid Waste Generation & Management ............................................... 30

6.6 INDUSTRIAL POLLUTION CONTROL ........................................................... 31

6.6.1 Air Pollution Control .......................................................................... 31

Table 6.1: Proposed Air Pollution Control Facilities ........................................ 31

6.6.2 Water Pollution Control ...................................................................... 31

6.7 MAN POWER REQUIREMENT ..................................................................... 31

CHAPTER -7 ...................................................................................................... 32

REHABILITATION & RESETTLEMENT ................................................................ 32




REHABILITATION & RESETTLEMENT .................................................................... 32

CHAPTER -8 ...................................................................................................... 33

PROJECT SCHEDULE ......................................................................................... 33

8.1 IMPLEMENTATION SCHEDULE ................................................................... 33

Table 8.1: Tentative implementation schedule: .............................................. 33

8.2 ESTIMATED PROJECT COST ...................................................................... 34

CHAPTER-9 ....................................................................................................... 35

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)..................................... 35

9.1 FINANCIAL & SOCIAL BENEFITS ............................................................... 35

9.2 SOCIAL INFRASTRUCTURE ....................................................................... 35

9.3 EMPLOYMENT POTENTIAL ........................................................................ 35

9.4 BENEFITS TO THE REGION AND THE COUNTRY ........................................... 35




CHAPTER-1

EXECUTIVE SUMMARY

M/s Maithan Steel & PowerLtd.has its 2x100 TPD coal based DRI Kilns located At/PO-

Bonra, PS- Neturia in Purulia district of WB with latitude:230 37’ 53.85’’ N and

longitude 860 50’ 08.10’’ E with 117m AMSL. The unit is running on CTE, Memo No-

787/2N-2383/2001 and CTO letter No-C 081367, bearing memo No-1348-WPBA/Red

(Prl)/ Cont (82)/02 dated 27.8.2015 and consent has been extended up to 30.11.2017.

The unit is manufacturing sponge Iron.

The location is well connected by road and Rail. The site is only 2.30 km away from the

SH 5 and is about 3.25 km from Madhu Kunda Rly Stn. The nearest town is Asansol,

which is about 21.8 km from the proposed site. Nearest Airport is at Burnpur

The company also proposes to install 2x9 MVA Ferroalloy plants to produce one or all of

Fe-Mn, Si-Mn , Fe-Si and Pig Iron. If only Fe-Mn is produced from both the SAFs, it will

be about 38,000 TPA, only Si-Mn 28,000 TPA ,for only Fe-Si it will be 14,000 TPA and for

pig Iron only 80,000 TPA. If all the three are proportionately produced total production

will be about 40,000 TPA out of which Pig Iron is 20,000; Si-Mn is 7000 Fe-Si is 3500

TPA & Fe-Mn 9500 from both the SAFs.

Fresh water requirement for the expansion project is estimated to be within

1800m3/day. Contaminated used water of plant will be settled, cleaned and reused in

the plant and there will be zero waste water discharge to outside project boundary. More

over rain water will be harvested and used in process, which will help in reducing fresh

water intake from river.

Power requirement for expansion project is estimated to be about 21 MW on full load

which is not the case all the time, and captive power generation from expansion project

will be 20 MW. So no power will be sourced from outside.

Land

The Company has in its possession 9.33 ha of land on which existing project is running

and giving production The proposed expansion units shall be accommodated and will be

suitably integrated with the existing plant units. Thereis no proposal at present for

further acquisition of land for expansion purposes.The proposed expansion will

advantageously utilise the existing infrastructure facilities.The layout also takes into

account the stage wise commissioning of the plant units.The general layout of the plant

shall be developed with requisite provision for landscaping and greenbelts with a view to

avoid adverse impact on the environment.

Pollution Control Features

Following pollution control measures will be taken up for integrated steel project of M/s

Maithan Steel & Power Ltd at Bonra, Neturia

Installation of ABC for dust removal from DRI kilns flue gas. Excess heat removal

from flue gas through West heat boiler




Dust extraction & dedusting bag house at DRI kiln, Raw material Stock house. This

will result in reduction in fugitive dust emission.

Bag filter for SAFs for dust and iron particle removal from fume.

Wastewater settling, cooling and treatmentfor reused/recycled in the process.

In-built noise control features in machineries & equipments like acoustic enclosure

or use of PPE by people working area.

ID fans and high stack for disposal of gases at height.

Manpower

On expansion all the existing infrastructure and man power of existing plant will be

utilized for expansion project also. However there will be additional man power skilled in

new installation will be required. Besides there will be increase in contract labor, security

and canteen personnel. It is estimated that about 450 will be regular employment plus

about indirect staffs.

Project cost

The estimated expansion project is 165 crore. This will be as follows.2.5 % of the total

capital cost will be spent under ESC activities.

Project completion schedule

After getting CTE from SPCB, WB and EC from MOEF & CC tenders will be floated for

purchase, installation and commissioning of equipment and units and earth work

activities will start parallel. It is estimated the completion of project will take 2.5 yrs of

time.




CHAPTER-2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

M/s Maithan Steel & PowerLtd.has its 2x100 TPD coal based DRI Kilns located At/PO-

Bonra, PS- Neturiain Purulia district ofWBwith latitude:230 37’ 53.85’’ Nand longitude

860 50’ 08.10’’ E with 117m AMSL. The unit is running onCTE, Memo No-787/2N-

2383/2001 and CTO letter No-C 081367, bearing memo No-1348-WPBA/Red (Prl)/ Cont

(82)/02 dated 27.8.2015 and consent has been extended up to 30.11.2017. The unit is

manufacturing sponge Iron.

Identification of Project proponent of M/s Maithan Steel &PowerLtdis as follows:

Promotor/Directors

Mr. Madhur Agarwalla, Sri Kaushal Agarwalla and Mr. Sitaram Bagaria are the three

promotors/director of the company.

Mr. Madhur Agarwalla

He is one of the Promotors director of company. His DIN is -00338133. He is aged about

35 years. S/o-Mr. Binod Kumar Agarwalla and permanent resident of Chirkunda,

Dhanbad, Jharkhand. At present he is staying at Flat No.2C, Mangalam,,Abhiripukur

Road, Kolkata-700019.

He is a graduate in Mechanical Engineering & holds MBA degree and having more than

12yrs experience in the field of Ferroalloys, Iron & Steel, Power & Cement and he has

more competencies in plant operation, marketing & brand building, supply chain

management, human resource management, project execution & Corporate

administration.

Mr. Kaushal Agarwalla


33 years. S/o-Mr. Binod Kumar Agarwalla and permanent resident of Chirkunda,

Dhanbad, Jharkhand. At present he is staying at Flat No.2C, Mangalam,,Abhiripukur

Road, Kolkata-700019.

Holds position as Executive Director of the company, having more than 10yrs of

experience in the field of Ferroalloys, Iron & Steel, Power & Cement and he has more

competencies in plant operation, marketing & brand building, supply chain management,

human resource management, project execution & Corporate administration. He holds

the degree of MBA with Engineering.

Mr. Sitaram Bagaria


70 years. S/o-Late LekharajBagaria and permanent resident of 21, S P mukharjee Road,

Murgasol, Asansol, West Bengal.




He is a commerce graduate and has about 44yrs of experience in the industry with the

specialization in financing & leasing. He is the whole time Director of the company and

presently looking after the Marketing & Financial matters of the company.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project is an expansion of existing 2x100 TPD sponge Iron Project running

on NOC from WBSPCB, proposing to setup 3x100 TPD DRI Kilns in two phases, 2x9 MVA

Ferroalloys plant to produce Fe-Mn, Si-Mn & Fe-Si, Pig Iron & 20 MW CPP (10 MW from

WHRBs of DRI kilns and 10 MW from FBC). Besides these facilities the company

proposes 2x20T Iron ore washery to meet the requirement.All the units of expansion

project will be set up on the vacant spaces of existing land of running plant.

The unit will consume Iron ore, Lime stone/dolomite & Coal and produce Sponge Iron

with Dolchar, Ferro Manganese, Silico-Manganese, Ferro-Silicon and Pig Iron. Sponge

Iron will be for sale and dolchar will be utilised.

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION

The sponge iron industry growth has been on rise since 2003-04 positioning India as

global leader in Sponge iron production. This rise is mainly because of growing demand

for steel and scarcity of coking coal for steel production in India and For the 12th FYP it

is expected that sponge iron sector will grow at a CAGR of 10 per cent and a likely

increase of 2 per cent may be seen therein after at a CAGR of 12 per cent till 2020.

The demand of coal will also rise in the same proportions for the sponge iron industry

during the period listed above is a need of 65 million ton in 10 years time. This

translates into an average growth requirement of about 10 million tons per year.

Business as usual (BAU):- In this scenario it is considered that the demand drivers of

sponge iron industry will grow at the same rate i.e. the infrastructure growth will be

registering a CAGR of 7 per cent till 2020. Thus, to meet the rising demand of the

infrastructure sector the sponge iron industry will grow at a CAGR of 10 per cent in lieu

of growing steel demand. Also, the demand of coal thus in turn by the sponge iron

industry will grow at a CAGR of 10 per cent.

Considering Sponge Iron demand in following scenarios:

Rapid infra growth scenario (RIG):- In this scenario it is assumed that the infra

growth for India will be at a CAGR of 8 per cent till 2020. Thus, sponge iron industry

growth and the coal demand by sponge iron industry will follow the same CAGR rate of

12 per cent till 2020.

Slow infra growth scenario (SIG):- In this scenario it is assumed that the infra

growth for India will be at a CAGR of 6 per cent till 2020. Thus, sponge iron industry

growth and the coal demand by sponge iron industry will follow the CAGR rate of 8 per

cent till 2020.

With over 400 units, India is the world‟s largest sponge iron (DRI) producer, boasting an

annual production of about 26-28 mnt against installed capacity of 46-47 mnt. The

Indian sponge iron industry is highly fragmented in terms of production capacities. Top

20 producers contribute about 60- 65% of total production, whereas the rest contribute

35-40% of the production. Sponge iron contributes 25% of India‟s total crude steel




production of 90 mnt. While sponge iron production increased in FY16, it may as well be

the reason for subdued prices in the ongoing fiscal.

Under the above mentioned scenario the demand of coal by sponge iron industry and

growth of sponge iron industry will grow at a same CAGR, as coal consumed in

production of sponge iron of designate quantity is one-fourth of the sponge iron

produced. The projected numbers are showcased in Exhibit 01, wherein the growth of

sponge iron industry and growth in coal consumption is scaled for different listed

scenarios.

Projected supply for coal

The sponge iron industry relies on domestic source as far as meeting coal demand is

concerned. Almost, 98 per cent of the coal required by the sponge iron industry is

sources locally. Earlier, in 2006-07 the share of imports in coal supplies to sponge iron

industry was around 1per cent but in 2016-17 imports has grown to 2 per cent

quantum of the total supplies to sponge iron industry. The chief source of coal supply

to sponge iron industry has been CIL with nearly meeting 85 per cent of the

demand.Most of the sponge iron companies have also been allocated coal blocks but

lately the non-production has become an issue for the sector leading the sponge iron

producer‟s source coal from coal traders.

The sponge iron sector in India faces major challenge of high calorific value domestic

coal availability and more allocations to power and cement sector. The issues likely to

impact coal supply for the sponge iron sector in future given the current scenario can

be listed as under:-

Lack of high calorific value of coal: – The sponge iron manufacturers are facing this as

the biggest challenge as most of the coals reaching sponge iron plants from domestic

sources are usually of low calorific value. This is so because in India high calorific value

coal are available to limited mine source of ECL and MCL and growing demand of

domestic non-coking coal from mainly power sector in lieu of UMMP‟s development in

the states of Jharkhand and Odisha. Although, as of now it is being managed but going

forward it will pose a major challenge for sustained production by sponge iron industry.

CIL eyeing to close down MoU route for coal supplies: – The move is going to lay its

huge impact on sponge iron industry if implemented as for power industry. This will

sponge iron manufacturers struggling to cope with fuel linkage tie-ups with CIL at a

higher cost.

Ferroalloys

Ferro alloys like Ferro Manganese, Ferro Chrome, Silico- manganese and pig iron are

additives whichimpart special quality to the special quality steel. As the production of

steel goes up theneed for various types of ferroalloys also are increasing.

Captive Power plant

The ferroalloy plants are also highly power intensive. The total power demand may

stress the state grid and the plant may suffer interruption of power supply. The company

therefore proposes to install power plants based on waste heat of flue gas generated in




the sponge iron kiln as well by utilizing the solid waste i.e. dolchar generated in DRI

Plant. Power Plant will not only to cater to the power demand of the plant but also will

utilize the wastes produced in the plant.

2.3.1 Domestic Scenario

The Indian steel industry has entered into a new development stage from 2007-

08, riding high on the resurgent economy and rising demand for steel.

Rapid rise in production has resulted in India becoming the 3 rd largest producer

of crude steel in 2015 and the country continues to be the largest producer of

sponge iron or DRI in the world.

As per the report of the Working Group on Steel for the 12th Five Year Plan, there

exist many factors which carry the potential of raising the per capita steel

consumption in the country. These include among others, an estimated

infrastructure investment of nearly a trillion dollars, a projected growth of

manufacturing from current 8% to 11-12%, increase in urban population to 600

million by 2030 from the current level of 400 million, emergence of the rural

market for steel currently consuming around 10 kg per annum buoyed by projects

like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas

Yojana among others.

India produced 88.97 mt , 89.79 mt and 96 mt of crude steel during 2014, 2015 and

2016 respectively. India‟s steel exports grew 150.0 per cent year-on-year to 0.75 MT in

February 2017, while steel imports declined 46 per cent year-on-year to 0.49 MT. Total

consumption of finished steel grew by 3.4 per cent year-on-year to 76.22 MT during April

2016-February 2017.

This was on account of higher output by the major Indian steel companies. The

imposition of Minimum Import Price (MIP) encouraged the producers to increase their

output. Care Ratings said that the consumption of steel, on the other hand, grew by just

3.2% to 73.75 MT during April-December 2016.

The National Steel Policy 2017, released by the government, aims to increase steel

production. Thus, both production and consumption of steel is expected to remain

buoyant in 2017-18, the report said.

Government Initiatives

Some of the other recent government initiatives in this sector are as follows:

The Government of India has approved a joint venture (JV) between MSTC Ltd

and Mahindra Intertrade Ltd, for setting up India's first greenfield auto shredding

and recycling facility, which will aide in saving of foreign currency, as a result of

import substitution of scrap.

Union Minister of Steel, Mines, Labor and Employment, has launched the National

Mineral Exploration Policy (NMEP), which will help to adopt comprehensive

exploration of non-fuel and non-coal mineral resources that would give a major

boost to the economy.

Metal Scrap Trade Corporation (MSTC) Limited and the Ministry of Steel have

jointly launched an e-platform called 'MSTC Metal Mandi' under the 'Digital India'

initiative, which will facilitate sale of finished and semi-finished steel products.

The Parliament of India has cleared amendments to the Mines and Minerals

Development and Regulation (MMDR) Act, which will enable companies to transfer

captive mines leases similar to mines won through an auction, and which is




expected to lead to increased Mergers and Acquisitions (M&A) of steel and

cement companies.

The Ministry of Steel has announced to invest in modernization and expansion of

steel plants of Steel Authority of India Limited (SAIL) and Rashtriya Ispat Nigam

Limited (RINL) in various states to enhance the crude steel production capacity in

the current phase from 12.8 MTPA to 21.4 MTPA and from 3.0 MTPA to 6.3 MTPA

respectively.

The Minister of Steel & Mineshas reiterated commitment of Central Government

to support the steel industry to reach a production target of 300 Million Tonne Per

Annum (MTPA) in 2025.

The Ministry of Steel is facilitating setting up of an industry driven Steel Research

and Technology Mission of India (SRTMI) in association with the public and

private sector steel companies to spearhead research and development activities

in the iron and steel industry at an initial corpus of Rs 200 crore (US$ 30 million).

The Central Board of Excise and Customs (CBEC) has issued a notification

announcing zero export duty on iron ore pellets, which will help the domestic

industry to become more competitive in the international market.

Government has planned Special Purpose Vehicles (SPVs) with four iron ore rich

states i.e., Karnataka, Jharkhand, Orissa, and Chhattisgarh to set up plants

having capacity between 3 to 6 MTPA.

SAIL plans to invest US$ 23.8 billion for increasing its production to 50 MTPA by

2025. SAIL is currently expanding its capacity from 13 MTPA to 23 MTPA, at an

investment of US$ 9.6 billion.

Some of the major investments in the Indian steel industry are as follows:

Tata Steel has signed an agreement to purchase a majority 51 per cent stake in

Creative Port Development (CPDPL), which has a concession agreement with the

Odisha government to develop a 10 million-tonnes-per-annum (MTPA)

Subarnarekha port at Chamukh village in Balasore district of Odisha.

Tidfore Heavy Equipment Group, the China-based infrastructure giant, is looking

to enter the Indian market by signing an investment agreement worth US$ 150

million with Uttam Galva Metallics, to expand its Wardha unit along with South

Korean steel major Posco.

ArcelorMittal SA is looking to set up a joint venture (JV) factory in India with

state-owned Steel Authority of India Ltd (SAIL), to manufacture high-end steel

products which could be used in defence and satellite industries.

JSW Group plans to invest around Rs 10,000 crore (US$ 1.5 billion) at Salboni in

West Bengal to set up 1,320 Megawatt (MW) coal-based power plant, 4.8 million

tonne cement plant and paints factory over a period of next five to seven years.

National Mineral Development Corporation (NMDC) has planned to invest Rs

40,000 crore (US$ 6 billion) in the next eight years to achieve mining capacity of

75 Million Tonnes Per Annum (MTPA) by FY2018-19 and 100 MTPA by FY2021-22,

compared to 48 MTPA current capacity.

Posco Korea, the multinational Korean steel company, has signed an agreement

with Shree Uttam Steel and Power (part of Uttam Galva Group) to set up a steel

plant at Satarda in Maharashtra.

ArcelorMittal, world‟s leading steel maker, has agreed a joint venture with Steel

Authority of India Ltd (SAIL) to set up an automotive steel manufacturing facility

in India.

Iran has evinced interest in strengthening ties with India in the steel and mines

sector, said ambassador of the Islamic Republic of Iran, Mr Gholamreza Ansari in

his conversation with Minister of Steel and Mines, Mr Narendra Singh Tomar.




Public sector mining giant NMDC Ltd will set up a greenfield 3-million tonne per

annum steel mill in Karnataka jointly with the state government at an estimated

investment of Rs 18,000 crore (US$ 2.7 billion).

JSW Steel has announced to add capacity to make its plant in Karnataka the

largest at 20 MT by 2022.

2.3.2 Global Steel Scenario

Steel production in the world is dominated by China followed by Japan. In 2016, the

world crude steel production reached 1628 million tonnes (mt) and showed a growth of

0.8% over 2015.

China remained world‟s largest crude steel producer in 2016 (808 mt)

followed by Japan (105 mt), India (96 mt) and the USA (79 mt).

World Steel Association has projected Indian steel demand to grow by

5.4% in 2016 and by 5.7% in 2017 while globally, steel demand has been

projected to grow by 0.2% in 2016 and by 0.5% in 2017. Chinese steel

use is projected to decline in both these years - by 1% in 2016 and by 2%

in 2017.

Per capita finished steel consumption in 2015 is placed at 208 kg for world

and 489 kg for China by World Steel Association

Steel is a key driver of the world's economy. The industry directly employs more than

two million people worldwide, with a further two million contractors and four million

people in supporting industries. According to the World Steel Dynamics (WSD)

organization, global steel production (as also demand for it or consumption) will grow at

an annual average compounded rate of growth of 1.28 per cent during 2015-2025 to

reach only 1873 million tonnes by 2025. Other well known forecasts, this figure was to

be achieved by 2020.

[Source: Ministry of Steel]

2.4 EMPLOYMENT GENERATION DUE TO PROJECT

The project will plan to give more employment opportunities to skilled & unskilled

workers by Direct & Indirect Employment. Some contractual workers are to be employed

to manage canteen, security and housekeeping during constructionas well as operation

phase.

2.5 METHODOLOGY OF THE STUDY

Environmental issues must be addressed during project planning before the actual

project is executed. In the same way as economic, financial, institutional, or technical

analysis, Environmental Impact Assessment (EIA) is an integral part of the project. EIA

is the process in which environmental factors are integrated into project planning and

decision-making so as to achieve ecologically sustainable development. Best-practice EIA

identifies environmental risks, lessens conflicts by promoting community participation,

minimizes adverse environmental effects, informs decision makers, and helps lay the

base for environmentally-sound projects. Benefits of integrating EIA have been observed

in all stages of a project, from exploration and planning, through construction,

operations, decommissioning, and beyond site closure.

The process of EIA usually consists of the following stages:

Screening

Scoping




Baseline Study

Environmental Impact Identification, Prediction and Assessment.

Environmental Management Plan

Decision making relative to the proposed action.

Study Documentation

Screening:Assessment the need for an EIA. Whether there is any possibility of

significant stress or shock on the supportive and assimilative capacity of the surrounding

environment.

Scoping: Identification of issues and impacts to be considered in the EIA study

Baseline Study: Conducting necessary field studies for generation baseline

data to define the pre-project environment. The baseline study shall be done

as per the approved TOR conditions given by MoEF.

For Impact Prediction and Assessment, the details of most of the baseline

data is collected during the study period of 03 months to be undertaken from

December to February. There is elaborate data collection with respect to

geology, geomorphology, hydrogeology, drainage pattern; land use pattern

etc. and the subsequent satellite map will be prepared with a 10 km radius

buffer zone.

Details of the micro-meteorological data is collected with respect to hourly

wind speed & wind direction, humidity, temperature, cloud cover, rainfall

data etc. The corresponding frequency distribution of wind behavior with wind

rose diagram is prepared. This will form the meteorological data input to Air

Quality Prediction Model.

The existing ground level concentration of Particulate Matter (PM10 and

PM2.5), Sulphur Dioxide (SO2), Nitrogen Oxide (NOx) and Carbon Monoxide

(CO) are analyzed during the study period in the core zone as well as buffer

zone including at least one in the down wind direction. The air sampling

location and others will be chosen studying the wind rose and using standard

procedures.

Surface water & ground water analysis will be done in core zone and buffer

zone as per the parameters in relevant standard.

The soil testing will be done in core and buffer zone.

The average noise quality will be monitored both in day and night.

All the procedure of collection of sample, frequency of collection, analysis

procedures etc will be done as per CPCB norms.

Details of the ecological survey will be taken up with respect to flora and

fauna including avifauna and aquatic fauna with an emphasis on endangered

species in the core zone as well as in the buffer zone.

Socio-economic data of the region is collected with respect to literacy,

economic status, occupation, living standard, health etc. of the local

population. There are detailed data collections about infrastructure facilities

like transportation, communication, education health etc.




Detailed survey of the 15 Km. region around the project is conducted to find

out any location of sensitive areas like wild life sanctuaries, historical

&archaeological sites, defence installations etc.

Environmental Impact Identification, Prediction and Assessment

Different environmental impact areas are identified and expressed in matrix

form.

Qualitative prediction of impact is done with respect to land use, ecology and

noise and socio-economic.

Details of water and waste water inventory are prepared to find out their

impact on the environment.

Solid wastes Inventory (both hazardous and non-hazardous in nature) is

done to predict and assess their impact on environment.

Detailed information about stacks with respect to height, diameter, flue gas,

temperature, velocity and flow and the inter stack distances is provided.

Emission inventory with respect to PM, SO2, NOx is calculated.

Micro-meteorological data along with stack and emission inventory data is

input to the air quality prediction modelling software.

Quantitative prediction of air pollutants in the form of incremental ground

level concentration (GLC) is done by Air Quality Prediction Modelling Software

(ISC-AEROMOD-ISCST-3) developed by USEPA.

Maximum resultant GLC is calculated at locations taking into consideration of

background GLC and predominant wind direction.

Subjective impact assessment using matrix method is carried out to calculate

the total impact score without mitigation measures.

This has been done as per the approved TOR conditions given by MoEF.

2.6 ENVIRONMENTAL MANAGEMENT PLAN:

Following environmental management plan is proposed to reduce the predicted adverse

impacts and to make provision to compensate for any residual adverse impact

Air Pollution control Equipments (APE) to be setup.

Disposal management of the solid waste and effluents generated from

these APC equipments will be chalked out.

Fugitive dust emission from the different storage & transfer point and haul

road emissions and their detailed control aspects shall be covered.

Considering water as important and valuable utility, company will formulate

a water management plan for minimum use of the fresh water.

Waste water management dealing with treatment methodologies and

recycling/reuse of treated waste will be prepared.

Storage of storm water in the monsoon in water harvesting ponds and the

use of the same water in lean season will be planned.

Zero discharge norms with a comprehensive water and waste water

management plan will be evaluated.




A detail of the solid waste inventory, its characterization and their usage

potentiality will be discussed. Solid waste plant process and reuse of the

solid waste for different purposes will be examined.

Noise control devices with different equipments at design stage, protective

measures at work zone sites and supply of protective gears to affected

personnel will given in detail.

Realizing the need for the greenbelt cover as a very good sink for pollutants

and the aesthetical aspects the company will go for a comprehensive

plantation program as per MoEF Norms.

Detailed plan for greenbelt development with respect to allocation of area,

fund allocation, selection of the species and maintenance plan will be

covered. Peripheral development plan that includes development in

infrastructure, health education and socio-cultural aspects will be

emphasized.

Details of the EMP cell with respect to monitoring laboratory, technical man

power and fund allocation is discussed. Details of monitoring program with

respect to pollutant parameters. Monitoring scheduled and reporting as per

statutory requirement will be planned.

Safety and disaster management plan with onsite emergency plan to deal

with the unforeseen accidents will be covered.

Beneficial aspects of project with respect to direct and indirect employment,

business opportunities and peripheral development will be discussed.

Trickledown effect of all the project benefits to affected local population will

be analyzed.

Taking in to consideration of the environmental degradations due to the

project implementation and the consequent environmental management

plan followed by the post project benefits, the subjective assessment with a

Total Impact Score will be analyzed to draw a summary conclusion.

2.7 LITIGATION/COURT CASE AGAINST THE COMPANY

No, litigation or court cases are pending against the project and/or no direction/order

has been passed by any court of law against the project.

2.8 AUTHORIZATION

M/s. Maithan Steel & Power Ltd, Bonra has entrusted M/S Global Tech Enviro Experts

Pvt. Ltd., Bhubaneswar for the preparation of TEFR for their expansion project. In

accordance to the scope of work, M/s. GTEEPL team has visited the project site to take

general view and will again visit the project site and collect base line data like Air, Water,

Soil & Noise from the project site and availability of infrastructure facilities like raw

materials, water, power and transportation facilities in detail.

The team will also make socio-economic study of 10km buffer zone of the project site to

know existing status of the locality and flora & fauna.




2.9 ACKNOWLEDGEMENT:

M/s GLOBAL TECH ENVIRO EXPERTS PVT LTD, Bhubaneswar expresses its deep

gratitude to management M/s. MaithanSteel & Power Ltd forthe assignment entrusted to

them.




CHAPTER-3

PROCESS DESCRIPTION

3.1 LOCATION OF THE PROJECT

M/s Maithan Steel & Power Ltd. Is located at& P.O:Bonra, in Purlia district of West-Bengal

with latitude 230 37’ 53.85’’ N and longitude 860 50’ 08.10’’ E with 117m AMSL.




Project site

Fig 3.1 Toposheet of Maithan Steel & Power Ltd, Bonra, showing project

site




Fig 3.2 Satellite Imagery of MSPL

3.2 DETAILS OF ALTERNATE SITES

M/s Maithan Steel & Power Ltd, at- Bonra, Neturia is running its 2x100 TPD sponge Iron

unit on a land of 23.06 Ac (9.33ha) and havingvacant space for accommodation of

proposed expansion. The site is also full filling the requirements for a steel unit, hence

no alternate site has been considered.

3.3 SIZE OR MAGNITUDE OF OPERATION

M/s MSPL in Purlia district of WB is running its 2x100 TPD DRI Kilns and proposing its

expansion by installing 3x100 TPD DRI Kilns in two phases based on coal. So that total

sponge Iron production from 5x100 TPD DRI kilns will be about 1,60,000 TPA.

The company also proposes to install 2x9 MVA Ferroalloy plants to produce one or all of

Fe-Mn, Si-Mn ,Fe-Si and Pig Iron. If only Fe-Mn is produced from both the SAFs, it will be

about 38,000 TPA, only Si-Mn 28,000 TPA ,for only Fe-Si it will be 14,000 TPA and for

pig Iron only 80,000 TPA. If all the three are proportionately produced total production

will be about 40,000 TPA out of which Pig Iron is 20,000; Si-Mn is 7000 Fe-Si is 3500

TPA & Fe-Mn 9500 from both the SAFs.

3.4 LAYOUT OF THE AREA




3.5 PROCESS DESCRIPTION

The process of sponge Iron production will be through Coal based SL/RN DRI process

Technology and Ferroalloy production through semi-closed Soderberg submersed Arc

Furnace.

3.5.1 DRI KILN

Sponge iron is the metallic form of iron produced from reduction of iron oxide below the

fusion temperature of iron ore (1535 ◦C) by utilizing hydrocarbon gases or carbonaceous

fuels as coal. The reduced product having high degree of metallization exhibits a

„honeycomb structure‟, due to which it is named as sponge iron. As the iron ore is in

direct contact with the reducing agent throughout the reduction process, it is often

termed as direct reduced iron (DRI).

Sponge iron, also known as "Direct Reduced Iron" (DRI) has emerged as prime feed

stock which replace steel scrap in IF as well as in other steel-making processes. It is the

resulting product (with a metallization degree > 82%) of solid state reduction of iron

ores or agglomerates (generally of high grade), the principal constituents of which are

metallic iron, residual iron oxides, carbon and impurities such as phosphorus, sulphur

and gangue (principally silica and alumina)..Direct reduction processes available can be

broadly grouped under two categories based on the type of reductant used. These are:

Solid based processes&Gas based processes

Solid based processes

Customized or Indigenous Process:

In India, the standard DRI processes are modified in a minor way and thereafter referred

to as customized / indigenous technology. Only trivial changes in terms of the feed ratio,




length and the diameter of the kiln are made in the name of customized technology.

These customized technologies are dominating the coal based sponge iron process in

India.

In India, the coal based DRI production process employs a rotary kiln as the main

reactor wherein the process of reduction of the iron oxide is carried out with coal as

reductant. Refractory lining of about 150-200 mm thickness is given inside the kiln to

protect the shell. The kiln has a general slope of 2.5 - 3% down towards the discharge

end. There is air blowers mounted on the kiln shell having dampers to provide required

air for combustion at different heating zones.

Sized iron ore and coal in required proportion are fed in to the kiln with the help of the

weigh feeders at the feed end. Due to the rotational motion of the kiln and due to the

slope provided, the charge moves forward to the discharge end. Thermocouples are

mounted on the kiln to measure and control the temperature of the different heating

zones. Fine coal is also injected through the discharge end of the kiln with the help of the

coal injector machines & lobe compressor, to meet the additional carbon and volatile

matter requirement of the reaction. Kiln discharge material which is a mixture of sponge

iron and char (mixture of unreduced iron, uncalcinated limestone, gangue and semi

burnt coal) is taken to a rotary cooler. Water is sprayed on the cooler shell to indirectly

cool the kiln discharge mix to about 120°C. The cooler also has a slope of about 2.5%.

The cooler discharge falls onto a hopper and taken through conveyors for screening of

fines and coarse materials. After separating the -3 mm and +3 mm sizes in the product

screen, the cooler discharge mix is subjected to magnetic separation where sponge iron

is separated from dolchar.

M/s MSPL is proposing to sale sponge Iron and utilise dolchar in FBC to generate steam

and there by power.

3.5.2 FERRO ALLOYS:

Ferroalloys have tremendous demand in steel industries for production of value added

steel products. So M/s Maithan Steel & Power Ltd, at Bonra, Raturia proposes to set up

2x9 MVA ferroalloy plants to manufacture Fe-Mn, Fe-Si, Si-Mn and pig iron, any or all the

products as per the demand of market. There will be flexibility of products and

accordingly production capacity, but configuration will be 2x9 MVA SAF.

Ferro Manganese

High carbon Ferro-manganese is commercially produced by carbothermic reduction of

Manganese ores, primarily in electric submerged arc furnaces (SAF). The produced metal

typically contains around 78% Mn, 7% Carbon and around 40% MnO (high MnO slag

practice). An increasing part of the metal is refined to medium or low carbon

manganese. Electric furnaces used in the production of manganese alloys are generally

circular and have three electrodes, each connected to a separate electrical phase. The

electrodes are submerged in the burden & the electric current runs through the area

below the electrode tip where electrical energy is converted to heat. Produced slag &

metal may be

tapped simultaneously from the sample tap-hole or separately in different slag and metal

tap holes arranged at a vertical distance of 0.5-1m.

Coke is the common source of carbon for the ore reduction

Ferro-Silicon




Silicon is a metalloid and a semiconductor.Ferro-silicon is made in submerged arc

Furnace provided with three-phase transformers. It is generally, Semi- Closed-type.

Physico-chemical Conditions of the Process:

A typical reaction producing ferro-silicon is shown below:

Fe2O3 + 2SiO2 + 7C= 2FeSi + 7 CO

During the course of the reaction of silicon reduction is determined by the applied

pressure of carbon monoxide.

Ferro-silicon is made in submerged arc Semi- Closed-type stationary or tilting furnaces

used for manufacturing ferro alloys.The physical state of the charge is of prime

importance for successful operation of a furnace.

The charge materials must have constant moisture content and lumps of coke breeze

and

quartzite should have only slightly varying size. The process of making Ferro-silicon

produces little slag and so is called slag less process. A little bit slag is tapped together

with the metal through the same tap hole.

A typical reaction producing ferro-silicon is shown below:

Fe2O3 + 2SiO2 + 7C = 2FeSi + 7 CO

During the course of the reaction of silicon reduction is determined by the applied

pressure of carbon monoxide.

Pig Iron

The modern trend is to manufacture Pig iron in submerged Arc furnace usually meant for

ferroalloy production against usual costly Blast furnace.

Iron ore sinter will be produced using Iron Ore fines, mill scale and Coal/coke fines. One

ton of Sinter will require 0.9T of Iron ore fines, 0.2T mill scale and 0.1T Coal/Coke fines.

This sinter will be charged with lime and coke/Coal to semi closed SAF. This molten

metal will be casted and cooled down to pig Iron slabs.

3.6 PROJECT CONFIGURATION & PRODUCT MIX

Facilities Existing

configuration

Proposed Ph-I

Configuration

Proposed

Ph-II

configuration

Final

configuration

After

expansion

Final

Capacity

In TPA

DRI Kilns 2x100 TPD 2x100 TPD 1x100 TPD 5x100 TPD 1,60,000

Power

(DRI

WHRB)

Nil 8 MW(from

4x100 TPD)

2 MW 10 MW 10 MW

Power

(AFBC)

Nil 10 MW Nil 10 MW 10 MW

Ferro

Alloys

Plant

Nil 1x9 MVA 1x9 MVA 2x9 MVA 40,000

(Fe-Mn, Si-

Mn, Fe-Si &

PigIron

combined)

Iron Ore

Sinter

Nil 1x250 TPD Nil 1x250 TPD As per

requirement




Plant

Iron Ore

Washery

Nil 1x20 TPH 1x20 TPH 2x20 TPH 2,40,000

From 2x9 MVA Ferro Alloy plant any one, two or all the three bulk alloys or Pig Iron has

been proposed to be produced. In case of single product from 2x9 MVA SAFs, following

will be the production capacity.

Only Fe-Mn 38,000 TPA

Only Si-Mn 28,000 TPA

Only Fe-Si 14,000 TPA or

Only Pig Iron 80,000 TPA

With due weightage to all the three products Fe-Mn 9,500 TPA; Si-Mn 7,000TPA; Fe-Si

3,500 TPA & Pig Iron 20,000 has been taken for estimation of Raw material.

3.7 RAW MATERIAL INVENTORY

Table 3.1 Major Annual Raw material inventory

Sl. No Material Quantity in TPA Source Mode of

transport

1 Hematite Iron ore 2,56,000 Barbil Rail/ Road

2 DRI grade coal 1,92,000 Asansol Rail/ Road

3 Boiler grade coal 65,000 Dhanbad Rail/ Road

4 Lime stone/Dolomite

(DRI & SAF)

9,000 Local Rail/ Road

5 Mn Ore

(Fe-Mn & Si-Mn)

36,000 Import Ship

6 Quartzite 10,000 Local Road

7 LAMCoke for ferroalloys 19,000 Local, Import

from NE , India

Rail/Road

8 Fine Iron ore for sinter 32,000 Barbil

Basis of Coal estimation for FBC has been done assuming dolchar calorific value 1800

kcal/kg and that of boiler coal 3200kcal/kg, which may vary.

3.8 WATER REQUIREMENT

Make up water requirement

Waste water generated from process will be given primary and secondary treatment and

will be reused in the process. Effort to be made to minimise fresh water consumption.




Domestic waste water will be taken to soak pit. Rain water harvesting, storing and use

has been proposed. The fresh water consumption has been estimated as follows.

Table 3.2 Water Requirement of the project

Facility Makeup water consumption in m3/day

5x100 TPD DRI kiln & Rotary coolers 50

2x9 MVA ferroalloy plant 180

20 MW power plant 1200

2x20 TPH Iron ore washery 300

Domestic & miscellaneous use 70

Total 1800

A part of waste water will be used in green belt and dust suppression. No contaminated

water will be discharged out of project boundary, in other words “Zero discharge” norm

to be followed.

At present the unit is using ground water for its existing plant with due permission from

Geological subdivision, Belguma, Purulia and has applied to Central water commission to

draw water from Disergarh Ghat & Chinakuri Ghat of nearby river.

3.9 POWER REQUIREMENT

Table 3.3 Power requirement

Facility Power requirement in MW

1x500 TPD DRI kilns 1.7

2x9 MVA SAF 14.5

20 MW CPP internal

consumption

2.0

2x20 TPH Iron ore washery 1.4

1x250 TPD I/O Sinter Plant 1.0

A/c and domestic use 0.4

Total 21.0

Power demand on full load plant running has been estimated to be 21 MW. Captive

power generation is estimated to be 20 MW (WHRB 10 MW & FBC 10 MW), therefore the

unit after expansion will be self-sufficient in power consumption. However all power

saving measures shall be taken to reduce power consumption, which are as follows.

Variable Frequency drive for ID fans

Capacitor bank to improve Power factor

LED lights in control room and working areas

Solar light for street lighting etc.

At present the unit is drawing power from DVC with revised contract demand since

1.7.2016.




3.10 SOLID WASTE

Table 3.4 Solid waste generation and its management

Solid waste Quantity in TPA Utilization

Dolchar 24,000 Use in FBC along with fresh coal support

DRI Fly ash 67,000 To be given free of cost to Brick

manufacturers & cement plants

CPP Fly ash 26,000 To be given free of cost to Brick

manufacturers & cement plants

CPP bottom Ash 17,000 To be given for Slag cement plant/ Land

fill

Fe-Mn Slag 12,700 To be used as raw material for Si-Mn

production

Si-Mn Slag 7,000 To be sold to cement plant for production

of Alkali activated cement

Fe-Si slag Negligible It is a slag less process

Pig Iron Slag 12,000 To be sold to cement Plant

3.11 PROJECT COST& TIME OF COMPLETION

Estimated project cost will include cost of Engineering consultation, Equipment and

errection cost, contingency and working capital. As total land is in possession and

levelled, cost on land will be minimum.

Estimated project cost for the expansion project is 165 crores and project completion

schedule is 2.5 years after getting EC.

Table 3.5 Breakup of the total project Cost

SL. NO ITEM COST IN LAKHS

1 Land & Site development & Infrastructure 150.50

2 Civil & Structural Works 437.00

3 Plant machineries and Equipments 15,400.00

4 Other Fixed Assets 100.00

5 ESC Cost 412.50

Total Project Cost 16,500.00




CHAPTER -4

SITE ANALYSIS

4.1 CONNECTIVITY

M/s MSPL has its existing Steel Plant at Bonra, Neturia, in Purulia district of West

Bengal.The Latitude of the place is 230 37’ 53.85’’ Nand longitude 860 50’ 08.10’’ E

with 117m AMSL.


SH 5and is about 3.25 km from Madhu Kunda Rly Stn. The nearest town is Asansol,

which is about 21.8 km from the proposed site. Nearest Airport is at Burnpur.

4.2 LAND FORM, LAND OWNERSHIP

The total land available for the proposed project is about 9.33 hectares. The total land

has been acquired.

Table 4.1: Land Use Pattern after Expansion

Sl.No. Different Units Area in

ha.

1 Facilities 4.10

2 Raw Material Storage 0.33

3 Water Facility 0.26

4 Rain water harvesting 0.5

5 Solid Waste disposal 0.5

6 Internal roads & others 0.57

7 Green belt 3.07

Total 9.33

4.3 TOPOGRAPHY

Geographically, the district Purulia is not a compact unit and consists of widely,

dissimilar tracts of expansive and fairly open country, dotted with isolated peaks,

inaccessible forests, river valley and mountainous terrain. Broadly it is an undulating

table-land of different elevations broken up by rugged hill ranges and cut off by

torrential hill streams and the river Damodar and Barkar. The general slope of the

district is from north to south. There is an open well-cultivated plain country land along

the valley of the Damodar River particularly in the south direction. A part of the northern

boundary runs through the centre of the Panchet reservoir whose water is shared by

Dhanbad and Purulia district.

4.4 LAND USE PATTERN

The project area is present at Bonra, Neturia in Purulia district of West Bengal. It is also

noted that the core zone i.e. the project boundary or the battery limit does not belong to

part of any National Park, wild life sanctuary or Natural/ Biosphere reserve. It also does

not contain any features of archaeological/ historical and cultural/aesthetic importance.




Table 4.2 Land distribution Pattern of the Buffer Zone

Sl No. LULC Features

Area in Sq.

Km.

Area in

Percentage

1 Reserved Forest 16.135 5.13%

2 Protected Forest 14.71 4.68%

3 Plantation 1.48 0.47%

4 Open scrub 13.37 4.25%

5 Reservoir 10.81 3.44%

6 River 8.69 2.77%

7 Settlement 40.24 12.81%

8 Stony waste 1.23 0.39%

9 Tank / Ponds 4.62 1.47%

10 Dry Water bodies 4.85 1.54%

11 Cropland 198.15 63.05%

Total 314.285 100.00%

4.5 EXISTING INFRASTRUCTURE

The project area is present at Bonra, Neturia in Purulia district of West Bengal. The

location is well connected by road and Rail. The site is only 2.30 km away from the SH 5

and is about 3.25 km from Madhu Kunda Rly Stn. The nearest town is Asansol, which is

about 21.8 km from the proposed site. The nearest Airport Burnpur Airport is located at

about 14.25 km away.

4.6 SOIL CLASSIFICATION:

The soils of the study area are predominantly red laterite or alluvial. Due to clayey

nature of the soil, the permeability is low and thus poor in fertility. Alluvial soil is very

fertile and mainly found in the catchments area of river Damodar. The cultivable soils are

spread over the maximum part of the study area

4.7 CLIMATIC DATA FROM SECONDARY SOURCE

The district experiences a warm temperate rainy climate with mild. The cold season

starts from about the middle of November and continues till the end of February. March

to May is dry summer intervened by tropical cyclones and storms. June to September is

wet summer while October and November is autumn.

Secondary information on meteorological conditions has been collected from the nearest

IMD station at Purulia and IMD Book (1970-2000). Predominant wind direction is SW.




CHAPTER -5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The plant is an integrated steel plant having semi-mechanized operation. It is a labor

intensive project. However, depending on the production schedule, there will be

additional technical labor engaged for operation.

The raw materials shall be transported through covered trucks by road up to the nearest

siding for further transportation by rail. And the finished products will be transported by

both rail and road. The transportation load will not add much to the existing load on the

said road system.

Appropriate plantation program shall be undertaken along with the developmental

program to at least cover the boundary areas with thick and tall plants for containment

of the air borne pollutants within the premises, which is duly reflected in the land use

plan.

There will not be any further infrastructural development other than needed for the

commissioning of the total project component machineries. This expansion-cum-

modification shall utilize the existing infrastructural facilities for all purposes.

5.2 PERIPHERAL DEVELOPMENT PLAN

M/s MSPL will make sincere efforts to improve the socio-economic status of the local

habitants. A welfare scheme will be prepared by the company for the socio economic

development of the area. The scheme will envisage promotion of education in the

adjoining villages by giving aid to the local schools, providing drinking water facility and

organizing health check up programs. Local people will be given free seedlings to

develop greeneries all around. The progress of the scheme will be reviewed periodically

and further action will be taken as deeming fit.

5.3 LAND USE PLANNING

The total land of 9.33 ha is available for the project and its expansion will be carried out

within the existing plant.The detailed breakup of the land is given in the following table:

Table 5.1: Land Use Pattern after Modernization & Expansion*

Sl.No. Different Units Area in

ha.

1 Facilities 4.10

2 Raw Material Storage 0.33

3 Water Facility 0.26

4 Rain water harvesting 0.5

5 Solid Waste disposal 0.5

6 Internal roads & others 0.57

7 Green belt 3.07

Total 9.33




5.4 ASSESSMENT of INFRASTRUCTURE DEMAND

The proposed expansion is project will put negligible amount of load on existing

infrastructure in terms of physical and social. So, demand for additional infrastructure is

not anticipated.




CHAPTER -6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA DISTRIBUTION

Proposed project will be planned in the existing plant premises. So, the area has already

been demarked as an industrial area. The expansion project will be accommodated

within the existing premises of 9.33 hectares of land.

6.2 GREENBELT DEVELOPMENT FACILITY

In order to combat the air pollution, noise pollution and also to improve the aesthetic,

the company proposes to develop greenbelt, landscaping and avenue plantation. 33% of

the total area i.e. about 3.07 ha of land will be demarcated for green belt purpose.

6.3 CONNECTIVITY

M/s MSPL has its existing Steel Plant at Bonra, Neturia, in Purulia district of West

Bengal.The Latitude of the place is 230 37’ 53.85’’ Nand longitude 860 50’ 08.10’’ E

with 117m AMSL.


SH 5 and is about 3.25 km from Madhu Kunda Rly Stn. The nearest town is Asansol,

which is about 21.8 km from the proposed site. Nearest Airport is at Burnpur.

6.4 DRINKING WATER MANAGEMENT:

Around 70 KLD of water will be used for drinking purposes and sanitation purposes. The

required water will be sourced from

6.5 INDUSTRIAL WASTE MANAGEMENT

6.5.1 Waste Management

The wastes which will be generated from the process are some used oil and sludge and

slag from Induction Furnace. The induction furnace slag being equivalent to river sand

can be used as land filling. The hazardous waste will be sold to recyclers and dealers.

The waste water from canteen and office toilets will be sent to a STP and after treatment

the sludge will be used as manure in green belt.Canteen waste water will be treated in a

separate ETP consisting of O & G trap, settling tank, anaerobic treatment system &

gravity sand filter. Sewage from toilets will be treated in STP and discharged to green

belt area.

6.5.2 Solid Waste Generation & Management

Solid waste Quantity in TPA Utilization

Dolchar 24,000 Use in FBC along with fresh coal support

DRI Fly ash 67,000 To be given free of cost to Brick manufacturers

& cement plants

CPP Fly ash 26,000 To be given free of cost to Brick manufacturers

& cement plants

CPP bottom Ash 17,000 To be given for Slag cement plant/ Land fill




Fe-Mn Slag 12,700 To be used as raw material for Si-Mn

production

Si-Mn Slag 7,000 To be sold to cement plant for production of

Alkali activated cement

Fe-Si slag Negligible It is a slag less process

Pig Iron Slag 16,000 To be sold to cement Plant

6.6 INDUSTRIAL POLLUTION CONTROL

6.6.1 Air Pollution Control

It is envisaged to install state of the art air pollution control measures in the proposed

project, as given below.

Table 6.1: Proposed Air Pollution Control Facilities

Sl No Plant/ Area Proposed Pollution Control Measures

1 Raw Material Handling

Raw Material Handling, Raw

Material Processing

Transfer Points, Junction

Houses

- Water sprinkling will be provided at the

transfer points of material at RMHP.

- Bag filter

2 SAF - Bag Filter

3 DRI - ESP

4 CPP - ESP

6.6.2 Water Pollution Control

The waste water from canteen and office toilets will be sent to a soak pit.Canteen waste

water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic

treatment system & gravity sand filter. Sewage from toilets will be treated in STP and

discharged to green belt.

6.7 MAN POWER REQUIREMENT

SL. NO. SHIFT PERIOD AVERAGE

EMPLOYMENT/DAY

1. A 0600-1400 Hrs 100

2. B 1400-2200 Hrs 100

3. C 2200-0600 Hrs 100

4. R - 100

5. G 0900-1800 Hrs

(Lunch Break: 1300-1400 Hrs)

50

Total 450

Depending on requirements employees are called in different shifts and few employees

are called on duty in national/ festival holidays and off days. The licensed capacity of the

unit is 450.




CHAPTER -7

REHABILITATION & RESETTLEMENT

REHABILITATION & RESETTLEMENT

The proposed expansion units will be implemented in the existing plant premises. The

existing lands were already derived as industrial land. As settlement will not be affected

so, no R&R facility is anticipated.




CHAPTER -8

PROJECT SCHEDULE

8.1 IMPLEMENTATION SCHEDULE

Time schedule for completion of various activities is given below in Table 8.1. The zero

date will commence after getting EC and consent to establish from SPCB.

Table 8.1: Tentative implementation schedule:

Sl.

No.

Activities Duration

1 Engineering

Concept Design 15 days

Basic Engineering 30 days

Detailed Engineering 150days

2 Civil Work

Land development 215 days

Finalization of layout & drainage 90 days

Construction of plant & auxiliary facilities 300days

3 Statutory Clearance for establishment

State clearance for establishment 20 days

State EC Clearance 90 days

4 Procurement

Place orders for long lead Equipments 90 days

Place orders for commodity items 30 days

Receipt of equipment 230 days

Installation of equipment & items 180 days

5 Erection & Commission

Inspection before commissioning 80 days

Commissioning & production trial run 40 days

Some works will proceed parallel and some in series. Critical Path Method (CPM) and

Project Evaluation & Review Technique (PERT) will be followed for completion of project

work.In short construction job will be completed within two years of time after getting

consent to establish from SPCB, WB.




8.2 ESTIMATED PROJECT COST

Project Cost

The estimated expansion project is 165 crore. This will be as follows.

SL. NO ITEM COST IN LAKHS

1 Land & Site development & Infrastructure 150.50

2 Civil & Structural Works 437.00

3 Plant machineries and Equipments 15400.00

4 Other Fixed Assets 100.00

5 ESC Cost 412.50

Total Project Cost 16500




CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 FINANCIAL & SOCIAL BENEFITS

The proposed expansion project is expected to bring socio-economic and environmental

benefits both at local and global level as listed below:

9.2 SOCIAL INFRASTRUCTURE

Social awareness programs will be further improved by the local authority such as

sanitation and hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding

area.

The proposed expansion project will set up training centre for the male and

female youth group by considering their skills and qualification which will support

the people for self employment.

9.3 EMPLOYMENT POTENTIAL

The project is going to create substantial employment and income. Due to this project

activity, some persons in the project area will be recruited as skilled and semi skilled

workers by the company as per its policy. Therefore, substantial amount of employment

and income is likely to be generated for the local people. So, the project will contribute

in a positive manner towards direct employment in the project area. Some employment

potential benefits are given below:

Long term employment of up to additional 1355 people in the operation phase of

the proposed expansion project.

Generating additional associated jobs due to establishment of the project.

9.4 BENEFITS TO THE REGION AND THE COUNTRY

M/s MSPL shall produce steel billets that are to be utilized in construction activities. The

products are in demand and production shall contribute to the GDP growth of the

country.

Techno Economic Feasibility Report of M/s Maithan steel ...

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