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PRE-FEASIBILITY REPORT

CREST STEEL & POWER (P) LIMITED

[EXPANSION]

Unit proposed Proposed Production

Wire Rod Mill 1,00,000 TPA

I/O Beneficiation 16,00,000 TPA

Pellet Plant 12,00,000 TPA

FBC Boilers 12 MW

Location : Joratarai Village, Mangatta (PO) Rajnandgaon Tehsil & District, Chhattisgarh

For

M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh

PRE-FEASIBILITY REPORT Page-2

PRE-FEASIBILITY REPORT

1.0 EXECUTIVE SUMMARY:

Sl. No Item Detail

1 Name of the project Crest Steel & Power Pvt. Ltd.

2 S.No. in the schedule 2(b) & 3(a)

3 Proposed capacity / area

/ length / tonnage to be

handled / command area

/ lease area / number of

wells to be drilled

The following units are proposed in further expansion

Unit proposed Proposed Production

Wire Rod Mill 1,00,000 TPA

I/O Beneficiation 16,00,000 TPA

Pellet Plant 12,00,000 TPA

FBC Boilers 12 MW

4 New / Expansion /

Modernization

Expansion

5 Existing capacity/Area

etc.

The following are the existing & Expansion (for which E.C. already accorded)

S. No. Products Existing Expansion* Further Expansion

1 Iron Ore Crushing Plant --- 17,95,200 TPA

2 DRI Plant (Sponge Iron) 1,15,500 TPA 8,08,500 TPA

3 Induction Furnace with LRF (Billets) 33600 TPA 5,44,500 TPA

4 Electric Arc Furnace (Billets) --- 3,30,000 TPA

5 Rolling Mill (TMT Bars & Str. Steel) --- 5,61,000 TPA

6 Wire Rod Mill --- 2,06,250 TPA 1,00,000 TPA

7 Generation of Power (WHRB) 8 MW 56 MW

8 Generation of Power (FBC) 8 MW 34 MW 12 MW

9 Submerged EAF (Ferro Alloys) * 3 x 12 MVA

Ferro Manganese 32,850 TPA 59400 TPA

Ferro Silicon 10,500 TPA 19,000 TPA

Silico Manganese 23,750 TPA 42,750 TPA

10 Coal Washery --- 3.20 MTPA

11 I/O Beneficiation --- --- 16,00,000 TPA

12 Pellet Plant --- --- 12,00,000 TPA

* Honorable MoEF has already accorded in for these Expansion Capacities vide letter no - J-11011/753/2008-IA II (I) dated 27th August 2010 & 22nd November, 2010.

6 Category of project i.e. ‘A’

or ‘B’.

A

7 Location

Village Joratarai


PRE-FEASIBILITY REPORT Page-3

Tehsil/Mandal Rajnandgaon

District Rajnandgaon

State Chhattisgarh

8 Nearest railway

station/airport along

with distance in kms.

Nearest Railway Station – Rasmada (3.1 Kms.) Nearest Air port - Raipur (65 Kms.)

9 Nearest Town, city,

District Headquarters

along with distance in

kms

Nearest Town: Durg (8.3 Kms.) District Head Quarter: Rajnandgaon (25 Kms.)

10. Address for

correspondence:

M/s. Crest Steel & Power (P) Limited

Joratarai Village, Mangatta (PO)

Rajnandgaon Tehsil & District,

Chhattisgarh - 491001

Name Mr. Jai Thomas

Designation(owner /

partner /CEO)

Vice President (Group Corporate Affairs)

Pin code 491 001

E-Mail [email protected]

Telephone No. 0788-2617341 - 44

Fax No. 0788-2617353


2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1 Identification of project and Project Proponent

M/s Crest Steel and Power Limited (CSPPL) has been promoted by well established

entrepreneur belongs to Raipur in Chhattisgarh state and already running Sponge Iron unit

at Village: Joratarai, Post: Mangatta, Tehsil & District: Rajnandgaon (C.G.). The products are

in high demand and are being regularly used in the national infrastructure development

projects, projects of strategic importance including railways & Defense organization &

different establishment. Strict adherence to quality is maintained through sophisticated

technology installed in the plants, which is a special feature of the Group.

The board of directors plays an important role in ensuring good governance and have laid

down the Code of Conduct for all Board members and senior management of the company.

Name : Designation

Shri Abhay Lodha : Director

Shri Ashwin Lodha : Director

Shri Narendra C. Lodha : Director

Shri Surendra C. Lodha : Director

In view of this Management is would like to obtain Environmental Clearance from MoEF, new

Delhi for their proposed Iron Ore Beneficiation & Pelletisation Plant, Wire rod Mill & FBC

based Power Plant for production of Pellets, Wire rods & Power.

2.2 Brief Description of Nature of Product

The proposed expansion Integrated Steel Plant involves manufacturing of following products

Concentrated Iron ore : Iron Ore Fines will be grinded in Ball Mills and beneficiated through gravity & magnetic separation.

Pellets : I/O concentrate will be sent to pellet plant comprising of Straight Grate Indurating Furnace. Green pellets will be produced which will be indurated in this process.

TMT bars : The manufactured Billets is being taken to reheating furnace to produce structural steels.

Power generation : Power will be generated by utilization of washery rejects as fuel in the FBC Boiler.


2.3 Need for the project and importance to the region

Availability of suitable high-grade iron ore fines in abundance for DRI making

They can be stored for a long time and transported to long distances without any

degradation in quality.

Pellets are an excellent feed material for DRI units both coal based and gas based.

Presently Iron ore fines are exported in large quantities for pellet making in other

countries.

Value addition to the rejected fines can be made by beneficiating and pelletizing

technology within the country, thereby conserving iron ore.

The feed for the sponge iron units are sized iron ore lumps.

Use of Pellets will increase productivity and less

Emission from Sponge Iron will be lower when Pellets are used.

Power generation is required to meet the plant requirements.

It is proposed to produce Structural steel / Wire rods / TMT bars / Rolled products as

consumption of iron and steel and expected growth of Indian economy the

requirement of steel will significantly increase and accordingly the domestic

manufacturing capacity needs to be increase.

MISSION

To be among the Top Iron Ore Pellet producers globally

To be one of the most cost effective iron ore pellet producers

To have significant presence across the globe.

To have the Maximum Energy Utilization thereby conserving fossil fuel.

To Create Environment Friendly Process and with minimum Emission.

2.4 Demand – Supply Gap: Pellet plant

PELLETS:

With the rapid development of Infrastructure and manufacturing sector, the Iron and

steel industry is poised for an accelerated growth. Steel demand in the country is

increasing at an average rate of 10% and is likely to remain in 10-12% range at least

for the next decade. In order to meet the steadily growing steel demand in the

country, domestic steel producing capacity is required to be higher than 110 mtpa

within next three years and, 150 mtpa by the year 2016-17. Indian economy is


growing at more than 10% rate, steel demand and supply will grow in the same way.

As good quality iron ore deposits are depleting fast beneficiation technologies will have

to be adopted to meet iron ore demand. Therefore good yield of beneficiation process

generally around 70 % will make this technology economically viable.

> Agglomeration technologies such as Pelletisation will have to be added to DRI Plant

/ Steel Plant so that concentrates can be used as feed material. Recycling of cheaper

raw material (fines) by beneficiation and Pelletisation process as feed material will

result in better Return on Investment as compared to using Iron ore as feed

material.

> With superior reducibility behavior of pellets compared to lump ore efficiency of

DRI production improves.

> It can be concluded from results obtained by conducting various tests on

manufactured pavement blocks that substitution of iron ore tailings for sand or

quarry dust shows better compressive strength without much change in water

absorption.

With gradual depletion of high Iron Ore reserves, the Iron and Steel sector world

over has been looking at alternatives to utilize the low grade iron ore fines for iron

making so that there is optimal utilization of the available iron ore resources. Growth

of Steel Industry, especially in China over the years despite the depletion of high grade

Iron Ore has taken place on the strength of technologies of Beneficiation, Sintering

and Pelletisation of Iron Ore Fines, which enhances the productivity of the blast

furnaces in Steel making and hence lowering the cost of steel production.

In the Indian context, by the year 2020, India's production of steel is expected to touch

110 Million Tonnes and it is imperative that the fines generated in the mining of iron

ore be utilized for the production of steel. The Indian steel industry which

predominantly uses expensive lump ore is gradually moving towards usage of iron ore

pellets.

The present Indian raw material scenario offers an opportunistic disposition

towards pellet making owing to the availability of large quantities of sub grade fines,

slimes and blue dust etc. at different mine heads. These materials are not suitable


for sinter making. Pelletisation is the only possible route for salvaging these, otherwise

waste but valuable materials. Recent techno-economic studies indicated favorable

indices for installation of pellet plants, both small and large scale. The demand supply

analysis also underlines the need for Pelletisation.

STATE OF THE STEEL WIRE ROD INDUSTRY:

Established in India in 1920s, the Wire rod Industry has progressed remarkably and has

successfully developed and manufactured various types of high carbon, alloy steel and special

steel wires in addition to mild steel wire rods. The industry has become versatile enough to

meet the requirements of numerous consuming sectors. This sophistication has been

possible due to continuous and well-planned R & D efforts on part of the manufacturers with

patronage of SWMAI. The result has been that the industry is in a position to manufacture

and supply steel wires, both in the domestic and the international markets, in accordance

with Indian (BIS) and international (ASTM, DIN, JIS, BSS) standards.

The product range of steel wire rod manufacturers is being continuously widened. An

indicative list of the various types of steel wire rods and wire products produced in India is

given below:

It is seen that this industry is growing about 5-6% during last two years. The demand of

wires is expected to increase in leaps and bounds in the years to come. Out of the total steel

consumed in India wire constitutes only 5%. However, if pace of development picks up the

domestic consumption of wires will increase by 2%–3% to 7%-8% of the steel consumption.

In our Country, if we closely look at the wire demand, almost 88% of it is for wires in plain

carbon steel grades, 5% would be for Stainless Steel grades and the balance would be for

Alloy Steel Wires.

On further analysis, out of the plain carbon wires almost 75% to 80% of the demand is for

black/uncoated wires and the balance 20% to 25% is for wires coated with other base metals

e.g. Zinc (Galvanized), Copper, Bronze, and other coating materials.

Moreover, the overall Steel Wire production scenario is as follows:

Size of the Steel Wire rod Industry in India is 2.6 million tonne approximately in terms of

volume & US $ 1.7 billion in terms of value, combining both organized and unorganized

sectors. Approximately, 70 per cent of total production comes from organized producers and


the rest from the unorganized counterpart. Wire rod Industry is accountable for 5 per cent of

total demand of steel in India. India constitutes 1 per cent of the global wire rod exports and

approximately 3 per cent of Indian production caters a portion of the global markets.

In 2010, the Global wire business has been something like 48-50 million tons and in terms of

Dollars it was US $ 29 billion. This market is also expected to grow to some 56 million tons of

wires by 2011 and in Dollar terms it would be something like US $ 32 billion. North America,

Europe and South East Asia each account for approximately 25% of the Global demand for

the Steel Wires.

The fortunes of the steel wire industry are closely linked to the fortunes of the Primary steel

Industry. Internationally steelmakers’ prospects to 2015 are mixed, due to consolidations in

most parts of the old industrial world; a resurgence of steelmaking capacity addition in the

Far East (particularly in India), in Latin America (Brazil) and in the Middle East; a

revitalization of the Russian steel industry and continued massive expansion in China. One

factor stimulating new capacity is the technological revolution which is sweeping the

industry.

The future of emerging market economies is looking bright. Developing countries,

particularly the BRIC countries (Brazil, Russia, India and China), are very optimistic about

their prospects since these economies are recovering and advancing more swiftly than many

had envisaged.

It has been estimated that, India’s steel consumption will continue to grow at an annual rate

of nearly 16% till 2012, fuelled by demand for construction projects worth US$ 1 trillion. The

scope for raising the total consumption of steel is huge, given that per capita steel

consumption is only 44.3 kgs – compared to 190.4 kgs across the world and 318.5 kgs in

China.

2.6 Employment generation (Direct & Indirect)

PHYSICAL INFRASTRUCTURE

Once the proposed activity is commissioned, the socio-economic status of the local people

will improve and there by infrastructure facilities like communication systems will improve.

Most of the villages at present do not have protected water supply. After the implementation


of the project, the affordability of the public to spend on water treatment, supply &

distribution will more along with the aid from the state government.

EMPLOYMENT POTENTIAL

The proposed project creates employment to 300 people during construction and 200 people

during operation of the proposed expansion project.

The following is the break-up of the man power requirement

Executive - 24 Nos.

Supervisors and staff - 48

Skilled Man power - 64

Semi Skilled Manpower - 36

Unskilled Manpower – 28


3.0 PROJECT DESCRIPTION

3.1 Type of the Project

To make the project viable management of CSPPL is proposed to establish I/O beneficiation,

Pelletisation plant, Wire rod mill & Power Plant in the expansion program for production of

Pellet, Wire rods / Structural Steel & Power generation at existing plant premises only. There

would be value addition to waste ore fines, that would be utilized for gainful purposes.

3.2 Location

Existing Plant is located at Joratarai Village, Mangatta (P.O.), Rajnandgaon Tehsil & District,

Chhattisgarh.

3.3 Details of the Alternate sites

No Alternate sites have been examined for the proposed project. The plant would be set up

within the existing site and no additional land requirement is envisaged.

3.4 Size or Magnitude of Operation

Crest Steel & Power (P) Limited proposed the following units and its capacity are

presented below.

S. No. Products Existing Expansion* Further Expansion 1 Iron Ore Crushing Plant --- 17,95,200 TPA 2 DRI Plant (Sponge Iron) 1,15,500 TPA 8,08,500 TPA 3 Induction Furnace with LRF

(Billets) 33600 TPA 5,44,500 TPA

4 Electric Arc Furnace (Billets) --- 3,30,000 TPA 5 Rolling Mill (TMT Bars & Str.

Steel) --- 5,61,000 TPA

6 Wire Rod Mill --- 2,06,250 TPA 1,00,000 TPA 7 Generation of Power (WHRB) 8 MW 56 MW 8 Generation of Power (FBC) 8 MW 34 MW 12 MW 9 Submerged EAF (Ferro Alloys) * 3 x 12 MVA Ferro Manganese 32,850 TPA 59400 TPA Ferro Silicon 10,500 TPA 19,000 TPA Silico Manganese 23,750 TPA 42,750 TPA

10 Coal Washery --- 3.20 MTPA 11 I/O Beneficiation --- --- 16,00,000 TPA 12 Pellet Plant --- --- 12,00,000 TPA

* Honorable MoEF has already accorded in for these Expansion Capacities vide letter no - J-11011/753/2008-IA II (I) dated 27th August 2010 & 22nd November, 2010.


3.5 Manufacturing Process

3.5.1 Iron Ore Beneficiation Process:

Beneficiation process is a combination of crushing, screening, washing, grinding, classifying

by gravity separation, magnetic separation, floatation processes. The final concentrate slurry

is filter pressed to get a dry enriched ore quality with Fe > 65% and moisture ~10%. The

water is recycled in the process. The tailings are processed in a thickener & Filter pressed

and the excess water will be recovered and circulated in the process. The tailings filter cake is

of low value with Fe <45% and moisture content ~10%. This Filter cake will be stored in

storage yard earmarked within the plant premises.

Pollution Free Technology

The process of beneficiation of iron ore can be rendered pollution free with no

effluents being discharged.

The fugitive emissions are arrested in the crushing and grinding zone by dust

suppression systems. Further the emissions are low as these circuits are wet and does

not allow high emissions.

The process does not use any hazardous chemical.

The quality of the iron ore concentrate is envisaged as follows:

Fe ; >65%

SiO2 +Al2O3 ; 4-5%

LOI ; 3.5 – 4.5%

Moisture content ; 10%

The Beneficiation plant would produce concentrate to the tune of 1.2 MTPA for

feeding the Pellet Plant.

3.5.2 Process of Iron Ore Pelletisation

In this process all raw materials will be proportioned as per requirement of the product

quality and intensely mixed to have homogeneity in the quality. The mixed material will be

processed in a battery of disc or a drum pelletizer for formation of green balls / pellets. The

pellets are controlled for size as well as certain amount of green strength. The pellets are

then classified in a roller screen to separate the undersize (-8 mm) and oversize (+18 mm).

The rest of the sized pellets are charged onto the pellet Cars. These pellet cars travel through

the straight grate Indurating Furnace over an endless chain where the pellets are subjected

to controlled rate of heating with updraft, downdraft, and two stages of preheating to a


temperature of ~1050deg. C. The recuperated heat from the process is utilized very

effectively resulting in lower fuel consumption. In the preheating zone small amount of heavy

oil may be used to stabilize the preheating zone temperature. At the end of the Indurating

Furnace the pellets would gain sufficient strength and then the hot pellets are passed through

the cooler area of the Inducting Furnace which maintains a fixed bed depth and the cooling is

done by updraft air from atmosphere. The pellets in the Indurating Furnace will be heated by

some long flame dual burner through-out the indurating Furnace fired by Furnace Oil. The

pellet cars moves slowly inside the Indurating Furnace, thereby indurating the pellets

homogeneously at a temperature ~ 1300deg. C. The cooler area is divided into three zones

and the recuperated hot gas from each zone is utilized for process requirements. The pellets

will be transported for processing where they are screened to sizes between 9 to 18 mm and

sent to the storage yard. These pellets are very stable and do not degrade on storage or

transportation.

The process flow diagrams are shown below

PROCESS FLOW DIAGRAM (I/O BENEFICIATION)

Here WR stands for Water Recovery being re-circulating.


PROCESS FLOW DIAGRAM (IRON ORE PELLETIZATION)


Quality of Raw Materials:

The typical analysis of input raw materials envisaged for the production of pellets are:

Main physical and chemical property of Hematite Iron ore Concentrate

Chemical Composition (%)

T Fe SiO2 Al2O3 CaO MgO S P

Around 65.0 2.59 1.65 0.07 0.02 0.03 0.01

Physical property

Sizes (-0.050 mm) Water % Bulk Density (t/m^3) Burn Loss (%)

80% 7.8 2.1 1.66

Main physical and chemical property of Bentonite SiO2 Al2O3 TFeO MgO CaO K 2O Na 2O S P Burnt

Loss

69.56 15.03 1.70 2.18 0.69 2.27 1.62 0.13 0.017 6.14 Physical property

Montmorillonite

Colloid -0.074 mm Expansion capacity

Water Content (%)

Water Absorption (2 Hour)

94.7% 10.5 mg/l >=98% 13.5mg/l <10 225.67%

Main technical parameter of Heavy Oil Flash Point

(Deg C)

Density (g/cm^3)

Sediment weight

(%)

RCR weight

(%)

S Weight (%)

Viscosity (cps)

(100 Deg C)

Ash Content

Condensate point

(deg C)

66 0.98 Max 0.25 Max 0.25 1 80 0.1 66 Calorific value of heavy oil is 38.46 MJ/kg Typical Analysis of coal (Indian & Anthracite Coal) is shown below.

ANALYSIS OF COAL

S.No Particulars Units Indian Coal

Anthracite

Coal

1 Proximate analysis By mass

(As received basis)

1.1 Moisture (Total) % 5.00 5.50

1.2 Volatile matter % 28.00 14.45

1.3 Ash % 30.95 12.00

1.4 Fixed Carbon % 36.00 68.0

1.5 Sulphur % 0.05 0.05

1.6 Gross Calorific Value Kcal / Kg 4800 7000


Major Equipment and Facilities:

The major equipment and facilities envisaged for the Pelletisation plant are described below

The pelletizing plant will mainly consist of the following sections:

Storage and handling of iron ore concentrate

Storage, handling and preparation of binder and additive

Iron ore improvement

Proportioning and mixing

Balling, in duration and cooling

Finished product storage

Iron Ore Storage and Handling:

Beneficiated ore cakes from the beneficiation plant will be stored in a covered storage. Ore

cakes from the above storage will be drawn out at requisite rate and delivered by belt

conveyor to the ore improvement section of the plant.

Dust Abatement Facilities:

The pellet plant comprising various process units, accessories and handling facilities will be

provided with adequate dust suppression and dust extraction facilities to restrict the

particulate emission level within acceptable limits i.e. 50 mg per Nm3.

The systems will consist of water spraying facilities, mechanical gas cleaning equipment, dust

recycle arrangement and exhaust stack. Exhaust gas from drying and grinding systems will

be cleaned using fans, ducting’s, suction hoods, cyclones, bag filters, ESPs etc. as applicable.

The indurating furnace gas will be made to pass through electrostatic precipitator (ESP)

before being released to the atmosphere.

Filtered air supply system has been envisaged for MCC rooms and basements to supply

adequate fresh air to stagnant air zones. The control rooms will be air-conditioned.

The system will be designed in such a way that no solid waste will be discharged outside the

system, the solid waste that is the dust generated in the system will be recycled back to the

system itself.


Product Characteristics:

The likely chemical analysis of pellets computed on the basis of qualities of raw material

could be as follows:

SN DESCRIPTION UNIT INDEX REMARKS 1 Output of Finished Goods 10^4 t/a 60 Finished Pellet product 2 Annual Working rate % 90.4 3 Quality of Finished Pellet

product

4 T (fe) % 64.43 With reference to Ore quality 5 FeO % 0.30 6 Basicity (CaO/SiO2) % 0.15 7 Acid Gangue 6.21 8 Granulometry mm 8.16 >90% 9 Crush Strength n/p >=2200 Average value

10 Tumbler Index % >90 +6.3mm 11 Abrasion Index % <5% -0.5mm

3.5.3 Rolling Mill (Structural & Wire rod Mill)

It is proposed to install a Wire rod mill of 1,00,000 tons/ annum capacity within the existing

plant premises. The process of rolling involves several steps: -

a. Selection of raw materials – blooms / Billets

b. Shearing and preparing.

c. Heating in Furnace Oil - fired furnace.

d. Rolling.

e. thermal Treatment (if required)

f. Inspection.

g. straightening and sheering (coil processing)

h. Dispatch.

The raw materials for proposed rolling mill are Semis i.e. Billets/ Blooms/ narrow Slab of

carbon or low alloy steel. The semis are segregated as per size and quality in the raw material

yard and are fed to the oil fired “pusher type” reheating furnace for heating up to the

requisite temperature. The steel is required to be heated uniformly to the re-crystallization

temperature for easy rolling. The usual temperature range maintained in the Furnace is

about 1150 – 1200 ºC depending on the quality of steel and section of semis. The semis are

heated as it moves through the furnace for a period of 1.5 to 2º depending upon the section

and rolling rate. The heated billets are rolled in the mill consisting of Rolling Strands of both

of three high and two high design. The size and configuration of the mill is different for

rolling of wire rod and structural like angles, channels and joist (Girders).


Rolling is performed in alloy semi chilled/ Chilled cast iron rolls – pairs moving in opposite

direction. The roll groves where rolling is performed are cooled with water. As the rolling

progress the rolled section is progressively reduced and the length of the stock increases. The

shapes of the final section i.e. round, angle, channel, beam etc. are progressively formed. The

final shape and size comes out of the last strand/ pans called finishing pass.

Water quenching and the heat treatment of rods in case of Wire Rods / TMT Bars are

performed after the finishing pass in the line. The bars/ sections after rolling are cooled in

cooling beds, wire rods coils are cooled in coil processing lines.

Sections like angles, channels and joist (girders) need to be straightened in rollers

straightening machines. These are further sheared in required lengths and made in to

bundles/ packets are dispatched.

During the process of heating the fuel oil is completely burnt with preheated combustion air

and the product of combustion is let in to atmosphere through chimney of adequate height

calculated as per Sulphur content in the Furnace Oil in accordance with CPCB norms.

Diagrammatic Presentation of the Material Flow:

Raw Material Receipt

Physical & Chemical Testing

Heating

Hot Rolling

Hot Inspection

Specially controlled Water Quenching

Dispatch


3.5.4 Captive Power Plant (1 X 12 Mw)

CSPPL proposes to install 1 x 12 MW Thermal Power Plant. The fuels proposed to be used in

FBC Boiler are Washery rejects /coal. The crushed coal will be fed to the boiler furnace

through feeders and nozzles with the aid of air from a primary fan. A forced draft fan draws

atmospheric air and circulates the same through an air heater in which the temperature of air

will raise to 140ºC and forces the same to the boiler furnace through air box and air nozzles.

The coal burns inside the furnace so as to maintain a furnace temperature of 880º – 900 ºC.

The boiler feed water through an economizer enters the boiler steam drum, mud drum and

water walls where it is heated and converted to saturated steam. The saturated steam will

then be heated to a temperature of 520º–540ºC in the super heater & carried to a steam

header to run Turbo generator for 12 MW.

3.6 Raw material requirement

The following will be the raw material requirement for the proposed expansion project.

Details Consumption (TPA) Sources of Supply Method of Transportation

Raw Material for I/O Beneficiation Iron Ore Fines 16,00,000 NMDC, Bastar Through Rail and Road

Raw Material for Pellet Plant

Iron ore Concentrate 12,00,000 In-House Through Belt Conveyors

Bentonite 9,000 Open Market, Durg By road

Lime Powder 24,000 Open Market, Durg By road

FO 13,800 Open Market, Durg By road

Coal & Coke Fines 36,000 SECL / Opwn Market Durg

By road

Raw Material for Wire rod Mill Billets/ Blooms/ Ingots 1,03,000 In-house Through Roller Tables

Furnace oil 3,600 TPA By road Raw Material for Power Plant (FBC Boiler)

Coal Washery Rejects 1,23,552 In-house Through Belt Conveyors

3.7 Water requirement and its source

Water required for the proposed plant will be supplied by CSIDC, Govt. of C.G. Water required

for the proposed plant will be 6130 KLD.

3.8 Quantity of waste generated

No wastewater will be discharged from the proposed unit operation. Slurry generated from

beneficiation plant will be fed to a specially designed press filter, which would separate the


water from slurry. All the water collected from this filter will be re-circulated to plant for

reuse. Closed circuit cooling system will be adopted in Pelletization plant & in Wire rod mill.

Boiler blowdown, CT Blow down & DM Plant regeneration will be the sources of effluent

generation from the power plant. This effluent will be treated in Neutralisation tank and

utilized for dust suppression and for greenbelt development. Zero effluent discharge will be

maintained in the premises.

Sanitary waste water will be treated in septic tank followed by sub surface dispersion trench.


4.0 SITE ANALYSIS

4.1 Connectivity

The proposed site is located at Joratarai Village, Mangatta (P.O.) Rajnandgaon Tehsil &

District, Chhattisgarh. The site is close to NH-6 & Rasmada Railway Station is situated at

distance of 3.1 Kms. from the plant. Nearest airport is Raipur at 65 Kms. The transportation

of heavy equipment & construction materials will be to site by road.

4.2 Land use

Total land under possession is 285.15 acres. The present use of the land is industrial land.

The proposed Iron Ore beneficiation, Pellet plant, Wire Rod Mill & Captive Power plant will

be taken up in the existing plant premises only.

4.3 Topography

The topography of the land is more or less flat without undulations.

4.4 Existing land use pattern

Present land use is mostly industrial. Joratarai village is nearest village at a distance of 0.6

Kms. from the site. Shivnath River is at distance of 2.8 Kms. from the existing plant. There are

no National Parks, wildlife sanctuaries, Elephant Corridors, etc present within the 10 Km

radius of the site.

4.4 Existing infrastructure

M/s Crest Steel & Power (P) Limited is operating an existing plant at Rajnandgaon Tehsil &

District, Chhattisgarh with valid Consent to Operate from CECB, Chhattisgarh.

Item Area in Acres Built up area (Existing) 24.00 Built up area (Expansion) 62.00 Internal roads (Existing) 4.00 Internal roads (Expansion) 9.00 Water Reservoir 10.00 Storage yard 26.00 Slag storage 5.00 Greenbelt (Existing) 35.00 Greenbelt (Expansion) 60.00 Open area 50.15 Total land 285.15


5.0 PLANNING BRIEF

5.1 Planning Concept

M/s. Crest Steel & Power (P) Limited has proposed to install Iron Ore Beneficiation &

Pelletisation Plant, additional wire rod Mill & 12 MW captive power plant as part of

expansion plan proposed at Joratarai Village, Mangatta (P.O.) Rajnandgaon Tehsil & District,

Chhattisgarh.

5.2 Amenities / Facilities

Facilities like canteen, rest room and sanitary facilities are already been provided in the

existing plant as basic facilities to workers. No other additional facilities are proposed.

5.3 Green Belt

Total 33% of the total area will be developed with Green belt with in the Plant premises.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area is being / will be developed in the plant premises as per

CPCB guidelines.

15 m wide greenbelt will be maintained all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

wind firm, deep rooted. A three tier plantation is proposed comprising of an outer

most belt of taller trees which will act as barrier, middle core acting as air cleaner and

the innermost core which may be termed as absorptive layer consisting of trees which

are known to be particularly tolerant to pollutants.

5.4 Social Infrastructure

Social infrastructure is being / will be developed as per need based in the Villages.

5.5 Drinking water management

The workers at the plant during construction shall be provided with water for their

requirement and for the construction activities. The construction labour will be provided

with sufficient and suitable toilet facilities to allow proper standards of hygiene. These

facilities would preferably be connected to a septic tank and shall be maintained properly to

have least environmental impact. Drinking water required for the workers will be met from

existing plant water facilities.


5.6 Air emission Management

High efficiency ESP will be provided to Pellet Plant & FBC boiler to bring down the particulate

matter in the exhaust gas to less than 50 mg/Nm3 and then discharged into the atmosphere

through stack whose heights are in accordance with CPCB norms.

Adequate stack height will be provided to Wire rod mill for effective dispersion of SO2

emissions into the atmosphere.

Hence there will not be any adverse impact on vulnerable groups due to the proposed

activity.

5.7 Industrial waste management

No wastewater will be discharged from the proposed unit operation. Slurry generated from

beneficiation plant will be fed to a specially designed press filter, which would separate the

water from slurry. All the water collected from this filter will be re-circulated to plant for

reuse. Closed circuit cooling system will be adopted in Pelletisation plant & in Wire rod mill.

Boiler blowdown, CT Blow down & DM Plant regeneration will be the sources of effluent

generation from the power plant. This effluent will be treated in Neutralisation tank and

utilized for dust suppression and for greenbelt development. Zero effluent discharge will be

maintained in the premises.

5.8 Sewerage system

There sanitary wastewater generation from the existing & proposed expansion project will

be treated in Septic tank followed by subsurface dispersion trench.

5.8 Solid waste management

Solid Waste Quantity Method of disposal Tailings from I/O beneficiation

4,00,000 TPA Ceramic Industries OR will be disposed off for low land filing.

End cuttings From Wire rod Mill

3,000 TPA Recycled back as raw material in own induction Furnaces

Mill scales from Wire rod mill

2,000 TPA Given to ferro alloys manufacturing units/ casting units

Bottom Ash 15,320 TPA It is a good-filling aggregate and utilized as sub base material; hence given to road making contractors.

Fly Ash 61,280 TPA Will be given to Cement Plants/Brick manufacturers./filling in abandoned mines


6.0 POWER REQUIREMENT & SUPPLY / SOURCE

During operation of the proposed unit, the power required for the industry will be sourced

from Captive Power Plant & from State Grid if required.

7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN

No rehabilitation or resettlement plan is proposed as the proposed expansion project will be

implemented in the existing plant premises only.

8.0 PROJECT SCHEDULE & COST ESTIMATES

The plant will be implemented in 24 months from the date of receipt of permission from the

Hon’ble MoEF, Govt. of India & CFE from CECB.

The estimated cost for the proposed project will be Rs. 740 Crores.

S.No. Particulars AMOUNT (Rs. In Laces) 1 Land : 0.00 2 Land Development & Civil Works : 8774 3 Plant & Machinery : 54940.00 4 Interest During Construction : 6734.20 5 Preliminary & Pre-Operative Expenses : 1486.00

6 Margin Money for Working Capital & Contingency : 2142.00

Total : 74076.20 MEANS OF FINANCE 1 PROMOTERS : 22222.86 2 TERM LOANS : 51853.34 Total : 74076.20

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

There is abundant availability of iron ore fines of Fe grade <60% that is normally not a direct

feed to DRI units. Hence after techno-economic considerations it is feasible to include Iron

Ore Beneficiation and Pelletisation unit in Expansion plan along with additional Wire

Rod Mill & captive power plant in the existing plant premises of Crest Steel & Power (P)

Limited.

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