SUBMISSION TO MINISTRY OF ENVIRONMENT, FORESTS &...

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PRE-FEASIBILITY REPORT

SUBMISSION TO

MINISTRY OF ENVIRONMENT, FORESTS & CLIMATE CHANGE,

NEW DELHI.

PREPARED FOR

GENEXT STEELS PRIVATE LIMITED [Pellet plant (800 TPD), DRI (600 TPD), Induction Furnace (1000 TPD), Rolling Mill

(1000 TPD), Power Generation – 17 MW (12 MW through Waste Heat Recovery Boiler

(WHRB) and 5 MW through Fluidized bed combustion (FBC) Boiler)]

at

Village: Bagodara, Tehsil: Baula,

District: Ahmedabad, State: Gujarat

Prepared by

6-3-652, Flat # 7-3, Dhruvatara Apartments, Amrutha Estates, Erramanjil, Somajiguda, Hyderabad- 82

Landline No. : 040-23314270

Accredited by ISO 9001: 2008 Certified

Prefeasibility Report Genext Steels Private Limited (Steel Plant)

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Table of Contents

Chapter –1:EXECUTIVE SUMMARY ......................................................................................................... 3

Chapter – 2: INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION .................................. 5

Chapter – 3 : PROJECT DESCRIPTION ...................................................................................................... 7

Chapter – 4 : SITE ANALYSIS .................................................................................................................. 22

Chapter – 5 : PLANNING BRIEF ............................................................................................................. 24

Chapter – 6 : PROPOSED INFRASTRUCTURE ......................................................................................... 26

Chapter – 7: REHABILITATION & RESETTLEMENT (R & R) PLAN ........................................................... 28

Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES ........................................................................ 29

Chapter – 9 : ANALYSIS OF PROPOSAL .................................................................................................. 30


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Chapter –1:EXECUTIVE SUMMARY

1.1 SALIENT FEATURES OF THE PROJECT

Genext Steels Private Limited (GSPL), have proposed to setup the steel plant at Village Bagodara, Tehsil

Baula, District Ahmedabad, State Gujarat. Following is the plant configuraton and production

capacity:

S.NO. UNIT PROJECT CONFIGURATION PRODUCTION CAPACITY

1. Pellet

(Pellets)

4 X 200 TPD 800 TPD

2. DRI Kilns

(Sponge Iron)

4 X150 TPD

600 TPD

3. Induction Furnace with

Concast (MS Billets)

2 X 25 MT

1000 TPD

4. Rolling Mill

(Structural Steel TMT&

Rolled products)

2 X 500 TPD

1000 TPD

5. Power Plant

(Electricity)

WHRB 1 X 12 MW 12 MW

FBC 1 X 5 MW 5 MW

1.2 PROJECT PROPONENT

Rapid industrialization leads to all-round development and improvement in quality of people in the

area. Gujarat is a very congenial state for industrial growth due to availability of manpower, raw

materials and other infrastructural facilities

About the Group:

Genext Steels Private Limited (GSPL), is public limited registred under company act in the year 2013.

List of directors / Background / Experience:

i) Mr Vinod Kedia – a commerce graduate having 25 years of experience in steel manufacturing

and presently Chairman and Managing Director of M/s Vinayak Steels Ltd., Hyderabad

having turnover of over Rs.165 Cr.


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ii) Mr.Rakesh Bansal, a commerce graduate having 30 years of experience in steel melting and

structural manufacturing and presently Chairman of Meenakshi Group of Industries,

Hyderabad having a group turnover of over Rs.500 Crores.

iii) Mr.Rajesh Naredi, a commerce graduate having 25 years of experience in manufacturers of

ceiling/table fans and other accessories and major suppliers to OEMs and export units

presently Chairman of YASH group of Industries having a group turnover of over Rs.900

Crores.

iv) Mr.Ritesh Naredi, a commerce graduate also a director in the YASH group of Industries as

above.

v) Mr.Pankaj Jindal, a Business Management Graduate having 20 years of t experience in pipe

manufacturers is currently Managing Director of Ravindra Pipes, Hissar, Haryana.

vi) Mr.Vineet Kedia, a Business management graduate having 10 years of experience in steel

manufacturing and commercial aspects and presently Director in M/s Vinayak Steels

Limited,. Hyderabad.


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Chapter – 2: INTRODUCTION OF THE PROJECT / BACKGROUND

INFORMATION

2.1 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT

Genext Steels Private Limited (GSPL), have proposed to setup the steel plant at Village Bagodara,

Tehsil Baula, District Ahmedabad, State Gujarat.

Company intends to

Manufacturing of 800 TPD of Pellets by installing 4 x 200 TPD pellet plant.

Manufacturing of 600 TPD of Sponge Iron by installing 4 x 150 TPD DRI Kilns.

Manufacturing of 1000 TPD of MS Billets by installing 4 x 25 T capacity Induction

furnace with Concast.

Manufacturing of 1000 TPD of bars/rods and Structurals by installing 2 x 500 TPD

capacity Rolling mill.

Power generation of 12 MW through Waste Heat Recovery from 4 x 150 TPD DRI Kiln.

Power generation of 5 MW through FBC based boiler.

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION

India’s economic growth is contingent upon the growth of the Indian steel industry. Consumption of

steel is taken to be an indicator of economic development. While steel continues to have a

stronghold in traditional sectors such as construction, housing and ground transportation, special

steels are increasingly used in engineering industries such as power generation, petrochemicals and

fertilizers. India occupies a central position on the global steel map, with the establishment of new

state-of-the-art steel mills, acquisition of global scale capacities by players, continuous modernization

and up gradation of older plants, improving energy efficiency and backward integration into global

raw material sources. Steel production in India has increased by a compounded annual growth rate

(CAGR) of 8 percent over the period 2002-03 to 2006-07. Going forward, growth in India is projected

to be higher than the world average, as the per capita consumption of steel in India, at around 52 kg,

is well below the world average (170 kg) and that of developed countries (400 kg). Indian demand is

projected to rise to 300 million tonnes by 2025. Given the strong demand scenario, most global steel

players are in a massive capacity expansion mode, either through brownfield or Greenfield route.


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Steel production capacity in India is expected to touch 170 million tonnes by 2020. While Greenfield

projects are slated to add 30 million tonnes, brownfield expansions are estimated to add 50 million

tonnes to the existing capacity of 90 million tonnes. Steel is manufactured as a globally tradable

product with no major trade barriers across national boundaries to be seen currently. There is also

no inherent resource related constraints which may significantly affect production of the same or its

capacity creation to respond to demand increases in the global market. Even the government policy

restrictions have been negligible worldwide and even if there are any the same to respond to specific

conditions in the market and have always been temporary. Therefore, the industry in general and at

a global level is unlikely to throw up substantive competition issues in any national policy framework.

Further, there are no natural monopoly characteristics in steel. Therefore, one may not expect

complex competition issues as those witnessed in industries like telecom, electricity, natural gas, oil,

etc.

2.3 DEMAND AND SUPPLY GAP

Demand for steel is high and as soon as they are processed they will be supplied to nearby industries.

2.4 EXPORT POSSIBILITY

As 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 4th largest producer of crude steel and the largest producer of sponge iron or DRI in

the world. As the demand is more the export possibility of Sponge Iron will also be more. As the

demand is more the export possibility will also be more.

2.5 DOMESTIC/EXPORT MARKETS

While the demand for steel will continue to grow in traditional sectors such as infrastructure,

construction, housing automotive, steel tubes and pipes, consumer durables, packaging, and ground

transportation, specialized steel will be increasingly used in hi-tech engineering industries such as

power generation, petrochemicals, fertilizers, etc. The new airports and railway metro projects will

require a large amount of steel. Hence the domestic and export markets for steel sector will rise.


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2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

The estimated manpower requirement for the proposed project is 500 numbers; the total manpower

requirement for the entire plant is 500 numbers inclusive of staff and security. They will comprise of

20 % of skilled labors, 40 % of semi- skilled labors and 40 % of unskilled labors.

Chapter – 3 : PROJECT DESCRIPTION

3.1 TYPE OF THE PROJECT


Tehsil Baula, District Ahmedabad, State Gujarat.

Company intends to

Manufacturing of 800 TPD of Pellets by installing 4 x 200 TPD pellet plant.

Manufacturing of 600 TPD of Sponge Iron by installing 4 x 150 TPD DRI Kilns.

Manufacturing of 1000 TPD of MS Billets by installing 4 x 25 T capacity Induction

furnace with Concast.

Manufacturing of 1000 TPD of bars/rods and Structurals by installing 2 x 500 TPD

capacity Rolling mill.

Power generation of 12 MW through Waste Heat Recovery from 4 x 150 TPD DRI Kiln.

Power generation of 5 MW through FBC based boiler.

3.2 LOCATION OF THE PROJECT

Project location is at Village Bagodara, Tehsil Baula, District Ahmedabad, State Gujarat.

37.5 acres of land is envisaged for the proposed project.

The entire project area will fall in the Survey of India topo sheet no. 46 B/2.

3.3 DETAILS OF THE ALTERNATE SITES

The following three sites alternative sites have been considered for the proposed Steel plant:

S.No. Particulars Site # 1

Site # 2

Site # 3


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1. Location (Village) Bagodara Shiyal Kothatalavdi

2. Geographical Coordinates 22°37'35.22"N 72° 9'48.72"E

22°41'47.77"N 72° 9'40.61"E

22°39'40.13"N 72° 4'43.94"E

3. Areas falling under the critically polluted areas (within 10 Kms. Radius)

No No No

4. National Parks / Wild life Sanctuaries / Bird Sanctuaries / Tiger reserve / Elephant corridors / Migratory routes for Birds / Forest (within 10 Kms. of the project site)

Nalsarovar Bird

sanctuary

-12 Kms

Nalsarovar Bird

sanctuary

-6.7 Kms

Nalsarovar Bird

sanctuary

- 4.5 Kms

5. Sensitive Areas with 10 Kms. radius of the site

No

Nalsarovar Bird

sanctuary

-6.7 Kms and falling ecosentive

zone

Nalsarovar Bird

sanctuary

- 4.5 Kms and falling

ecosentive zone

6. Type of Land (As per records)

Agriculral Agriculral Agriculral

7. Distance of nearest Habitation Bagodara – 2.7 Kms

Shiyal – 0.4 Kms Kothatalavdi – 0.8 Kms

8. Nearest Water body Bhogava river – 0.7 Kms

Bhogava river – 1.1 Kms

Bhogava river – 5.5 Kms

9. Road Connectivity

NH # 8A – 0.14 Kms

NH # 8A – 7.3 Kms NH # 8A – 7.00

Kms

Based on the above criteria, Site # 1 village has been selected for the proposed Steel plant.

3.4 SIZE OR MAGNITUDE OF OPERATION


1. Pellet (Pellets) 4 X 200 TPD 800 TPD

2. DRI Kilns (Sponge Iron) 4 X 150 TPD

600 TPD

3. Induction Furnace with Concast (MS Billets)

4 X 25 T

1000 TPD

4. Rolling Mill (Bars, Rods and Structurals)

2 X 500 TPD

1000 TPD

5. Power Plant WHRB 1 X 12 MW 12 MW


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(Electricity) FBC 1 X 5MW 5 MW

3.5 MANUFACTURING PROCESS

3.5.1 PELLET PLANT

The process of pelletization enables converting Iron Ore Fines /Iron Oxide (Mill scale) Ore into

“Uniformed Sized Iron Ore Pellets” that can be charged into the blast furnaces or for Production of

Direct Reduced Iron (DRI).Pellets are uniform size, with purity of 63%- 65% contributing to faster

reduction and high metallization rates.Pellets with their high, uniform mechanical strength and high

abrasive strength increase production of sponge iron by 25% to 30% with same amount of fuel.

Process Description

The iron ore pelletization unit comprises of following sections:

a) Drying & Prepn. of Iron Ore Fines

b) Grinding

c) Mixing and Blending

d) Pelletization

e) Screening

f) Travel Grate Furnace

g) Rotary Kiln

h) Cooler

i) Stacking

j) Recovery of Dust and Spillage

Drying & Preparation of Iron ore Fines:

Generally Iron Ore Fines,/ Iron Oxide (Mill Scale) Lime Stone and Dolomite fines available, contain

more than 6-7% moisture and require drying before grinding. The drying is carried out in Rotary

Drum Dryer. The moisture content in the dry material is controlled. The low grade Iron Ore Fines is

feed in a screen for separation. Oversize/ under size moves to the primary grinding circuit.

Grinding

Iron Ore Fines, Dolomite and Lime Stone are mixed in required proportion and fed into a Ball Mill.

The fineness of the product is controlled as may be necessary for particular ore and Pellet quality.

Mixing and Blending

Iron Ore powder blended with Bentonite and other binding materials in desired proportion. Small

quantity of water is added during blending operation. This raw mix is ready for Pellet making and

store in feed hopper.


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Pelletization

Controlled quantity of raw mix is fed on disc Pelletizer. Some amount of water is sprinkled for

producing Pellets. These Pellets are passed through oversize and undersize screens. Sized Pellets are

then sent to sintering section.

Screening

Pellets produce in Pelletization sections are passed through oversize and undersize screens. Rejects

Pellets are sent back to raw mix silos sized Pellets are fed in to Indurations Furnace.

Travel Grate Furnace

A Travel Grate Furnace is used for drying of Pellets. This is divided into 3 sections (Drying–

Preheating–Heating). Hot Pellets at around 950ºC to 1000ºC from this Travel Grate are dropped into

the Kiln for further strengthening/ Induration.

Rotary Kiln

Rotary Kiln receives Pellets from the grate kiln where Pellets have to withstand at high temperature

approx. 1050ºC – 1200ºC. Here the Pellets gain more hardness due to high temperature. Furnace Oil

/ Producer Gas is used as a fuel inside the Kiln. After the Kiln the Pellets are passed to the Grate

Cooler.

Cooler

Grate Cooler receives hot Pellet with temperature up to 1200ºC coming from Rotary Kiln. Cooler has

its own blowers to blast the air from bottom. The hot air from the first zone is used as a combustion

air in kiln. The hot blast of the second zone is used in the pre-heating zone-1 of travel grate and the

air from the 3rd zone is discharged to the atmosphere through chimney as its dust concentration is

well within the permissible limits of pollution norms. Volume of cooling air in all the three zones is

regulated automatically through the temperature control loops as per the requirement. Cold Pellets

at about 100ºC are discharged on conveyors and they are quenched by the cold water for further

cooling and then conveyed to the stock pile/ loading hoppers.

Stacking

The screened Pellets of required size duly cooled at air cooler and subsequently natural cooling are

transported to Bunkers.

Recovery of Dust and Spillage : Spillage from drying zone and preheating zone of traveling grate,

dust from the wind box of traveling grate and dust collected through de-duster of technological

process shall meet and will be sent to dust bin via belt conveyor, after they are ground together with

iron ore concentrate at grinding mill. Spillage (dry Pellets) produced at the discharge end of traveling


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grate will be fed into the kiln from the feed chute of the kiln feed end by bucket elevation. Almost all

the dust and spillage are re-circulated and recovered

3.5.2 DRI KILN BASED SPONGE IRON PLANT

The Direct Reduced Iron (DRI) plant will comprise of 4 x 150 TPD Kiln and related accessories

including Waste Heat Recovery power generating unit.

The major plant facilities for the Sponge Iron plant envisaged are as follows:

Day bins

Rotary Kiln & Cooler

Central Control Room

Product processing and product storage

Off gas system including waste heat recovery power generation

The day bin building will have bins for meeting raw material required for kiln. This bin will have the

storage facility for pellets, feed coal, dolomite etc.

A refractory lined rotary kiln will be used for reduction of Iron ore in solid state. A central Burner

located at the discharge end will be used for initial heating of the kiln. Sized Iron ore will be


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continuously fed into the kiln along with coal which has dual role of fuel as well as reductant.

Dolomite will be added to scavenge the Sulphur from the coal. A number of air tubes will be

provided along the length of the kiln. The desired temperature profile will be maintained by

controlling the volume of the combustion air through these tubes. The Carbon monoxide generated

due to the combustion of coal, reduces the iron ore and converts it into sponge iron. The rotary kiln

is primarily divided into two zones viz. the pre heating zone and the reduction zone. The preheating

zone extends over 30 to 50 % of the length of the kiln and in this the moisture in the charge will be

driven off and the volatile matter in the coal will be burnt with the combustion air supplied through

the air tubes. Heat from the combustion rises the temperature of the lining and the bed surface. As

the kiln rotates, the lining transfers the heat to the charge. Charge material, pre-heated to about

1000oC enters the reduction zone. Temperature of the order of 1050oC will be maintained in the

reduction zone, which is the appropriate temperature for solid state reduction of iron oxide to

metallic iron. This hot material will be transferred to rotary cooler. In rotary cooler the material will

cool from 1000oC to 100oC in cooler by spraying water. The cooler discharge material consists of

sponge iron lumps, sponge iron fines and char. Magnetic and non-magnetic material will be

separated through magnetic separators and stored in separate bins


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3.5.3 STEEL MELTING SHOP

In Steel Melting Shop (SMS), Sponge Iron will be melted along with melting scrap and fluxes to make

pure liquid steel and then to mould it in required size billets. The SMS will consist of following

equipment and subassemblies:

Induction Furnace: Induction Furnaces is a device to melt the charge material using electrical power.

It consists of Crucible consisting of water cooled induction coils lined with refractory material lined

with water cooled induction coils, Electrical system to give controlled power to induction coil,

Hydraulic tilting system, Heat exchanger to cool the circulating water, water softener for generating

soft water, furnace transformer, Power Factor improvement system and surge suppressor.

Ladles: Ladles are pots with refractory lining inside to withstand 17500C temperature. It has side

arms so that can be lifted with the help of crane. Ladles are used to stores the liquid steel from

Induction Furnace and take it for further processing. Ladles are with bottom nozzle and

pneumatically operated gate for discharge of liquid.


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Cranes: Electric Over-head (EOT) cranes of various capacities are used to carry the ladles/materials at

different places. Cranes are used in Melting hall to charge melting scrap, remove the ladles to the

LRF, further to place it over the Tundish of the Continuous Caster, to remove billets from the cooling

bed and store at designated places, and also for other petty use. Accordingly, the sizes, capacity and

numbers of cranes are decided.

Continuous Casting Machine (CCM): CCM is used to continuously cast the liquid steel in required

cross section and in length. It consists of Tundish, Mould, Bow with Withdrawal mechanism,

straightening mechanism and cooling bed, hydraulic system for withdrawal mechanism, water pumps

and cooling towers for water spray on the withdrawn section as well as on the cooling bed. Dummy

bar is provided to start the casting. Tundish is a rectangular vessel, lined with refractory and having

discharge nozzle with pneumatically operated gate. A stand is erected over it where the ladle is

stationed for discharging the liquid in it. Mould is of copper with water cooled jacked. Its cross-

section in the bottom is of the size of which billet is to be drawn. Initially the dummy for of the same

size is kept inserted. When the liquid steel is poured in the mould, the dummy bar is drawn slowly, so

that the liquid steel in partially frozen state comes out of the mould. Water spray nozzles are

installed to spray water over the just drawn billet to cool it further and to harden the skin of the

drawn billet.

There will be 4 nos. of 25 T Induction Furnaces in the SMS plant. MS Billets will be produced in

Continuous Casting Machine.

3.5.4 ROLLING MILL

A pusher type furnace has been envisaged for the heating of Billets. The furnace will be end charging

and side discharging. It will have single row as well as double row charging facility. The furnace will

be heated with FO. The furnace combustion system will comprise of air blowers, FO storage, supply

and preheating system and other associated facilities. The product of combustion will leave the

furnace at charging end and exhausted through underground flue tunnel and passed through a

metallic tubular recuperator before finally let off to a self-supporting steel chimney of sufficient

height. A set of instrument will be used for smooth operation of the furnace. Facility for direct

charging of billets from continuous casting to the rolling mill is also envisaged.

Rolling Mill (Bars, Rods and Structurals)

A cross country type mill has been envisaged for the plant. The stands have been grouped into

roughing, intermediate and finishing groups. Roughing group will have 4 (four) stands, intermediate


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group will have 8 (eight) stands and finishing mill will have 8 (eight) stands. Roughing group of stands

will be driven by one motor. 4 nos. of intermediate stands will be driven by two motors and balance

4 nos. will be driven by a separate motor. Each stand of finishing group will be driven by single

motor. Necessary guides and troughs will be provided at entry and exit of mill stands.

Automated tilting, drop type tilter and feeding arrangement will be provided in roughing group of

stands. Repeaters have been provided in roughing / intermediate stands as necessary.

Design provision has been made for introduction of slit rolling facility in future to roll 8 mm, 10 mm &

12 mm rebars in two strands. The rebars discharged from the mill will pass through a water cooling

system comprising cooling pipes with high pressure water nozzles for rapid water quenching. At the

cooling pipes the bar skin temperature will be reduced to about 600oC. The core of the bar still

remains hot. This entrapped heat tempers the bar. This thermo-mechanical treatment of the bars

increases tensile strength without adversely effecting weldability and elongation properties. This

process eliminates requirement of cold twisting of bars for production of rebars.

A dividing shear, to cut the products to cooling bed length, will be located immediately after the

water cooling system. This shear will divide all products to cooling bed lengths. Rake type cooling

beds have been envisaged to receive the rolled product. Cooling bed will be provided with incoming

and outgoing roller tables. One cold shear has been provided to cut the bars coming out of cooling

bed into commercial length of 6 to 12 m. The rolled products will be formed into bundles and will be

strapped by strapping machine manually.

The finished products will be removed by overhead EOT crane and stored in the storage area or

dispatched through road vehicles.

In the proposed project, 2 x 500 TPD capacity Rolling Mill will be installed for producing 1,000 TPD of

bars, rods and Structural Rolled Products.


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3.5.5 POWER PLANT

Its is proposed to install 12 MW WHRB & 5 MW FBC based power plant to meet the power

requirement for various processes of integrated plant including auxillaries of power plant.

WHRB Power Plant:

Production of sponge iron in DRI kiln generates huge quantities of hot flue gases carrying

considerable sensible heat. The energy content of these gases can effectively be used to generate

electric power as well as steam for meeting various process requirements. Thus a WHRB (Waste Heat

Recovery Boiler) power plant would be an ideally suited proposition to effectively make use of this

waste gas. This WHRB Power plant would not only make the plant independent of external source of

electric power to some extent but would also result in energy conservation and environment

protection.

Steam Turbo-generators (STGs) envisaged for the Power plant will be single cylinder, multistage,

extraction – cum – condensing type complete with condenser, air evacuation system, 2 x 100%

condensate extraction pumps, electronic governing system, lubricating oil system, regenerative feed


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heating system etc. The turbine will be fed with steam generated from HRSG in DR kiln. The STGs will

be located in the machine hall of the power plant.

FBC Power Plant:

The unit will have one FBC boiler connected to 5 MW Steam Turbine Generator. The boiler will be

designed for continuous operation at Turbine Maximum Continuous Rating (TMCR). A margin of 10%

over TMCR shall be taken into account to arrive at Boiler rated capacity. The boiler will be natural

circulation, fluidized bed combustion, two pass, non reheat, single drum, balanced draft, semi-

outdoor type. The boiler will have continuous evaporation rating of approx. 360 tonnes/hr. (BMCR

shall not be less than 110% of TMCR) with steam parameters at super heater outlet as 98 kg/cm2 and

5400C (± 50C). The feed water temperature at MCR at inlet to economizer is expected to be around

230 degree C. Steam parameter are to be fine tuned at Boiler outlet based on actual plant layout and

piping arrangement. The boiler will be complete with ash /solid separator, economizer, air heater,

ducting, FD fans, ID fans and PA fans. Air cooled condensers envisaged for Power plant to conserve

water.

Process Flow Diagarm

FBC Power plant


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3.6 RAW MATERIAL REQUIREMENT

The following will be the raw material requirement for the proposed project:

Raw Material Quantity (TPD) Source Mode of Transport

For pellet plant

Iron ore fines/Iron Oxide

(Mill Scale)

832

Rajasthan Chattisgarh,

Karnataka,Odissa

By road (through covered trucks)

Bentonite 48

Kutch (Gujarat) By road

(through covered trucks)

Imported Coal

128

South African

from Kandla port (Gujarat)


For DRI (Sponge Iron)

Pellets 798

Internal Through covered

conveyors

Imported Coal

570

South African

from Kandla port

(Gujarat)


Dolomite 48

Local/Gujarat By road


For Steel Melting Shop (MS Billets)

Sponge Iron

582

Internal Through covered

conveyors

M.S.Scrap 562

Bhavnagar/

Alang Imported

By road


Ferro alloys 12.5

Local /Gujarat By road


For Rolling Mill (Bars/Rods/Structurals)

Billets 1000 Internal Through Conveyors

Imported Coal 155 South African

from Kandla port

By road



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Raw Material Quantity (TPD) Source Mode of Transport

(Gujarat)

For FBC Boiler [Power Generation 5 MW]

Char/Dolochar 100 Internal/local through covered

conveyors

Imported Coal (100 %) 30 South African

from Kandla port

(Gujarat)

By road


3.7 WATER REQUIREMENT AND ITS SOURCE

Water required for the proposed project will be 1680 KLD and same will be sourced from Ground

Water source. Following is the break up of water requirement:

S.NO. WATER REQUIREMENT FOR QUANTITY IN KLD

1 Pellet 140

2 DRI kilns 100

3 Steel Melting Shops 800

4 Rolling Mills 400

5 Power Plant 200

6 Domestic 40

Total 1680

3.8 WASTEWATER GENERATION & ITS MANAGEMENT

There will be no effluent generation in the Pellet, DRI plant, SMS, Rolling Mill as closed

circuit cooling system will be adopted.

Effluent from power plant will be treated and after ensuring compliance with SPSB norms,

it will be utilized for dust suppression, ash conditioning and for greenbelt development.

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

trench.

3.9 SOLID WASTE GENERATION AND ITS MANAGEMENT

The following will be the solid waste generation & disposal method from the proposed project.


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S.NO WASTE QUANTITY (TPD) METHOD OF DISPOSAL

Pellet plant :

1 Ash 32 Will be used in own brick manufacturing unit

and remaining quantity will be given to other

brick manufacturers.

Sponge Iron plant :

2 Ash

36 Will be given to Cement Plants & Brick manufacturers.

3 Char/ Dolochar 100 Will be used in FBC power plant as fuel/ brick manufacturing.

Induction Furance :

4 Slag 90 Slag from SMS will be crushed and iron will be recovered & then remaining non -magnetic material being inert by nature will be used as sub base material in road construction/brick manufacturing

Rolling mill :

5 Mill scales 10 Will be reused in the Pellet Plant

Power plant :

6 Ash from Power Plant

1.5 Ash generated will be given to Cement Plants/ Bricks manufacturers.

3.10 POWER REQUIREMENT

Power requirement for the proposed project will be met from Gujarat State Electricity Corporation

Limited during construction phase. Power required for proposed project will be met from proposed

12 MW WHRB and 5 MW FBC based power plant & remaing from Gujarat State Electricity

Corporation Limited during operation. Following is break up of power requirement:

S.No. Plant Power Requirement (in MW)

1 Pellet (2,64,000 TPA) 5.00

2 DRI (1,98,000 TPA) 3.5

3 SMS (3,40,000 TPA) 40.00

4 Rolling Mill (3,30,000 TPA)

6.00

5 Power Plant – WHRB 1.5


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(12 MW)

6 Power plant – FBC ( 5 MW)

1.0

Total 57.00


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Chapter – 4 : SITE ANALYSIS

4.1 INFRASTRUCTURE

For establishment and successful operation of plant, it is imperative to ensure availability of the

following infrastructure:

Availability of raw coal & iron ore and its proximity to the plant to reduce cost of

transportation.

Road / Rail head connection so that the raw materials and products can be easily and

economically transported.

Availability of water.

Permanent and reliable source of power.

Adequate land for the plant, storage of raw material and products & disposal of waste

material.

4.2 CONNECTIVITY

The proposed site is well connected with Road network. The following table gives brief regarding

connectivity of the proposed site:

Component Description

Road : NH#8A ( Ahmedabad – Rajkot) – 0.14 Kms.

Rail : Nearest station – Baula Railway Station – 30.5 Kms.

Air : Ahmedabad Airport – 67.0 Kms.

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 agricultural land and converted to industrial purpose.


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4.4 EXISTING INFRASTRUCTURE

No infrastructure facilities are available at the project site.

4.5 SOIL CLASSIFICATION

The soils in the tehsil are classified in to the following soils.

Black soils

Goradu soils

Kyari

4.6 CLIMATIC DATA FROM SECONDARY SOURCES

The climate of the district is characterised by hot summer and general dryness except during the

southwest monsoon seasons. The year can be divided into four seasons. The period from March to

May is the hot season (summer) followed by southwest monsoon from June to September. October

and November constitute the post-monsoon or retreating monsoon season. The cold season (winter)

starts from December and ends in February. The mean maximum temperature ranges between

28.4ºC during January to 41.8ºC during May and the mean minimum temperatures vary between

11.7ºC during January and 27ºC during June. The relative humidity varies between 32 % (March) and

79% (August). The wind velocity varies from 74 km/d (November) and 174.2 km/d (June). The

potential Evapo-transpiration varies between 3.2 mm (December) and 7.8 mm/d (June). Long-term

average annual rainfall recorded by IMD station at Ahmedabad is 799.6 mm. Most of the rainfall

(about 766 mm) is received from south-west monsoon between June to September.


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Chapter – 5 : PLANNING BRIEF

5.1 PLANNING CONCEPT


Tehsil Baula, District Ahmedabad, State Gujarat. Following is the plant configuraton and production

capacity:


1. Pellet

(Pellets)

4 X 200 TPD 800 TPD

2. DRI Kilns

(Sponge Iron)

4 X150 TPD

600 TPD

3. Induction Furnace with

Concast (MS Billets)

4 X 25 MT

1000 TPD

4. Rolling Mill

(Structural Steel &

Rolled products)

2 X 500 TPD

1000 TPD

5. Power Plant

(Electricity)

WHRB 1 X 12 MW 12 MW

FBC 1 X 5 MW 5 MW

5.2 POPULATION PROJECTION

Bagodara is a large village located in Bavla of Ahmadabad district, Gujarat with total 1040 families

residing. The Bagodara village has population of 5088 of which 2596 are males while 2492 are

females as per Population Census 2011.

In Bagodara village population of children with age 0-6 is 761 which makes up 14.96 % of total population of village. Average Sex Ratio of Bagodara village is 960 which is higher than Gujarat state average of 919. Child Sex Ratio for the Bagodara as per census is 987, higher than Gujarat average of 890. Bagodara village has lower literacy rate compared to Gujarat. In 2011, literacy rate of Bagodara village was 70.95 % compared to 78.03 % of Gujarat. In Bagodara Male literacy stands at 84.23 % while female literacy rate was 57.05 %.


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5.3 LAND USE PLANNING

The following is the Land use planning of the proposed project area.

ITEM EXTENT OF LAND (ACRES)

Built up area 8

Internal roads 2

Storage yard 5

Greenbelt 12

Paking area 5

Open land 5.5

Total land 37.5

5.4 AMENITIES / FACILITIES

Facilities like canteen, rest rooms will be provided in the existing plant as basic facilities to workers.

No other additional facilities are proposed.


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Chapter – 6 : PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The main plant area comprises of Pellet, DRI Kilns, Furnace sheds, Rolling mill area, raw material

storage and product storage etc.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No colonization is proposed; however, facilities like canteen, rest room and indoor games facilities

will be provided in the proposed plant and one Admin building is also proposed.

6.3 GREEN BELT

More than 1/3rd of total land availability is reserved for plantation i.e. greenery.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

10 m wide greenbelt is being maintained all around the plant.

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

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

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

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

are known to be particularly tolerant to pollutants.

6.4 SOCIAL INFRASTRUCTURE

Social infrastructure will be developed as per need based in the Villages of the close vicinity of the

project.


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6.5 CONNECTIVITY

The proposed site is well connected with Road network. The following table gives brief regarding

connectivity of the proposed site:

Component Description

Road : NH#8A ( Ahmedabad – Rajkot) – 0.14 Kms.

Rail : Nearest station – Baula Railway Station – 30.5 Kms.

Air : Ahmedabad Airport – 67.0 Kms.

6.6 DRINKING WATER MANAGEMENT

The required amount of drinking water will be suppled from Mineral water plant.

6.7 WASTEWATER GENERATION & ITS MANAGEMENT

There will be no effluent generation in the Pellet, DRI plant, SMS & Rolling Mill as closed

circuit cooling system will be adopted.

Effluent from power plant will be treated and after ensuring compliance with SPCB

norms, it will be utilized for dust suppression, ash conditioning and for greenbelt

development.

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

trench.


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Chapter – 7: REHABILITATION & RESETTLEMENT (R & R) PLAN

No rehabilitation and resettlement is required for the proposed project did not have any

habitation.


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Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE

Proposed Project will be implemented in 48 months from the date of receipt of Environmental

Clearance from the MoEF&CC, New Delhi & Consent from SPCB.

8.2 PROJECT COST

The estimated cost for the proposed project for will be Rs. 261.0 Crores. The following is the breakup

of the proposed project cost.

Particulars Rs. in Crores

1 Iron Ore Pelletization Plant 25.0

2 Sponge Iron 40.0

3 Induction Furnace with CCM 80.0

4 Rolling mill 40.0

5 Power plant 68.0

Total Investment 253.0

6 Land 8.0

Grand Total 261.0

Means of Finance Rs. in Crores

Particulars

i. Promoters contribution 86.0

ii. Financial institutions 175.0

Total Investment 261.0


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Chapter – 9 : ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS

With the implementation of the proposed project, the socio-economic status of the local people will

improve substantially. The land rates in the area will improve in the nearby areas due to the

proposed activity. This will help in upliftment of the social status of the people in the area.

Educational institutions will also come-up and will lead to improvement of educational status of the

people in the area. Primary health centre will also be developed by us and the medical facilities will

certainly improve due to the proposed project.

9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by undertaking

following activities / responsibilities as the part of Corporate Social Responsibility.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

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