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.
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
2 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
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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
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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
Techno Economic Feasibi l i ty Report of M/s Maithan steel & Power Ltd At
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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
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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.
Techno Economic Feasibi l i ty Report of M/s Maithan steel & Power Ltd At
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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
He is one of the Promotors director of company. His DIN is -00338133. He is aged about
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
He is one of the Promotors director of company. His DIN is -00338133. He is aged about
70 years. S/o-Late LekharajBagaria and permanent resident of 21, S P mukharjee Road,
Murgasol, Asansol, West Bengal.
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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
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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
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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
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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.
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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
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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.
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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.
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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.
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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.
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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.
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Project site
Fig 3.1 Toposheet of Maithan Steel & Power Ltd, Bonra, showing project
site
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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
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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,
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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
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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
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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.
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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.
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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
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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.
The location is well connected by road and Rail. The site is only 2.30 km away from the
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.
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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.
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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
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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.
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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.
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.
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
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
31 Global Tech Enviro Experts Pvt. Ltd.
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.
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
32 Global Tech Enviro Experts Pvt. Ltd.
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.
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
33 Global Tech Enviro Experts Pvt. Ltd.
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.
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
34 Global Tech Enviro Experts Pvt. Ltd.
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
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
35 Global Tech Enviro Experts Pvt. Ltd.
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.
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