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1
DETAILS PROJECT REPORT
FOR
IRON ORE PELLETIZATION PLANT
(CAPACITY-2X1200 TPD)
(2X0.4) 0.8 MILLION TPA
VILLAGE: PARAGHAT
TEHSIL: MASTURI DISTRICT: BILASPUR
CHHATTISGARH
SUBMITTED BY
M/s RASHI STEEL AND POWER LIMITED BF-1,FIRST FLOOR, RAJIV PLAZA
OPP.AXIS BANK- BILASPUR, (CHHATTISGARH) 495001
email [email protected]
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INTRODUCTION
PROJECT AT A GLANCE
The Rashi Steel And Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari Halka
No. - 38 Village : Paraghat Tehsil - Masturi and DistrictBilaspur, in Chhattisgarh
State.
Name of the Company M/s Rashi Steel and Power Ltd.
BF-1, First Floor, Opp. Axis Bank
Rajiv Plaza-Bilaspur,
PIN - 495001 (Chhattisgarh)
email [email protected]
Phone: 07752-408405
Factory Office Village : Paraghat
Post Office : Jairamnagar
Tehsil : Masturi
District : Bilaspur, (C.G.)
Name of the Directors Sh. Mahesh Gupta
Sh. Rakesh Jindal
Sh. Amar Agrawal
Sh. Ashok Kumar Agrawal
Sh. Ashok Agarwal
Project Cost 15,000.00 Lakhs (150 Cr.)
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Product & Production Capacity:
Project Prouduct Existing Proposed Total
2 x 0.4 Million TPA Palletization Plant
Pallet NIL 2x1200TPD 0.80 Million TPA
Location of the Plant : At - Paraghat Village
Tehsil : Masturi
District· Bilaspur, (C.G.)
Coordinates details
Point: A N220 01’ 54.3’’ E820 19’ 23.6’’
Point: B N220 02’ 08.2’’ E820 19’ 25.5’’
Point: C N220 02’ 09.2’’ E820 19’ 42.1’’
Point: D N220 01’ 52.0’’ E820 19’ 38.1’’
Total Land Area : 34.12 Acres
Land for Green Belt : 11.25 Acres (33%of total land area)
Working Days : 330 Days
Raw Materials :
(1) Palletization Plant :
(A) Iron Ore fines - 8,71,200TPA - From open market.
(B) Coal - 22,440TPA - From open market and SAIL.
(C) Bentonite - 11,880 TPA - From open market.
(2) Producer Gas Plant:
(A) Coal - 46200 TPA - From open market and SECL.
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Water Requirement
(A) Source : From Bore well and River
(B) Annual Requirement : 1,32,000 KL per Annum (400.00 KLD)
(C) Rainwater harvesting : Will be provided to recharge the ground
water. D.G. Set : 02 Nos. (Less than 500 KVA)
Power Requirement : Source - Chhattisgarh State Electricity
Board (CSEB), Bilaspur District.
(A) Pellet Plant - 4000 KVA
Solid/Hazards Waste & it's Disposal : No Hazardous waste was
generated
(A)Palletization Plant : Iron Ore Fine Dust: 343 TPD /1,13,256 TPA)
Reused in Palletization Plant
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PROJECT COST ESTIMATED PROJECT COST:
(ii) Factory Building & Civil Works etc. 3800.00
(iii) Plant & Machinery 7750.00
(iv) Pollution Control Devices 1100.00
(v) Electrical Installation 580.00
(vi) Misc. Fixed Assets 120.00
(vii) Preliminary and Preoperative Expenses 030.00
(viii) Deposits 070.00
Sub-Total 14000.00
Margin Money for Working Capital 1000.00
Grand -Total 15000.00
MEANS OF FINANCE
PARTICULARS AMOUNT IN
LACS
(i) Land & Site Development and 550.00
Infrastructure
PARTICULARS AMOUNT IN
LACS
(i) Share Capital 5160.00
(i i) Unsecured Loan 2640.00
(iii) Tearm Loan 7200.00
Grand-Total 15000.00
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OVERVIEW OF THE COMPANY
Preamble: Steel a basic commodity for all industrial activities, quantum of its
consumption is considered an index of industrial prosperity. Since
independence, there has been a substantial growth in the steel sector in India
from 1.5 Million Tons in 1950-51 to about 31 Million Tons at present. Additional
Steel making capacity of about 8 to 10 Million TonsNear exists in the
secondary steel sector. Further, with nearly 20% of the world population,
India's contribution is only of the order of 3.4% of world steel production.
Hence, short term and long term strategies are necessary in planning the
development of the steel industry in the country to improve the level of per
capita steel consumption. It is expected that with the measures taken by Govt.
of India for promotion consumption of iron and steel and expected growth of
Indian economy the requirement of steel will significantly increase and
accordingly the domestic manufacturing capacity needs to be increase.
Considering the potential of iron and steel in India and the experience gained
by the group in this sector, M/s RASHI STEEL AND POWER LTD (RSPL) has
decided to install pallet plant in the state of Chhatisgarh.
Brief Profile: Promoters of the company belong from erudite families of Raipur.
The management of the company believes that "Successful operation,
performance and long term viability of any business depends on a continuous
sequence of sound decision made individually or collectively by the
management team. Everyone of this decisions ultimately causes for better or
worse, an economic impact on the business. In essence, the process
managing any enterprise amounts to making an on going series of economic
choices, every time trading off costs or benefits."
The brief Bio-data of the promoters are given below:
Shri Ashok Agrawal, Promoter/Director
Shri Ashok Agrawal, S/o Late Gajanand Agrawal hails from an illustrious and
prominent family of Chhattisgarh. He is extremely hard working, dynamic and
intelligent businessman. Ashok Agrawal has gained business experience in
last 15 years and presently Director of many companies like Rukmani
Infrastructure Pvt. Ltd., Hotel ANS international Ltd. And also partners in Dadu
Buiders and Developers. Having sharpened his business acumen in the above
referred company, he is being taken in as promoter director in the new venture
of the family.
7
Mr. Rakesh Jindal, Promoter / Director
Mr. Rakesh Jindal, aged 46 Years, is a Chartered Accountant. He is a
seasoned professional of steel sector and has rendered more then 20 years of
valuable service at Jindal Steel & Power Ltd. (JSPL) in the capacity of V.P.
(Commercial). During his tenure he had handled commercial aspects of various
projects of JSPL. He is quite respectable at higher level in JSPL. He brings with
him immense experience which would be of great help to the company.
Mr. Amar Agrawal, Promoter / Director
Mr. Agrawal, aged 47 years, is a B Com. Graduate. His business interest varies
from Ferro Alloys, Power, and Infrastructure to Logistics etc. He is the key
strategist for the new venture i.e. Integrated Steel Plant. He has extensively
traveled to USA, China & Middle East, Africa etc. He is known for his foresight
ness and resourcefulness. He is presently successfully running a 15 MW
thermal power plant at Raigarh (CG).
Mr. Mahesh Gupta, Promoter / Director
Mr. Gupta, aged 43 years is an Engineer- Mechanical has very vast experience
in Power and Steel Sector. He has good knowledge of the technology for
making steel through sponge iron. He has rendered his services in various
organizations in last 17 years. His last service with Scania Steel & Power Ltd.,
Raigarh as a General Manager, Technical & Production.
Shri Ashok Agrawal, Promoter/ Director
Shri Ashok Agrawal, aged about 43 years is a graduate in commerce, he is
involved In a business of real estate from last 15 years and manufacturing of
cement capsules from last 5 years. His responsibility in this unit to supervise the
production and maintenance of the plant. Since his vast experience in the field
and wide contacts shall have good supports to the unit.
As mentioned above the promoters and key personal are experienced,
energetic and resourceful men with good links. The promoters are also
financially stable and will be able to execute the project successfully and in
specified time and run it profitably and smoothly in future too.
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LIST OF DIRECTOR’S
M/s RASHI STEEL AND POWER LTD.
a)
SL. NO. 1 2 3 4 5
DESIGNATION DIRECTOR DIRECTOR DIRECTOR DIRECTOR DIRECTOR
NAME MAHESH
GUPTA
RAKESH
JINDAL
ASHOK KUMAR
AGRAWAL
AMAR
AGRAWAL
ASHOK KUMAR
AGRAWAL
FATER NAME Lt. GIAN
CHAND GUPTA
Lt. ANAND
SURUP
Lt. JAGMOHAN
DAS AGRAWAL
Shri
SATYANARAYAN
AGRAWAL
Lt. GAJANAND
AGRAWAL
CITIZENSHIP INDIAN INDIAN INDIAN INDIAN INDIAN
PAN NO AFEPG0838D ACHPJ2881P ADLPA9437H ADPPA3753Q ACHPA9792L
PASSPORTNO J0219069 H5763011 G7859009 G1014283 G2258565
MOBILE NO 09993520981 07752-408405 07752-408405 07752-408405 07752-408405
EMAIL ID maheshgp70@
yahoo.co.in
rakeshjindal88
@gmail.com
bilaspur@mail.
com
amar.rrenergy@
gmail.com
ashokkumaragrawal@
live.com
ADDRESS
House No. 25,
Ring Road No
2, Mahima
Vihar, Bilaspur
District:
Bilaspur (C.G.)
B-1 Jindal
Nagar, Jindal
Steel & Power
Ltd.
sh-63,
Chhendipada
Road, Nisa,
Jindal Nagar
Post Office,
Angul-759111
Piteshwar
P/34B, Jain
Mandir Road
Kranti Nagar
Bilaspur, C.G.
495001
District:
Bilaspur (C.G.)
krishna vihar,
dhimrapur
chowk,
raigarh-496001
District: Raigarh
(C.G.)
House No. 10/45,
Dabhra Road, Kharsia
496661, Chhattisgarh
District: Raigarh (C.G.)
ADDRESS DETAILS
Corporate Office: Registered Office: Site Office:
M/s Rashi Steel and Power Ltd. M/s Rashi Steel and Power Ltd. M/s Rashi Steel and Power Ltd.
BF-1, First Floor, Rajiv Plaza A-184, First Floor, Meera Bagh Village: Paraghat/Beltukri
Opposite Axis Bank, New Delhi, 110087 Near Lilagar River Bridge,
Bilaspur C.G. 495001 Tehsil Masturi ,Post Off: Jairamnagar,
District: Bilaspur C.G.
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PROJECT DESCRIPTION
SALIENT FEATURES OF THE SITE SITE LOCATION
The Rashi Steel and Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari Halka
No. - 38 Village: Paraghat Tehsil - Masturi and District - Bilaspur, in Chhattisgarh
State.
The project location is well connected by road and rail. The nearest railway station
is Bilaspur, which is at a distance of 22 km from the site. The nearest airport is
Raipur and sea port is Paradeep - Orissa.
The site was selected based on the following factors
• Nearness to source of main raw materials . r
• Location of consumer center
• Availability of sufficient stretch of land
• Convenient Rail & Road links (plant located near SH)
• Perennial & adequate sources of water supply
• Availability & closeness to source of adequate power supply .
There are no ecological sensitive places like national park, Sanctuary, biosphere
reserves, heritage site, archeological monuments, defense installation, health
resorts, scenic beauty, etc. around 10 kms of the site. There is no route of
migratory animals within the project site.
METEOROLOGICAL DATA
Maximum dry bulb temperature Minimum dry bulb temperature Design dry bulb
temperature Design wet bulb temperature Max. Relative Humidity
Maximum dry bulb temperature : 48 Deg C
Minimum dry bulb temperature : 12 Deg C
Design dry bulb temperature : 35 Deg C
Design wet bulb temperature : 28 Deg C
Max. Relative Humidity : 85 % Min. Relative Humidity : 50 % Design Relative Humidity : 65%
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WIND AND SEISMIC DATA
Basic wind speed : As per IS 875
Seismic zone : Zone II As per IS 1893
DETAILS
The Rashi Steel And Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari
Halka No. - 38 Village: Paraghat Tehsil - Masturi and District - Bilaspur, in
Chhattisgarh State.
Details of Land - Total avaible Land is 34.12 Acres
The proposed Steel Plant is at National Highway connecting Raipur, Bilaspur NH-
200. A connecting road from the plant site to the highway has been constructed
by State Govt.
LAND AREA STATEMENT
(Total Land Area = 34.12 Acres)
I S.NO. PARTICULARS
AREA in Acres
1 Built up area - 07.00
2 Roads and Drains 05.00
3 Greenbelt and greenery 11.25
4 Parking 01.87
5 Temporary Dump Yard 05.00
6 Open area 04.00
Total Land Area 34.12 Acres
Rail
Project site is connected via S.E.C. Railway line between Raipur and
Rourkela, which is main line between Mumbai and Howrah.
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Airport
The nearest civilian airport is at Mana, Raipur, and the capital of
Chhattisgarh at about 120 Km from the plant site.
IMPORTANCE OF PROJECT TO REGION & COUNTRY
Our country has been progressing very fast requiring inter alias, high
production of steel. Steel plays a very important role in improving the economic
condition of any country. Thus, the project will improve the economic condition
of the country to a great extent.
As a result of the proposed project various facilities like educational,
medical and other tangible benefits will enhance in the area. Thus, the project
will greatly improve the economic condition of the area.
JUSTIFICATION OF PROJECT
The project is situated at Paraghat Village; there are no ecologically
fragile areas.
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PELLETISATION PLANT (2 X 0.4 MilLION TPA CAPACITY)
INTRODUCTION
The proposed 2 x 0.4 Million TPA Pelletisation Plant will be established based
on the requirement of the raw material for the present established plant.
Considering the scenario in the state and projected requirement of MIs RSPl is
setting up of a 2 x 0.4 Million TPA pelletisation plant. Adequate land is available
for the project. For plant cooling, services and potable water requirement, the
source of water will be from ground water. Product of the proposed plant will be
sold to local market of Sponge Iron Plant and later on for self consumption in
the proposed plant.
M/s RSPL will be implementing the project through loan requirements from
financial institutions and internal accruals and investments from promoters. The
plant. will be executed through package wise system and unit is proposed to be
commissioned in 12 months from zero date.
M/s RSPL is doing in house Engineering & execution as Promoters are
experienced in power sector and has done many projects. M/s RSPL Limited
Engineers will prepare the project report for proposed project.
The DPR covers:-
• Reasons for selection of site.
• Details of clearances and approval.
• Availability of various facilities.
• Technical details of plant & equipment.
• Availability of water, fuel, transportation of water fuel.
• Methodology for evacuation of power.
• Total project cost.
• Financial structure & financial modeling.
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PROPOSED PROJECT: 0.8 (2 x 0.4) Million TPA Pelletisation Plant
DETAILS OF SITE SELECTION
Considerations for selection of site
A power station requires a number of basic inputs such as land, fuel, water
etc. for setting up of power station and is primarily governed by the following
basic considerations:
a) Availability of land
b) Rail/road accessibility
c) Availability of fuel and proximity to source
d) Availability of water and proximity to source
e) Load demand and proximity to the grid
f) Environmental consideration
g) Suitability of the land from topography and geological aspects These
factors have been found very favorable to establish and operate the
project.
Land & Site Details & Availability of Facilities
:)
Land selected for this project is coming under Paraghat village, Masturi -Block,
Bilaspur, CG. Required land is already in the possession of M/s Rashi Steel
And Power Limited. Nearest town is Masturi which is around 10 kms from the
project site. Nearest Railway station is Bilaspur which is around 22 kms from
the project site. Commercial Airport is Raipur and
nearest port is Vishakapattanam.
Availability of Land
Adequate land is available in project site. The site terrain is generally plain
requiring minimum efforts to grade them. The land is currently not in use and
there are no inhabitants requiring rehabilitation or resettlement. The topsoil is
clayey soil. Suitable foundation, based on soil investigation results, will be
adopted. Entire land is under the possession of the company.
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Details of Land : 34.12 Acres Khasra No. and area is enclosed as issued by
revenue department.
a) Accessibility
The site is around 7 kms from National highway-connecting Raipur to Bilaspur
NH 200 . Bilaspur is at a distance of 22 kms from the proposed site. As such
there is no problem in accessibility and transportation of heavy equipment to
site by road.
b) Finished Product:
In Bilaspur area sponge Iron plant is situated about 25 km. radius from RSPl
plant site, which is at a distance of around 25 km by road. Finished product of
pelletisation plant will be utilized in the sponge iron division as raw material.
later on in own Sponge Iron plant which is under consideration.
c) Water Requirement
Requirement of raw water is estimated as 400 m3/day only. The required water
will be from surface water i.e. from near by River and ground water also.
d) Power Requirement The power requirement for the plant will be around 4 MW.
e) Environmental Consideration
The land for the proposed pelletisation plant site is already in possession of MIs
Rashi Steel And Power Limited. The site will be developed based on the
recommendations of the state environmental authorities, as well as the
guidelines of MOEF. Suitable provisions will be incorporated in the design of
buildings, structures, and selection of equipment so that there are no adverse
effects due to emissions, noise, and contamination of soil, water and air.
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PELLETISATION PLANT (2 X 0.4 MILLION TPA CAPACITY) Manufacturing Process of Pelletisation Plant
The grinding process is adopted to improve granularity constitution of
concentrated iron ore and make material fully blended and grinded so that it
can be suitable for palletizing. The sophisticated disc palletizer is adopted to
reduce circulating load and improve utilization efficiency.
The characteristic of grate-annular cooler production process is as follows:
(1) Drying and preheating roasting and cooling proceed in grate kiln and
annular cooler respectively so its equipment is sample and reliable and
product quality is even.
(2) The equipment of roasting system with high adaptability to raw material
can be individually controlled and flexibly regulated.
(3) The consumption of fuel is low and power low as well.
The advanced air flow system is adopted, which fully reclaim-and utilize
sensible heat of high-heat flue gas from annular cooler reduce heat rate of
pellet with maximum utilization of heat energy. The main production process is
controlled by PLC with high automatically. Exhaust gas with dust is purified
and discharged by static de-duster to protect environment. Returned material
and dust arrested are sent to stock yard and damp mill so as to resources can
be fully re-utilized.
PRODUCTION FLOW AND WORKSHOP CONSTITUTION:
Main Workshop:
The main workshop of this pellet production line stockyard proportioning room
drying room damp mill room pelletizer room grate oven building (including
screening and distribution of green pellets), rotary kiln annular cooler air flow
system spillage return system (including spillage lifting) fuel preparation room.
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Stockyard and Proportioning System
A stockyard has storage capacity sufficient amount of concentrated iron
ore. Concentrate iron ore piled open in the stock yard and is delivered to a
receiving bin by the help of shovel cars. It is then extracted from the bottom
part of the bin with the help of vibrating feeder, and then transported into
proportioning bunkers by a reversible belt conveyer. There are two
bentonite receiving bin in the stock yard and 4 proportioning bunkers for
concentrate iron ore. The bentonite is charged by man. The four nos. of
concentrate proportioning bunkers can store iron ore for 8 hour usage. Two
bentonite bin with the capacity of 15 m3 can store usage. Under these
concentrate bunkers, belt scales are equipment for feed proportioning and
by means of frequency speed control of the belt, feed amount of
concentrate iron ore can be regulated. Under the bentonite bin, a weighing
machine is mounted for batching. The speed ratio is controlled by
computer.
Drying Room:
This is a drum like structure of dimension 3x20 m for drying purpose.
Mixture of proportioned concentrate and bentonite is sent to drier drum for
the purpose of heating and drying with the help of flue gas with temperature
of 700°C supplied by a combustion furnace. After heating the end gas with
a temperature of 1200°C is discharged through the chimney. The initial
water content of the mixture is about 11.0% and after drying it comes to
7.0~8.0%.
The dried mixture is then discharged through a chute to a belt conveyer, and
then transported to damp grinding room. The drier has normal processing
capacity of 90 tons per hour.
Grinding Room:
In normal state, the dried blended mix is distributed to belt conveyor by disc
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feeder and conveyed to a blended bin located at damp mill room by belt
conveyer. Then it is filled into the damp mill through a charging conveyer for
mixing, homogenizing and grinding. The grinded material is transferred to a
pallefizin9 belt and then to a blending bin at palletizer house.
Palletiser House:
Dimension of palletiser house covers 15x34.4 m2• The mixture is sent to upper
part of the pelletiser house by belt conveyor then separately discharged to three
bins with level gauges. Each blended mix bin has an effective content of 60 m3
under them tight type belt conveyor are laid respective to 36.0 m disk palletiser.
The speed of tight type belt conveyor can be regulated by a frequency variable
controller, and their speed is matched with that of disk palletizer. Each palletiser
has a production capacity of 50 T/hr. Generally during normal operation two
sets are in operation and the third one is on standby. During palletizing an
amount of water is added to the mixture so that it can have optimal water
content for palletizing. Green pellets from the palletizer are collected and
shipped to screening and distribution system through palletisation belt.
Grate Oven Building:
The green pellets screening & distribution system is composed of spillage
return conveyor. The shaking conveyor evenly distributes the green pellets
transferred by palletisation belt to the conveyor oversize ball roll screen. The
oversize green pellets (>16mm) on the screen are gathered by return conveyer
and transferred to blending bin in palletizer house for re-palletizing. The green
pellets below 16mm in size are transferred to the roller conveyer screen by the
frequency controlled wide belt. Through these two screens, green pellets
between 8-16mm in size are distributed onto receiving area of the oven,
However the pellets below 8mm under the roller conveyer screen are gathered
by return conveyer for re-palletizing.
Grate oven
The plant building for grate oven covers 14 x 59 m2 and the effective width and
length of grate oven is respectively 2.8m and 36m, the depth of pellets
18
distribution on the grate oven bed is 120-180mm. The grate oven is divided into
four chambers from inside with whole preheating section I, II.
Blast drying section I
In this section circling hot air is at about 150°C. Mixed air is blast through pellet
bed, so that circulating hot air at dewatered and get dried. The main heat
source is wasting heat from section III of annular cooler. The air can be give out
directly a lot of steam and mini-dust.
Downdraft drying section
In this section circling hot air at about 300°C mixed with air is downdrafted
through pellet bed so that the green pellets are dried further. The main heat
source is wasting hot air from preheating section I, II. The wasting hot air collect
main pipes in the side blast box and the give through static de-duster, main
draught fan and chimney.
Preheating section I
The hot air from annular cool section II connects the preheating section I by hot
air pipe. The lacking heat is supplies by hot air from preheating section II to get
the hot air temperature of 900°C.
This preheats the pellet from the downdraft section. The wasting hot air is
collected by collecting main pipe in the side blast box and into h) Preheating section II
In the preheating section II, pellets are further heated under hot air of 1100°C,
at the same time partially become hardened. These partial hardened pellets
can bear the impact of drifting-down from grate oven to rotary kiln, and will not
break during rotation of the kiln. Heat sources in this section comes from hot
flue of the kiln tail, end the lacking heat is supplied hood of the section, a flue
and a relief valve are fixed for the lacking heat is supplied hood of the section,
a flue or additional burner. Over the top part of furnace hood of the section, a
flue and a relief valve are fixed for baking furnaces and emergency operation.
19
Green pellets dried and preheated totally about 28 minutes, with enough
strength, are sent into the rotary kiln by way of a shovel and a chute at tail end
of the kiln.
Rotary kiln
The kiln is supported by 2 lintel girders. Compound precast bricks and high
strength heat insulation castable are resistance to wear and thermal insulation,
which can decrease temperature of the kiln's surface and extend its working
life.
The preheated pellets are loaded at feed end of rotary kiln by a shovel and
chute. A special designed collapsible spray gun is mounted at kiln discharge.
Combustion intensity and flame profile can be regulated by means of extension
and contraction of the collapsible spray gun as well as adjustment of blast
volume. Roasting temperature in the kiln is 13001350 °C and rotating speed
and position of the kiln can be controlled. The discharge hood is sealed by a
device, which is protected by a structural cooling blower.
Annular cooler
The baked and roasted pellets from rotary kiln, fall into the receiving bin
(capacity-50m3) of annular cooler through the kiln discharge hood. And then
leveled off on pellets cars of the annular cooler by help of a roller pusher and
cooled by air blast. Its processing capacity is 80t/h, while its cooling time is
around 45 minutes at a normal depth of 680-760 mm of pellets. The annular
cooler is divided into three cooling sections, each equipped with cooling fans,
partition wall and the receiving bin.
The fume hood of the cooler is divided into four areas. In the area i.e. blowe air
to chills the pellets and its heated to 1000-1100°C then directly returns to the
rotary kiln through the kiln discharge hood over the receiving bin and the
parallel fume duct. This hot fume is used to increase temperature and oxygen
content of kiln and change the flame profile from the spray gun. In the second
area, i.e. section II cold blasted and further cools the section I at the same time.
20
The temperature increases to 400-600°C then is right led to drying section I of
the grate oven via a hot air pipe, for further drying and preheating of green
pellets. In section II & IV, the pellets should be cooled to 1500°C and collected
by a buffer bin and then sent out by a heat resistant belt conveyer. Air
temperature in cooling section III is 35000C and is introduced to Drying
Section. Air temperature in cooling section is at 90-100 °C and fume is directly
freed through the chimney of the annular cooler. Blast volume of blowers is
automatically adjusted by a throttle installed in the blast inlet, which is used to
control hot air temperature, so that the most part of heat volume recovered
from pellet cooling can be utilized for palletizing production process.
Air flow system
The air flow system of roasting system including: cool blower hot air circling
and hot air disposal. Circling cool air is the main air source. The air cool the
hot pellets, on the annular cooler and become hot. This hot air from annular
cooler section 1 is used as the second air of rotary kiln and lead to rotary kiln
through hot air pipe directly.
The hot air from annular cooler section II lead to great oven preheating
section I. 'Hot air circling' is the process in which waste hot air grate oven
preheating section I, II to blower drying section and downdraught drying is that
wasting hot air of downdraught drying section give out through static de-
duster and main draught fan and chimney. The dust content off wasting hot air
is less than 50mg/Nm3, the dust collected by multi-cyclone and static de-
duster is returned to damp mill room through spillage system.
The materials conveyer by spillage includes dust collected by process de-
duster and environment de-duster, dust collected by grate oven dust box,
broken and Jacking pellet collected by lower grate bed lacking pellet under
scriber plate, dust collected by charging & discharge end of rotary kiln. The
spillage will regrind in damp mill room through scrape and heat-resistant belt
conveyer and make ball again. Dust lacking pellets, broken pellets are
collected from side blast boxes. Lower grate bed and end funnels, then sent
to a duty vibration sieve for grading. Over 8mm pellets will be delivered to the
21
kiln charge chute by a heat resistant bucket elevator .
Fuel:
The various types of fuels like liquid, solid and gaseous fuels are available as
a heating source in industrial use. The selection of right type of fuel depends
on various factors such as availability, storage, handling, pollution and landed
cost of fuel. Keeping the pollution status of proposed Pelletisation plant, Coal
Gas has been selected as heating fuel in the process. The knowledge of the
fuel properties helps in selecting the right fuel for the right purpose and
efficient use of the fuel.
Storage of Coal I Furnace Oil
Coal will be stored in covered shed with pucca platform. Bag filter will be provided to
control the fugitive emission.
It can be potentially hazardous to store furnace oil in barrels. A better practice is to store it
in cylindrical tanks, either above or below the ground. Furnace oil, that is delivered, may
contain dust, water and other contaminants.
The sizing of storage tank facility is very important. A recommended storage
estimate is to provide for at least 10 days of normal consumption. Industrial
heating fuel storage tanks are generally vertical mild steel tanks mounted
above ground. It is prudent for safety and environmental reasons to build bund
walls around tanks to contain accidental spillages.
As a certain amount of settlement of solids and sludge will occur in tanks over
time, cleaning should be carried out at regular intervals annually for fuels. A
little care should be taken when oil is decanted from the tanker to storage tank.
All leaks from joints, flanges and pipelines must be attended at the earliest.
Fuel oil should be free from possible contaminants such as dirt, sludge and
water before it is fed to the combustion system.
The physical properties and chemical composition of the raw material and fuel
used in production, and those of finished product must be checked in
22
accordance with those items list.
The following are the major raw material required for the manufacturing of
Iron Ore Pellets.
1) Raw Material- Hematite Iron Ore fines 2) Binding Material - Bentonite.
3) Coal.
RAW MATERIAL DETAILS
The following are the major raw material required for the manufacturing of iron ore
Pellets.
1) Raw Material- Hematite/Magnetite Iron Ore fines
2) Binding Material - Bentonite.
3) Fuel- Coal
Iron Ore fines: Fe (T) : 64 ± 1% Si02 : 0.85 Max. Al2O3 : 1.80 Max. S : 0.01 Max. P : 0.05 Max. Size : 200 mesh
Bentonite:
Si02 : 66.70%
AI203 : 28.30%
CaO : 1.50%
MgO : 3.50%
H20 : 5.00%
Coal: Fixed carbon : 45% plus.
Volatile matter : 35% plus.
Ash : 35 to 45%.
Sulphur : 0.1 max.
G.C.V : 3500 (k.cal/kg)/min
Ash fusion temperature: 2000 °C/1600 °C (min)
Size : 0 to 300mm/200mm.
23
Moisture : 10 to 15 % max.
Raw Material Requirements
Unit Raw Material
Raw Material Required Per Day (T)
Raw Material Required Per Month(T)
Raw Material Required Per Annum 330 Days (T)
Pelletization Plant (2x1200 TPD)
Iron Ore Fines
2640 72600 871200
Bentonite 36 990 11880 Coal 68 1870 22440
Material Balance (Iron Ore Pelletization Plant)
Solid Waste Details & Management Plan (Iron Ore Pelletisation)
There is no as such Solid Waste Generated, because the waste
generated is reused as input with fresh charge.
Power Requirement:
Total Power requirement for the Pelletisation plant will be around
4.00 MW
Manpower Requirement:
Total Manpower requirement for Iron Ore Pelletisation Plant will be
90 persons.
Input Output Iron Ore Fines 1.1000 Tons B.F. Sinter 1.0 Tons Coal 0.02883 Tons Input Return Fine
Dust 0.143 Tons
Betonite 0.0150 Tons Total Input 1.143 Tons Total Output 1.143 Tons
24
TYPICAL FLOW DIAGRAM OF IRON ORE PELLETIZING PLANT
25
TECHNICAL ASPECTS CIVIL WORKS:
This proposed project envisages various civil works related to complete plant
apart from other facilities like construction of road, culverts, rest house, canteen,
water works etc. Further there is no past history of flood in the area. The project
also provides, in view of socio economic development of the surrounding
areas/villages, construction of roads, culverts, Primary health centre, School,
Community Hall, Water works etc as per requirement.
SOIL FOUNDATION SYSTEM
Detailed geo-technical investigation in the area of the proposed plant shall be
carried out by contractor before the execution of the project. It is assumed that
normal soil conditions will be encountered in the proposed area. Accordingly,
all major foundations will require pile foundations.
MAIN PLANT BUILDING CIVIL AND STRUCTURAL:
Roof of hall, de-aerator bay, bunker building and control tower shall be
provided with colour coated metal deck sheet over which an RCC layer shall
be provided. For all other areas cast-in-situ RCC slabs I metal decking shall be
provided based on the type of framing arrangement adopted. Roof of hall roof
skylight with leak proof polycarbonate with anodized aluminum frame of
approved colour shall be provided with for Natural Light. Intermediate floors of
all building including building shall be provided with cast-in-situ RCC
slab/gratings floors.
Control Room area shall have Brick wall on external face, over which un-
insulated single Metal Cladding shall be provided. ESP, Control Room Building,
Air Washer Building and all other facilities buildings shall be of RCC I Steel
frame structure within-fill Brickwork I Insulated Metal Cladding.
ARCHITECTURAL CONCEPTS
Layout of the plant area shall have definite hierarchy of road network ;
26
depending upon its usage, aesthetic, visual sensibilities for creating road vistas,
focal points, building back drops, building frames. General layout shall be
evolved taking over the basis of landform & local climate and due consideration
shall be given to orientation & wind direction. Overall emphasis shall be on
developing eco-friendly architecture, merging with the nature with its own
sustainable energy management systems .
STRUCTURAL STEEL WORKS MAIN POWER HOUSE:
This shall be multi span-framed structure consisting of structural steel columns,
beams and trusses. The building shall be braced in longitudinal direction and
moment resistant in transverse direction.
CHIMNEY
A reinforced concrete I MS chimney of 60 m height with steel liner shall be
provided for the project. The liner shall essentially be constructed from
structural steel and shall be of the hung type (with multiple point liner support
systems). The liners shall be provided with resin bonded wool type thermal
insulation. The portion of the liners projecting above the chimney roof,
however, shall be constructed of stainless steel liners over the roof slab of the
chimney. Internal platforms shall be provided for enabling access to various
elevations of the stack and to provide support to the steel liner. External
platforms shall also be provided.
COOLING WATER SYSTEM:
The proposed CW pump house shall have five numbers CW pumps (4
working and 1 standby). The substructure shall be of M-25 Grade of RCC. The
superstructure shall be of structural steel framework in-filled with brick
cladding and I or with RCC framework in-filled with brick cladding.
The water is pumped from the pump house to the condenser through steel
lined concrete r encased pipe for each unit. Hot water from condenser shall
also be conveyed through a similar pipe of same size to induced draught
cooling towers.
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The cooling towers (2 Nos.) shall be of induced draught type, which includes
cooling water basin made up of RCC of grade M 25 with suitable foundation
system.
The cold water discharge from cooling tower shall flow by gravity to the CW
pump house fore bay through RCC open channel. The concrete grade for the
open channel shall be M25. All gates, stop logs and trash racks shall be of
structural steel, which shall be hot double dip galvanized and I or epoxy
painted.
A firewater tank and pump house shall be provided. Superstructure of the pump
house shall be of ReC with in-filled brick masonry a panel wall. Foundation for
firewater tanks shall also be provided.
CRUSHER HOUSE
Crusher house shall be of structural steel with permanently colour coated steel
sheet cladding. Floors and roof slabs shall be of RCC. Crushers shall be
supported on RCC deck slab, which in turn will rest on Vibration Isolation
System consisting of springs & dampers. IPS flooring has been considered for
floors.
AUXILIARY' ANCILLARY BUILDINGS D.G. SET BUILDING:
A single storey D.G. Set building of suitable area and height is envisaged to
be constructed for this plant,
EFFLUENT TREATMENT PLANT
Water required in this process is totally consumed and no waste water is
generated from the process. Water required for dust suppression at handling
plant will also evaporate which leads to zero generation of waste water.
ROADS, DRAINS & SEWERAGE ROADS:
All roads for the complete plant area shall be provided. All works related to
maintain continuity of road system shall be constructed in addition to approach
roads to different buildings' facilities related to storage, equipment areas where
28
access is necessary from inspection and operation and maintenance point of
view as well as functional point of view.
DRAINS
Drains shall be constructed on both sides of roads. In a well planned manner as
well as integrated with the existing drain facilities overall grid system of main
drains l artillery drains are to be provided , designed to dispose off by gravity to
the main drain.
SEWERAGE
R.C.C. concrete pipes' C.1. pipes shall be used for sewage disposal and t or to
be extended to the existing system to match the future requirement. Extended
aeration type permanent sewage treatment plant shall be provided for
treatments of sewage disposal system including Central Monitoring Basin
(CMB) as per applicable local bylaws l environmental standard l conditions of
State and l or Central authorities.
AUXILIARY STEAM SYSTEM
Boiler will be provided with two auxiliary PRD stations i.e., high capacity and
low capacity PRDS taking their steam tap-offs from MS line and CRH line
respectively. The high capacity auxiliary PRDS will be designed so as to meet
total auxiliary steam requirement 'of one (1) unit plus start up requirement of
other unit. Low capacity auxiliary PRDS will be sized for normal requirement of
its own unit.
Auto -changeover between the low and high capacity aux. PRDS stations
depending on the station auxiliary steam requirement is also envisaged. Each
unit will have its own auxiliary steam header whereas for station services a
common station auxiliary steam header is also proposed. A high temperature
station auxiliary steam header taking its tap off from the auxiliary PRD station
before the de-superheater will also be provided, to take care of the mill fire
fighting and air heater soot blowing.
29
ELECTROSTATIC PRECIPITATOR
ESP with high efficiency will be used to limits the outlet emission to 50 mg/Nm3
and will be designed and modified later as per the desired requirement.
ESP transformer rectifier sets will use high fire point oil as the cooling medium.
The dust collection hoppers at all strategic locations will have a minimum
storage capacity of eight (8) hours. The hoppers will have heating
arrangements to prevent ash sticking to the sloping sides and down pipes.
Level indicators to indicate and trip the ESP in case of high ash levels in the
ash hoppers, which will jeopardize the safety of ESP otherwise.
ENVIRONMENTAL & EFFICIENCY CONSIDERATIONS
In order to meet the environment norms and maintain the sustained efficiency of
ESP, it shall be adequately designed with sufficient margins for all operating
conditions. The Electrostatic Precipitator Management System (EPMS) in
conjunction with opacity monitor shall continuously monitor and maintain the
optimum energy level to achieve higher efficiency of ESP. For obtaining the
sustained high efficiency and availability of other equipment, it shall be
designed for low NOx formation by adopting the appropriate burners, high
efficiency at part load, flexibility to fuel within the range specified, quick startup
and two shift operation capability, adequately sized furnace for burning and low
flue gas velocities to minimize erosion.
WATER SYSTEM & PLANT UTILITIES: WATER PRETREATMENT
PLANT
It is proposed to construct raw water pump house near CW pump house. Raw
water pumps shall be provided to feed to water pretreatment plant before using.
The pre-treatment plant would be designed to remove suspended/colloidal
matter in the raw water.
FIRE PROTECTION SYSTEM
A comprehensive fire detection and protection system is envisaged for the
complete plant. This system shall generally be as per the recommendations of
30
TAC (INDIA)/IS: 3034 & NFPA - 850. The system shall have various types of
protection systems at each required stages. Complete Instrumentation and
control system for the entire fire detection and protection system shall be
provided for proof safe operation of the complete system.
AIR CONDITIONING SYSTEM
Air conditioning system shall be provided for all those areas, which require close
control of environment conditions and shall cover the following areas:
Main plant area
Control rooms
Control equipment rooms
Telecommunication rooms
Microprocessor, Computer and programmers rooms
Data Storage rooms
UPS Rooms
Instrumentation Laboratory and Steam & water analysis rooms
Conference room
Shift Charge Engineer's room
AVR Room and inverter room.
Generator Exciter panels room (if applicable)
Relay rooms
Required areas in Administrative building.
Control room, water and fuel analysis room, instruments room, ESP etc.
31
VENTILATION SYSTEM
Ventilation system shall be designed to supply fresh outdoor air and shall be
selected for maintaining inside conditions for those areas where close control of
temperature is not required, but nevertheless have a stipulated maximum
temperature.
CONTROL & INSTRUMENTATION SYSTEMS:
The function of the Control & Instrumentation System would be to aid the
operator in achieving safe and efficient operation of the units, resulting in cost
effective power generation with optimum fuel consumption and reduced
emission levels. The C&I system would be of the type which normally relieves
the operator of continuous duties and would take pre-planned corrective actions
in case of process drift or if unsafe trends or conditions develop in any regime of
operation viz., startup, shutdown, normal working and emergency conditions.
The design of C&I system would be such as to permit on-line localization,
isolation and rectification of fault in the minimum possible time.
DDCMIS SYSTEM
In line with current practices, microprocessor based digital control, monitoring &
Information System would be provided for the safe, reliable and efficient
operation of the equipments and their auxiliaries.
POWER SUPPLY SYSTEM (UPS SYSTEM)
To provide AC & DC power supplies to various C&I systems under SG, TG &
BOP C&I systems, following power supply has been envisaged in line with
present practices.
i. Uninterrupted Power Supply (UPS) system to feed AC load system,
backup secondary instruments, communication system, etc. The UPS
would consist of chargers, inverters, batteries and distribution boards.
EMERGENCY POWER SUPPLY SYSTEM:
For the safe shutdown of the plant under emergency conditions, i.e. in case of
32
total power failure, diesel generating sets shall be installed for lighting, essential
air conditioningl ventilation and all auxiliaries necessary for baring operation of
main turbines. One no. DG set of suitable capacity has been envisaged for
each unit. One 415V emergency AC board would be provided for each unit.
This emergency board will normally be fed from the associated 415V AC unit
switchgear and DG set will fed power to it in case of AC failure. One No. stand
by DG, common for both the units shall be provided. Cable interconnections
shall be provided from DG to respective unit emergency switchgear.
STATION LIGHTING SYSTEM
Adequate lighting arrangement shall be made for the entire power plant area,
employing distribution boards and lighting panels. Lighting fixtures would be of
HPSV and fluorescent type for AC lighting and of incandescent type for D.C.
lighting. Normal lighting of the plant will operate with the station AC supply.
About 200/0 of these fixtures will also have arrangement for being fed from
Emergency A.C. supply on failure of station A.C. supply. Emergency D.C.
lighting, which will normally be off, would be provided for all strategic locations
in the main plant area and balance of plant area.
COMMUNICATION SYSTEM
For effective communication within and outside the plant, an
intercommunication system will be provided and distributed throughout the
plant. The major components of the system are:
a) EPABX and intercom
b) Telephone system (P&T lines)
c) Public address system
CONSTRUCTION POWER
The construction power required for the construction of the power plant wiI be
derived from the nearest CSEB's 33 kV source as per the requirement in a
33
phased manner.
PUBLIC ADDRESS SYSTEM
Public Address (PA) system provides two channel voice communication with
"paging" and "private" modes. It consists of central control cabinet;
microphones, handset stations, loud speakers and amplifiers for transmitting of
acknowledging messages distributed at all important locations within the plant
area.
ENVIRONMENTAL POLLUTION CONSIDERATION
Every industry creates pollution up to certain extent. Raw material handling,
finished product handling industrial process becomes sources of pollution.
Environmental considerations, therefore, have a major bearing in the planning of
any project.
SOURCES OF POLLUTION
The major sources of pollution from a project can be classified under the following
heads:
Pollutants in the waste gases namely, suspended particulate matter (SPM),
sulphur dioxide, NOx, Carbon Monoxide & Hydrocarbons (HC) etc
Fugitive dust generated during solid fuel handling and processing.Fugitive dust
generated during conveying, storage and disposal etc.
Thermal pollution
Noise pollution
Waste water and sewage
The various measures proposed to mitigate the impact of these pollution sources
on the environment are discussed below:
34
POLLUTION CONTROL MEASURES AIR POLLUTION
High efficiency electrostatic precipitators (ESPs) will be installed to limit the
particulate emission to 50 mg/Nm3 in line with the State Govt. Policy. To facilitate wider
dispersion of remaining particulates and gaseous pollutants (SO2 and NOX), a chimney of
suitable height will be provided. The chimney will be provided with personal
access for monitoring of stack emissions.
For control of fugitive dust emissions within and around the raw material handling and
finished product handling areas, dust extraction and suppression systems would be
provided. Dust suppression system shall be installed at all requisite points in the plant.
WATER POLLUTION
An effluent management scheme, consisting of collection, treatment,
recirculation and disposal of effluents, shall be implemented in order to optimize
the make up water requirement as well as liquid effluent generation. The details
of water system for the project is described as follows:
• Neutralization of D.M. plant regeneration waste and disposal through;
Central Monitoring Basln.
• Recirculation type C.W. system with induced draft cooling towers, with
C.W. blow down from cold water side to ensure that there is no thermal
pollution.
• Filling firewater storage tanks.
NOISE POLLUTION
The major noise generating sources are those pumps, fans, handling plant etc.
from where noise is continuously generated. Acoustic enclosures shall be
provided wherever required to control the noise level below 75 dB (A). Wherever
it is not possible technically to meet the required noise levels, the personal
protection appliances shall be provided.
35
SOLID WASTE MANAGEMENT
The solid waste management scheme for solid waste generated from project
shall involve collection, supply to entrepreneurs for utilization, promoting solid
waste utilization and safe disposal.
ENVIRONMENTAL MANAGEMENT PLAN CONSTRUCTION PHASE Air Environment
The installation of plant during construction phase would result in the increase of
SPM concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of
the construction sites would be undertaken and will be continued after the
completion of plant construction, as there is scope for heavy truck mobility. It will be
ensured that both gasoline and diesel powered vehicles are properly maintained to
comply with exhaust emission requirements.
Noise Environment
There will be marginal increase in noise levels during construction phase, which is
temporary. No construction activities are planned during night time, which may
contribute to the existing baseline.
Water Environment
During construction, provrston for infra-structural services including water supply,
sewage, drainage facilities and electrification will be made. The existing toilet
facilities will be available for the workers to allow proper standards of hygiene.
These facilities are connected to a septic tank and soak pits. Waste water drainage
system of the plant is well connected to the sewerage channel.
Land Environment
Generally cutting of herbaceous vegetation, during the construction phase results in
36
the loosening of the top soil. There is no such removal of vegetation in the proposed
site. Further plantation measures would help in preventing soil erosion.
Any hazardous material required for constructional activity will be sorted as per
safety norms. Further construction site will be provided with suitable toilet and
treatment facilities etc for maintaining hygienic conditions.
Socio-economic Environment
Any construction activity will benefit the local population in a number of ways. The
company management shall give preference to local people through both direct and
indirect employment. It shall provide ample opportunity to the locals to up-lift their
living standards by organizing events that propagate mutual benefits to all, such as
health camps, awareness campaigns, donations to poorer sections of society and
downtrodden. Educational needs of the region should be improved by encouraging
the workers to allow their children to attend schools. Sufficient funds shall be
allocated for these and other emergency needs. Compensation packages to the kin
of those workers who loose I disable their working ability due to any accident.
Safety and Health
Adequate space will be provided for construction of temporary sheds for
construction workers for rest purpose. M/s. Vandana Global Limited. Raipur will
supply potable water for the construction workers. The safety department will
supervise the safe working of the contractor and their employees. Work spots will be
maintained clean, provided with optimum lighting and enough ventilation to eliminate
dust/fumes. A comprehensive Occupational Health and Safety management plan is
put in place to address any sort of eventuality.
OPERATIONAL PHASE Air Environment
The dust generated from the various conveyors points, crushing etc, will be
controlled by covering the conveyor belt and approaching the transfer points
37
and then installing one centralized dust extraction system which extract all the
dust from various points. These dust later be trapped by ESP .
Noise Environment
The following are the noise control measures proposed to be undertaken in the
proposed plant.
• Provision of acoustic dampeners in foundations and insulators at high noise
producing equipments and machnies,
• A thick greenbelt will be developed all around the plant boundary to act as
noise attenuator.
• In addition personnel working near high noise level generating sources will
be provided with ear muffs.
• Proper and suitable acoustic barrier will also be provided around areas
generating high noise to maintain noise levels below 90 dB (A).
• Effective preventive maintenance and vibration measurement of all rotating
equipment will help in the improvement of plant life and also noise
reduction.
• Automatic door enclosures for control room and laboratory etc
Water and Wastewater Management
An effluent management plan will be implemented with collection, treatment,
recirculation and disposal of effluents. Rain water will is collected and
recharged through a recharge tank .
• Storm rain water drainage will be routed through a silting tank, for arresting
of silt. Rain water will be used during the rains for the purpose of the plant
water requirement.
38
An independent plant affluent drainage system is proposed to ensure that
plant effluent doesn't contaminate storm water drains. After individual
treatment of effluents, these will be disposed off through a central monitoring
basin. Efficient operation of various treatment schemes will be ensured to
conform quality of treated effluents to relevant discharge standards.
The sewage from plant will be directed to STP. The capacity of STP will be
adequate and the treated effluent would be either utilised for plantation
purposes or will be discharged.
Storm Water Management
Underground sewers are preferable to collect the storm waters, storm waters
of open road drains are often misused as open sewers for the discharge of
industrial and domestic wastewater and as well as dumps for disposal of solid
wastes. Further more, it creates obstacle to the access of industries.
In general, the storm water run-off is often polluted through dust, garbage and
unprotected solid wastes. Hence, primary treatment in setting tanks is
essential in order to minimize the pollution to a significant level before the
disposal of these waters into natural environment.
Rainwater Harvesting
Underground sewers are preferable to collect the storm waters, storm waters
of open road drains are often misused as open sewers for the discharge of
industrial and domestic wastewater and as well as dumps for disposal of solid
wastes. Rainwater Harvesting technique will be adopted by the industry as per
guideline of the MoEF and CGWB.
Solid Waste Management
The disposal of solid waste is planned by utilising safe and scientific procedures its
handling, storage and disposal activities. Solid waste generated will be disposed
safely through a well planned handling and cisposal management plan.
39
Few measures are further elaborated below, which would promote sustainable
development in this expansion activity.
i. Water blanket will be maintained over material heaps, and other dust
ii. Thick green belt will be developed all around the periphery of the plant and
some free areas within the premises so as to reduce the pollution and improve
the aesthetics of the area.
iii. Adoption of good house-keeping measures shall be the company's
commitment for a pollution free environment. One of the measures that is
proposed by the company is to install a separate electric energy meter for
monitoring the electrical consumption of ESP and its statistics shall be made
available on monthly basis for any energy audits in future.
Green Belt Development
The plan for attenuation of the noise and air pollutant levels includes design for
plantations around the plant boundary, roadside, office buildings and stretches
of open land. The vegetation for the attenuation of air pollution shall be most
needed in the areas where ground level concentrations of the pollutant are to
be highest. 33% plantation will be carried out, by consultation with DFO
Bilaspur of State Forest Department according to guideline of MoEF and
CPCB.
Occupational Safety & Health Management
The proponent will provide all necessary provisions stipulated under The
Factories Act. In addition a Safety committee has been formed and manned by
equal participants from Management and Workers. Personnel Protection
equipment (PPE) is being issued to each worker. Other safety equipments shall
be used according to the nature of job involved. A detailed structure of risk
analysis is already presented in previous sections in this chapter.
40
POST OPERATIONAL MONITORING PROGRAM
Regular monitoring of pollutants in different environmental disciplines like air,
water, noise etc will be conducted for proposed units and the data will be
regularly submitted to Chhattisgarh Environmental Conservation Board.
INSTITUTIONAL SET-UP
The post operational monitoring program will be under the supervision of the
Environmental Management Group (EM G) at the project site. The EMG at site
will interact with state Environment Conservation Board for all environmental
related issues during operation of the station.
STATUTORY CLEARANCES
A comprehensive study is in process to prepare Environmental Impact
Assessment report for this project. After receipt for No Objection Certificate
from Chhattisgarh Environmental Conservation Board, Ministry of
Environmental & Forests will be approached for obtaining Environmental
Clearance. This will be in accordance with the procedure laid down in the EIA
Notification 2006 and its subsequent amendments.
PERFORMANCE GUARANTEES
The plant and facilities will be designed, engineered, manufactured, tested,
erected and commissioned ensuring compliance to international standards
and incorporating state of the art technology. Quality assurance programs will
be implemented meticulously to ensure high quality for the equipments and
systems. At every stage right from the selection of raw materials till
conductance of performance guarantee tests, inspection shall be carried out
at every stage of manufacture and tests such as type tests and routine tests
will be carried out on the components, equipment and systems so as to
ensure that the plant will give integrated optimal performance. While it is not
the intent to elaborate all the inspection, testing and performance guarantee
41
tests involved, the following specific guarantees will be adhered to:
a. Design of plant and equipment as per Indian and or international
applicable standard like ISO, ASME, ASTM, IEC, DIN, JIS standards
etc.
b. Establishment of equipment ratings as per the detailed design through
international acceptable test procedures.
c. To comply with the applicable statutory rules and regulations.
d. To follow the stipulated health, safety and environmental requirements
e. Compliance of all applicable environmental codes, standards and
regulations in vogue as on date including.
o Particulate emission within 50 mg/Nm3 under all conditions.
o Sulphur emission within the prescribed limits of CPCB norms.
o To maintain effluent discharge within permissible limit.
PERFORMANCE MONITORING SYSTEM
The operation of this project will be optimized by following the performance
monitoring system. This system covers organizational structure and clear
definition of responsibilities of all key personnel detailed analysis of 0 & M
problems. It also covers the system of daily reporting and periodic review and
monitoring. The following important aspects will be covered during the periodic
review.
a. Review of actual performance of each unit vis-a-vis targets and norms for key
operating parameters.
b. Review of specific O&M problems of the project and progress of corrective
actions.
c. Review of external constraints like material supply problems, power
42
problems and related difficulties.
d. Review of flnanclal performance.
e. Review of house keeping standard.
f. Review of performance to meet environmental standards. g.
Review of safety program.
MAINTENANCE PHILOSOPHY
With a view to build up to required expertise and institute the best maintenance
practices, initially for the first few years, major overhauls and maintenance of
major equipments will be carried out directly by the respective equipment
manufacturers or their licensed representative. The overhaul and maintenance
procedures will then be tuned suitably to have an optimal customized
maintenance system for the equipment and systems covered under the plant.
The maintenance procedure aims at maximizing the availability of generating
units while ensuring minimum maintenance cost and safety of plant and
personnel.
HUMAN RESOURCE DEVELOPMENT
This chapter deals with assessment of manpower required for the proposed plant:
Looking to the automation with advanced technology, the manpower would be
quit limited. The estimated manpower requirement is indicated as below.
TRAINING
Depending on the level and experience of O&M staff, training programs will be
designed and implemented by contractor in association with O&M contractor and
the owner. The covered includes the following:
- The Training at manufacturer's works
- Training at operating plants in India and abroad where similar equipment are in
43
operation.
- Maintenance training.
- Simulator training.
- Workshops.
In high-tech areas including environment monitoring etc., special training
programs will be arranged for imparting right exposure and building up expertise.
TRAINING POLICY:
An appropriate training policy would be adopted at the outset aiming to fulfill the
main objectives of improving the organizational efficiency & effectiveness as a
whole and also to maintain a high technological status and develop an
understanding of the importance of cooperation & teamwork.
AFFORESTATION
The project envisages a good quantum of afforestation glvmg it the highest
priority to maintain as a pollution free area as far as possible. Afforestation and
green belt development activities would be implemented in a massive way for
which specific land is also separately proposed. Extensive plantation program will
be commenced right from the procurement of the land so that the trees are
appreciably grown up till the plant is commissioned.
Green belt has been considered to be one of the major components of
Environment Maintenance Practice (EMP). The site preparation does not need of
felling trees as the site is covered with negligible bushes and shrubs and is
already within existing plant premises. However, the industry will develop green
belt which will further enhance environmental quality through; mitigation of fugitive
emissions, attenuation of noise levels, balancing Eco-environment, consumption
of treated effluent prevention of soil erosion, and creation of aesthetic
environment. It is proposed to develop green belt/forestation for about 330/0 of
land.
44
Factors for selection of plant species for green belt development; fast growing,
perennial and ever green, thick canopy cover, large leaf area index, resistant to
specific air pollutants, preferably indigenous, will maintain regional ecological
balance and soil and hydrological conditions of the region. The species to be
planted will be selected based on the available land soil quality and the quantum
of water available. The following aspects would be considered in the placement of
plants.
(i) Trees growing up to two meters or more in height with thick canopy cover
and perennial foliage will be planted around the installation.
(ii) Planting of trees will be done is rows (minimum three rows) while planting
trees care will be taken so that the green envelop would conceal the installation
when observed from outside the premises. For preventing the horizontal
dispersion pollutants if any, the trees planted in alternative row will fall in straight
line.
(iii) Trees will be planted on roadside for vehicular traffic emissions.
(iv) Sensitive species like magnifera indica will be planted in patches along the
entire green belt to work as an indicator of pollution potential.
SOCIO-ECONOMIC DEVELOPMENT:
The project provides full opportunity for local people/village to get employment
directly or indirectly and helps in the up-liftment of socioeconomic status of the
area, which is one of the most essential factors. The project envisages
involvement of social activities of the surrounding community by planning
betterment of neighboring social conditions through awareness and welfare
programs that will ensure improved relations. The commitment of management
includes upIiftment of social, health, basic needs of drinking water supply and
provision of educational facilities. Many of the beneficiaries of such programs
shall include own employees as well. Goodwill of the local population can never
be ignored. The channels employed may vary either through direct contact or by
means of local organizations. Another important fact of social environment
identified by the project proponents is a green appearance; hence the
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management will develop a green belt towards aesthetic beautification, as the
same is necessary to be considered as a responsible, social neighbor.
PROJECT MANAGEMENT
Project management covering various aspects of the project will be implemented
following appropriate systems for which experienced Personal and suitable
management tools specially developed for the purpose will be deployed. The
project management activities are ammged in phases and accordingly project co-
ordination procedures will be developed in association with contractor.
Computerized systems with advanced software will he followed for materials
management, cost control, budgetary control, finance management, scheduling,
resource allocation, monitoring etc. An integrated project management and
control system is envisaged for the project planning, scheduling, monitoring and
control. This system encompasses all areas of engineering management,
contract, management, construction and commissioning management. This
system would envisage development of a master network, which is the overall
program of the project.
This is based on Project work systems classification. It identifies the key
milestone dates for each work system in the areas of engineering, procurement,
manufacturing, dispatch, construction, erection testing and commissioning.
PROJECT CONTRACTING
The main features of the project contracting followed by VVL would be as
follows:
All the plant and works involved in this project including detailed design,
engineering, procurement, construction, testing and commissioning of the plant
to a performance specification consistent with International standards, and in
accordance with the current Indian Legislation will be carried out by a single
contractor. This approach minimizes contractual interfaces,shortens project
implementation time scale and places design and contraction risks with the
party best able to manage them. Detailed engineering co-ordination and sub-
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contracting activities are all simplified and shortened.
ENGINEERING MANAGEMENT
The project engineering activities will be planned to schedule within the time
frame specified for the engineering milestones in the master network schedule.
The contractor will obtain the approval of the Owner/Owner's Engineer
regarding compliance of criteria for selection, sizing of all equipment, systems,
design margins, design calculations, control philosophy, etc. before proceeding
with detailed engineering designs and manufacture. This will ensure a good
design and installation ensuring high efficiency, operability, availability,
reliability, maintainability etc. Periodic reviews will be conducted to evaluate
progress and take corrective actions to meet said targets and quality. For any
delays likely to occur, corrective action will be identified and advance action will
be taken to meet the project schedule. Project monitoring tool will enable such
preventive measures.
QUALITY MANAGEMENT
The Quality Management will be implemented through various system and
procedure, which shall follow the model of ISO 9000. The apex document for
the Quality Management shall be a Quality program which shall cover system
& procedure for various activities which may have effect on Quality like design
control, document and data control, document and data control, process
control inspection and testing,corrective and preventive actions, quality audit,
control of document and records etc.
This Quality program will include detailed quality control plans for major
equipment & services and it will ensure that the equipment & services under
the scope of contract whether manufactured or performed within the
contractor's works or subcontractor's works or at site, are in accordance with
the contract specification, codes and standards, statutory requirements, etc.
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CONTRACTOR
The contractor will have dedicated team headed by a Project Manager who
will be the chief coordinator for the Project, and will be responsible for the
project execution. The project ream of Contractor will have sufficient
technical personnel for various areas like engineering, procurement,
execution, quality, finance etc. to co-ordinate all matters pertaining to the
Project.
In addition the contractor will maintain a site organization headed by a site
construction manager for all site operations. The organization at site will cover
various levels of experts for execution of all works in the areas of Mechanical.
Electrical, Control & Instrumentation, Quality Assurance etc., during
construction, erection and commissioning of the Project.
The Civil works contractor will carry out all civil works required for the project
including all detailed design work. However EPC contractor will carry out the
basic design.
HEALTH, SAFETY AND ENVIRONMENT
The maintenance of a healthy and safe working environment regarded as a
major mutual objective for management and employees at all levels. We
believe that every accident can be prevented and aim to achieve the highest
possible standard in safety and health with an ultimate goal of zero accidents.
To achieve the above objective, construction management will encompass a
comprehensive health, safety and environment management systems, which
includes followings major activities.
• Ensuring all safety features in the equipment, system and layout in the
design stage itself.
• Identification of all site hazards and assessment of risks.
• Safety meetings, safety training and safety drills.
• Safety inspections and auditing.
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• Preparation of site emergency plans I Disaster Management Plan.
• Safe storage and handling of hazardous materials .
• Clearing and disposal of all combustible wastes generated at site.
• Arrangement of fire protection system and maintenance.
• Inspection and maintenance of all electrical installation.
• Usage of Safety equipments.
• Accident reporting and analysis procedures.
• Establishment of first aid post with necessary facilities. _
• Health screening and recording system.
The Construction management system will include development of a
comprehensive environmental management plan in the construction phase of
the project. This will deal with both planned and unplanned occurrences.
Specific areas of control during construction and commission will include
correct disposal of any wastewater, control of oil spills, control of noise
emission, control of dust emission etc. . The contractor will be responsible
through various measures including appropriate provisions in the contract, for
discharging their safety obligations. Area covered under construction safety
includes various areas of civil construction, mechanical erection, electrical etc.
RAIN WATER HARVESTING
Rashi Steel and Power Limited are planning to have a system of rainwater harvesting at
village Paraghat and Beltukri, district Bilaspur, Chhattisgarh. Rainwater harvesting is
primarily dependent on various site characteristics such as soil property, catchments
characteristics; rainfall characteristics, and ground water tables etc.
49
There are artificial as well as natural rainwater harvesting systems. The collecting system
can be implemented for i) Individual units and ii) Centralized collection system
Scheme I: Collection of rainwater harvesting from individual building units. Rainwater
falling on other open area is to be collected, through constructed drainage system and
discharge system and discharge to surface out-fall (by passed for rainwater harvesting)
Scheme II: Construction of rainwater filter bed at centralized place where water from
individual unit as well as storm water from open area shall be diverted
The reference is hydrological data of Bilaspur from the IMD. The maximum rainfall in july
in the year of 2011-12 is 300.3 mm. The yearly rainfall is 1041 mm in 2011-12 and 1100
mm is the average rainfall in the last five year from 2008 to 2012. 1,01,700 m3 maximum
water will be collected from the rain fall in the rain water harvesting pond in a month.
Approximately 3,52,899 m3 water will be collected from the rain fall in the rain water
harvesting pond, which will fulfill the 47 days requirement of the plant.
Rain Water harvesting calculation for the proposed project
Areas Area m2 Run Off -
Coefficient
Assuming
1mm Rain
Fall( in meter)
RWH potential m3
Roof top area 203720 0.8 0.001 163
Paved Area 255690 0.6 0.001 153
Green open land 230290 0.1 0.001 23
Total Storm water Load on the site for 1 mm rain fall 339
Considering maximum rainfall in the month of july is 300 mm, So the total
storm water load
101700
Total storm water load on the site for 1041 mm rain fall 352899
101700 m3 is the maximum capacity of the rain water harvesting pond and the water which we
collect within the project premises in a month.
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PROJECT FINANCIAL, COST ESTIMATION ETC.
ESTIMATE OF PROJECT COST
The cost of the palletisation plant of proposed project is estimated on
the basis of the prevailing prices and rates and the estimation is for, the
installation of pallet facilities described in the earner sections with air and
water pollution control equipments. The estimates are derived by dividing the
total quantum of work into three categories, viz., civil works, electrical system
equipment & mechanical equipment no provision for escalation is considered.
The cost of the Iron Ore Palletisation Plant covers all the costs associated
with the construction of the plant, and includes the civil construction cost, cost of
equipment for production, cost of auxiliaries utilities. The total project cost is
arrived at by adding to this cost, the pre operative expenses inclusive of
project design and engineering, sa-t-up and training expenses, interest during
construction and the margin money to meet the working capital requirements. The
table given below gives the details of the Project Works Civil, Mechanical and Electrical
Cost estimate and the overall project cost estimate.
PROJECT COST
PARTICULARS
AMOUNT IN LACS
(i) Land & Site Development Infrastructure 550.00
(ii) Factory Building & Civil Works etc. 3800.00
(iii) Plant & Machinery 7750.00
(iv) Pollution Control Devices 1100.00
(v) Electrical Installation 580.00
(vi) Misc. Fixed Assets 120.00
(vii) Preliminary and Preoperative Expenses 030.00
(ix) Deposits 070.00
SUB TOTAL 14000.00
Margin Money For Working Capital 1000.00
Grand Total 15000.00
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MEANS OF FINANCE
PARTICULARS AMOUNT IN LACS
(i) Share Capital 5160.00
(ii) Unsecured Loan 2640.00
(iii) Term Loan 7200.00
Grand Total 15000