Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 1
PRE-FEASIBILITY REPORT
OF
GREENFIELD STEEL PLANT
AT
Borai Industrial Growth Centre, Dist: Durg
(Chhattisgarh)
Pushp Steels & Mining Private Limited, 751, GF, Kundewalan Street,
Ajmeri Gate, New Delhi-110006
NOVEMBER 2018
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 2
Title Page
1. Executive Summary 3
2. Introduction / Background Information 8
3 Project Description 12
4 Site Analysis 31
5. Planning Brief 35
6 Proposed Infrastructure 36
7. Rehabilitation and Resettlement (R & R) Plan 38
8. Project Schedule & Cost Estimates 39
9. Analysis of Proposal 40
LIST OF ANNEXURES
A-1 Location Map 41
A-2 Map Showing Site & Surrounding 10 km Area 42
A-3 General Plant Layout 43
A-4 Previous EC & CTE 44
A-5 Land Allocation Letter from CSIDC 59
A-6 Water Comfort Letter from CSIDC 71
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 3
1.0 EXECUTIVE SUMMARY
M/s Pushp Steels & Mining Pvt Ltd (PSM) proposes to install a Steel Plant at Borai
Industrial Growth Centre, Rasmara, District Durg (Chhattisgarh) through a combination
of Direct Reduced Iron (DRI) - Induction Furnace (IF) to produce Billets. Part of the
Billets will be used to make Automobile Components in a Press Shop. Billets and
Automotive Components will be sold. Iron ore pellets will be used in DRI plant for which
a Pellet Plant has been envisaged. Ferro Alloy Plant will be established to make Ferro
Manganese, Ferro Silicon and Silico Manganese. The waste heat from DRI kiln and
solid wastes char from DRI making will be used to generate power. Iron ore for the
proposed steel plant will be obtained from its Captive Iron Ore Mines located in
Hahaladdi, Tehsil Bhanupratappur, Dist Kanker, Chhattisgarh. Environmental
Clearance for 0.4 Million Tons Per Annum iron ore mining has been obtained from the
Ministry of Environment, Forests & Climate Change vide letter No.J.11015/484/2006-
IA.II (M) dated 28th January 2008. Production of iron ore from this mine is expected
soon. The EC was amended on 13th June 2018. PSMPL will apply for expansion of the
iron ore mines in due course of time.
PSMPL obtained Environmental Clearance (EC for the proposed Steel Plant from the
Ministry of Environment, Forests & Climate Change (MOEF&CC) vide letter No.
J.11011/1011/2007-IA.II (I) dated19th December 2008. The EC was amended on 25th
April 2011 and 23rd January 2012. In between PSMPL requesting MOEF&CC to extend
the validity of EC, though the same has not been permitted till date. Since, 10 years
has passed since the EC has been obtained. Therefore, PSMPL decided to apply for a
fresh EC in order to avoid any further delays.
Proposed project / capacity and products
Name of proposed unit Size / Production Capacity / Product
1 Pellet Plant 1 x 0.6 MTPA
(600000 TPA iron ore pellets)
2 DRI Plant 2 x 350 TPD, 1 x 500 TPD
(420000 TPA Sponge Iron)
3 Induction Furnace (with
Laddle Refining Furnace &
Induction Furnace: 4 x 15 tons, 3 x 12 tons
Laddle Refining Furnace: 15 tons & 30 tons
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 4
Continuous Casting
Machine)
CCM: combicaster (2 Nos.)
(400000 TPA Billets)
4 Ferro Alloy Plant 3 x 9 MVA (52000 TPA Ferroalloys)
Product mix of Ferromanganese/ Ferrosilicon / Silicomanganese within the allowed capacity
5 Press Machines for
Automotive Components
Manufacture
125 tons, 60 tons, 40 tons, 2 x 25 tons for making Automotive Components using Billets 120000 TPA Automotive Components
6 Captive Power Plant 34 MW (24 MW through WHRB) (10 MW through AFBC)
7 Utilities DM Plant, Air Compressor, AC & Ventilation,
Laboratory, Water System, etc
Land: 11.421 hectares (28 acres) land allotted by Chhattisgarh State Industrial
Development Corporation (CSIDC). 100% land is industrial land and is in the
possession of the company. Since EC has been obtained in 2008, boundary wall and
partial civil foundation of one kiln has been completed. Thereafter due to certain
changes in law, poor market conditions, force majeure circumstances resulting into
non-availability of financial assistance from lenders, the work was stopped, though
substantial investment already done from own resources.
Location: Borai industrial Growth Centre is located adjoining the National Highway 6
(Durg Bypass) at Rasmara, District Durg, Chhattisgarh. The transportation infrastructure
like rail and road is available. Nearest railway station and siding is located at
Rasmara on the Mumbai-Kolkata route. Approach road is available from NH6 (Durg
Bypass). The adjoining industries are mostly steel making plants and steel
fabrication units (Topworth Steel, Raipur Power & Steel, Jai Balajee Steel, etc).
Shivnath river is located on the east side of Borai industrial Area. Rasmara railway
station and village is located about 1 km away in north side of industrial area. Durg
town is located about 7-8 km away of the south east side. Bhilai Nagar and Bhilai
steel plant is allocated about 13-14 km away in the east to southeast direction.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 5
Power: Power lines of CSEB is already available in the industrial area. Source of
power for the proposed steel plant will be CPP and CSEB. 2 x 500 KVA DG Sets will be
installed to meet the power requirement during load shedding.
Water: CSIDC has committed required water to PSMPL.
Name of proposed unit
Requirement KLD
Wastewater for Disposal KLD
Management Scheme
1 Pellet Plant 300 NIL 100% evaporation
2 DRI Plant 950 45 CT b/d Cooling Tower blowdown water will be taken to settling tank and reused for ash handling in closed circuit
3 SMS 1000 30 CT b/d
4 Ferro Alloy Plant 100 10 CT b/d
5 Captive Power
Plant
2400 240 Boiler b/d and cooling tower b/d will be collected in central monitoring basin and reused for ash handling in closed circuit
6 Utilities & Misc
uses
100 20 Collected in settling tanks and reused for dust suppression
7 Domestic &
Potable use
150 30 Taken to STP and used for greenery development
Total 5000 ZLD concept. No discharge outside the plant boundary
Raw Materials
Name of Raw Materials
Quantity TPA
Source
Iron Ore 660000 (Fines) 350000 Lumps)
Captive mines in CG and from other mines located in CG and Orissa.
Coal 575000 Purchase from SECL/Imported, Coal with less than 0.5% sulphur content will be used.
Coke 42000 Purchase from Dhanbad area, Jharkhand
Dolomite 31000 Purchase from Bilaspur area, CG
Lime 10000 Purchase from Katni area, CG
Quartzite 5000 Purchase from Bilaspur area, CG
MS Scrap 120000 Purchase from Durg, Raipur. Also available internally
Mn ore 126000 Purchase from Balaghat District, MP
Bentonite 12000 Purchase from Kutch District, Gujarat
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 6
Transportation: Most of the raw materials will be transported by road. The nearest rail
siding is Rasmara, about 1 km from the project site. This siding will be also used to
transport raw materials and finished products, depending upon the feasibility
Air Pollution Control
Name of proposed unit Name of Air Pollution Control Equipment
1 Pellet Plant ESP and Bag Filters, PM emission <30 mg/Nm3
2 DRI Plant ESP and Bag Filters, PM emission <30 mg/Nm3
3 SMS Fume Extraction System and Bag Filters PM emission <30 mg/Nm3
4 Ferro Alloy Plant Fume Extraction System and Bag Filters PM emission <30 mg/Nm3
5 Captive Power Plant ESP and Bag Filters, PM emission <30 mg/Nm3
Solid Wastes
Unit Quantity, TPA
Utilization / Disposal
Dust from DRI Plant 3300 Used for civil constructions & road making.
Char from DRI Plant 100000 Used for power generation in AFBC Boiler
Accretions from DRI plant 1000 Used for civil constructions &road making.
Slag from Induction Furnace 48000 Used for civil constructions and road making after extracting iron
Dust from Induction Furnace 1500 Reused in Induction Furnace.
Coal ash from power plant 32000 Used in cement making, brick making and as civil construction material. It will be utilised as per MOEF&CC Notification
Slag from Ferro Alloy Plant 7000 Reused for making SiMn. Used for civil constructions and road making.
Dust from Ferro Alloy Plant 1500 Used for civil constructions & road making.
Greenbelt Development: Around 3.8 ha area, (33% of total area) has been earmarked
for green belt development. It is proposed to plant 6500 trees in three tiers all along the
plant boundary.
Rehabilitation and Resettlement Plan: Not Applicable
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 7
Project Schedule: The project will be executed in phases. Some of the units will be
commissioned within 18 months of zero date. All the units are expected to be
commissioned within 60 months of obtaining the EC
Project Cost: Rs. 480 Crores
Manpower: About 500 people will get direct employment and about 500 will get
indirect employment from the project.
Financial and Social Benefits
Ministry of Steel, Govt. of India has projected a capacity of 180 MTPA steel
requirement by 2019-20. The project will bridge the demand supply gap of steel and
ferroalloys in India. Part of the billets will be used for making automotive components
for use in cars and trucks. Ferroalloy will be used for making various quality of steel
products. The project will contribute to government treasury by way of direct and
indirect taxes. The project will employ 500 persons and provide in-direct employment to
500 persons in transport, upkeep & maintenance, ancillary units. Local people (Average
200, maximum 500) will get employment during the construction stage. PSMPL will
budget 2% of the project cost for Enterprise Social Commitment (as per prevailing
norms), which will be spent for the socio-economic development of villages located
around the project site.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 8
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 Identification of project and project proponent
2.1.1 Project Proponent
M/s Pushp Steels & Mining Private Limited is a company incorporated under the
Companies Act 1956. Its Registered Office is located at Ajmeri Gate, Delhi. Mr.Atul Jain
and Mr. Sanjay Jain are the Directors of the Company. The Company was allotted Iron
Ore Mines in Hahaladdi, Bhanupratappur Tehsil in Kanker District, CG. The production
capacity of the mine is 400000 Tons/annum.
2.1.2 Identification of Project
The proposed steel plant project was planned to be established in Borai Industrial
Growth Centre, Durg in 2007. Land was acquired through lease from CSIDC.
Environmental Clearance was obtained in 2008. Consent to Establish for the project
has already obtained from Chhattisgarh Environment Conservation Board, Raipur.
Construction of the project was started in year 2010. Boundary wall, internal road
and civil foundation of one DRI kiln was done. Abruptly the project construction was
stopped due to force mejure circumstances leading non availability of financial
assistance from financial institutions. Now the steel market has revived and financial
institutions are considering financing the project. PSMPL on advise of CECB,
Chhattisgarh have been requesting for revalidation of EC, however the same has not
been done as yet. Since, the validity of EC has expired after 10 years, PSMPL has
decided to approach MOEF&CC to obtained a fresh EC for the project in order to
avoid any further delays.
2.2 Brief Description of Nature of the project
The proposed project falls under Category A, 3a of EIA Notification 2006. PSMPL is
operating an iron ore mine in Kanker District. Iron ore from this mine will be used
captively in the proposed steel plant. The iron ore fines will be converted to pellets and
used for making DRI. DRI and MS scrap will be used to make Billets. Billets will be
used for making automotive components in a machine shop. Surplus billets will be sold
to rolling mills located in CG. Ferroalloy plant will produce FeMn, SiMn and FeSi. Ferro
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 9
alloys are used as alloys for steel making. Steel Making using best Available
Technology pollution control systems is energy efficient and also generates less
wastes. Waste heat and dolochar wastes will be used for generating power. The project
will add to resource conservation by utilizing iron ore fines generated during the mining
of iron ore. Water is not required for iron and steelmaking process. Water is required
only for cooling of various machines and equipment. Therefore, no wastewater will be
discharged outside the plant premises. Wastewater will be appropriately treated and
reused / recycled within the plant premises. Domestic wastewater will be treated in
STP/ETP. Treated water will be used for gardening and dust suppression purpose.
Solid wastes will be utilized for various beneficial purposes. The solid wastes are not
hazardous. However, if any solid wastes is required to be disposed, it will be done in an
engineered landfill site. Spent oil and lubricants will be collected in drums and sold to
authorized re-processors. Proper Disaster Management Plan will be implemented
based on the risk assessment and mitigation measures. Therefore, this project will
cause minimal damage to the environment and all discharges will be far below the
prescribed limit.
2.3 Need of the Project and its importance to the country and or region
Steel is a basic commodity for economic growth of any country and the per capita
consumption is a measure of prosperity of a country. India is just entering the
developing mode. The per capita steel consumption has risen from 38 kg in 2005-06
to 59 kg in 2011-12. It is envisaged to rise to 77 Kg per capita by the year 2019-20,
which as per historical trends puts the country on the curve of steep growth.
The crude steel production capacity had increased from 51 million tonnes per annum
(MTPA) in 2005-06 to 125 MTPA in 2016-17.The world wide steel scenario also
shows a continuous growth in steel production. There was a growth of average 5.9%
in world crude steel production from 752 million tons in 1995 to 1329.7 million ton in
2008. In the year 2012 it has increased to 1547.8 million tons. Global Steel
Production has been growing consistently, driven by the growing demand all over the
globe. The Indian steel industry is ranked 4th in the world with an annual production
of 125 million tons in 2017.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 10
2.3.1. Importance to the Country:
Considering the recent trend in production and consumption of steel globally and in
India, the National Steel Policy, 2005 had projected 110 MTPA steel making capacity in
India by 2019-2020 at 7.3% growth rate. It was noted subsequently in year 2006-07
that domestic production grew at 10.9% and domestic consumption by 11%.
Ministry of Steel, Govt. of India, has revised the goal and projected a capacity of 180
MTPA by 2019-20. This creates huge opportunity for investment in steel industry with
high returns.
The proposed project will bridge the demand supply gap of steel in the country. The
project will add revenue to the Government by way of direct and indirect taxes.
2.3.2. Importance of the Project to the Region
Ministry of Steel, Govt. of India has projected a capacity of 180 MTPA steel
requirement by 2019-20. The project will bridge the demand supply gap of steel and
ferroalloys in India. Part of the billets will be used for making automotive components
for use in cars and trucks. Ferroalloy will be used for making various quality of steel
products. The project will contribute to government treasury by way of direct and
indirect taxes. The project will employ 500 persons and provide in-direct employment to
500 persons in transport, upkeep & maintenance, ancillary units. Local people (Average
200, maximum 500) will get employment during the construction stage. PSMPL will
spent 2% of the project cost for Enterprise Social Commitment, which will be helpful for
the socio-economic development of villages located around the project site.
2.4 Demand – Supply Gap
Ministry of Steel, Govt. of India, has revised the goal and projected a capacity of 180
MTPA by 2019-20. Presently the steelmaking capacity of the country including those in
the under construction sector is approximately 160million tons.
2.5 Import vs Indigenous Production
Proposed steel plant will meet the Indigenous demand of quality steel and reduce the
import requirement of steel.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 11
2.6 Export Possibility
Re-bars (TMT) can be exported to Nepal, Bhutan and Bangladesh.
2.7 Domestic/ Export Markets
For Billets there is huge market is available in Chhattisgarh and nearby areas. The billet
production will give boost to the state infrastructure development.
2.8 Employment generation (Direct and Indirect) due to the project
Type of employment Skilled Semi & Un-Skilled
Direct 200 300
Indirect 100 400
Total 300 700
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 12
3.0 PROJECT DESCRIPTION
3.1 Type of project including interlinked and interdependent projects, if any
The proposed project falls under Category A, 3a of EIA Notification 2006. PSMPL is
operating an iron ore mine (EC obtained for 0.4 MTPA capacity) in Hahaladdi,
Bhanupratappur, Kanker district, CG. Iron ore from this mine will be used in the
proposed steel plant. The capacity of the iron ore production may be increased in future
for which EC will be obtained in due course of time. The iron ore fines will be converted
to pellets and used for making DRI. DRI and MS scrap will be used to make Billets.
Billets will be used for making automotive components in a machine shop. Surplus
billets / Sponge will be sold to rolling mills located in CG. Ferroalloy plant will produce
FeMn, SiMn and FeSi. Ferroalloys are used as alloys for steelmaking. Steel Making
using Best Available Technology pollution control systems is energy efficient and also
generates less wastes. Waste heat and dolochar wastes will be used for generating
power.
3.2 Location with coordinates
Location (map showing general location, specific location, and project boundary and
project site layout) with coordinates is attached. The location of site with type of land
and boundary coordinates is as below:
Feature Description
Location Borai Industrial Area Village: Rasmara, District: Durg, Chhattisgarh
Type of land/ land use Industrial land (100%) acquired through lease from CSIDC
Coordinates
(As per Google Map)
Latitude & Longitude A 21ò11’42.77”N to 81o12’47.58”E B 21ò11’26.14”N to 81o12’50.00”E C 21ò11’27.50”N to 81o12’58.80”E D 21ò11’32.00”N to 81o13’01.00”E E 21ò11’43.80”N to 81o12’57.00”E
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 13
Google Map of Project Site and Surroundings
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 14
3.3 Details of alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted
Alternate sites not considered because land has been acquired in a industrial area and
EC obtained in 2008. The industrial area is basically for iron and steel making units.
The application / proposal is for fresh EC because the validity of the EC has expired.
3.4 Size or magnitude of operation
The proposed project falls under Category A project of EIA Notification 2006.
Name of proposed unit Size / Production Capacity / Product
1 Pellet Plant 1 x 0.6 MTPA
(600000 TPA iron ore pellets)
2 DRI Plant 2 x 350 TPD, 1 x 500 TPD
(420000 TPA Sponge Iron)
3 Induction Furnace (with
Laddle Refining Furnace &
Continuous Casting
Machine)
Induction Furnace: 4 x 15 tons, 3 x 12 tons
Laddle Refining Furnace: 15 tons & 30 tons
CCM: combicaster (2 Nos.)
(400000 TPA Billets)
4 Ferro Alloy Plant 3 x 9 MVA (52000 TPA Ferroalloys)
Product mix of Ferromanganese/ Ferrosilicon / Silicomanganese within the allowed capacity
5 Press Machines for
Automotive Components
Manufacture
125 tons, 60 tons, 40 tons, 2 x 25 tons for making Automotive Components using Billets 120000 TPA Automotive Components
6 Captive Power Plant 34 MW (24 MW through WHRB) (10 MW through AFBC)
7 Utilities DM Plant, Air Compressor, AC & Ventilation,
Laboratory, Water System, etc
The project will be located on 11.421 ha land. The project will require 5000 KLD water.
The project will employ 1000 people and the project cost is Rs.480 crores.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 15
3.5 Project Description with Process Details
3.5.1 Pellet Plant
The pellet making process comprises following steps:
Mixing & Balling: Iron ore fines containing 60-61% Fe, to be received from
Hahaladdi mines of the Company will be mixed with Bentonite and Water and
transferred to balling disc rotating with adjustable angle, frequency and speed for
higher degree of balling. Water (upto 1% depending on the moisture of ore) is
added by regulating valve during the process of balling to achieve the optimal
moisture of the mixed material for balling.
Drying and Pre Heating: The green ball produced by the balling disc will be sent
to the green ball distribution system in Traveling Grate room by belt conveyor. The
undersize (-8mm) and oversize (+16mm) balls will be separated and sent back to
the balling room via return system. The green balls of 8 to 16mm size range, called
qualified balls, are passed on to the grate bed of Travelling grate. The thickness of
the material (balls) bed on the grate will be kept 185mm. The green balls will pass
through 4 zones of the grate viz. drying zone-I and II, preheating zones I and II.
The temperature of these zones will be 300°C, 500°C, 700°C and 1100°C resp.
The green ball will be dried and preheated on the Travelling grate. After preheating
the green balls will attain enough strength, they will be discharged into Kiln through
discharging plate and large chutes.
Induration in Rotary Kiln:The preheated balls discharged into the Rotary Kiln will
be indurate for about 35 minutes while rolling, mainly due to heat radiation of the
flame produced by burning of pulverized coal. The induration temperature of 1200º
to 1250º is attained in the Rotary Kiln. The speed of the Kiln will be adjusted
according to variation of the raw material to determine retention time and
consequently the quality of the pellet. The indurated pellet will be discharged to the
receiving hopper of the annular cooler through Chute and fixed screen in the Kiln
head hood.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 16
Annular Cooler: The Annular Cooler receives the red-hot-pellet with temperature
upto 1230º discharged from the Kiln, its particle size being 8-16mm. The pellet will
be distributed on the pallet bed in the annular cooler, upto 760mm thickness. The
annular cooler is provided with 3 air blowers. The pellets are cooled in 3 stages,
from 1230º C to 900ºC, from 900º to 550ºC and from 450ºC to 90-105ºC. The
discharged hot air from annular cooler will be used for drying, pre-heating and
indurating sections, thus most of the heat generated during pellet cooling will be
effectively utilized in the pellet production process. The pellet discharged from
annular discharge hopper after cooling is stacked in the finished Storage yard.
Main induced draught system: The waste fume is collected from the wind boxes of
travelling grate preheating section I, draught drying section I & II, dedusted by
electro static precipitator to reach the standard,and induced by main induced fan to
be discharged by chimney. The collected dust will be pneumatically transported
from duct channel, through duct and to dust bin in proportioning room.
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Pushp Steels & Mining Pvt Ltd Page 17
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 18
3.5.2 DRI Plant:
Iron Ore and Coal along with Dolomite are fed continuously to the charge end of Rotary
Kiln which is inclined at 2.5% of drum length. Coal is also injected through a Coal
Throw Pipe at the discharge end of Kiln. Due to the inclination and rotation of Kiln the
charge material moves along the length of Kiln and it is discharged continuously after
processing. To supply heat for the process air is blown into the Kiln through central
burner and air pipes mounted on the Kiln shell. As the charge moves along the kiln, it is
heated by the gases which flow in opposite direction. The first section, approximately
half of kiln is called preheating zone where iron ore, coal and dolomite are dried and
heated to reaction temperatures using the heat released from the combustion of volatile
matter and carbon in the coal . The second half of kiln is called reduction zone where
major amount of Oxygen contained in the iron ore is removed leaving metallic iron (Fe).
De-sulphurisation in the Rotary Kiln is effected by calcined limestone/dolomite. The
chemical reactions taking place at various zones in the rotary kiln are as given below.
In the pre-heat zone, the reduction of iron oxide proceeds only to ferrous oxide (FeO)
Fe3O4 + CO = 3 FeO + CO2 ............................ (I)
Final reduction to metallic iron occurs in the metallization zone by reaction of CO with
FeO to form CO2 and metallic iron.
FeO + CO = Fe + CO2 ........................... (II)
Most of the CO2 reacts with the excess solid fuel in the kiln and is converted to CO.
CO2+C = 2CO ............................ (III)
The reduced iron ore -SPONGE IRON with unburnt char from rotary kiln gets
discharged into a Rotary Cooler. The heat will be dissipated indirectly by water spraying
into the outside of Cooler Shell. The material gets cooled to around 120°C.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 19
Process flow of DRI production is given below
3.5.3 Billet Making Process
The project envisages steel making facility through Induction Furnace route along with
Ladle refining furnace and continuous casting machine. The process involves charging
mix of raw material, mainly Sponge iron and M.S. Scrap into molten bath with constant
power track, by which, heat transfers into molten bath at constant voltage and KW to
melt the Iron and Steel at a temperature of 1550oC.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 20
Melting the Charge in Induction furnace
Sponge Iron,Scrap and Lime form the charge for steel making in induction furnace.
After the furnace is switched on; current starts flowing at a high rate and a
comparatively low voltage through the induction coil of the furnace, producing an
induced magnetic field inside the central space of the coils where the crucible is
located. The induced magnetic fluxes thus generate cut through the packed charge in
the crucible. As the magnetic fluxes cut through the scraps and complete the circuit,
they generate an induced current in the scrap. This induced current, as it flows through
the highly resistive path of the scrap mix, generates tremendous amounts of heat and
melting of scrap starts. As soon as the charge has melted clearly, any objectionable
slag is skimmed off, and the necessary alloying elements are added. When these
additives have melted completely, the power input may be increased to bring the
temperature of metal up to the point most desirable for pouring. The current is then
turned off and the furnace is tilted for pouring into a ladle. As soon as pouring has
ceased the crucible is cleaned completely from any slag or metal droplets adhering to
the wall of the crucible and the furnace is now ready for charging again.
Ladle Refining Furnace (LRF)
After tapping the ladle is transferred on the tapping car to a position where the
overhead crane pick it up and transport it to the heating station where the remaining
slag builders are added. Ar/N2 bubbling is performed during all operations in the
secondary treatment station. The first heating period will last until the slag is fused, the
steel analysis is uniform and the steel temperature is high enough to enable good
sampling. While waiting for the sample analysis, heating is continued and trimming
alloying additions are given as soon as the laboratory analysis is received. The
temperature is increased to the aim temperature for casting. The main objectives of
secondary metallurgy include mixing and homogenizing; adjustment of chemical
compositions; temperature adjustment; de oxidation; removal of undesirable gases
(e.g. hydrogen, nitrogen and oxygen); and improvement of the oxide purity by
separating non-metallic-inclusions.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 21
Billet making through Continuous Casting Machine
Liquid Metal from Induction Furnace is carried in a ladle over the Con-cast Machine. The
liquid metal flows from the ladle through a slide gate system underneath it into water
cooled copper mould tubes which solidifies the liquid metal into a square shaped mould
which we call as M.S. Billets. From the considered casting cycle time, the number of
strands required to cast 100 mm2and 110 mm2 billets is worked out to be two. Based on
the above, 2-strand billet casting machine suitable for casting up to 160 mm2 Billets have
been selected.
Continuous Casting Machine (CCM): The liquid steel after secondary metallurgy is
transported to the “tundish” of CCM. This is an intermediate ladle with controllable
outlet. The ladles are preheated prior to accepting a liquid steel charge in order to avoid
temperature stratification in the tundish. When the liquid steel reached the desired
temperature; it is poured into the tundish. From the tundish it passes to a short water-
cooled copper mould in which no air is present and which performs oscillating
movements to prevent the steel from sticking. The mould gives the metal the desired
shape. When the metal leaves the casting mould, a “skin” of solidified steel has formed
and a large number of rolls guide the cast steel with a gentle curve toward a horizontal
position. At this point, the endless casting is cut into pieces with torch cutter. Billets and
round are cast in this way.
Automotive Components Making: The Billets will be used to make various
automotive components (like exhaust systems) in a Press Shop for use in cars, trucks,
scooters, etc using CNC machines of various capacities (25 tons to 125 tons capacity
CNC machines). There will be no water or air pollution or solid wastes generation from
this process.
3.5.4 Ferro Alloy Plant
In the submerged arc furnace electric power heats the raw materials and provide
energy to reduce the ore to a metallic state. Carbon serves as reducing agent and
fluxes are often added to facilitate removing the gangue materials present in ore as
slag. The practice is to mix the ore materials, the reducing agent, and any flux
outside of the furnace and then periodically charge this mixture (often called charge
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 22
mixture) in to furnace. Although the charge mix is added periodically, the reduction
reaction and the metal production proceed continuously. The metal is usually allowed
accumulate until tapping occurs at appropriate intervals.
The term “submerged arc” is used because the carbon electrode is usually buried
deep in the furnace charge mix and the reduction reaction takes place near the tip of
the electrode. At the top of the charge mix little current flows between the electrodes
because of the high resistivity of the unmelted charge. As the charge mix descends
in the furnace, the non carbon portion of the charge begins to melt. As the carbon
heats, its resistance decreases providing a conductivity path between the electrodes.
This current flow creates intense heat needed for the high temperature and energy
required for the reduction reactions.
Most submerged arc furnace that produce ferroalloys uses self -baking electrode
system invented by the team led by C.W Soderberg. This system takes advantage of
the electric power used for the process to bake the electrode in place. A series of
cylindrical steel casings welded on the top of each other forms the electrode column.
Operators periodically add solid green carbon “paste” blocks to the top of the
column. The paste blocks melt to form the unbaked electrode shape. Vertical fins
which are attached to the casing carry the power into the carbon paste so that the
paste bakes to a solid carbon electrode in the casing. As the process consumes the
baked electrode, more electrode is slipped into the furnace. The self -baking
electrode system reduces electrodes cost then the purchase of prebaked amorphous
carbon electrodes. It allows the furnace to be larger since prebaked electrodes are
limited to some size.
The ferroalloys are manufactured in a submerged electric furnace by using the
following raw materials:-Manganese Ore, Carbonaceous/Reducing agent such as
coke/coal, Fluxes like quartz, dolomite.
The raw materials are mixed at a desired proportion in a weigh hopper and charged
into the furnace through charging tubes. Input of electrical energy through Soderberg
electrodes cause generation of heat energy, as the charge is having definite
resistance. Due to evolved heat, smelting of charges (Manganese / Silicon etc.)
takes place according to the following chemical reactions:-
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 23
MnO + 2C === > Mn + 2CO
SiO + 2C === >Si + 2CO
2CO + O2 ==== > 2CO2
The respective ores and reducing agent (Carbon) is having gangue material like
SiO2, CaO, MgO etc. Addition of fluxes makes the reaction exothermic which
ultimately removes the gangue material present in ore & reductants.
During the process at an interval of 3-4 hrs. (Depending upon the capacity to handle
liquid Alloy & Slag), the liquid Alloy & Slag is tapped & drained out from the furnace
tap hole. The metal & slag are separated by virtue of difference in density by
providing a skimmer block placed in the sand pit. After cooling for 2-3 hours metal is
removed from the beds and allowed to cool further before it is sent for onward
processing as per desired size fraction. The alloys in lump from are then manually
broken and sieved for sizing. Input/Output ratio of metallurgical process is not
constant and purely depends on quality/ size of input material like ore, reductants &
fluxes. This also depends on operating parameters while producing different alloys.
For Ferro Manganese – 52,765 TPA (max):
Material Quantity/Ton of product (in kg) Source
Manganese Ore 2400
Balaghat (MP), Local
Market & Private mines in
Odhisa
Coke 800
Dolomite 250
Carbon Paste 30
Quartz 100
Total 3,580
For– Silico Manganese – 35,180 TPA (max):
Material Quantity/Ton of product (in kg) Source
Manganese Ore 1600
Bhalaghat(MP), Local
Market & Private mines in
Odhisa
Coke 800
Dolomite 250
Carbon Paste 30
Ferro Slag 700
Total 2,480
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 24
For Ferro Silicon – 17,380 TPA (max)
Material Quantity/Ton product (in Kg) Source
Quartzite 1800
Bhalaghat(MP),
Local Market & Private
Mines in Odhisa
Mill Scale 300
Char Coal 900
Coke Breeze Low Ash 500
Scrap 100
Total 3,600
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 25
3.5.5 Captive Power Plant
34 MW power plant based on utilization of hot gas from DRI Kiln based on WHRB
technology and AFBC/CFBC technology has been proposed. Hot flue gas from 1200
TPD DRI plant will generate 24 MW power using suitable capacities of Waste Heat
Recovery Boilers. Dolochar and coal will be mixed to improve the calorific value of
dolochar and used as fuel in the 10 MW AFBC/ CFBC Power Plant. Power plant will
have all necessary auxiliary systems such as feed water heating and pumping system,
dust handling system, Condenser cooling water system, DM water plant, electrical
system including power distribution and evacuation equipment, fire-fighting system, air-
conditioning and ventilation system, cranes.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 26
3.5.6 Utilities
DM Plant: 2 x 5 m3/h demineraliser chains are proposed for meeting the boiler feed
water requirement. Each of the DM chains would comprise activated carbon filter,
strongly basic cation exchanger, degasser tower, strongly basic anion exchanger and
mixed bed unit. The system will be complete with necessary pumps, control valves,
instrumentation and controls etc. for complete sequential, semi-automatic push button
operation from the common control panel. The DM water from the mixed bed unit outlet
will be stored in a mild steel rubber lined water storage tank. The ion-exchangers in the
DM chains will be regenerated by HCl (cation resins) and caustic soda (anion resins).
Appropriate handling, storage, mixing and injecting facilities of the chemicals will be
provided for convenient operation of the plant.
The DM plant will be regenerated once every two days using acid and alkali. The
regeneration wastewater coming out of the DM plant will be taken to neutralization pit.
After neutralization the wastewater will be used for dust suppression in raw material
yard using water sprinklers. There will be no air pollution, noise generation or solid
waste generation from the DM plant.
Compressed Air System: Dry compressed air will be used at various points like DR
plant, SMS, CPP, etc. The exact capacity of the air compressors is not available at
present. The compressors, dryers and associated pipework will be located in one place,
within a building. Compressed air to various consumers will be distributed through a
compressed air piping system. There will be no air pollution, water pollution or solid
waste generation from the Compressed Air Plant. Noise generated from compressors
will be confined within the compressor building, with noise absorbent materials.
Liquid Fuel Storage: LDO and HSD shall be stored in small tanks inside the plant
premises. 1 x 10 KL LDO Tanks& 1 x 5 KL HSD Tanks
Liquid fuel will be brought by tankers and unloaded into the storage tanks by means of
pumps. Delivery pumps will be provided for circulating oils in the ring main. From the
ring main oil will be supplied to the consuming points. Necessary unloading header,
hoses, piping, valves and fittings will be provided for the system. The fuel oil storage
tanks will be provided with sealed fixed roof, to prevent leakage of hydrocarbons.
Dykes will be made around the Tanks and then the area fenced using barbed wires.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 27
There will be no water and noise generation from the fuel oil storage tanks. Safety
measures as per OISD guidelines will be provided.
Laboratory: Quality assurance will be possible in the form of chemical analysis, which
can be provided by well-equipped laboratories with day to day quality control at all
stages of processing and quality evaluation of outgoing products. Separate laboratory
will be installed within the steel plant complex. The laboratory will generate water
pollution, which will be taken to Effluent Treatment Plant. The treated wastewater will
be reused for ash handling in the power plant. Fumes generated from the laboratory will
be scrubbed with water and the scrubbed water will be recycled. The final scrubbed
water will be taken to ETP for treatment, and reused in the ash handling system of
power plant. Solid wastes in the form of chemical bottles and cans will be given to
recyclers.
Air Conditioning and Ventilation Systems: Ventilation and air conditioning system
comprises fans, air filters, air conditioning units, duct work, pumps, cooling tower, air
supply grills, dampers, insulation, electrical and instrumentation and controls required
for protection of equipment from excessive thermal loading and working comfort for
plant personnel. All control rooms, offices, laboratories will be air conditioned, the type
depends on specific requirement and application (room air conditioners or centralized
air conditioners). Highly energy efficient HVAC system comprising water cooled chillers
and cooling systems will be installed. CFC and HCFC free refrigerants will be used in
the air conditioning system. Cooling towers will be provided for dissipation of water
vapours. All work areas will be provided natural ventilation and where required,
mechanical ventilation will be provided. Cast house, SMS and shops will be provided
with mechanical ventilation and exhaust / pressurized system for adequate dispersal of
fugitive dust and fumes. Air-coolers will be provided in work areas that are subjected to
high heat radiation stress. The details and type of systems proposed are shown below
Location / Shop Ventilation Facility
Electrical premises Pressurized ventilation with washed air
Compressed air station Exhaust ventilation
Battery rooms Exhaust ventilation
Pump houses Exhaust ventilation
Toilet Exhaust ventilation
Stores Exhaust ventilation
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 28
Repair shops Exhaust ventilation & man-coolers
Transformers room in SMS
Pressurized ventilation with fan and filter
SMS (IF, LRF) Exhaust ventilation
Casting Shop Exhaust ventilation
Press Shop Exhaust ventilation
Laboratory Exhaust ventilation
TG Building Pressurized ventilation with washed air
Water System: Probable source of water is Shivnath river (supplied by CSIDC). Water
will be clarified for making it fit for industrial use in raw water treatment plant. Part of the
industrial water will be treated in softening plant and distributed to closed circuit of the
plant as soft water make-up. Part of the water will be used to produce DM water,
necessary for boiler feed requirement. Water for drinking will be taken from the water
reservoir and treated. The raw water treatment will be done by chemical coagulation,
flocculation and clarification process. Lime and polyelectrolyte will be added for
coagulation and flocculation. The sludge generated at the bottom of clarifier will be
collected and dewatered in filter press. The sludge will be disposed as landfill material
inside the plant premises / mixed with soil and used as manure. Softener regeneration
water will be reused in the ash handling unit of the power plant.
3.6 Raw Material required along with estimated quantity, likely source, marketing
area of final products, mode of transport of raw materials and finished products :
Name of Raw Materials
Quantity TPA
Source
Iron Ore 660000 (Fines) 350000 Lumps)
Captive mines in CG and from other mines located in CG and Orissa.
Coal 575000 Purchase from SECL/Imported, Coal with less than 0.5% sulphur content will be used.
Coke 42000 Purchase from Dhanbad area, Jharkhand
Dolomite 31000 Purchase from Bilaspur area, CG
Lime 10000 Purchase from Katni area, CG
Quartzite 5000 Purchase from Bilaspur area, CG
MS Scrap 120000 Purchase from Durg, Raipur. Also available internally
Mn ore 126000 Purchase from Balaghat District, MP
Bentonite 12000 Purchase from Kutch District, Gujarat
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 29
Saleable finished products
Billets and Automotive Components: 400000 TPA
Ferroalloys: 52000 TPA
Pellets: 300000 TPA
Sponge Iron: 100000 TPA
The raw materials and finished products shall be transported by road. Nearest railway
siding is located at Rasmara, 1km away from the proposed project site, which will be
used for bringing raw materials and sending finished products, as prefeasibility of
source and market.
3.7 Resource optimisation / recycling and reuse envisaged in the project
Steel Making using Best Available Technology pollution control systems is energy
efficient and also generates less wastes. Waste heat and dolochar wastes will be used
for generating power. The project will add to resource conservation by utilizing iron ore
fines generated during the mining of iron ore. Water is not required for iron and
steelmaking process. Water is required only for cooling of various machines and
equipment. Therefore, no wastewater will be discharged outside the plant premises.
Wastewater will be appropriately treated and reused / recycled within the plant
premises. Domestic wastewater will be treated in STP/ETP. Treated water will be used
for gardening and dust suppression purpose. Solid wastes will be utilized for various
beneficial purposes. The solid wastes are not hazardous. However, if any solid wastes
is required to be disposed, it will be done in an engineered landfill site. Spent oil and
lubricants will be collected in drums and sold to authorized re-processors. The solid
wastes being used are given below
3.8 Availability of water, its source, Energy / Power requirement and source
Water will be supplied by CSIDC. Overhead water tank exists in the Borai Industrial
Growth Centre for water supply to industries. Letter of intent have been provided by
CSIDC.Power from the 34 MW Captive Power Plant will be the main source of power
for the units. Any shortfall will be met through grid supply by CSEB. 2 x 500 KVA DG
sets shall be installed to meet any emergency power requirement.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 30
3.9 Schematic representations of the feasibility drawing which gives information
of EIA purpose
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 31
4.0 SITE ANALYSIS
4.1 Connectivity
The connectivity of the project site with the major road/ railways/ ports and human
settlement is as given in table
Description Distance
Transportation
Road : ~ NH6 –approx. 0.5 KM
Rail :Rasmara railway station approx. 1 km
Nearest Town/City
Durgtown-approx 5 km
Nearest Village
Rasmara - approx 0.5 km
4.2 Land form, land use and land ownership
11.421 ha land has been acquired on lease from CSIDC. Land is in the name of Pushp
Steels & Mining Pvt Ltd.
4.3 Topography: Flat
4.4 Existing land use pattern: Industrial
4.5 Existing Infrastructure
Approach Road from Highway and Railway Station, Internal Road (Arterial, double lane
and divider roads), Overhead Water Tank, Sewerage system, Petrol Pump, Weigh
Bridge, Electric substation and transmission lines, Food Stalls, fire tenders, Office of
CSIDC are available in Borai Industrial Area. Nearest residential area is Rasmara,
Bhilai and Durg. Excellent road and rail connectivity available.
4.6 Soil classification: Sandy loam type.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 32
4.7 Climate data from secondary sources:
Temperature – November and December represents post-monsoon months in the
area with daily mean minimum temperature around 14oC and daily mean maximum
temperature around 26.1oC. May is the hottest month with daily mean maximum
temperature at 40.2oC and daily mean minimum temperature at 22.6oC. In the
remaining months, temperature is pleasant with the daily mean maximum and minimum
temperature around 30oC and 25oC respectively.
Relative Humidity – The air is generally dry in the region except during south-west
monsoon. The summer is driest with relative humidity below 40%. The maximum
humidity during rainy season is 86%. High humidity is found during daytime and low
humidity values during nighttime in all the months.
Atmospheric Pressure – The maximum atmospheric pressure is recorded at 982.6mb
during winter season and minimum pressure at 967.8mb during monsoon season. The
atmospheric pressure during daytime is found to be higher than the nighttime pressure
in all the months.
Rainfall – The annual total rainfall is 1388mm. Over 90% of the total annual rainfall
occurs during the southwest monsoon period between June to September.
Cloud Cover – In the study area, clear weather prevails in most of the time during post
monsoon, winter and summer seasons. Only during monsoon months of July, August
and September, moderate to heavy clouds are observed. Relevant details about the
number of days with zero oktas of cloud cover (all clouds) for all months are presented
below (IMD station Raipur).
Wind Speed– The mean wind speed ranges from 4.1 to 5.0 kmph during winter months
and 10.7 to 12.1 kmph during monsoon months. During the months of February, March
and April, the mean wind speed is around 6.0 to 8.4 kmph.
Wind Direction – The predominant wind direction in Raipur is from North East in all the
months, except monsoon. The second most predominant wind direction is from South
West during the monsoon months of July, August and September. During March to May
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 33
the most predominant wind direction fluctuates between South-West and West. During
post-monsoon the predominant wind direction was observed from North East.
Calm Periods – The wind speed of less than 1.8 kmph are treated as calm periods. In
Raipur, the calm periods are always less during night time compared to daytime. The
maximum calm periods occurs during November, December and January and minimum
calm periods occurs during May, June, July and August months. The calm period
constitute an important factor in the dispersion of air pollution. The monthly values of
calm periods are as follows (IMD data):
Weather Phenomena – The occurrence of thunderstorm is not common in Raipur and
the frequency is 39 days in 365 days, mostly spread across the months of February to
September. The frequency of dust-storm is 1.6 days in a year and spread during April
to June. On an annual average basis, 116 days have visibility in the range of 4-10 km
and 132 days have visibility above 20 km. The visibility upto 1 km is only 0.5 day per
year.
Inversion Occurrence - The nearest IMD station is Nagpur where radiosonde flight
data are available for calculation of mixing height and observing inversion conditions.
Therefore data from IMD station Nagpur (representing Central India) has been
considered for knowing inversion occurrence of the study area. High ground based
inversions at 5.30 AM of the order of 90% and above are observed over central India
during November and December. At 5.30 PM the ground based inversions are below
5% all over central India. The distribution of the top heights of the inversion layers over
central India for 5.30 AM shows deep formation with heights varying between 400 and
1500 m. At 5.30 PM the distribution is insignificant.
The frequency of occurrence of elevated inversions at 5.30 AM and 5.30 PM over
Central India shows lower values of 15% and less. The percentage frequencies of
ground based inversions with top heights at 00 GMT and 12 GMT as well as the
percentage frequencies of elevated inversions at 00 GMT and 12 GMT are shown
below (IMD Nagpur Station, representing Central India).
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 34
4.8 Social infrastructure available
Nearest residential area is Rasmara, Bhilai and Durg. Excellent road and rail
connectivity available. Good Hospitals, School, Education Institutes, Coaching Centres,
Markets and Shopping Malls, Ambulance, Fire Brigade Offices, District Court, are
available in Bhilai and Durg. Health Centre, Hospital and School is also available in
Rasmara.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 35
5.0 PLANNING BRIEF
5.1 Planning concept (type of industries, facilities, transportation etc) Town and
country planning/ Development authority classification.
The proposed project is green field project and located in industrial land. Also the
industrial area and the related facilities are already developed hence no planning is
envisaged. Also, due to the presence of many steel making and fabricating industries
inside the industrial area led to conducive infrastructural facilities like paved roadway
and electrical substation, for establishing an Industry.
5.2 Population projection
There would not be any significant increase in the population of surrounding area as
the workers for the proposed project will come from the local residents in the
surrounding villages and town. No major influx of people in the area due to project.
5.3 Land use planning (break up along with green belt etc)
TOTAL AREA 11.421 Ha
MAIN PLANT 3.021 Ha
ROADS AND DRAINS, WATER
RESERVOIR, RAW MATERIAL YARD
3.7 Ha
GREEN BELT in Ha 3.7 Ha
GREEN BELT in % 33%
5.4 Assessment of infrastructure demand (Physical & social)
As the proposed project is with the existing industrial premises the basic infrastructure
like water, electricity and road are available at the project site. Hence no major
infrastructure is envisaged at the project site.
5.5 Amenities/Facilities
Existing facilities are adequate. No additional facilities are required.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 36
6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial area (Processing area)
TOTAL AREA 11.421 Ha
MAIN PLANT 3.021 Ha
ROADS AND DRAINS, WATER
RESERVOIR, RAW MATERIAL YARD
3.7 Ha
GREEN BELT in Ha 3.7 Ha
GREEN BELT in % 33%
6.2 Residential area (Non processing area)
No labour colony is envisaged for proposed project.
6.3 Green belt
Around 3.7 ha area, out of 11.421 ha of total project area, which is about 33%, has
been allocated for green belt development. It is proposed to plant 600 trees per acre of
land area. Plantation will start along with the plant construction. Layout plan showing
green belt area for the project is shown in attached layout. The list of plant species,
which is proposed to be used for the green belt development, is given in below.
Pongamia, Kadamb, Peltaform, Pipal, Bargad, Mango, Amaltas, Cassia,
Kaner,Tamarind, Semal, Amla, Bel, etc.
The pit size for the plantation of saplings will be about 1m ×1m×1m. These pits will be
filled with soil and manure, about 5 to 10 days in advance before plantation. After fifth
year, efforts will be taken to replace the dead plants, which have been planted during
the five years.
6.4 Social infrastructure
No additional infrastructure is required.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 37
6.5 Connectivity (Traffic and transportation road/rail/metro/ water ways etc)
Excellent connectivity available.
6.6 Drinking water Management (Source & Supply of water)
CSIDC is supplying water through an Overhead Tank. This water is fit for drinking after
preliminary treatment through Aqua-guard type -Candle filter + Carbon adsorption-UV
light.
6.7 Sewerage system
Existing facility is adequate.
6.8 Industrial waste management
PSM will create its own industrial waste management system as per rules and norms.
6.9 Solid Waste/by product Management
PSM will create its own solid waste management system as per rules and norms.
6.10 Power requirement & supply/ source
Total power requirement of proposed plant will be 34 MW which will be sourced from
the CPP and CSEB. PSMPL will add two 500 KVA DG sets for emergency power..
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 38
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
7.1 Policy to be adopted (Central/ state) in respect of the project affected
persons including home oustees, land oustees and landless laborers
Not applicable, because no human settlement or agriculture land is involved in the
project. The proposed project is within the existing industrial premises.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 39
8.0 PROJECT SCHEDULE & COST ESTIMATES
8.1 Likely date of start of construction and likely date of completion
Likely date of start of construction: June 2019 (after obtaining EC)
Likely date of completion of construction: January 2021
8.2 Estimated project cost along with analysis in terms of economic viability
of the project
Estimated project cost: Rs. 480 Crores
Economic viability: The project will be economically viable because land is already
available with PSMPL, the project promoters are financially sound and experienced,
capable of contributing 25% equity in phases. PSMPL owns captive iron ore mine of
400000 tons / annum. Other raw materials required for the proposed project is available
locally. The location of the steel plant is close to major steel marketing hub of Bhilai and
Raipur.
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 40
9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
9.1 Financial and Social Benefits
Based on the future demand of steel in the market over the next 5 years, the proximity
to raw materials and finished products, there is an advantage with respect to price
logistics. The techno-commercial viability also shows a good rate of return from the
project. Other financial and social benefits that could be obtained from the proposed
project, and why this project is recommended, is described below:
• The plant will result in considerable growth of service sector in the region.
• Provide direct & indirect employment opportunities and development of
peripheral/supporting services and amenities.
• Supporting infrastructure development like road, power supply, reality sector
• No environmental significant impacts are envisaged.
• Best applicable mitigative measures have been proposed for management of
anticipated environmental impacts.
• Community development activates will be initiated under CSR programs.
• The project will provide significant revenue to the exchequer in the form of excise
and taxes etc.
• The project will create opportunity for industrial development in the state.
PSM will focus on the all-round development of the communities in and around the
plant and promote social & welfare activities of the surrounding society.2% of the
project cost will be spent for various social & welfare activities of the nearby society.
Over and above company resources has also been deployed for improving society &
welfare programs. Apart from providing suitable employment for local populations, the
key focus of social & welfare activities are
- Improving hygiene & sanitary conditions, Drinking water
- Green Belts development & Society parks
- Medical facilities & health awareness
- Education promotion & support
- Support for natural calamities & emergencies
- Religious & Cultural activities support, Fodder for animals
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 41
A-1 Location Map
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 42
A-2 SOI Toposheet Showing Project Site and 10 Km Area Around the Site
Prefeasibility Report of Steel Plant at Durg, Chhattisgarh
Pushp Steels & Mining Pvt Ltd Page 43
A-3 Preliminary Plant Layout
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