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PRE-FEASIBILITY REPORT
CREST STEEL & POWER (P) LIMITED
[EXPANSION]
Unit proposed Proposed Production
Wire Rod Mill 1,00,000 TPA
I/O Beneficiation 16,00,000 TPA
Pellet Plant 12,00,000 TPA
FBC Boilers 12 MW
Location : Joratarai Village, Mangatta (PO) Rajnandgaon Tehsil & District, Chhattisgarh
For
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
PRE-FEASIBILITY REPORT Page-2
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY:
Sl. No Item Detail
1 Name of the project Crest Steel & Power Pvt. Ltd.
2 S.No. in the schedule 2(b) & 3(a)
3 Proposed capacity / area
/ length / tonnage to be
handled / command area
/ lease area / number of
wells to be drilled
The following units are proposed in further expansion
Unit proposed Proposed Production
Wire Rod Mill 1,00,000 TPA
I/O Beneficiation 16,00,000 TPA
Pellet Plant 12,00,000 TPA
FBC Boilers 12 MW
4 New / Expansion /
Modernization
Expansion
5 Existing capacity/Area
etc.
The following are the existing & Expansion (for which E.C. already accorded)
S. No. Products Existing Expansion* Further Expansion
1 Iron Ore Crushing Plant --- 17,95,200 TPA
2 DRI Plant (Sponge Iron) 1,15,500 TPA 8,08,500 TPA
3 Induction Furnace with LRF (Billets) 33600 TPA 5,44,500 TPA
4 Electric Arc Furnace (Billets) --- 3,30,000 TPA
5 Rolling Mill (TMT Bars & Str. Steel) --- 5,61,000 TPA
6 Wire Rod Mill --- 2,06,250 TPA 1,00,000 TPA
7 Generation of Power (WHRB) 8 MW 56 MW
8 Generation of Power (FBC) 8 MW 34 MW 12 MW
9 Submerged EAF (Ferro Alloys) * 3 x 12 MVA
Ferro Manganese 32,850 TPA 59400 TPA
Ferro Silicon 10,500 TPA 19,000 TPA
Silico Manganese 23,750 TPA 42,750 TPA
10 Coal Washery --- 3.20 MTPA
11 I/O Beneficiation --- --- 16,00,000 TPA
12 Pellet Plant --- --- 12,00,000 TPA
* Honorable MoEF has already accorded in for these Expansion Capacities vide letter no - J-11011/753/2008-IA II (I) dated 27th August 2010 & 22nd November, 2010.
6 Category of project i.e. ‘A’
or ‘B’.
A
7 Location
Village Joratarai
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
PRE-FEASIBILITY REPORT Page-3
Tehsil/Mandal Rajnandgaon
District Rajnandgaon
State Chhattisgarh
8 Nearest railway
station/airport along
with distance in kms.
Nearest Railway Station – Rasmada (3.1 Kms.) Nearest Air port - Raipur (65 Kms.)
9 Nearest Town, city,
District Headquarters
along with distance in
kms
Nearest Town: Durg (8.3 Kms.) District Head Quarter: Rajnandgaon (25 Kms.)
10. Address for
correspondence:
M/s. Crest Steel & Power (P) Limited
Joratarai Village, Mangatta (PO)
Rajnandgaon Tehsil & District,
Chhattisgarh - 491001
Name Mr. Jai Thomas
Designation(owner /
partner /CEO)
Vice President (Group Corporate Affairs)
Pin code 491 001
E-Mail [email protected]
Telephone No. 0788-2617341 - 44
Fax No. 0788-2617353
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
2.1 Identification of project and Project Proponent
M/s Crest Steel and Power Limited (CSPPL) has been promoted by well established
entrepreneur belongs to Raipur in Chhattisgarh state and already running Sponge Iron unit
at Village: Joratarai, Post: Mangatta, Tehsil & District: Rajnandgaon (C.G.). The products are
in high demand and are being regularly used in the national infrastructure development
projects, projects of strategic importance including railways & Defense organization &
different establishment. Strict adherence to quality is maintained through sophisticated
technology installed in the plants, which is a special feature of the Group.
The board of directors plays an important role in ensuring good governance and have laid
down the Code of Conduct for all Board members and senior management of the company.
Name : Designation
Shri Abhay Lodha : Director
Shri Ashwin Lodha : Director
Shri Narendra C. Lodha : Director
Shri Surendra C. Lodha : Director
In view of this Management is would like to obtain Environmental Clearance from MoEF, new
Delhi for their proposed Iron Ore Beneficiation & Pelletisation Plant, Wire rod Mill & FBC
based Power Plant for production of Pellets, Wire rods & Power.
2.2 Brief Description of Nature of Product
The proposed expansion Integrated Steel Plant involves manufacturing of following products
Concentrated Iron ore : Iron Ore Fines will be grinded in Ball Mills and beneficiated through gravity & magnetic separation.
Pellets : I/O concentrate will be sent to pellet plant comprising of Straight Grate Indurating Furnace. Green pellets will be produced which will be indurated in this process.
TMT bars : The manufactured Billets is being taken to reheating furnace to produce structural steels.
Power generation : Power will be generated by utilization of washery rejects as fuel in the FBC Boiler.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
2.3 Need for the project and importance to the region
Availability of suitable high-grade iron ore fines in abundance for DRI making
They can be stored for a long time and transported to long distances without any
degradation in quality.
Pellets are an excellent feed material for DRI units both coal based and gas based.
Presently Iron ore fines are exported in large quantities for pellet making in other
countries.
Value addition to the rejected fines can be made by beneficiating and pelletizing
technology within the country, thereby conserving iron ore.
The feed for the sponge iron units are sized iron ore lumps.
Use of Pellets will increase productivity and less
Emission from Sponge Iron will be lower when Pellets are used.
Power generation is required to meet the plant requirements.
It is proposed to produce Structural steel / Wire rods / TMT bars / Rolled products as
consumption of iron and steel and expected growth of Indian economy the
requirement of steel will significantly increase and accordingly the domestic
manufacturing capacity needs to be increase.
MISSION
To be among the Top Iron Ore Pellet producers globally
To be one of the most cost effective iron ore pellet producers
To have significant presence across the globe.
To have the Maximum Energy Utilization thereby conserving fossil fuel.
To Create Environment Friendly Process and with minimum Emission.
2.4 Demand – Supply Gap: Pellet plant
PELLETS:
With the rapid development of Infrastructure and manufacturing sector, the Iron and
steel industry is poised for an accelerated growth. Steel demand in the country is
increasing at an average rate of 10% and is likely to remain in 10-12% range at least
for the next decade. In order to meet the steadily growing steel demand in the
country, domestic steel producing capacity is required to be higher than 110 mtpa
within next three years and, 150 mtpa by the year 2016-17. Indian economy is
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
growing at more than 10% rate, steel demand and supply will grow in the same way.
As good quality iron ore deposits are depleting fast beneficiation technologies will have
to be adopted to meet iron ore demand. Therefore good yield of beneficiation process
generally around 70 % will make this technology economically viable.
> Agglomeration technologies such as Pelletisation will have to be added to DRI Plant
/ Steel Plant so that concentrates can be used as feed material. Recycling of cheaper
raw material (fines) by beneficiation and Pelletisation process as feed material will
result in better Return on Investment as compared to using Iron ore as feed
material.
> With superior reducibility behavior of pellets compared to lump ore efficiency of
DRI production improves.
> It can be concluded from results obtained by conducting various tests on
manufactured pavement blocks that substitution of iron ore tailings for sand or
quarry dust shows better compressive strength without much change in water
absorption.
With gradual depletion of high Iron Ore reserves, the Iron and Steel sector world
over has been looking at alternatives to utilize the low grade iron ore fines for iron
making so that there is optimal utilization of the available iron ore resources. Growth
of Steel Industry, especially in China over the years despite the depletion of high grade
Iron Ore has taken place on the strength of technologies of Beneficiation, Sintering
and Pelletisation of Iron Ore Fines, which enhances the productivity of the blast
furnaces in Steel making and hence lowering the cost of steel production.
In the Indian context, by the year 2020, India's production of steel is expected to touch
110 Million Tonnes and it is imperative that the fines generated in the mining of iron
ore be utilized for the production of steel. The Indian steel industry which
predominantly uses expensive lump ore is gradually moving towards usage of iron ore
pellets.
The present Indian raw material scenario offers an opportunistic disposition
towards pellet making owing to the availability of large quantities of sub grade fines,
slimes and blue dust etc. at different mine heads. These materials are not suitable
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
for sinter making. Pelletisation is the only possible route for salvaging these, otherwise
waste but valuable materials. Recent techno-economic studies indicated favorable
indices for installation of pellet plants, both small and large scale. The demand supply
analysis also underlines the need for Pelletisation.
STATE OF THE STEEL WIRE ROD INDUSTRY:
Established in India in 1920s, the Wire rod Industry has progressed remarkably and has
successfully developed and manufactured various types of high carbon, alloy steel and special
steel wires in addition to mild steel wire rods. The industry has become versatile enough to
meet the requirements of numerous consuming sectors. This sophistication has been
possible due to continuous and well-planned R & D efforts on part of the manufacturers with
patronage of SWMAI. The result has been that the industry is in a position to manufacture
and supply steel wires, both in the domestic and the international markets, in accordance
with Indian (BIS) and international (ASTM, DIN, JIS, BSS) standards.
The product range of steel wire rod manufacturers is being continuously widened. An
indicative list of the various types of steel wire rods and wire products produced in India is
given below:
It is seen that this industry is growing about 5-6% during last two years. The demand of
wires is expected to increase in leaps and bounds in the years to come. Out of the total steel
consumed in India wire constitutes only 5%. However, if pace of development picks up the
domestic consumption of wires will increase by 2%–3% to 7%-8% of the steel consumption.
In our Country, if we closely look at the wire demand, almost 88% of it is for wires in plain
carbon steel grades, 5% would be for Stainless Steel grades and the balance would be for
Alloy Steel Wires.
On further analysis, out of the plain carbon wires almost 75% to 80% of the demand is for
black/uncoated wires and the balance 20% to 25% is for wires coated with other base metals
e.g. Zinc (Galvanized), Copper, Bronze, and other coating materials.
Moreover, the overall Steel Wire production scenario is as follows:
Size of the Steel Wire rod Industry in India is 2.6 million tonne approximately in terms of
volume & US $ 1.7 billion in terms of value, combining both organized and unorganized
sectors. Approximately, 70 per cent of total production comes from organized producers and
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
the rest from the unorganized counterpart. Wire rod Industry is accountable for 5 per cent of
total demand of steel in India. India constitutes 1 per cent of the global wire rod exports and
approximately 3 per cent of Indian production caters a portion of the global markets.
In 2010, the Global wire business has been something like 48-50 million tons and in terms of
Dollars it was US $ 29 billion. This market is also expected to grow to some 56 million tons of
wires by 2011 and in Dollar terms it would be something like US $ 32 billion. North America,
Europe and South East Asia each account for approximately 25% of the Global demand for
the Steel Wires.
The fortunes of the steel wire industry are closely linked to the fortunes of the Primary steel
Industry. Internationally steelmakers’ prospects to 2015 are mixed, due to consolidations in
most parts of the old industrial world; a resurgence of steelmaking capacity addition in the
Far East (particularly in India), in Latin America (Brazil) and in the Middle East; a
revitalization of the Russian steel industry and continued massive expansion in China. One
factor stimulating new capacity is the technological revolution which is sweeping the
industry.
The future of emerging market economies is looking bright. Developing countries,
particularly the BRIC countries (Brazil, Russia, India and China), are very optimistic about
their prospects since these economies are recovering and advancing more swiftly than many
had envisaged.
It has been estimated that, India’s steel consumption will continue to grow at an annual rate
of nearly 16% till 2012, fuelled by demand for construction projects worth US$ 1 trillion. The
scope for raising the total consumption of steel is huge, given that per capita steel
consumption is only 44.3 kgs – compared to 190.4 kgs across the world and 318.5 kgs in
China.
2.6 Employment generation (Direct & Indirect)
PHYSICAL INFRASTRUCTURE
Once the proposed activity is commissioned, the socio-economic status of the local people
will improve and there by infrastructure facilities like communication systems will improve.
Most of the villages at present do not have protected water supply. After the implementation
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
of the project, the affordability of the public to spend on water treatment, supply &
distribution will more along with the aid from the state government.
EMPLOYMENT POTENTIAL
The proposed project creates employment to 300 people during construction and 200 people
during operation of the proposed expansion project.
The following is the break-up of the man power requirement
Executive - 24 Nos.
Supervisors and staff - 48
Skilled Man power - 64
Semi Skilled Manpower - 36
Unskilled Manpower – 28
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
3.0 PROJECT DESCRIPTION
3.1 Type of the Project
To make the project viable management of CSPPL is proposed to establish I/O beneficiation,
Pelletisation plant, Wire rod mill & Power Plant in the expansion program for production of
Pellet, Wire rods / Structural Steel & Power generation at existing plant premises only. There
would be value addition to waste ore fines, that would be utilized for gainful purposes.
3.2 Location
Existing Plant is located at Joratarai Village, Mangatta (P.O.), Rajnandgaon Tehsil & District,
Chhattisgarh.
3.3 Details of the Alternate sites
No Alternate sites have been examined for the proposed project. The plant would be set up
within the existing site and no additional land requirement is envisaged.
3.4 Size or Magnitude of Operation
Crest Steel & Power (P) Limited proposed the following units and its capacity are
presented below.
S. No. Products Existing Expansion* Further Expansion 1 Iron Ore Crushing Plant --- 17,95,200 TPA 2 DRI Plant (Sponge Iron) 1,15,500 TPA 8,08,500 TPA 3 Induction Furnace with LRF
(Billets) 33600 TPA 5,44,500 TPA
4 Electric Arc Furnace (Billets) --- 3,30,000 TPA 5 Rolling Mill (TMT Bars & Str.
Steel) --- 5,61,000 TPA
6 Wire Rod Mill --- 2,06,250 TPA 1,00,000 TPA 7 Generation of Power (WHRB) 8 MW 56 MW 8 Generation of Power (FBC) 8 MW 34 MW 12 MW 9 Submerged EAF (Ferro Alloys) * 3 x 12 MVA Ferro Manganese 32,850 TPA 59400 TPA Ferro Silicon 10,500 TPA 19,000 TPA Silico Manganese 23,750 TPA 42,750 TPA
10 Coal Washery --- 3.20 MTPA 11 I/O Beneficiation --- --- 16,00,000 TPA 12 Pellet Plant --- --- 12,00,000 TPA
* Honorable MoEF has already accorded in for these Expansion Capacities vide letter no - J-11011/753/2008-IA II (I) dated 27th August 2010 & 22nd November, 2010.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
3.5 Manufacturing Process
3.5.1 Iron Ore Beneficiation Process:
Beneficiation process is a combination of crushing, screening, washing, grinding, classifying
by gravity separation, magnetic separation, floatation processes. The final concentrate slurry
is filter pressed to get a dry enriched ore quality with Fe > 65% and moisture ~10%. The
water is recycled in the process. The tailings are processed in a thickener & Filter pressed
and the excess water will be recovered and circulated in the process. The tailings filter cake is
of low value with Fe <45% and moisture content ~10%. This Filter cake will be stored in
storage yard earmarked within the plant premises.
Pollution Free Technology
The process of beneficiation of iron ore can be rendered pollution free with no
effluents being discharged.
The fugitive emissions are arrested in the crushing and grinding zone by dust
suppression systems. Further the emissions are low as these circuits are wet and does
not allow high emissions.
The process does not use any hazardous chemical.
The quality of the iron ore concentrate is envisaged as follows:
Fe ; >65%
SiO2 +Al2O3 ; 4-5%
LOI ; 3.5 – 4.5%
Moisture content ; 10%
The Beneficiation plant would produce concentrate to the tune of 1.2 MTPA for
feeding the Pellet Plant.
3.5.2 Process of Iron Ore Pelletisation
In this process all raw materials will be proportioned as per requirement of the product
quality and intensely mixed to have homogeneity in the quality. The mixed material will be
processed in a battery of disc or a drum pelletizer for formation of green balls / pellets. The
pellets are controlled for size as well as certain amount of green strength. The pellets are
then classified in a roller screen to separate the undersize (-8 mm) and oversize (+18 mm).
The rest of the sized pellets are charged onto the pellet Cars. These pellet cars travel through
the straight grate Indurating Furnace over an endless chain where the pellets are subjected
to controlled rate of heating with updraft, downdraft, and two stages of preheating to a
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
temperature of ~1050deg. C. The recuperated heat from the process is utilized very
effectively resulting in lower fuel consumption. In the preheating zone small amount of heavy
oil may be used to stabilize the preheating zone temperature. At the end of the Indurating
Furnace the pellets would gain sufficient strength and then the hot pellets are passed through
the cooler area of the Inducting Furnace which maintains a fixed bed depth and the cooling is
done by updraft air from atmosphere. The pellets in the Indurating Furnace will be heated by
some long flame dual burner through-out the indurating Furnace fired by Furnace Oil. The
pellet cars moves slowly inside the Indurating Furnace, thereby indurating the pellets
homogeneously at a temperature ~ 1300deg. C. The cooler area is divided into three zones
and the recuperated hot gas from each zone is utilized for process requirements. The pellets
will be transported for processing where they are screened to sizes between 9 to 18 mm and
sent to the storage yard. These pellets are very stable and do not degrade on storage or
transportation.
The process flow diagrams are shown below
PROCESS FLOW DIAGRAM (I/O BENEFICIATION)
Here WR stands for Water Recovery being re-circulating.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
PROCESS FLOW DIAGRAM (IRON ORE PELLETIZATION)
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
Quality of Raw Materials:
The typical analysis of input raw materials envisaged for the production of pellets are:
Main physical and chemical property of Hematite Iron ore Concentrate
Chemical Composition (%)
T Fe SiO2 Al2O3 CaO MgO S P
Around 65.0 2.59 1.65 0.07 0.02 0.03 0.01
Physical property
Sizes (-0.050 mm) Water % Bulk Density (t/m^3) Burn Loss (%)
80% 7.8 2.1 1.66
Main physical and chemical property of Bentonite SiO2 Al2O3 TFeO MgO CaO K 2O Na 2O S P Burnt
Loss
69.56 15.03 1.70 2.18 0.69 2.27 1.62 0.13 0.017 6.14 Physical property
Montmorillonite
Colloid -0.074 mm Expansion capacity
Water Content (%)
Water Absorption (2 Hour)
94.7% 10.5 mg/l >=98% 13.5mg/l <10 225.67%
Main technical parameter of Heavy Oil Flash Point
(Deg C)
Density (g/cm^3)
Sediment weight
(%)
RCR weight
(%)
S Weight (%)
Viscosity (cps)
(100 Deg C)
Ash Content
Condensate point
(deg C)
66 0.98 Max 0.25 Max 0.25 1 80 0.1 66 Calorific value of heavy oil is 38.46 MJ/kg Typical Analysis of coal (Indian & Anthracite Coal) is shown below.
ANALYSIS OF COAL
S.No Particulars Units Indian Coal
Anthracite
Coal
1 Proximate analysis By mass
(As received basis)
1.1 Moisture (Total) % 5.00 5.50
1.2 Volatile matter % 28.00 14.45
1.3 Ash % 30.95 12.00
1.4 Fixed Carbon % 36.00 68.0
1.5 Sulphur % 0.05 0.05
1.6 Gross Calorific Value Kcal / Kg 4800 7000
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
Major Equipment and Facilities:
The major equipment and facilities envisaged for the Pelletisation plant are described below
The pelletizing plant will mainly consist of the following sections:
Storage and handling of iron ore concentrate
Storage, handling and preparation of binder and additive
Iron ore improvement
Proportioning and mixing
Balling, in duration and cooling
Finished product storage
Iron Ore Storage and Handling:
Beneficiated ore cakes from the beneficiation plant will be stored in a covered storage. Ore
cakes from the above storage will be drawn out at requisite rate and delivered by belt
conveyor to the ore improvement section of the plant.
Dust Abatement Facilities:
The pellet plant comprising various process units, accessories and handling facilities will be
provided with adequate dust suppression and dust extraction facilities to restrict the
particulate emission level within acceptable limits i.e. 50 mg per Nm3.
The systems will consist of water spraying facilities, mechanical gas cleaning equipment, dust
recycle arrangement and exhaust stack. Exhaust gas from drying and grinding systems will
be cleaned using fans, ducting’s, suction hoods, cyclones, bag filters, ESPs etc. as applicable.
The indurating furnace gas will be made to pass through electrostatic precipitator (ESP)
before being released to the atmosphere.
Filtered air supply system has been envisaged for MCC rooms and basements to supply
adequate fresh air to stagnant air zones. The control rooms will be air-conditioned.
The system will be designed in such a way that no solid waste will be discharged outside the
system, the solid waste that is the dust generated in the system will be recycled back to the
system itself.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
Product Characteristics:
The likely chemical analysis of pellets computed on the basis of qualities of raw material
could be as follows:
SN DESCRIPTION UNIT INDEX REMARKS 1 Output of Finished Goods 10^4 t/a 60 Finished Pellet product 2 Annual Working rate % 90.4 3 Quality of Finished Pellet
product
4 T (fe) % 64.43 With reference to Ore quality 5 FeO % 0.30 6 Basicity (CaO/SiO2) % 0.15 7 Acid Gangue 6.21 8 Granulometry mm 8.16 >90% 9 Crush Strength n/p >=2200 Average value
10 Tumbler Index % >90 +6.3mm 11 Abrasion Index % <5% -0.5mm
3.5.3 Rolling Mill (Structural & Wire rod Mill)
It is proposed to install a Wire rod mill of 1,00,000 tons/ annum capacity within the existing
plant premises. The process of rolling involves several steps: -
a. Selection of raw materials – blooms / Billets
b. Shearing and preparing.
c. Heating in Furnace Oil - fired furnace.
d. Rolling.
e. thermal Treatment (if required)
f. Inspection.
g. straightening and sheering (coil processing)
h. Dispatch.
The raw materials for proposed rolling mill are Semis i.e. Billets/ Blooms/ narrow Slab of
carbon or low alloy steel. The semis are segregated as per size and quality in the raw material
yard and are fed to the oil fired “pusher type” reheating furnace for heating up to the
requisite temperature. The steel is required to be heated uniformly to the re-crystallization
temperature for easy rolling. The usual temperature range maintained in the Furnace is
about 1150 – 1200 ºC depending on the quality of steel and section of semis. The semis are
heated as it moves through the furnace for a period of 1.5 to 2º depending upon the section
and rolling rate. The heated billets are rolled in the mill consisting of Rolling Strands of both
of three high and two high design. The size and configuration of the mill is different for
rolling of wire rod and structural like angles, channels and joist (Girders).
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
Rolling is performed in alloy semi chilled/ Chilled cast iron rolls – pairs moving in opposite
direction. The roll groves where rolling is performed are cooled with water. As the rolling
progress the rolled section is progressively reduced and the length of the stock increases. The
shapes of the final section i.e. round, angle, channel, beam etc. are progressively formed. The
final shape and size comes out of the last strand/ pans called finishing pass.
Water quenching and the heat treatment of rods in case of Wire Rods / TMT Bars are
performed after the finishing pass in the line. The bars/ sections after rolling are cooled in
cooling beds, wire rods coils are cooled in coil processing lines.
Sections like angles, channels and joist (girders) need to be straightened in rollers
straightening machines. These are further sheared in required lengths and made in to
bundles/ packets are dispatched.
During the process of heating the fuel oil is completely burnt with preheated combustion air
and the product of combustion is let in to atmosphere through chimney of adequate height
calculated as per Sulphur content in the Furnace Oil in accordance with CPCB norms.
Diagrammatic Presentation of the Material Flow:
Raw Material Receipt
Physical & Chemical Testing
Heating
Hot Rolling
Hot Inspection
Specially controlled Water Quenching
Dispatch
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
3.5.4 Captive Power Plant (1 X 12 Mw)
CSPPL proposes to install 1 x 12 MW Thermal Power Plant. The fuels proposed to be used in
FBC Boiler are Washery rejects /coal. The crushed coal will be fed to the boiler furnace
through feeders and nozzles with the aid of air from a primary fan. A forced draft fan draws
atmospheric air and circulates the same through an air heater in which the temperature of air
will raise to 140ºC and forces the same to the boiler furnace through air box and air nozzles.
The coal burns inside the furnace so as to maintain a furnace temperature of 880º – 900 ºC.
The boiler feed water through an economizer enters the boiler steam drum, mud drum and
water walls where it is heated and converted to saturated steam. The saturated steam will
then be heated to a temperature of 520º–540ºC in the super heater & carried to a steam
header to run Turbo generator for 12 MW.
3.6 Raw material requirement
The following will be the raw material requirement for the proposed expansion project.
Details Consumption (TPA) Sources of Supply Method of Transportation
Raw Material for I/O Beneficiation Iron Ore Fines 16,00,000 NMDC, Bastar Through Rail and Road
Raw Material for Pellet Plant
Iron ore Concentrate 12,00,000 In-House Through Belt Conveyors
Bentonite 9,000 Open Market, Durg By road
Lime Powder 24,000 Open Market, Durg By road
FO 13,800 Open Market, Durg By road
Coal & Coke Fines 36,000 SECL / Opwn Market Durg
By road
Raw Material for Wire rod Mill Billets/ Blooms/ Ingots 1,03,000 In-house Through Roller Tables
Furnace oil 3,600 TPA By road Raw Material for Power Plant (FBC Boiler)
Coal Washery Rejects 1,23,552 In-house Through Belt Conveyors
3.7 Water requirement and its source
Water required for the proposed plant will be supplied by CSIDC, Govt. of C.G. Water required
for the proposed plant will be 6130 KLD.
3.8 Quantity of waste generated
No wastewater will be discharged from the proposed unit operation. Slurry generated from
beneficiation plant will be fed to a specially designed press filter, which would separate the
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
water from slurry. All the water collected from this filter will be re-circulated to plant for
reuse. Closed circuit cooling system will be adopted in Pelletization plant & in Wire rod mill.
Boiler blowdown, CT Blow down & DM Plant regeneration will be the sources of effluent
generation from the power plant. This effluent will be treated in Neutralisation tank and
utilized for dust suppression and for greenbelt development. Zero effluent discharge will be
maintained in the premises.
Sanitary waste water will be treated in septic tank followed by sub surface dispersion trench.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
4.0 SITE ANALYSIS
4.1 Connectivity
The proposed site is located at Joratarai Village, Mangatta (P.O.) Rajnandgaon Tehsil &
District, Chhattisgarh. The site is close to NH-6 & Rasmada Railway Station is situated at
distance of 3.1 Kms. from the plant. Nearest airport is Raipur at 65 Kms. The transportation
of heavy equipment & construction materials will be to site by road.
4.2 Land use
Total land under possession is 285.15 acres. The present use of the land is industrial land.
The proposed Iron Ore beneficiation, Pellet plant, Wire Rod Mill & Captive Power plant will
be taken up in the existing plant premises only.
4.3 Topography
The topography of the land is more or less flat without undulations.
4.4 Existing land use pattern
Present land use is mostly industrial. Joratarai village is nearest village at a distance of 0.6
Kms. from the site. Shivnath River is at distance of 2.8 Kms. from the existing plant. There are
no National Parks, wildlife sanctuaries, Elephant Corridors, etc present within the 10 Km
radius of the site.
4.4 Existing infrastructure
M/s Crest Steel & Power (P) Limited is operating an existing plant at Rajnandgaon Tehsil &
District, Chhattisgarh with valid Consent to Operate from CECB, Chhattisgarh.
Item Area in Acres Built up area (Existing) 24.00 Built up area (Expansion) 62.00 Internal roads (Existing) 4.00 Internal roads (Expansion) 9.00 Water Reservoir 10.00 Storage yard 26.00 Slag storage 5.00 Greenbelt (Existing) 35.00 Greenbelt (Expansion) 60.00 Open area 50.15 Total land 285.15
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
5.0 PLANNING BRIEF
5.1 Planning Concept
M/s. Crest Steel & Power (P) Limited has proposed to install Iron Ore Beneficiation &
Pelletisation Plant, additional wire rod Mill & 12 MW captive power plant as part of
expansion plan proposed at Joratarai Village, Mangatta (P.O.) Rajnandgaon Tehsil & District,
Chhattisgarh.
5.2 Amenities / Facilities
Facilities like canteen, rest room and sanitary facilities are already been provided in the
existing plant as basic facilities to workers. No other additional facilities are proposed.
5.3 Green Belt
Total 33% of the total area will be developed with Green belt with in the Plant premises.
Greenbelt development plan
Local DFO will be consulted in developing the green belt.
Greenbelt of 33% of the area is being / will be developed in the plant premises as per
CPCB guidelines.
15 m wide greenbelt will be maintained all around the plant.
The tree species to be selected for the plantation are pollutant tolerant, fast growing,
wind firm, deep rooted. A three tier plantation is proposed comprising of an outer
most belt of taller trees which will act as barrier, middle core acting as air cleaner and
the innermost core which may be termed as absorptive layer consisting of trees which
are known to be particularly tolerant to pollutants.
5.4 Social Infrastructure
Social infrastructure is being / will be developed as per need based in the Villages.
5.5 Drinking water management
The workers at the plant during construction shall be provided with water for their
requirement and for the construction activities. The construction labour will be provided
with sufficient and suitable toilet facilities to allow proper standards of hygiene. These
facilities would preferably be connected to a septic tank and shall be maintained properly to
have least environmental impact. Drinking water required for the workers will be met from
existing plant water facilities.
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
5.6 Air emission Management
High efficiency ESP will be provided to Pellet Plant & FBC boiler to bring down the particulate
matter in the exhaust gas to less than 50 mg/Nm3 and then discharged into the atmosphere
through stack whose heights are in accordance with CPCB norms.
Adequate stack height will be provided to Wire rod mill for effective dispersion of SO2
emissions into the atmosphere.
Hence there will not be any adverse impact on vulnerable groups due to the proposed
activity.
5.7 Industrial waste management
No wastewater will be discharged from the proposed unit operation. Slurry generated from
beneficiation plant will be fed to a specially designed press filter, which would separate the
water from slurry. All the water collected from this filter will be re-circulated to plant for
reuse. Closed circuit cooling system will be adopted in Pelletisation plant & in Wire rod mill.
Boiler blowdown, CT Blow down & DM Plant regeneration will be the sources of effluent
generation from the power plant. This effluent will be treated in Neutralisation tank and
utilized for dust suppression and for greenbelt development. Zero effluent discharge will be
maintained in the premises.
5.8 Sewerage system
There sanitary wastewater generation from the existing & proposed expansion project will
be treated in Septic tank followed by subsurface dispersion trench.
5.8 Solid waste management
Solid Waste Quantity Method of disposal Tailings from I/O beneficiation
4,00,000 TPA Ceramic Industries OR will be disposed off for low land filing.
End cuttings From Wire rod Mill
3,000 TPA Recycled back as raw material in own induction Furnaces
Mill scales from Wire rod mill
2,000 TPA Given to ferro alloys manufacturing units/ casting units
Bottom Ash 15,320 TPA It is a good-filling aggregate and utilized as sub base material; hence given to road making contractors.
Fly Ash 61,280 TPA Will be given to Cement Plants/Brick manufacturers./filling in abandoned mines
M/s Crest Steel & Power (P) Limited Rajnandgaon Tehsil & District, Chhattisgarh
6.0 POWER REQUIREMENT & SUPPLY / SOURCE
During operation of the proposed unit, the power required for the industry will be sourced
from Captive Power Plant & from State Grid if required.
7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No rehabilitation or resettlement plan is proposed as the proposed expansion project will be
implemented in the existing plant premises only.
8.0 PROJECT SCHEDULE & COST ESTIMATES
The plant will be implemented in 24 months from the date of receipt of permission from the
Hon’ble MoEF, Govt. of India & CFE from CECB.
The estimated cost for the proposed project will be Rs. 740 Crores.
S.No. Particulars AMOUNT (Rs. In Laces) 1 Land : 0.00 2 Land Development & Civil Works : 8774 3 Plant & Machinery : 54940.00 4 Interest During Construction : 6734.20 5 Preliminary & Pre-Operative Expenses : 1486.00
6 Margin Money for Working Capital & Contingency : 2142.00
Total : 74076.20 MEANS OF FINANCE 1 PROMOTERS : 22222.86 2 TERM LOANS : 51853.34 Total : 74076.20
9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
There is abundant availability of iron ore fines of Fe grade <60% that is normally not a direct
feed to DRI units. Hence after techno-economic considerations it is feasible to include Iron
Ore Beneficiation and Pelletisation unit in Expansion plan along with additional Wire
Rod Mill & captive power plant in the existing plant premises of Crest Steel & Power (P)
Limited.