form-1environmentclearance.nic.in/writereaddata/...1a&2c, redifice signature, no 6, hospital...

FORM-1

On

PROPOSED EXPANSION OF EXISTING FERRO ALLOYPLANT TO 1.0 MTPA INTEGRATED STEEL PLANT COMPRIS-ING OF SINTER PLANT, BLAST FURNACE, PIG CASTING MA-

CHINE, COKE OVEN PLANT, ROLLING REBAR MILL , OXY-GEN PLANT & WHRB

OF

M/s. THE SANDUR MANGANESE & IRON ORES LTD.AT DANAPUR, DANAYAKANKERE & HANUMANHALLI

VILLAGES, HOSPET, BELLARY DISTRICT, KARNATAKA

Prepared by:- DECEMBER 2016

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

M/s. THE SANDUR MANGANESE & IRON LIMITED

Form-1 Report for Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA Integrated Steel Plant

comprising of Sinter Plant, Blast Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen Plant

and WHRB At-Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary

District, Karnataka

Page 1Visiontek Consultancy Services Private Limited

APPLICATION FORM-1(AS PER EIA NOTIFICATION 2006 & REVISIONS THEREOF)

(I) Basic Information

SerialNumber

Item Details

1. Name of the project/s

Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPA

Integrated Steel Plant in 3 Phases comprising of Sinter Plant, Blast

Furnace, Pig Casting Machine, Coke Oven Plant, Rebar Mill, Oxygen

Plant and WHRB.

2. Sl. No. in the schedule 3(a)

3. Proposedcapacity/area/length/tonnage to behandled/commandarea/lease area/numberof wells to be drilled

Proposed production:

1.0 MTPA Steel

Plant Area: 320.79 acres (129.81 Ha.).

The expansion is within the existing plant premises.

Proposed configuration:

Sl.No.

Plant/Unit Name

ConfigurationFinal

AnnualProduct

ion

FinalCapac

ityin

MTPA

Phase-I Phase-II

PhaseIII

1Blast

Furnace

1x0.4MTP

A BF( Size350-

400m3 )~

1212.12TPD

-

1x0.4MTPA BF( Size350-

400m3)~

1212.12 TPD

2 x400000

TPA

0.800

PigCastingMachine

1212.12TPD

- -1 x

400,000TPA

0.400

2

CokeOven

Plant andWHRB

0.4MTPA~

1212.12TPD

- -1 x

400,000TPA

0.400





District, Karnataka


WHRB-

130TPH

SteamGenerat

ion

3SinterPlant

1 x 50m²

~1600TPD

-

1 x 50m²

~1600TPD

2 x528,000

TPA

1.056

4

EnergyOptimiza

tionFurnace(EOF)

-

1 X50 T

~1602

TPD

1 X 50T

~1602TPD

2 x528,710

TPA

1.057

5

LadleRefiningFurnace (LRF) &VacuumDegasser

(VD)

-

1 X50 T~160

2TPD

1 X 50T

~1602TPD

2 x528,710

TPA

1.057

6

Continuous

Castingmachine(CCM)

-

1 X4

Strand

9/16m

radius

~1570

TPD

1 X 4Strand9/16 mradius~1570TPD

2 x518,135

TPA

1.036

7Rolling(RebarMill)

-

1 X100TPH~151

5TPD

1 X100TPH

~1515TPD

2 x500,000

TPA

1.0

8Oxygen

Plant1 X 100

TPD

1 X350TPD

--

1 x33000

TPA + 1X

-





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115500TPA

Maximum No. of Working Days considered for all units - 330

4.New/Expansion/Modernization

Expansion units will be installed in the existing Ferro Alloy Plant

5.Existing capacity/areaetc.

Sl. No. Description Existing capacity(MTPA)

1

Ferro AlloyPlant havingthree submergedarc furnaces

55 MVA(20MVA-02No’s., 15MVA-01No.)

2 Sinter plant 1.5 MT

3coal basedcaptive powerplant

32 MW

4Manganese OreBeneficiationPlant

2 tph

6. Category of the projecti.e. ‘A’ or ‘B’

A

7.Does it attract thegeneral condition? Ifyes, please specify.

No.

8.Does it attract thespecific condition? Ifyes, please specify.

No.

9.

Location

Plot/Survey/KhasraNo.

SurveyNos.2/1C/2,2/1C/3,3/3B,4/2C/2,65,Partsof66(A,A2,A3&B),72,73,74,75,76,77,78,79,80,81,144,145,146,147,148,411/A1/a-15,411/1A/a16,415/E/2,417/A/1,563,564,565,567,590, 591&592 of Danapurvillage546,547,548,549,552&552A/1of Danayakanakere village

Village Danapur & Danayakanakere villages

TehsilDanapur Panchayath, MMHalli , Hobli, HospetTaluk





District, Karnataka


District Bellary

State Karnataka

10.Nearest railwaystation/airport alongwith distance in kms.

Vyasankere–3.6KmsVyasaColonyCrossOverStation–300m-E HubliAirport(Operational)–150Kms

11.

Nearest town, city,District Headquartersalong with distance inKms.

Hospet-7.1km–N(15Kmbyroad) Bellary -58km–E(75Kmbyroad)

12.

Village Panchayats,Zilla Parishad,Municipal Corporation,Local body (completepostal address withtelephone nos. to begiven)

Danapur Panchayath, MMHalli, Hobli, HospetTaluk, Bellary District

13. Name of the applicant M/s.The Sandur Manganese & Iron Ores Limited

14. Registered AddressLakshmipur, Sandur, Bellary District, Pin–583119,KarnatakaState

15.

Address forcorrespondence:

Name ShriA.G.Suresh

Designation(Owner/Partner/CEO)

Director(Projects)

Address

1A&2C, Redifice Signature, No 6 , Hosp i t a lRoa d , Sh iva j i Na ga r , Bengaluru, Karnataka.

Pin Code 560001

E-mail [email protected]

Telephone No. (080)41520176-80

Fax No. (080)41520182

16.

Details of AlternativeSites examined, if any.

Location of these sitesshould be shown on atopo sheet.

Coke plant will be within the existing Plant premises. All otherunits shall be installed adjacent area to the existing plant





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17. Interlinked Projects No.

18.

Whether separateapplication ofinterlinked project hasbeen submitted?

Not Applicable

19.If yes, date ofsubmission

Not Applicable

20. If no, reason. Not Applicable

21.

Whether the proposalinvolves approval/clearance under: ifyes, details of the sameand their status to begiven.

(a) The forest(Conservation)Act, 1980?

(b) The wildlife(Protection)Act, 1972?

(c) The C.R.Z.Notification,1991?

Not Applicable

22.

Whether there is anyGovernmentOrder/Policy relevant/relating to the site?

No

23.Forest land involved(hectares). No

24.

Whether there is anylitigation pendingagainst the projectand/or land in whichthe project is proposedto be set up?

(a) Name of theCourt

No





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(b) Case No.(c) Orders/directio

ns of the Court,if any and itsrelevance withthe proposedproject.

25. Expected Project Cost Rs.5300 Crore

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions,which willcause physical changes in the locality (topography, land use, changes in water bodies, etc.)

S.No.

Information/Checklist confirmation

Yes/No

Details thereof (with approximate quantities /rates,wherever possible) with source of information data

1.1 Permanent ortemporary change inland use, land cover ortopography includingincrease in intensityof land use (withrespect to local landuse plan).

No. Land Use of the Project Site:

The land proposed to be utilized for the Expansion is underthe premises and complete land of 320.79 acres (129.81Ha.) is Industrial Land.

Land utilization pattern of the proposed site is given below:

Area of 33% land out of 320.79 Acres (129.81 Ha.) isdedicated for Green Belt development.

1.2 Clearance of existingland, vegetation andbuildings?

No Existing clearing of vegetation shall be kept to minimumwhile planning the layout.

1.3 Creation of new landuses?

Yes Industrial setup for 1.0 MTPA Integrated Steel Plant alongwith other auxiliary facilities.

1.4 Pre-constructioninvestigations e.g.bore holes, soiltesting?

Yes Soil testing shall be carried out for design of civil structuresat adequate locations within the proposed site. This shall becarried out at the time of detailed engineering on receipt ofenvironment clearance.

1.5 Construction works? Yes Required for erection of the plant & machinery duringinstallation process, roads, storage sheds etc.

1.6 Demolition works? No No demolition work is envisaged.

1.7 Temporary sites usedfor construction worksorhousing ofconstruction workers?

No All the workers will be engaged from the nearby villages.

Executive and technical staff shall be accommodated in theexisting guest house of SMIORE.





District, Karnataka


1.8 Above groundbuildings, structuresorearthworksincluding linearstructures, cut and fillor excavations

Yes Most of the structures shall be located above the ground.

1.9 Underground worksincluding mining ortunneling?

Yes An underpass shall be constructed to cross the

existing railway line.

1.10 Reclamation works? No Not Applicable

1.11 Dredging? No Not Applicable

1.12 Offshore structures? No Not Applicable

1.13 Production andmanufacturingprocesses?

The process steps

1. Blast Furnace (BF)

- Iron ore, coke and limestone are charged by a skip ordirectly through conveyor from top of the furnaceusing devices like two bell system with or withoutmovable throat armour or bell less top for burdendistribution.

- Preheated air is blown from near the bottom throughtuyers close to the junction of the hearth and bosh.Combustion of coke in front of tuyers generates heat andreducing gases. The ascending gases carry thisthermal energy and transfer the same to the descendingburden resulting in reduction of iron ore to iron. The ironin liquid state with nearly four percent (4%) carbon iscollected at the bottom of furnace.

2. Sinter Plant

- The process starts from receiving of fuel, flux and iron-bearing material to finished sintering ore out of the plant,including raw material and fuel receiving, fuel crushing,flux crushing and screening, proportioning, mixing,balling, distributing, igniting, sintering, hot orecrushing, screening and cooling as well as transferringof finished sinter ore out of the plant.

- Returned sinter and dust during production is sent back tothe process directly in order to protect environment frompollution. Furthermore, facilities of exhausting,dedusting, dust discharging and silencing, can makeenvironment well protected.

3. Cooking process

- This process production facilities consist of coalpreparation plant, coke making plant, coke screening





District, Karnataka


plant and boiler & desulphurization plant and powergeneration unit.

- The coking plant consists of 2 batteries with 56ovenseach. Its coke yield will be 0.4MTPA

4. Power Plant

- Blast furnace exhaust gas and flue gases from cokeovens are fed to waste heat recovery boiler wherethe hot gases convert the water in the circulatingtubes into super-heated steam at high pressure. Thissuper-heated high pressure steam is sent to turbineswhereby the turbine is rotated and power is generated.

- Coal based power plant is based on Rankinecycle.

1.14 Facilities for storageof goods or materials?

Yes Iron Ore lumps, Iron Ore Fines, Coke or Coking Coal andFluxes (Limestone & Dolomite) will be stored in sheds

1.15 Facilities fortreatment or disposalof solid waste orliquid effluents?

Yes

Solid WasteSource Quantity

(TPA)Disposal

Blast furnaceslag

Will be sold to cementplant

SMS slag Used as road ballast orgeneral land fill material

Waste water generated from the different areas of the plantwill be treated to the desired extent in suitable treatmentfacilities and recycled back to the process, as far aspracticable.

NOT REQUIRED AS THERE IS NO BY PRODUCTPLANT

1.16 Facilities for longterm housing ofoperational workers?

Yes A self contained township to house the employees and theirfamilies of the proposed plant is envisaged outside theplant boundary. Development will be ensuring thehigh qualities of functionality and attractiveness, throughthe fulfillment of needs of the users with safety andamenity.

As per man power requirement of the plant, thecategorized manpower on payroll shall be 898.Considering 100% satisfaction level for housing provision898 families in different categories will be housed inthe proposed township. Housing density of 75 families /hectare has been considered according to “GroupHousing” norm of “UDPFI Guidelines”. Thus the landrequirement shall be 12 hectares.





District, Karnataka


1.17 New road, rail or seatraffic duringconstruction oroperation?

No Existing facility shall be utilized.

1.18 New road, rail, airwaterborne or othertransportinfrastructureincluding new oraltered routes andstations, ports, airportsetc?

No. Not applicable.

1.19 Closure or diversionof existing transportroutes or infrastructureleading to changes intraffic movements?

No. Not applicable.

1.20 New or divertedtransmission lines orpipelines?

No. Not applicable.

1.21 Impoundment,damming, culverting,realignment or otherchanges to thehydrology ofwatercourses oraquifers?

No. Not applicable.

1.22 Stream crossings? No. Not applicable.

1.23 Abstraction ortransfers of waterform ground orsurface waters?

Yes Requirement for the proposed plant shall be 685 cu m perhour out of which 25 cu m shall be soft water. Thus, rawwater at the rate of 685 cu m per hour shall have to bedrawn from Tungabhadra dam & bore wells.

Tungabhadra (TB) division Munirabad has sanctionedpumping of 185 m3/hr raw water from Tungabhadrareservoir. SMIORE’s application for enhancement of400 m3/hr is under active consideration. Also, withdrawalfrom bore wells of 208 m3/hr has been assured. Hence,from both the water sources a total of 600 m3/hr raw waterwill be made available for the proposed plant.

1.24 Changes in waterbodies or the landsurface affecting

No Not applicable.





District, Karnataka


2. Use of Natural resources for construction or operation of the Project (such as land, water,materials or energy, especially any resources which are non-renewable or in short supply):

Sl.No. Information/checklistconfirmation

Yes/No Details thereof (with approximate quantities /rates,wherever possible) with source of information data

2.1 Land especiallyundeveloped oragricultural land (ha)

Yes The whole land is of Industrial type, with mostlyundeveloped barren nature.

2.2 Water (expected source& competing users) unit:KLD

Yes Water requirement for integrated steel plant andcaptive power plant is estimated to be about 16440KLD. This requirement will be met from water

drainage or run-off?

1.25 Transport ofpersonnel ormaterials forconstruction,operation ordecommissioning?

Yes Transportation of personnel and materials will be inevitableduring construction and operation phase of the project.

Transportation of personnel will be done through officevehicles and materials will be carried out by closedcontainerized trucks.

The finished product will be transported by road/rail.

1.26 Long-termdismantling ordecommissioning orrestoration works?

No Not applicable.

1.27 Ongoing activityduringdecommissioningwhich could have animpact on theenvironment?

No Not applicable.

1.28 Influx of people toan area in eithertemporarily orpermanently?

Yes Workers will be employed from the local area only.

1.29 Introduction of alienspecies?

No Not applicable.

1.30 Loss of native speciesor genetic diversity?

No Not applicable.

1.31 Any other actions? No Not applicable.





District, Karnataka


allocated from Tungabhadra Reservoir by TB DivisionMunirabad.

2.3 Minerals (MT) Yes Iron ore, limestone, dolomite, manganese Forproduction of hot metal

2.4 Construction material –stone, aggregates, sand /soil (expected source –

MT)

Yes Civil construction materials like stone, cement,concrete, sand, iron rods etc. shall be required and itwill be estimated during the detailed engineering andshall be procured from local area.

2.5 Forests and timber(source – MT)

No Not Applicable

2.6 Energy including elec-tricity & fuels (source,competing users) Unit:fuel (MT), energy (MW)

Yes The Total power requirement for the proposed 1.00MTPA Integrated steel plant comprising of CokeOvens, Sinter Plant, Blast Furnace, Steel Melt Shopand Continuous Caster as the main units is estimated tobe about 92 MW.

Sources :

Sent out power from Coal based Power

Plant - 32 MW

Balance to be drawn from Karnataka Powertransmission Corporation Limited (KPTCL).

2.7 Any other naturalresources (useappropriate standardunits)

No Not Applicable.

3. Use, storage, transport, handling or production of substances or materials, which could beharmful to human health or the environment or raise concerns about actual or perceivedrisks to human health.

S.No. Information/Checklistconfirmation

Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data

3.1 Use of substances or materials,which are hazardous (as perMSIHC rules) to human health

No Not Applicable





District, Karnataka


or the environment (flora,fauna, andwater supplies)

3.2 Changes in occurrence ofdisease or affect diseasevectors (e.g. insect or waterborne diseases)

No Not Applicable.

3.3 Affect the welfare of peoplee.g. by changing livingconditions?

Yes. Direct and indirect benefits for the localpeople will have better bearing on the livingcondition of people.

3.4 Vulnerable groups of peoplewho could be affected by theproject e.g. hospital patients,children, the elderly etc.

No Not envisaged.

3.5 Any other causes No Not envisaged

4. Production of solid wastes during construction or operation or decommissioning(MT/month)

Sl.No. Information/Checklistconfirmation


4.1 Soil, overburden or minewastes

Yes. The solid by-products produced due to theproposed plant will be BF-slag, steel meltshop (SMS) slag, flue dusts, effluenttreatment plant sludge, caster scrap, fly ash,bottom ash and mill scales etc. Flue dust,product fines, raw material fines etc will beutilized in the process, i.e. in the sinter plant.Mill scale would be utilized in sinter plantafter de-oiling the same to prevent damage toESPs in the sinter plant and to minimizegeneration of PCDD/F.

BF slag would be granulated and sold tocement plants. The SMS slag will beprocessed for metal recovery for partrecycling in the Sinter Plant, BOF and BF.Fly ash collected from ESP hoppers of thecaptive power plant shall be collected in drycondition for supply to cement and brickmanufacturers or used for land filling.

An additional land of 149 acres outside theplant vicinity (falling under the jurisdiction of





District, Karnataka


Danayakankere village) is being procured fordumping slag.

Bottom ash would be collected for future usein land reclamation, road construction etc

4.2 Municipal waste (domesticand or commercial wastes)

Yes A fully fledged Sewage treatment plant willbe provided for treating wastewatergenerated from the plant and township

4.3 Hazardous wastes (as perHazardous Waste ManagementRules)

Yes During Construction Phase

Recyclable

Used batteries

Waste metal from welding and cuttingDuring Operation Phase

Recyclable

Used Batteries

Containers of hazardous materials (viz. oildrums, chemical drums)

4.4 Other industrial process wastes Yes Blast furnace flue gas, Hot gases from BOFetc.

4.5 Surplus product No No surplus product is envisaged.

4.6 Sewage sludge or other sludgefrom effluent treatment

Yes A fully fledged Sewage treatment plant willbe provided for treating wastewater generatedfrom the plant and township. Sludgegenerated will be dried and used as manure.Sludge resulting from neutralization of boilerblow down, Water treatment plant back washshall be disposed as per KSPCB guidelinesappropriately.

4.7 Construction or demolitionwastes

Yes Negligible quantity of top soil will beexcavated for construction, which shall beutilized for greenbelt development. Wastesteel – shall be sold to recyclers. Wastecement plaster & waste cement concrete– shall be used for making base layer forroads within premises.

4.8 Redundant machinery orequipment

No Not Applicable





District, Karnataka


4.9 Contaminated soils or othermaterials

No Not Applicable

4.10 Agricultural wastes No Not Applicable.

4.11 Other solid wastes Yes Organic waste generated from canteen shallbe composted and will be used as manure.

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)



5.1 Emissions from combustionof fossil fuels fromstationary or mobile sources

Yes Source PollutantsCoke Oven plant SO2,NOx,COBOF, EAF and ladleFurnace

SO2, NOx, CO

5.2 Emissions from productionprocesses

Yes Particulate matter, SO2 and NOx, CO,Iron Oxide, etc

5.3 Emissions from materialshandling including storageor transport

Yes Fugitive Dust

5.4 Emissions from constructionactivities including plant andequipment

Yes From all combined sources in plant, theambient air quality (24 hrs) will be asfollows:

o PM10< 100 µg/m3

o PM2.5< 60 µg/m3

o SO2< 80 µg/m3

o NOx < 80 µg/m3

5.5 Dust or odours fromhandling of materialsincluding constructionmaterials, sewage and waste

No Fugitive dust

5.6 Emissions from incinerationof waste

No No Incineration of waste is involved

5.7 Emissions from burning ofwaste in open air (e.g. slashmaterials, constructiondebris)

No Not Applicable

5.8 Emissions from any othersources

No Dust will rise during demolition.





District, Karnataka


6. Generation of Noise and Vibration, and Emissions of Light and Heat:


Yes/No Details thereof (with approximatequantities/rates, wherever possible) withsource of information data with source ofinformation data

6.1 From operation of equipmente.g. engines, ventilation plant,crushers

Yes Cumulative noise shall be < 75 dB(A)within the project boundary and

Heat shall be emitted near the tap holearea of SMS, during tapping, which willbe taken care providing heat resistantaprons and working hours of theworkers will be inter-changed.

6.2 From industrial or similarprocesses

Yes Cumulative noise shall be <75 dB (A) at theboundary of the plant.

6.3 From construction ordemolition

Yes Maximum cumulative noise shall vary from70 to 75 dB(A) at the construction site.

6.4 From blasting or piling No There is no blasting or piling activity relatedto the erection & commissioning of Plant.

6.5 From construction oroperational traffic

Yes Noise levels from constructionequipment for very short duration.

6.6 From lighting or coolingsystems

No Not applicable

6.7 From any other sources No Not applicable

7. Risks of contamination of land or water from releases of pollutants into the ground or intosewers, surface waters, groundwater, coastal waters or the sea:


Yes/No Details thereof (with approximatequantities/rates, wherever possible)with source of information data

7.1 From handling, storage, use orspillage of hazardous materials

No Not Applicable

7.2 From discharge of sewage or othereffluents to water or the land(expected mode and place ofdischarge)

No Not Applicable





District, Karnataka


7.3 By deposition of pollutants emittedto air into the land or into water

Yes Air emissions shall be maintainedwithin the standard stipulated byKSPCB.

7.4 From any other sources No Not applicable.

7.5 Is there a risk of long term build upof pollutants in the environmentfrom these sources?

No Proper management plan shall beimplemented to maintain the risk at theminimum.

8. Risk of accidents during construction or operation of the Project, which could affect humanhealth or the environment

Sl.No. Information/Checklistconfirmation


8.1 From explosions, spillages,fires etc. from storage,handling, use or production ofhazardous substances

Yes Risk assessment and appropriate safety measureswill be taken as per OSHA Standards, incongruence with Inspector of Factory & BoilersGuidelines.

8.2 From any other causes Yes Due to mishandling ofmachinery/equipment and falling fromheight during construction and operationphase.

Heat exposure around furnace area. Electrical hazards

8.3 Could the project be affectedby natural disasters causingenvironmental damage (e.g.Floods, earthquakes,landslides, cloudburst etc)?

No Not applicable

9. Factors which should be considered (such as consequential development) which could leadto environmental effects or the potential for cumulative impacts with other existing orplanned activities in the locality

Sl. No. Information/Checklistconfirmation


9.1 Lead to development ofsupporting facilities, ancillarydevelopment ordevelopmentstimulated by theproject which could haveimpact on the environment

Yes

Shall be carried out to fulfill the requirementof project, if any and facilities shall beextended to public to the possible extent.Proposed project shall provide direct andindirect employment and businessopportunities to locals. This in turn shall





District, Karnataka


e.g.:• Supporting infrastructure(roads, power supply, wasteor waste water treatment,etc.)• housing development• extractive industries• supply industries• other

increase per capita income.

9.2 Lead to after-use of the site,which could havean impacton the environment

Yes An aesthetic, pleasant environment withlush greenery and greenbelt will bedeveloped in the plant.

9.3 Set a precedent for laterdevelopments

Yes Implementation of Proposed projectshall support the other industrial &social developments in the region.

Proposed project shall provide directand indirect employment and businessopportunities to locals.

9.4 Have cumulative effects dueto proximity to other existingor planned projects withsimilar effects.

No None

(III) Environmental SensitivityThe 15km radius topographical location map is enclosed as Annexure-I.

Sl.No.

Areas Name/Identity

Aerial distance (within 15km.)Proposed project locationboundary

1 Areas protected underinternational conventions,national or local legislation fortheir ecological, landscape,cultural or other related value

Not applicable Notapplicable

2 Areas which are important orsensitive for ecological reasons– Wetlands, watercourses orother water bodies, coastalzone, biospheres, mountains,forests

Back water ofTungabhadra (TB)dam

2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance

3 Areas used by protected, Not applicable Not applicable





District, Karnataka


Sl.No.

Areas Name/Identity

Aerial distance (within 15km.)Proposed project locationboundary

important or sensitive speciesof flora or fauna for breeding,nesting, foraging, resting, overwintering, migration

4 Inland, coastal, marine orunderground waters

Back water ofTB dam

2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance

5 State, National boundaries None Not applicable6 Routes or facilities used by the

public for access to recreationor other tourist, pilgrim areas

NationalHighwayNo.13Hospet Railway station

500m from the proposedexpansion activities7.2Km(Aerial)away from thePlant/15Kmsbyroad

7 Defence installations No Not applicable8 Densely populated or built-up

areaHospet 7.2Km(Aerial)away from the

Plant/15Kmsbyroad9 Areas occupied by sensitive

man-made land uses (hospitals,schools, places of workshop,community facilities)

Yes Hospitals situated in Hospetsituated at 7.2 Kms(Aerial)away from the Plant/15Kmsby road. Schools/ facilitiesrun by SMIORE adjacent toexisting ferro alloy plantpremises.

10 Areas containing important,high quality or scarce resources(ground water resources,surface resources, forestry,agriculture, fisheries, tourism,minerals)

Back water ofTungabhadra DamIron Ore Mines

2.8Kmsawayfromtheplantbyroad.1.8Kmsaerialdistance4KmsfromSiteGunda RF-adjacent to thePlant site towards NorthSandurRF-7.0km–ERamgadRF-3.1km–SEHospetRF-3.6km-NE

11 Areas already subjected topollution or environmentaldamage (those where existinglegal environmental standardsare exceeded)

No Not applicable

12 Areas susceptible to naturalhazard which could cause theproject to present environ-mental problems (earthquakes,subsidence, landslides, erosion,flooding or extreme or adverseclimatic conditions)

No Not applicable





District, Karnataka


(IV) Proposed Terms of Reference for EIA studies

The following are the terms of reference for EIA studies:

1. Baseline data will be generated as per the stipulated guidelines in EIA manual prescribed byMoEF in the study area of 10 km radius around the proposed site for the following:

1. Description of Environment

Ambient Air Quality

Ambient air quality monitoring will be carried out at adequate stations representing the study area asper guidelines of MoEF.

Meteorology

Meteorological parameters such as wind speed, wind direction, temperature, relative humidity, cloudcover and rainfall will be generated at one station on hourly basis for 24 hours during the studyperiod.

Noise level

Measurement of noise levels within the study will be carried out at adequate locations at regularintervals for 24 hours during the study period.

Traffic Volume Counts

Traffic volume counts will be carried out at adequate locations within the study area on hourly basisfor 24 hours, once in each month during the monitoring period.

Water Quality

Adequate water samples (surface water and ground water) will be collected as per standardguidelines. The samples will be analyzed for essential parameters as per CPCB standard.

Soil Quality

Testing of soil samples will be carried out from adequate locations within the study area for physicaland chemical parameters.

Flora & Fauna

Survey will be carried out in the study area as per the guidelines of MoEF. Species of flora will belisted in detail with local name, scientific name and species including endangered species, whilefaunal species will be identified as per the Wildlife Protection Act, 1972 and as amendedsubsequently and shall be listed as endangered, endemic, migratory and aquatic.

Remote Sensing Study

This study will be carried out based on the satellite imagery of the study area to assess the land usepattern.

Socio-economic Survey





District, Karnataka


Socio-economic survey in the study area will be carried out to assess the status of demographicpattern, employment pattern and general amenities available based on the Census 2011, secondaryinformation available with different government agencies and Survey.

2. Impact Assessment

Impacts shall be identified based on the actual and foreseeable events, including operational events

and typical events of the proposed project activities. Processes that may create risks to the natural

environment and socio economic environment shall be considered in terms of key potential

environmental impacts.

3. Environment Management Plan

Mitigation measures to be adopted under EMP for all specified significant environmental impactslikely to result out during the construction and subsequently during operation shallalso be a part ofthe EIA/EMP report. The likely identified impacts and recommended mitigation measures shall bebased on the following:

Various applicable environment laws/acts/standards/guidelines;

Project information provided by project proponent;

Baseline information and reconnaissance survey of the study area;

Past experience in similar type of projects; and

Standard National/International environmental management guidelines/practices.

“I hereby give an undertaking that the data and information given in the application and enclosures

are true to the best of my knowledge and I am aware that if any part of the data and information

submitted is found to be false or misleading at any stage, the project will be rejected and clearance

given, if any to the project, will be revoked at our risk and cost.”





District, Karnataka























District, Karnataka























District, Karnataka


Annexure-ITopo Map





District, Karnataka


Annexure-II

Baseline data collection is under process for the period December2016 to February 2017 as perthe ToR letter vide letter no. F. No. J-11011/205/2014-IA-II (I) dated 07.04.2015.

AIR SAMPLING LOCATIONS

NOISE SAMPLING LOCATIONS

Sl.No.

Locations StationCode

Aerial Distance fromplant site (Km)

Directionfrom plant

siteType of Area

1.SMIORE PlantPremises

A1 -- -- Industrial Area

2. Rajapura A2 3.8 Km N Industrial/ Mines Aea

3. Hanumanhall A3 1.9 Km S Residential Area

4. Munirabad A4 9.5 KmNW

DownwindResidential Area

5. Vyasankere A5 3.0 Km WNear Reservoir(Residential Area)

6. Venkatagiri A6 6.5 Km E Industrial Area

7. Hospet A7 7.8 Km SSW Residential Area

8. Ramgard A8 7.0 Km SE Near Reserve Forest

Sl.No. Locations

StationCode

Aerial Distance fromplant site (Km)

Directionfrom plant

siteType of Area

1.SMIORE PlantPremises

N1 -- -- Industrial Area

2. Rajapura N2 3.8 Km N Industrial/ Mines Aea

3. Hanumanhall N3 1.9 Km S Residential Area

4. Munirabad N4 9.5 KmNW

DownwindResidential Area

5. Vyasankere N5 3.0 Km WNear Reservoir(Residential Area)

6. Venkatagiri N6 6.5 Km E Industrial Area





District, Karnataka


7. Hospet N7 7.8 Km SSW Residential Area

8. Ramgard N8 7.0 Km SE Near Reserve Forest





District, Karnataka


.7TOPOSHEET – SHOWING THE AAQ & NOISE MONITORING LOCATIONS





District, Karnataka







District, Karnataka



Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : [email protected], [email protected], Visit us at : www.vcspl.org

Committed For Better Environment

PRE – FEASIBILITY REPORT

On

PROPOSED EXPANSION OF EXISTING FERRO ALLOYPLANT TO 1.0 MTPA INTEGRATED STEEL PLANT COMPRIS-ING OF SINTER PLANT, BLAST FURNACE, PIG CASTING MA-

CHINE, COKE OVEN PLANT, ROLLING REBAR MILL , OXY-GEN PLANT & WHRB

OF

M/s. THE SANDUR MANGANESE & IRON ORES LTD.AT DANAPUR, DANAYAKANKERE & HANUMANHALLI

VILLAGES, HOSPET, BELLARY DISTRICT, KARNATAKA

Prepared by:- DECEMBER 2016

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

TABLE OF CONTENT

SR. NO DESCRIPTION PAGENO

1.0 INTRODUCTION 42.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT 52.1 Need for the project & its importance to the country or Region 62.2 Employment Generation 73.0 PROJECT DESCRIPTION 73.1 Location 73.2 Site Selection 73.3 Technology Selection 73.4 Project Description 83.5 Raw material Requirement 83.6 Water and Power Requirement 93.7 Waste Generation and Management 94.0 SITE ANALYSIS 94.1 Connectivity 94.2 Present Landuse 104.3 Existing Infrastructure 104.4 Climate data from secondary sources 115.0 PLANNING BRIEFF 115.1 Planning concept 115.2 Landuse Planning 116.0 PROPOSED INFRASTRUCTURE 116.1 Industrial and Residential area 116.2 Green Belt 126.3 Others 127.0 REHABILITATION AND RESETTLEMENT (R&R)PLAN 128.0 PROJECT SCHEDULE AND COST ESTIMATES 128.1 Project Schedule 128.2 Project Cost 139.0 ANALYSIS OF PROPOSAL 132.0 INTRODUCTION2.1 Identification of project and project proponent 142.2 Description of Nature of the project 142.3 Need of the Project and its Importance to the Country and/or Region 172.4 Supply- Demand Gap 182.5 Major Steel Consuming Sectors 242.6 Alloy & Special Steel Sector 262.7 Employment generation (Direct & Indirect) due to the project 283.0 PROJECT DESCRIPTION3.1 Type of project 303.2 Location 313.2.1 Plant Location 31

3.2.2 Alternative Sites Examined 343.2.3 Land Requirement 343.2.4 Plant Layout 343.3 Site Selection 363.5 Process Description 513.6 Raw Materials Requirements 723.7 Water & Power Requirement with its Source 733.8 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for

their Management/Disposal73

3.8.1 Waste Water Generation and Treatment 753.8.2 Solid Waste Generation and Utilization 763.8.3 Noise Levels 773.8.4 Green Belt Development 774.0 SITE ANALYSIS

4.1 General 784.2 Connectivity 784.2.1 Topography 784.2.2 Existing Land Use Pattern 794.4 Climate Data 795.0 PLANNING BRIEF5.1 Planning Concept 805.1.1 Technical Concept 805.2 Land Use Planning 806.0 PROPOSED INFRASTRUCTURE6.1 Industrial and Residential Area 816.2 Green Belt 816.3 Others 817.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN8.0 PROJECT SCHEDULE & COST ESTIMATES8.1 Project Schedule 838.2 Project Cost 859.0 ANALYSIS OF PROPOSAL9.1 Financial and Social Benefits 869.1.1 Improvements in the Physical Infrastructure 869.1.2 Improvements in the Social Infrastructure 869.1.3 Employment 869.1.4 Other Benefits 86

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill ,Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka

Visiontek Consultancy services Pvt. LtdBhubaneswar Page 1

CHAPTER – 01

EXECUTIVE SUMMARY

1 Name of theproject

Proposed Expansion of Existing Ferro Alloys Plant to 1.0 MTPAIntegrated Steel Plant in 3 Phases comprising of Sinter Plant, BlastFurnace, Coke Oven Plant, Rebar Mill, Oxygen Plant and WHRB byM/s The Sandur Manganese & Iron Ores Limited.

2 S.No in theschedule

Activity 3(a)

3 RegisteredOffice

M/s The Sandur Manganese & Iron Ores LimitedLakshmipur, Sandur , Bellary District, Pin – 583119, Karnataka

4 Name of theApplicant

M/s The Sandur Manganese & Iron Ores Limited.

5 Area ofplant

320.79 acres (129.81 Ha.). (Existing)

6 Topo SheetNo

57 A/8

7 LatitudeLongitude

Latitude: 15° 11' 47" NLongitude: 76° 22' 50"E

8 Proposedcapacity

The proposed expansion is comprising of the following:

Sl.No.

Plant/UnitName

ConfigurationFinal

AnnualProductio

n

FinalCapacit

yin

MTPA

Phase-IPhase

-IIPhase

III

1Blast

Furnace

1x0.4MTP

A BF( Size350-

400m3 )~

1212.12TPD

-

1x0.4MTP

A BF( Size350-

400m3 )~

1212.12TPD

2 x400000

TPA

0.800

Pig CastingMachine

1212.12TPD

- -1 x

400,000TPA

0.400

2Coke OvenPlant andWHRB

0.4MTPA~

1212.12TPD

WHRB -130TPHSteam

Generation

- -1 x

400,000TPA

0.400



3SinterPlant

1 x 50 m²~1600TPD

-

1 x 50m²

~1600TPD

2 x528,000

TPA

1.056

4

EnergyOptimization Furnace

(EOF)

-

1 X50 T

~1602

TPD

1 X 50T

~1602TPD

2 x528,710

TPA

1.057

5

LadleRefiningFurnace (LRF) &VacuumDegasser

(VD)

-

1 X50 T~160

2TPD

1 X 50T

~1602TPD

2 x528,710

TPA

1.057

6

ContinuousCastingmachine(CCM)

-

1 X 4Stran

d9/16

mradius~157

0TPD


2 x518,135

TPA

1.036

7Rolling(RebarMill)

-

1 X100TPH~151

5TPD

1 X 100TPH

~1515TPD

2 x500,000

TPA

1.0

8Oxygen

Plant1 X 70TPD

1 X200TPD

-

1 x 23100TPA +

1 x 66000TPA

-


9 Cost ofProject

Rs. 5300.00 Cr.

10

Man powerRequirement

898

11

WaterRequirement

685 m³/Hr will be sourced from Tungabhadra Dam & Bore wells.

12

PowerRequiremen

92 MW (32 MW will be sourced from existing Coal based CPP andbalance will be sourced from Karnataka Power Transmission Corporation



t Limited.

13

Nearestrailwaystation/airport alongwithdistance inkms

Nearest Railway Station: Tungabhadra R.S- 7.8 Km NWHospet R.S- 9.8 Km NE

Nearest Airport: Vidyanagar – 26 km. E

14

NearestTown, City,DistrictHeadquartersalong withdistance inkms.

Hospet-7.1km–N(15Km byroad)Bellary -58km–E(75Kmbyroad)

15

Villagepenchants,Parishad,Municipalcorporation,localtelephonenos to begiven) body(completepostaladdresseswithtelephoneno.s to begiven)

Village- Danapur & Danayakankere & HanumanhalliPanchyat- DanapurTaluk- HospetDist-BellaryKarnataka



1.0 INTRODUCTION

M/s The Sandur Manganese & Iron Ores Limited (Here after SMIORE) currently

operating a Ferro Alloy plant ( 3 Submerged Arc Furnaces with total capacity 55 MVA, 1

Sintering plant of 1.5 MT, Manganese Ore Beneficiation Plant 2 t/Hr input and 32 MW Coal

based CPP) at Hanumanhalli village, Danapur Mandal, Hospet Taluk, Bellary District of

Karnataka State. Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant

to 1.0 MTPA Integrated Steel Plant in 3 phases comprising of following units:-

Table 1.1 Proposed Configurations (Expansion)

Sl.No.

Plant/UnitName

Configuration FinalAnnual

Production

FinalCapacityin MTPAPhase-I Phase-II Phase III

1 Blast Furnace

1x 0.4MTPABF

( Size 350-400m3 )

~ 1212.12TPD

-

1x0.4MTPA

BF( Size 350-

400m3 )~ 1212.12

TPD

2 x 400000TPA

0.800

Pig CastingMachine

1212.12 TPD - -1 x 400,000

TPA 0.400

2Coke Oven Plant

and WHRB

0.4MTPA~ 1212.12

TPDWHRB -130TPHSteam

Generation

- -1 x 400,000

TPA 0.400

3 Sinter Plant1 x 50 m²

~1600 TPD-

1 x 50 m²~1600 TPD

2 x 528,000TPA

1.056

4Energy

OptimizationFurnace (EOF)

-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

5

Ladle RefiningFurnace ( LRF)

& VacuumDegasser (VD)

-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

6Continuous

Casting machine(CCM)

-


1 X 4 Strand9/16 mradius

~1570 TPD

2 x 518,135TPA

1.036



7Rolling (Rebar

Mill)-

1 X 100TPH

~1515TPD

1 X 100TPH

~1515 TPD

2 x 500,000TPA

1.0

8 Oxygen Plant 1 X 70 TPD1 X 200

TPD-

1 x 23100TPA +

1 x 66000TPA

-


2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

The project is being promoted by the Sandur Manganese & Iron Ores Limited

(SMIORE) having their registered office at

Sandur Mangenese & Iron Ore Ltd.

Lakshmipur,

Hospet District - 583119 (Karnataka).

And

The Project Division Office at;

First & Second Floor

Redifice Signature

No.6, Hospital Road, Shivajinagar

Bangalore- 560 001

Karnataka

The Sandur Manganese & Iron Ores Limited is Flagship Company of the reputed Sandur

Group of Karnataka. SMIORE was founded in 1954 by the former ruler of the Princely

State of Sandur Mr. Yeshwanthrao Hindurao Ghorpade.

Associated with the management of the Company from its inception, Mr. M.Y.

Ghorpade with a Master’s Degree in Economics from Cambridge nurtured and

developed SMIORE into one of the finest professionally managed companies in India,

doing business in the fields of manganese ore, ferroalloys and electronics. Mr. M.Y.

Ghorpade is known world-wide for his black and white wildlife photography. His rich

experience as Karnataka's Minister for Finance in the 1970s and later for Rural Development,

and his sustained effort of socio-economic reconstruction and service at Sandur over the

years set the tone for the company's progressive growth.



Sandur was once described by Mahatma Gandhi as an oasis and is renowned for its

sylvan beauty and abundant resources of manganese and iron ores. The Sandur mines are

situated in the picturesque and historic valley of Sandur in Hospet district of Karnataka at

an elevation of about 1,000 metres and extending over an area of about 20 sq. kms.

The mines are estimated to contain reserves in the region of 25 million tons of the low

grade, low phosphorous manganese ore and about 50-60 million tons of low grade iron

ore. SMIORE produces about 2.2 million tonnes of manganese and iron ores per annum.

Presently, the major activities of SMIORE are mining of low grade, low phosphorous,

manganese and iron ores, facility for production of ferroalloys and management of

hydro-electric power generation. The group also owns facilities to produce resistor

networks and copper clad laminates. The Ferro-alloy plant has two working submerged

arc furnaces. The first furnace is a 15 MVA furnace and the second furnace is 20MVA

furnace both furnaces are producing 24,000 tpy of Silico- manganese.

2.1 Need for the project & its importance to the country or Region

Steel consumption in India is closely associated with manufacturing, housing and

infrastructure sectors. Being a developing country, most of the industries are far away from

their maturity which kept the steel consumption rate intact in domestic market even during

the testing times of recession.

The scope for raising the total consumption of steel is huge, given that per capita steel

consumption is only 73.3 kg – compared to 210 kg across the world.

Carbon steel products are currently dominating steel consumption in the country. Fast

infrastructural developments and consumer durables industries have fueled the demand. The

government has also supported the steel industry with the announcement of massive

investment in railways, airport and power sectors.

Keeping in view the rate of growth of economics and with India becoming a sourcing hub for

auto components of auto companies’ word wide, demand projection for the alloy steels, it

will be necessary to create additional capacities in order to meet the projected requirements

during the post 2016-17 period. It is estimated that around 3.8 million tonnes per annum of

additional capacities would need to be created during the next 5-year period in order to meet

the requirements projected by the year 2021-22.

The trends indicate that the country's steel imports are gaining significant momentum to meet

the strong demand. We anticipate that this trend will see an upward growth trajectory in



coming years on the back of some concrete industry attributes analyzed thoroughly in the

report.

2.2 Employment Generation

Direct and indirect employment will be generated to the local population. The total man

power requirement during construction for the project will be 898.

3.0 PROJCET DESCRIPTION

The proposed project is an expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated

Steel plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill &

Oxygen Plant.

3.1 Location

The proposed facilities of the 1.0 MTPA Integrated Steel Plant comprising of Sinter

Plant, Mini Blast Furnace, Pig Casting Machine, Steel Melt Shop, Continuous Casting

Machine, Rebar Mill and WHRBower Plant will be installed at Vyasanakere, near

Hospet in the State of Karnataka in the land owned by SMIORE to South and South

East of their existing/ adjoining Ferro Alloy Plant complex. The proposed location of

steel plant site bears the following coordinates. The proposed site falls under the Survey of

India Toposheet No. 57A/8 and the buffer zone falls under the Survey of India Toposheet 57

A/7. The Latitude and Longitude of the proposed site is 15°11'47"N and 76° 22'50"E

respectively.

3.2 Site Selection

The total project land area including existing & Expansion is 320.79Acre (129.81 Ha.).. The

site has following facilities:

Proximity to the sources of base raw material,

Availability of common Infrastructure facilities / utilities (water / power etc.),

Availability of land, approach roads & accessibility

Topography of land and geological aspects

Nearness to rail head, transport logistics

3.3 Technology Selection

Technology selection involves an analysis of past achievements, present status and future

prospects of each technology under consideration keeping in view the following criteria.



Availability of project plant capacity/module.

Suiting to selected product mix & raw materials

Conservation of scarce inputs such as power & water.

Considerations of capital cost & maintenance cost.

Delivery schedule

Operational flexibility

3.4 Project Description

Following are the steps involved in production process:

i. Raw Materials to Metallics;

ii. Metallics to Liquid Steel;

iii. Liquid Steel to Refined Liquid Steel; and

iv. Refined Liquid Steel to Semis, i.e. Billets & Blooms.

3.5 Raw Material Requirement

Following are raw material required for the cement production along with their sources

Table.1.1 Raw Materials Requirement

Sl. No. Raw material Quantity in TPACoke oven

1 Hard Coal 3,78,0002 Soft Coal 1,62,000

Sinter Plant1 Iron Ore Fines 8,44,7972 Mill Scale 26,4003 Burnt Lime 5,2804 Lime Stone 1,16,1605 Dolomite 95,6406 Coke Breeze 68,640( 18,000 from Coke Oven

Plant0Blast furnace

1 Sinter 10,08,0002 Iron Ore Lumps/Pellets 3,36,0003 Coke 3,60,0004 Pulverized Anthrasite Coal 96,000

Energy Optimization Furnace1 Scrap 2,35,0002 Flux 12,6883 LimeStone & Dolomite 1,00,453



3.6 Water and Power Requirement

Water requirement for the project is as follows:

Table 1.2 Water RequirementSl.No.

Plant Unit Water Requirement in m3/HrFresh Water Soft Water DM Water Total in

m3

1 Sinter Plant 10 10 -- 202 BF Shop 95 100 -- 195

3

Pig Casting Machine(Considering 10%Utilization of PCM thewater requirement)

20 -- -- 20

4

EOF +LRF +VD(Transformer, Reactor &H.C. Cable Cooling)

64 60 26 150

5 Coke Oven Plant 70 -- -- 706 WHRB --7 CCM 50 -- -- 508 Rebar Mill 130 -- -- 1309 Oxygen Plant 20 -- -- 20

10Green belt & DustSuppression 20

-- -- 20

11 Miscellaneous Use 10 -- -- 10Total 489 170 26 685

Source of Water

The water requirement will be sourced from Tungabhadra Dam & Bore wells.Power Requirement

The total connected power of the plant is expected to be about 92 MW.

3.7 Waste Generation and Management

Waste water generated from the different areas of the plant will be treated to the

desired extent in suitable treatment facilities and recycled back to the process, as far

as practicable, facilitating adequate reuse of water and economizing on the make-up

water requirement. The treated effluent water will be collected in a sump located in a low

lying area. The water thus collected shall be used for dust suppression at raw material

handling system, slag cooling in SMS and road sprinkling etc.

4.0 SITE ANALYSIS

4.1 Connectivity



The site is at 7.1 km West away from nearest town Hospet. National Highway [NH-13] is

550 m towards West and South Western Railway Hospet – Kottur broad gauge railway

line of South Western Railway passes close to the east side boundary of the existing Ferro

Alloy Plant.

The suitability of the project site has been assessed in the report. As the proposed

project shall be located in the existing well developed unit, there shall be minimal

cutting and filling activity. Easy access to raw material.

The following factors were considered while selecting the subject site:

a. Availability of adequate land free from extensive cultivation and forest for locating

the power plant with provision for future expansion.

b. Suitability of land from topography and geological aspects.

c. Location with respect to fuel sources and road/rail linkage.

d. Availability of adequate supply of water to meet condenser cooling water and other

service water requirements.

e. Facilities for ash disposal.

f. Ease of transportation of imported coal from the port

g. Facility for transportation of power plant equipment and construction materials to site.

h. Power Evacuation facilities.

i. Proximity to major load centres in the power system

j. Environmental aspects

4.2 Present land use

The present land is gently undulating and suitable for industrial development.

Topography and Existing Land use Pattern

The topography of the land is gently undulating and well suited for development of industrial

projects. Land for the proposed project is industrial land & Plant is not coming under the

dense forest category land. This area also does not form part of any National Park, Wild Life

Sanctuary and Natural/Biosphere reserve.

4.3 Existing Infrastructure

a. Ferro Alloy Plant having three submerged arc furnaces with a total capacity of 35 MVA

(20 MVA-01 No., 15 MVA-01 No.) & sintering plant of 1.5 MT.



b. 32 MW coal based captive power plant (CPP) belonging to Star Metallics & Power

Private Limited (Subsidiary of SMIORE).

c. 32 MW CPP (existing CPP) is coal based with fluidized bed combustion technology.

Power from the CPP is used to run Ferro alloy plant and the surplus power if any is being

exported to the grid.

4.4 Climate Data from secondary sources

May month is usually the hottest with daily maximum of 38 ⁰C and December is the coldest

month with mean daily minimum of 17.2 ºC. The average annual rainfall of the area is 529

mm.

5.0 PLANNING BRIEF

5.1 Planning Concept

Technical Concept

The Sandur Manganese & Iron Ores Limited proposes to setup an Integrated Steel Facility for

the production of 1.00 MTPA Steel with finished product of 5.5 to 20 mm diameter wire

rods at Vyasanakere, Near Hospet in the State of Karnataka. The captive power

generation will be to utilize the waste heat from the Coke Ovens and waste gases of Blast

Furnace.

Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updating of the existing human resources

and generating new talents in consonance with the needs of the industry are vital for the

progress of the industry.

5.2 Land Use Planning

Total land required for the plant including existing & expansion is 320.79 Acre (129.81 Ha.).

Total land has already been acquired.

6.0 PROPOSED INFRASTRUCTURE6.1 Industrial and Residential Area

The setting up of the 1.0 MTPA integrated steel plant comprising of Sinter Plant, Mini Blast

Furnace, Coke Oven Plant, Rebar Mill, WHRB & Oxygen Plant along with existing ferro



alloys plant requires 320.79 Acre (129.81 Ha.) of land. Coke plant will be within the existing

Plant premises. All other units shall be installed adjacent area to the existing plant.

6.2 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total

green belt area shall be of 33% of total area and will be developed in the plant.

Green belt Development plan

Green belt of 33 Acre will be developed in the plant premises as per CPCBguidelines.

10m wide greenbelt will be developed all around the plant.

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

firm, deep rooted. A three tire 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 will act as barrier.

6.3 Others

A garland drain around the plant is envisaged to collect surface run-off during rainy

season.

Drinking water facilities will be provided for employees as well as nearby villagers.

Existing road and rail network will be utilized for raw material and final products

transportation.

7.0 REHABILITATION AND RESSETTLEMENT (R & R) PLAN

The proposed project is an expansion of the existing ferro alloys plant and will be

build in existing available land, hence there will be no displacement of residents.

Local people will be engaged for construction and operation activities. Surrounding

area have all the infrastructure facilities, hence no housing colony/township is

envisaged.

8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 Project Schedule

The commissioning of the plant is 24 months from ordering of main machinery. The external

agencies such as consultant, machinery suppliers, contractors of civil construction and

equipment will be selected carefully well in advance.



An effective project team shall be formulated with an experienced Project Manager as its

leader.

8.2 Project Cost

An estimated capital cost of the proposed expansion is 5300.00 Cr. including the Pre-

operative expanses, contingency and interest during construction.

9.0 ANALYSIS OF PROPOSAL

The benefits of the proposed unit shall be as follows,

Improving and building road network in the adjoining villages.

Strengthening local school buildings with playgrounds.

Improvement in social awareness programme such as sanitation and hygiene, HIV

Prevention Program.

Adult education and female education programmes will be provided to the illiterate

adults and backward females of the villages in the project surrounding area.

Long term employment of up to 898 people in the operation of the proposed plant

apart from contract labourers.

Generation of additional jobs by local business in the supply of raw materials,

finished products and services. Development of the local area in terms of an enlarged

market will provide the farmers with a good outlet of their agricultural products to

enjoy the price effect. Thus, the proposed project will usher in the social and

economic upliftment of the persons living in the vicinity of the Project i.e. of society

at large.



CHAPTER – 02

INTRODUCTION

2.1 Identification of Project and Project Proponent

The project is being promoted by the Sandur Manganese & Iron Ores Limited

(SMIORE) having their registered office at

Sandur Mangenese & Iron Ore Ltd.

Lakshmipur,

Hospet District - 583119 (Karnataka).

And

The Project Division Office at;

First & Second Floor

Redifice Signature

No.6, Hospital Road, Shivajinagar

Bangalore- 560 001

Karnataka

The Sandur Manganese & Iron Ores Limited is Flagship Company of the reputed Sandur

Group of Karnataka. SMIORE was founded in 1954 by the former ruler of the Princely

State of Sandur Mr. Yeshwanthrao Hindurao Ghorpade.

Associated with the management of the Company from its inception, Mr. M.Y.

Ghorpade with a Master’s Degree in Economics from Cambridge nurtured and

developed SMIORE into one of the finest professionally managed companies in India,

doing business in the fields of manganese ore, ferroalloys and electronics. Mr. M.Y.

Ghorpade is known world-wide for his black and white wildlife photography. His rich

experience as Karnataka's Minister for Finance in the 1970s and later for Rural Development,

and his sustained effort of socio-economic reconstruction and service at Sandur over the

years set the tone for the company's progressive growth.

Sandur was once described by Mahatma Gandhi as an oasis and is renowned for its

sylvan beauty and abundant resources of manganese and iron ores. The Sandur mines are

situated in the picturesque and historic valley of Sandur in Hospet district of Karnataka at

an elevation of about 1,000 metres and extending over an area of about 20 sq. kms.

The mines are estimated to contain reserves in the region of 25 million tons of the low



grade, low phosphorous manganese ore and about 50-60 million tons of low grade iron

ore. SMIORE produces about 2.2 million tonnes of manganese and iron ores per annum.

Presently, the major activities of SMIORE are mining of low grade, low phosphorous,

manganese and iron ores, facility for production of ferroalloys and management of

hydro-electric power generation. The group also owns facilities to produce resistor

networks and copper clad laminates. The Ferro-alloy plant has two working submerged

arc furnaces. The first furnace is a 15 MVA furnace and the second furnace is 20MVA

furnace both furnaces are producing 24,000 tpy of Silico- manganese.

2.2 Description of Nature of the project





Karnataka State.

Table 2.1 Plant Configuration (Existing)

Sl.No. Description Existing capacity (MTPA)

1Ferro Alloy Plant having threesubmerged arc furnaces

55MVA(20MVA-02No’s.,15MVA-01No.)

2 Sinter plant 1.5 MT

3 coal based captive power plant 32 MW

Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant to 1.0 MTPA

Integrated Steel Plant in 3 phases comprising of following units:-

Table.2.2 Plant Configuration (Expansion)

Sl.No.

Plant/UnitName


Production


1 Blast Furnace

1x 0.4MTPABF

( Size 350-400m3 )

~ 1212.12TPD

-

1x0.4MTPA

BF( Size 350-

400m3 )~ 1212.12

TPD

2 x 400000TPA

0.800



Pig CastingMachine

1212.12 TPD - -1 x 400,000

TPA 0.400

2Coke Oven Plant

and WHRB

0.4MTPA~ 1212.12


Generation

- -1 x 400,000

TPA 0.400


~1600 TPD-

1 x 50 m²~1600 TPD

2 x 528,000TPA

1.056

4Energy


-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

5



-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

6Continuous


-


1 X 4 Strand9/16 mradius

~1570 TPD

2 x 518,135TPA

1.036

7Rolling (Rebar

Mill)-

1 X 100TPH

~1515TPD

1 X 100TPH

~1515 TPD

2 x 500,000TPA

1.0

8 Oxygen Plant 1 X 70 TPD1 X 200

TPD-

1 x 23100TPA +

1 x 66000TPA

-




Table.2.2 Raw Material




Plant0Blast furnace



2.3 Need of the Project and its Importance to the Country and/or Region

Steel is traditionally considered the backbone of national economic development. It is a major

input into sectors which support economic growth such as infrastructure, machinery, power

and railways, as well as being important for fast growing sectors, in particular automobiles

and consumer durables. In 2013 global crude steel output reached 1,607 million tonnes up by

3.5% as compared to 2012. Table 2.1 shows the year-wise global crude steel production since

year 2005.

Table 2.3 Year Wise crude Steel Production

S. No. Year Steel Production ‘000 tonnes YOY Change %1. 2005 1,146,686 7.32. 2006 1,251,196 9.13. 2007 1,351,289 8.04. 2008 1,307,339 -3.35. 2009 1,219,715 -6.76. 2010 1,395,000 14.27. 2011 1,527,000 6.88. 2012 1,559,200 3.19. 2013 1,607,200 3.5



As suggested by Brief report on Iron & Steel Industry in India March, 2013 by Corporate

Catalyst India, the demand for steel in India is expected to rise about 7 percent in this

financial year as compared to the last financial year. The overall outlook for the steel sector is

positive and the demand is likely to pick up on the back of revival in economic growth and

the government’s measures to ease infrastructure investment rules.

India is currently the World’s fourth largest producer of crude steel after China, Japan and

US. India is expected to leave behind USA and Japan in a couple of years. The steel

production is expected to reach 300 million tones by 2025 as compared to 81 million tones

recorded last year.

Table 2.4 Top Ten Steel Producing Countries, production in million T (Source – World

Steel Association)

Country Rank 2010 2011 2012 2013 % 13/12China 1 638.7 695.5 724.7 779.0 7.5Japan 2 109.6 107.6 107.2 110.6 3.1UnitedStates

3 80.5 86.2 88.7 87.0 -2.0

India 4 68.3 72.2 77.3 81.2 5.1Russia 5 66.9 68.7 70.4 69.4 -1.5SouthKorea

6 58.9 68.5 69.1 66.0 -4.4

Germany 7 43.8 44.3 42.7 42.6 0.0Turkey 8 29.1 34.1 35.9 34.7 -3.4Brazil 9 32.9 35.2 34.5 34.2 -1.0Ukraine 10 33.4 35.3 33.0 32.8 -0.5As seen from this Table, India is ranked 4th in world steel production and is amongst the

three nations that had a positive growth in 2013 in comparison to 2012 against 7-countries

reporting negative change.

2.4 Supply-Demand Gap

2.4.1 Global Steel Scenario:

The increase of 3.5% in World crude steel production over 2012 is mainly from Asia and

Middle East, while the crude steel production in all other regions decreased in the same

period.

Steel production had declined in nearly all the major steel producing countries and regions

including the EU, North America, South America and the CIS. However, Asia, in particular

China and India, and the Middle East showed positive growth. The region’s share of world



steel production increased slightly from 65.7% in 2012 to 67.3% in 2013. China’s crude steel

production in 2013 reached 779.0Mt an increase of 7.5% on 2012. China’s share of world

crude steel production increased from 46.7% in 2012 to 48.5% in 2013 and apart from China

it can also be seen that Taiwan was up by 8%, India was up by 5% and Japan increased by

3% with South Korea the only major Asian producing country to show a decline, down by

4%. Other notable increases were Iran, up by 7% and Mexico, up by 2%. Apart from

Mexico, the NAFTA countries did not fare well with Canada down 8% and the US falling by

2%. Indeed, if the current rates continue, it will not be long before India overtakes the US as

the world’s 2nd largest steel producing region. It should also be noted that despite the well

documented problems with Europe, crude steel production only fell by 2% year on year.

The world steel industry is now firmly set on a path to recovery. The recovery is not only like

earlier times, but also stronger than expected. It was driven in large part by government

stimulus packages and recent inventory re-stocking. The Steel Demand across the world is

clearly on a rising trend and the same is shown in figure-2.1 below.

Figure 2.1 (Source – World Steel Association)

2.4.2 Indian Steel Scenario:

The Indian steel industry has witnessed an impressive performance in recent years and had

achieved growth rate of 5%. With production of 81.2 million tonnes of steel, India has

maintained 4th position and is expected to become the 2nd largest producer of crude steel in

the world. India also maintained its lead position as the world's largest producer of direct

reduced iron (DRI) or sponge iron.



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The worldwide meltdown beginning mid-2008 had put a question mark on future of all

segments of economy including manufacturing, automobile and construction. Nevertheless,

the fiscal measures being taken by the Govt. of India assured that the growth in economy will

be sustained through emphasis on infrastructure development and employment

generation.

The steel industry in India is expected to grow at around 7% p.a. feel experts. This is higher

than the rate at which it has grown in the last financial year. The recent reforms announced by

the Government as well as the expected monetary policy easing to be announced by the RBI

may play the accelerator for growth in the steel industry. The lifting of the iron ore ban down

south will also help in this regard.

Another positive factor for steel industry is the very low per capita steel consumption of India

as shown in figure-2.2 below.

Figure 2.2 (Source – 2012 Steel Industry Outlook, BOC International)

India’s steel consumption grew 3.3%, lowest in three years, to 73.3 million tonne in 2012-13

on subdued demand due to slackening economy and high interest rates. It grew by 5.5% in

2011-12 and 9.9% in 2010-11.

Indian economy grew by 4.9% last fiscal. The government expects it to clock 5.6% growth in

2014-15.

Broadly, steel consumption of an economy grows by 1.2 times of the GDP. Though it did not

happen for India in last fiscal, government officials believe it could actually happen this time

around.



India’s per capita steel consumption is just around 60 kg, as against the world average of over

210 kg, and 460 kg in China.

In this respect, one of the major initiatives that need to be taken is to focus on increasing the

consumption of steel in the rural areas of India. The potential for the growth of consumption

of steel in the rural areas of India for purposes like rural housing, rural infrastructure, etc is

high which needs to be tapped efficiently. The growing involvement of private sector in

steel production would lead to adoption of innovative marketing techniques to boost steel

demand. This falls in line with the objectives and intentions of the Ministry of Steel as part of

the National Steel Policy.

2.4.3 Projection of Demand and Capacity

Steel demand has been forecast based on a projected growth path of the GDP as growth in

steel demand is closely linked to the growth in GDP and the intensity of steel use in the

economy.

Taking into account the recent developments around the world and the Indian economy and

observing the general pattern of growth in other middle income and emerging economies,

steel demand has been projected under two likely scenarios of 7% and 8% GDP growth rates

per annum. (Table–2.3) Also, another scenario of 6.0% GDP growth rate, however unlikely

this may be, has also been drawn up to assess the critical minimum requirement of the

economy in the worst case scenario.

Table 2.5 Estimated Steel Demand and Required Crude Steel Capacity, 2011-12 to 2025-26.Growth Scenario Projected Demand for Finished Steel (MT)

2011-12(Actual)

2025-26 CAGR (%) Implicit GDPElasticity

GDP Growth at 7%

70.92 202 7.8% 1.11

GDP Growth at 8%

70.92 233 8.9% 1.11

GDP Growth at 6%

70.92 175 6.7% 1.11

Crude Steelcapacity Requiredto SustainProjected Demandin the Base case

88.40 244

The basic assumptions of the steel demand forecast adopted here are as follows.

a) GDP growth is sustained around 7–8 percent per annum with perceptible improvements in

basic structural strength of the economy so that the projected growth rates can be sustained

over a long term. Projections made here, however, assume that no drastic structural change of

the economy will take place involving major parameters such as savings and investment.



b) The projections of demand has been made on the assumption of zero trade balance in

steel e.g., imports and exports of steel balance out.

2.4.4 Outlook for Steel Demand and Steel Supply

(a) Domestic Demand

(i) Demand for steel is closely linked with production activities in various sectors of the

economy. Being the basic material for development of economic and social infrastructure,

steel is used for producing capital goods as well as final consumption goods. As a result one

may establish a direct relationship between economic growth as measured by Gross Domestic

Product (GDP), Gross Fixed Capital Formation (GFCF) & Index for Industrial Production

(IIP) and demand for steel. The same methodology based on the estimated relationship

between GDP and steel demand was adopted while making the projections of steel

demand for the 11th Plan period and it did give a fairly accurate assessment.

(b) Export Demand

(i) India has enormous potential, necessary resources and capabilities to become a global

supplier of quality steel. Also there exists ample market opportunities in the neighbouring

regions of Asia, Africa and the Middle East. The policy framework while according top

priority to meet domestic demand should also take into account the large export possibilities.

Table 2.6 Estimated Demand and Capacity CreationCategory Explanatory

Variable(CAGR during

2005-06 to2010-11)

Growth Rate

assumed for 12th

Plan (%)

Projection based onassumed growth rate

(2016-17)-MT

Long ProductsBars &Rods

Construction(8.3%)

11.0 44.1

Structural Construction(8.3%)

9.5 9.4

Rly.Material

Construction(8.3%)

5.0 1.4

Total Non-Flat 10.5 54.9Flat Products

Plates Consumption ofOil & Gas(8.9%), GDFCin Plant &machinery 8.9%)

7.5 7.3

HRCoils/Sheet/Skelps

IIP inmanufacturing(9.7%)

9.0 23.8



Cr Coils/Sheet

IIp in transportequipment(12.8%),consumption ofpetrol (4.3%)

11.0 11.8

CoatedSheets

10.8 8.8

ElectricalSheets

InstalledCapacity inPower (6.6%)

8.0 0.8

Tin Plates GDFC inPlant &machinery(8.9%)

8.0 0.6

Pipes GDFC inPlant &machinery(8.9%)

12.0 2.9

Total Flat 11 56.0Total Carbon Steel 110.9Demand for Alloy/StainlessSteel

5.0

Total Domestic Demand forSteel

115.9

Total Requirement of crudesteel

139.9

Likely Capacity of CrudeSteel

140.0

Source: Development and Growth scenario for Steel Industry in India by SAIL2.5 Major Steel Consuming Sectors

There are four major drivers of steel consumption: Auto sector, Construction, Capital goods

and Consumer durables.

Among these the “Construction” has close to 50% share as per analysis of the World Steel

Association (formerly International Iron & Steel Institute-IISI) for the year. In context of

India this is expected to be still higher in view of the need for housing and the vast potential

of infrastructure development in the form of Roads, Bridges, Ports, Railways etc. Steel has

emerged as an ideal construction material. With suitable composition and thermal treatment,

steel exhibits a wide range of properties: a very high strength for use as load bearing member,

and toughness for use in extreme temperatures, etc.

2.5.1 Sector-Wise Projected Consumption

Developed countries have higher per capita consumption as these countries have higher

consumption of flat products which is used to produce consumer oriented products. In



comparison, the developing countries require more of long products for the development of

infrastructural facilities of the nation.

In Indian scenario the scope of consuming steel has long way to go. The potential is mainly in

the constructional industry which is expected to move from concrete-intensive construction to

steel- intensive construction.

The four major drivers of steel consumption are:

Auto Sector, Construction, Capital Goods, Consumer Durables.

Figure 2.3 below gives the future consumption pattern in various sectors.

Figure 2.3 Future ConsumptionThe usage of steel in construction has increased due to tremendous change in construction

technology namely Composite Construction, Light Steel Framing and Modular

Construction etc.

2.5.2 Rebars Production & ConsumptionAt present Rebar market is dominated by regional players due to high logistics expenses.

Eastern and Western Regions have the largest concentration of small re-rolling mills for steel

rebars. There are about 1800 small producers and the market is highly fragmented and un-

organized. Also these producers produce Induction Furnace based steel having quality

problems. Thus there is great scope for development of quality producers going through Blast

Furnace / Electric Arc Furnace route. The break-up of rebars by various producers is

presented in the bar chart below. As can be clearly seen the unorganized sector

accounts for over 74% of the total rebar production in 2012-13.



The annual consumption of Rebar from 2008-09 to 2013-14 and future forecast of demand

from 2015-16 to 2020-21 is shown in following chart. It will be seen the annual demand is

expected to grow from present level of 23.91 million ton to 41.82 million tons by 2020-21

giving a CAGR of 10.16%.

2.6 Alloy & Special Steel Sector

Alloy steel industry registered a rapid growth during the last two decades. Many existing

alloy steel manufacturers undertook expansion and modernization programmes to update the

technology, improve productivity, reduce costs, conserve energy and achieve better quality.

Currently, there are 24 recognized alloy and special steel manufacturers in the

country with an installed capacity of almost 6.5 million tonnes per annum. The product range

of the industry is quite comprehensive as it covers nearly 250 grades of alloy and special

steels. The capacity of individual units lies in the range of 24 to 800 thousand tonnes per



annum. 13 manufacturers produce Alloy Steels from scrap, whereas 11 manufacturers have

Ore based units.

Imports constituted a significant share of the overall availability of alloy and special steels in

the country during early 80's. Imports have since come down with improved availability from

indigenous manufacturers. Other than certain specialty products for critical applications,

imports are resorted to by a few consumers based only on price preference. Major imports in

the field comprise CHQ (Cold Heading Quality) wire rods for the high tension fastener

industry; blooms for seamless pipe industry and tool & die steels. Currently, aggregate import

of alloy and special steels in the country is of the order of 100 thousand tonnes per annum,

comprising CHQ wire rods, forging quality steels and seamless pipe quality blooms. Exports

of alloy and special steels have been varying over the years and have been quite erratic. From

time-to-time, certain categories of alloy steels have been exported either through MMTC - the

canalizing agency or through manufacturers directly. Currently direct exports of alloy and

special steels from India are estimated at around 50 thousand tones per annum. Additionally,

substantial quantities of alloy and special steels are being exported indirectly from India in

the form of semi-finished / finished products. Taking into account the domestic production,

imports and exports, apparent domestic consumption of alloy and special steels during the

year 2012-13 works out at around 4.3 million tones.

The Indian alloy and special steel industry registered an ACGR of 10.3 percent per annum

during the period 2003-04 to 2007-08. During the year 2008-09, the industry witnessed a

negative growth of 21 percent as a result of global melt down, following the Lehman

Brothers crisis. Thereafter, the industry registered an ACGR of 12 percent till the year 2012-

13. Based on the past performance, current status and future outlook for the industry, the

domestic alloy and special steel industry is likely to register an ACGR of around 9 percent

per annum till the year 2021-22.

Table 2.7 Past & Projected Demand: 2003-04 to 2021-22

Year Demand (Th. Tonnes) ACGR (%)2003-04 2,300 10.32007-08 3,410 --2008-09 2,700 (-)21.02012-13 4,250 12.02021-22 9,230 9.0

Based on the above, the domestic consumption of alloy & special steels is likely to increase

from 4.3 million tonnes in 2012-13 to almost 9.2 million tonnes per annum by the year 2021-



22. Currently, there is over capacity in the country for the manufacture of alloy &: special

steels. At an average growth in domestic consumption of around 9 percent per annum from

2012-13 onwards, the existing capacities would be adequate to meet the emerging demand

only till the year 2016-17. It will be necessary to create additional capacities in order to meet

the projected requirements during the post 2016-17 period. It is estimated that around 3.8

million tonnes per annum of additional capacities would need to be created during the next 5-

year period in order to meet the requirements projected by the year 2021-22.

Table 2.8 Need for Additional Capacity: 2012-13 & 2021-22(Th. Tonnes)Year Demand Potential

DomesticAvailability

Surplus/Gap Additional CapacityRequirement

2012-13 4,250 4,250 -- --2021-22 9,230 5,850 3,380 3,750

2.7 Employment Generation (Direct and Indirect) Due to the Project

The organizational structure that would be required for the Plant operations has been given

due consideration. The total man power requirement for the project during operation will be

898. The manpower requirement has been planned keeping in view the following:

Smooth & efficient running of the plant with optimum manpower.

Capacity utilization with optimum energy consumption.

Effective coordination

Rational distribution of responsibilities

The organizational development would be started from the project phase itself as

those involved with the project would also be trained for Operations.

The total manpower requirement for the Plant and Administration has been estimated on

the basis of functional requirement of a modern plant. For loading of packed cement in

trucks and for housekeeping, contract / casual labour have been considered.

Table 2.9 Manpower Requirement during operation

Sl. No Category Proposed Manpower

1 Managerial Staff 602 Executives 803 Skilled 1354 Unskilled 4505 Office staff 73

Total 898



Training of Personnel

Training of the required manpower for the proposed project shall be planned, well in

advance. The key personnel shall be selected and trained suitably. The training shall be

carried out in the following manner:

Onsite training during the construction phase of the Project

On job training during the commissioning phase of the project.

On job training during operation of the plant immediately after commissioning.

The training of the key engineering personnel such as Process Engineer, Mechanical

Engineer, Electrical Engineer and Instrumentation Engineer shall be carried out in all the

facets.

The training of the key operating personnel such as cement mill operator, Packer

operator, mechanic, welder, fitter and electrician shall be suitably carried out during the

construction, erection and operation phases.

The training program shall include the following aspects among others so as to impart

knowledge and training to the key personnel in relevant aspects of the plant design, operation

and maintenance:

Understanding the functions of various units.

Understanding the equipment in respective sections.

Important parts and control in each equipment.

The hazards in respective sections and precautions to be taken for safety of the

equipment & personnel.

Inspection, preparation and start up of equipment in respective sections.

Routine operation of respective sections.

Shut down procedures for respective sections.

Procedure for attending to emergency stoppage due to failure of power, water and

air supply.



CHAPTER - 3

PROJECT DESCRIPTION

3.1 Type of Project





Karnataka State. Now SMIORE is proposing for expansion of its existing Ferro Alloys Plant

to 1.0 MTPA Integrated Steel Plant in 3 phases comprising of following units:-

Table 3.1 Proposed Configurations (Expansion)

Sl.No.

Plant/UnitName


Production


1 Blast Furnace

1x 0.4MTPABF

( Size 350-400m3 )

~ 1212.12TPD

-

1x0.4MTPA

BF( Size 350-

400m3 )~ 1212.12

TPD

2 x 400000TPA

0.800

Pig CastingMachine

1212.12TPD

- -1 x 400,000

TPA 0.400

2Coke OvenPlant andWHRB

0.4MTPA~ 1212.12


Generation

- -1 x 400,000

TPA 0.400


~1600 TPD-

1 x 50 m²~1600 TPD

2 x 528,000TPA

1.056

4Energy


-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

5



-1 X 50 T

~1602TPD

1 X 50 T~1602 TPD

2 x 528,710TPA

1.057

6Continuous


-1 X 4Strand9/16 m

1 X 4Strand 9/16

m radius

2 x 518,135TPA

1.036



radius~1570TPD

~1570 TPD

7Rolling (Rebar

Mill)-

1 X 100TPH

~1515TPD

1 X 100TPH

~1515 TPD

2 x 500,000TPA

1.0

8 Oxygen Plant1 X 100

TPD1 X 350

TPD--

1 x 33000TPA + 1 X

115500 TPA -


3.2 Location

The proposed facilities of the 1.0 MTPA Integrated Steel Plant comprising of Sinter

Plant, Mini Blast Furnace, Pig Casting Machine, Steel Melt Shop, Continuous Casting

Machine, Rebar Mill and WHRB will be installed at Vyasanakere, near Hospet in the

State of Karnataka in the land owned by SMIORE to South and South East of their

existing/ adjoining Ferro Alloy Plant complex. The proposed location of steel plant site

bears the following coordinates. The proposed site falls under the Survey of India Toposheet

No. 57A/8 and the buffer zone falls under the Survey of India Toposheet 57 A/7. The

Latitude and Longitude of the proposed site is 15°11'47"N and 76° 22'50"E respectively.

3.2.1 Plant Location



Figure 3.1 Index Map

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated Steel Plant comprising of Sinter Plant, Mini BlastFurnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka


Figure 3.2 Topo map- 10Km Radius



3.2.2 Alternative Sites Examined

As this is an expansion project proposed to be set up within the existing plant premises so no

alternative site has been considered.

3.2.3 Land Requirement

The requirement of total land including existing plant , proposed expansion and Green Belt is

320.79 Acre (129.81 Ha.). The proposed expansion shall be located within the existing plant

premises at- Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet

Taluk,Bellary District, Karnatak. The land has been already identified & acquired.

3.2.4 Plant Layout

The layout of the plant when developed will have the following features.

Process departments will be consolidated into comprehensive production units

requiring short conveying distances;

The major utilities and service facilities will be centrally located in respect to points

of high consumption;

Sufficient space will be provided for ease of operation and maintenance;

The lengths of power cables will be minimized by suitably locating load distribution

centres in respect of process departments;

Outward movements of materials from customers/suppliers will be segregated from

internal plant traffic

Sufficient space for storage of raw materials.

Adequate green belt & provision for future expansion.

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated Steel Plant comprising of Sinter Plant, Mini BlastFurnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka


Figure 3.3 Plant Layout

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integratedSteel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant& WHRB At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,BellaryDistrict, Karnataka


3.3 Site Selection

The site selected by SMIORE for setting up the Integrated Steel Plant has the following features

and infrastructure facilities:

The nearest railway station is Vyaspuri Colony about 200 meters from plant site on the

Hospet – Kottur broad gauge railway line of South Western Railway which passes close to

the east side boundary of the existing Ferro Alloy Plant of SMIORE and the proposed

Integrated Steel.

Railway culvert to connect the existing plant site of SMIORE to the proposed site is

proposed to be constructed under the railway line. Statuary approvals for the same are in

process.

Tungabhadra River Dam with perennial source of sweet water is running at distance of about

12 kms from the plant site.

The National Highway NH-13 passes on Western periphery of the plant site providing

excellent connectivity for road transport.

Hospet town is about 12 kms from the plant site facilitating residential needs of the

staff.

A 110 KV line supplies power to the Main Receiving Sub Station (MRSS) in the existing

plant facility of SMIORE.

3.4 Technology Selection

Correct selection of production technology is vital for the long term viability and sustainability

of the project. This requires an in-depth study of the technological developments with regard to

productivity, energy efficiency, environmental emissions and disposal of effluents etc. The

diagram showing different stages of the Production Process Flow and material balance on net &

dry basis for the proposed 500,000 tpa Integrated Steel making facility is attached as

Annexure-3.1. The project shall include Iron making facilities i.e. Sinter Plant, Blast Furnace &

Pig Casting machine. The Coke Producing unit along with WHRB for power generation and a

Blast furnace gas based power plant shall also be installed. The Steel Making & Rolling unit

shall be setup as down steam units of the project.

The Pig Iron manufacturing technologies related to Integrated Steel Plant can be divided into the

following broad Steps:



i. Raw Materials to Metallics;

ii. Metallics to Liquid Steel;

iii. Liquid Steel to Refined Liquid Steel; and

iv. Refined Liquid Steel to Semis, i.e. Billets & Blooms.

Raw Materials to Metallic

Basic raw materials for an integrated steel plant are Iron Ore Lumps, Iron Ore Fines, Coke or

Coking Coal and Fluxes – Limestone, Dolomite etc. Metallics can be defined as the intermediate

products which are then converted to steel. The metallics include intermediate products like

Molten Pig Iron called Hot Metal (HM), Direct Reduced Iron (DRI), Recycled Scrap and Cold

Pigs.

The three different methods that can be used for the production of iron from Iron ore are:

Coke-Ovens -Sinter-Blast Furnace (BF) Route, Direct Reduction Technique and Smelting

Reduction Technologies.

Hot metal as a metallic feed in steel making has the advantage of both thermal heat content of the

metal and the chemical energy of the charge in subsequent processing. The most popular process

route for production of hot metal is “Sinter Plant + Blast Furnace”.

3.4.1 Blast Furnace Process

In an integrated steel plant, Blast Furnace plays a vital role in controlling production and

economics of plant and it normally accounts for about 60 percent of the energy consumption for

production of one ton of steel.

Irrespective of the developments in iron making processes, Blast Furnace remains the

undisputed leader due to established technology. Even today more than 60% steel is

manufactured though the BF Route. Only disadvantage is the shortage of Coke worldwide. Coke

is produced by controlled combustion of coking quality coal in coke ovens. Due to this, cost of

coke is rising day by day and the route is becoming Costlier. Technologies are being developed

to reduce the consumption of coke in BF’s.

The technology of Iron making through blast furnace is one of the time tested metallurgical

processes which is continuing for many decades without any sign of being made obsolete by

modern developments. It is projected in the international scenario that this technology will

continue easily for the next fifty years without threat of obsolescence. The process is based

upon a moving bed reduction furnace which reduces iron ore with coke and limestone. The



blast furnace essentially works on the counter-current principle. The descending solid charge

meets a current of ascending gases and reduction of iron ore takes place along with its

progressive heating. The reduction of iron ore is the most important and most difficult one also.

Iron ore, Coke, Sinter and limestone are charged by a skip or directly through conveyor from the

top of the furnace. Mini and Medium Blast furnaces range around 4 to 6 m in hearth diameter

and are around 30 m tall. The furnace is basically a vertical shaft of circular cross-section and is

made of five main sections. Bottom-most part of the furnace is called hearth, where liquid metal

and slag is collected. This is surmounted by an inverted cone known as bosh. A short vertical

section, called bosh parallel connects the bosh to the truncated upright cone called stack, which

in turn support the throat.

Operating procedures comprise; charging of ore, sinter, coke and fluxes either by skip or

conveyor to the furnace top and using one of the devices like two bell systems with or without

movable throat armour or bell less top for burden distribution.

Preheated air is blown from near the bottom through tuyeres close to the junction of hearth and

bosh. Combustion of coke in front of tuyeres generates heat and reducing gases. The ascending

gases carry this thermal energy and transfer the same to the descending burden. Simultaneously,

the carbon monoxide (CO) rich gases when they leave the combustion zone partially reduce the

iron oxide present in the ore and sinter.

About 65% of oxygen in the iron bearing material is reduced by the gases, called indirect

reduction and the rest of oxygen and the metalloids (Mn, Si, P) are reduced directly by the

carbon (this is called direct reduction) at lower zone of blast furnace.

Coke carbon reacts with iron oxides in the furnace, releasing the iron and producing CO and

CO2 gas. The iron sinks to the furnace hearth whereas the impurities present in ore and sinter

called gangue material like SiO2, Al2O3 etc and the ash component of coke combines with

fluxes (CaO, MgO) to form a fluid slag. Being lighter, slag floats on the top of the molten iron.

The gas leaving from the top of the furnace, carries with it fine dust which is separated and

recovered through a gas cleaning plant. The combustible BF gas, after cleaning, is used for

heating of the stoves and for generating steam at boiler house. This BF gas can also find

application in Reheating furnaces of Rolling Mills.

The iron and slag are tapped by opening the tap hole at regular intervals. Iron is collected

in refractory lined ladles. The hot metal so produced is sent to the steel melting shop for steel



making. The slag is granulated in cast house by high pressure water and is generally used for

cement making or for construction related activities. Metallurgical coke suitable for BF is a

scarce commodity but still the BF route is preferred.

3.4.1.1 Smelting reduction technology

It is a is a coal-based iron making process and thus different from the conventional coke-based

conventional blast furnace. Most smelting reduction processes also avoid the agglomeration of

iron ore. Smelting reduction technology, as the name clearly suggests, involves both solid-state

reduction and smelting. Unlike Direct Reduction, SR produces liquid hot metal like a Blast

Furnace.

Smelting is melting involving chemical reduction reactions. Smelting reduction technology

exploits the principle that coal can be gasified in a bath of molten iron. Smelting reduction

technology is the only recent serious contender to replace the conventional energy- intensive

blast furnace that has been the dominant iron making technology for centuries.

Some of the important processes of SR technique are COREX, FINEX,

HISmelt, and Blast Furnace (to extend BF technology to small capacity) COREX has couple of

commercial plants in operation including one at JSW in India and FINEX has been

commercialized with the operation of first 1.5 Mtpa plant at POSCO, Pohang Works in Korea.

All these SR processes make use of non-coking coals. A brief introduction of some of these

processes is given below:

3.4.1.2 COREX Process

COREX is an industrially and commercially proven smelting-reduction process developed by

Siemens VAI for the cost-efficient and environmentally friendly production of hot metal from

iron ore and coal. The process differs from the conventional blast furnace route in that non-

coking coal can be directly used for ore reduction and melting work, eliminating the need for

coking plants.

The Corex process was developed in the late 1970s and its feasibility was confirmed during the

1980s. Following the first industrial application of a Corex C-1000 plant (nominal production of

1,000 tons of hot metal per day) at Iscor Pretoria, South Africa, four C-2000 plants (nominal

production of 2,000 tons of hot metal per day) were subsequently put into operation at

Posco/Korea, Mittal Steel/South Africa and at JSW Limited/India. In early November 2007, the



first Corex C-3000 plant was started up at Baosteel, China. It has a nominal production capacity

of 1.5 million tons of hot metal per year.

In the Corex Process all metallurgical work is carried out in two separate process reactors – the

reduction shaft and the melter gasifier. Lump ore, sinter, pellets or a mixture thereof are first

charged into a reduction shaft via a lock-hopper system where they are reduced to direct-reduced

iron (DRI) by a reduction gas moving in the counter-flow direction. Discharge screws convey the

DRI from the reduction shaft into the melter gasifier where final reduction and melting takes

place in addition to all other metallurgical and slag reactions. Hot metal and slag tapping are

carried out as in conventional blast furnace practice. The quality of the hot metal is equivalent to

that produced in a blast furnace.

Viewing the process from the coal-route perspective, non-metallurgical coal is directly charged

into the melter gasifier via a lock-hopper system. Due to the high temperatures predominating in

the dome of the melter gasifier (in excess of 1000 °C), a portion of the hydrocarbons released

from the coal during de-volatilization are immediately dissociated to carbon monoxide and

hydrogen. Undesirable by-products such as tars and phenols, etc. are destroyed and therefore

cannot be released to the atmosphere. Combustion with oxygen injected into the melter gasifier

results in the generation of a highly efficient reduction-gas.

The reduction gas exiting from the melter gasifier consists mainly of CO and H2 laden with fine

coal, ash and iron dust. This dust is largely removed from the gas stream in a hot-gas cyclone and

is then recycled to the process. Through the addition of a cooling gas, the reduction-gas

temperature is adjusted to its optimum working range. After leaving the hot-gas cyclone, the

reduction gas is then blown into the reduction shaft via a bustle, reducing the iron ores in counter

flow.

The top gas is subsequently cooled and cleaned in a scrubber, after which it is available as a

highly valuable export gas with a net calorific value of approximately 7,500 – 8000 kJ/m³ (STP).

This gas is suitable for use for a wide range of applications, including:

Power Generation

Production of DRI

Heating Purpose within the Iron & Steel Complex.

3.4.1.3 FINEX Process



FINEX process of iron making has been developed jointly by Siemens VAI and POSCO. It

makes use of iron ore fines and non-coking coal and a plant has been put in operation with

operating capacity of 1.5 million ton per annum in the year 2007-08. It is claimed that the

process can make use of low-grade ore and low-ranked coal, has flexible operation with

independent control of reduction & melting processes. The process is claimed to be

environmental friendly with relatively low emission of SOx, NOx & dust and scope of CO2

sequestration. It is claimed to be Cost Competitive with capital investments shown to be 80%

and operating cost 85% in comparison to BF route.

3.4.1.4 HIsmelt Process

HIsmelt Process was started by a consortium of Rio Tinto, Nucor Corporation, Mitsubishi

Corporation, and Shougang Corporation. The group has set up an 800,000 tpa plant in Kwinana,

Western Australia. The merchant pig iron facility has been designed and engineered with a 6-

metre hearth diameter Smelt Reduction Vessel. It is claimed that HIsmelt Technology can make

use of low grade iron ore and can be started, stopped or simply kept idle without any problem.

The HIsmelt Corporation has started marketing of the technology based on its success at the

Kwinana project.

3.4.1.5 Direct Reduction Processes for Iron Making

Electric arc furnace (EAF) route of steelmaking originated essentially to recycle the scrap steel.

Faster growth in the sector led to shortage of scrap and the direct reduced iron (DRI) or sponge

iron has served as an alternative feed stock that involves reduction of iron ore in solid state.

Besides replacement of scrap, DRI has additional advantage of being virgin feed for quality

steels where tramp elements accompanied with recycled scrap need be avoided or diluted to the

extent desirable.

The technology of Iron making through blast furnace is one of the time tested metallurgical

processes. Irrespective of the developments in iron making processes, Blast Furnace remains the

undisputed leader due to established technology. Even today more than 60% steel is

manufactured though the BF Route. It is projected in the international scenario that coal reserves

would be available for next fifty years and that this technology will continue easily without

threat of obsolescence. To reduce the consumption of coke Technologies like Pulverized Coal

Injection, Oxygen Enrichment of the Combustion air have been developed and adopted. On

analyzing the available technologies, BF is the best route and is recommended.



3.4.2 Coke Oven

Coking coal contributes to approximately 50% of the cost of hot metal. Therefore, it is logical

that coke quality and price needs to be kept under control in the iron and steel industry to be

competitive. The two primary variables that influence the price and quality of BF coke are –

coke making technology and raw materials used. Some of the technological developments that

have improved performance of industry are:

Stamp Charging of Coal

Partial Briquetting of Coal Charge (PBCC)

Selective Crushing of Coals

Dry Coke Quenching

3.4.2.1 Types of Coke Oven Plants

The coke making process involves carbonization of coal to high temperatures (1100°C) in an

oxygen deficient atmosphere in order to concentrate the carbon. There are two commercial coke

making processes-

By-product Coke making

Majority of coke production in the world is from by-product coke oven batteries. The coke

making operation comprises of the following steps:

Coal from different mines is blended, pulverized, and oiled. The blended coal is charged into

a number of slot type ovens.

Coal carbonized in reducing atmosphere and the off-gas is collected and sent to the by-

product plant.

Non-Recovery/Heat Recovery Coke making.

Non-Recovery coke plants, originally referred to as beehive ovens, have large oven chambers.

The carbonization process takes place from the top by radiant heat transfer and from the bottom

by conduction.

Primary air for combustion is introduced into the oven chamber through several ports located

above the charge level in both pusher and coke side doors of the oven. Combusted gases exit

through common tunnel via a stack which creates natural draft. Since by-products are not

recovered, the process is called Non-Recovery Coke making.



The waste gas is fed into a waste heat recovery boiler to convert waste heat into steam for power

generation; hence, the process is also called Heat Recovery Coke making.

The Non-Recovery Coke Ovens are considered eco-friendly in comparison to recovery type. It is

less capital intensive and has shorter construction periods as compared to recovery type Coke

Oven. Main features are:

Energy of carbonisation is supplied by burning the gaseous volatile products released from

the coal charge during carbonisation.

Heat generated by the combustion of the volatile matter, produces high temperature zone in

the free space above the coal charge. This radiates back into the coal charge downwards.

The products of combustion are drawn through the various points in the oven arch and passed

through side wall off-take flues into a series of sole flues located below the oven floor.

Application of heat takes place from above, sides and below the charge. Temperature at the

point where burning gases are drawn into the side off take ports is of the order of 1200 oC.

3.4.2.2 Selection of Oven Technology

Out of the two types of ovens – horizontal and vertical type, the later has been considered

technologically advantageous. Technical benefits of Vertical Type Coke Ovens are:-

Lower cost and higher yield: Coking and combustion chambers of vertical type heat recovery

ovens are completely apart from each other. The oven door is smaller, does not get deformed and

is easy to seal.

Since heating is carried out in the combustion chamber, air is kept out of contact with coal. Thus

burning up to ash in the final stage of coal-to- coke conversion is avoided reducing loss of

material.

In horizontal type heat recovery coke ovens, the air leakage around the oven door can occur as it

is difficult to have a perfect sealing. Correspondingly, inlet air increases leading to burning loss

in the range of ~ about 5%, which is a large waste.

Good utilization of heat energy, as the vertical type heat recovery coke ovens have theadvantages of modern recovery coke ovens.

3.4.3 Sintering Process

Sintering is one of the technologies for agglomeration of iron ore fines into useful BF burden

material. This technology was developed in the early 20th century for treatment of waste fines.



Since then, sinter has been widely accepted and is the preferred BF burden material. Presently

more than 70% of hot metal in the world and about 50% in India is produced through sinter. The

major advantages of using sinter in BF are:

Facilitates use of fines of iron ore, lime, dolomite, coke breeze, and other metallurgical waste

for hot metal production;

It has better reducibility and other high temperature properties;

BF productivity is enhanced with improved quality of hot metal;

Facilitates reduction in coke rate;

3.4.3.1 Basic Technology

Raw materials for sinter are: iron ore fines (-8mm), coke breeze (-3 mm), limestone & dolomite

fines (-3 mm) and other metallurgical wastes. Proportioned raw materials are mixed and

moistened in a mixing drum. The mix is loaded on sinter machine through a feeder on to a

moving grate (pallet) and then rolled through a segregation plate so that coarse materials settle at

the bottom and fines on the top.

Top surface of mix is ignited through stationary burners at ~ 1000 °C. As pallets move forward,

air is sucked through wind boxes situated under the grate. A high temperature combustion zone

is created in the charge-bed with burning of solid fuel of the mix and regeneration of heat of

incandescent sinter and outgoing gases. Due to forward movement of the pallet, the sintering

process travels down.

Sinter is produced as a combined result of locally limited melting, grain boundary diffusion and

re-crystallization of iron oxide. On completion of the process, the sintered cake is cooled,

crushed and screened.

3.4.3.2 Main Features of the Sintering Machine

i. Sinter plant to have Irish mixer (High intensified mixer) to maximize usage of ultra fines

from the mines.

ii. Fuel preparation system adopts open-circuit crushing consisting of four- roller crushers to

ensure more than 85% fuel particle size 3-0 mm to reduce fuel consumption and achieve better

chemistry.

iii. Automated weighing dosing is employed to improve dosing accuracy, ensuring consistent

quality of sinter, reducing fuel consumption and achieving stable production.

iv. Deep-bed sintering for economical operation of the process



v. Circular Sintering Machine with Circular cooler has been considered for its high productivity

and compact Design. It has simple structure with ease of operation and maintenance.

vi. Electric dust removers are installed at machine head and tail end with dust removal efficiency

of more than 99 %.

vii. Standard air draft device adopted for high efficiency and low power consumption.

3.4.4 Metallics to Liquid Steel

The options available for conversion of Metallics to Liquid Steel are:

i. BOF/LD- Basic Oxygen Furnace/LD Convertor

ii. EAF- Electric Arc Furnace

iii. EOF- Energy Optimizing Furnace

iv. IF- Induction Furnace

3.4.4.1 Basic Oxygen Furnace (BOF)

Among various technologies for steelmaking, Basic Oxygen Furnace (BOF) or LD

Converter is the predominant steelmaking route accounting for over 55% or more of the

world steel production. It requires approximately 85-90% feed as hot metal with balance scrap as

coolant to take care of the thermal energy generated during oxygen blowing. The process is

very fast and suits capacities with various converter size. The infrastructural requirements

of the shed and pollution control arrangement make it capital intensive.

The process differs from the EAF in that it is autogenous, or self- sufficient in energy. The

primary raw materials for the LD Convertor are

80-85% liquid hot metal from the blast furnace and the balance is steel scrap. These are charged

into the Furnace vessel. Oxygen (>99.5% pure) is "blown" into the LD Convertor at

supersonic velocities. It oxidizes the carbon and silicon contained in the hot metal liberating

great quantities of heat which melts the scrap. There are lesser energy contributions from the

oxidation of iron, manganese, and phosphorus.

The product of the process is molten steel at 1600°C-1650°C with a specified chemical analysis.

From here it may undergo further refining in a secondary refining process or be sent directly to

the continuous caster where it is solidified into semi finished shapes: blooms, billets, or slabs.

Trends and Drivers in the BOF/ LD Convertor can be summarized as follows:



Advances in slag splashing that extend refractory life and use of post- combustion lances

have improved furnace availability.

Increasing demand for ultra-low-carbon (ULC) steels has made secondary processes more

important.

Hot metal desulfurization is usually done in the BOF transfer ladle.

Meanwhile, steelmakers constantly experiment with BOF oxygen lance configurations,

oxygen batching and flux additions practice.

Technological Challenges:

Life incompatibility of the lower hoods shorter than the furnace, and related maintenance

issues.

Environmental standards are getting tougher.

Furnace vessel shell distortion and destruction during a long campaign are a constant

challenge.

3.4.4.2 Electric Arc Furnace (EAF)

EAF offers an alternative method of bulk steel making. Unlike the BOF route, the Electric Arc

Furnace does not use 85-90% hot metal but can definitely work with 50-60% hot metal and

the remaining charge consists of material such as steel scrap or sponge iron. EAF requires

heavy pollution control equipment. Modern electric arc furnaces typically make up to 150 tonnes

of steel in each heat which takes around 70 minutes.

Due to principle of operation EAF’s require high short circuit levels and heavy transmission

lines for back up. This in itself is expensive equipment and adds to the cost of EAF

installation. Regular maintenance of electrical components is also an additional requirement.

In India the early 70’s and 80’s saw a massive growth of electric arc furnace (EAF) and

induction furnace (IF) based steelmaking units respectively. This had created a growing demand

for steel scrap, as a result of which the scrap was in short supply. Moreover, significant

improvements in steel plant yield, rolling technology and continuous casting processes have

decreased the amount of in-plant generation of scrap. This ultimately has resulted into the

shortage of scarp supply throughout the world and its fluctuating prices.



Although steel scrap is rather a tailor made input material, problems faced by steelmakers are its

short supply, fluctuating prices, heterogeneous nature and above all higher content of tramp

elements (0.1 to 0.8%).

The non-availability of consistent quality scrap at a reasonable price necessitated the search for

an alternative to scrap for use in secondary steel sectors. This problem has been tackled using

direct reduced iron (DRI) or sponge iron which is not only a substitute for steel scrap as a feed

material in EAF but also a more suitable melting stock for the production of good quality steels.

Unlike scarp and pig iron, the DRI is characterized by a high porosity, low density, low thermal

conductivity, high specific surface area, relatively high oxygen content and intermediate carbon

percentages. DRI has uniform chemical and physical characteristics; it hardly contains any tramp

metallic elements (about 0.02%) and low sulphur content. This promotes the use of DRI in the

charge as a partial replacement to scrap which ultimately improves the mechanical and

metallurgical properties of the products. Advantages of using DRI as a feed material are reported

elsewhere. Thus DRI is particularly suitable for the production of quality steels. The DRI melting

in EAF is a well-established technology.

3.4.4.3 Energy Optimizing Furnace (EOF)

EOF is a melting and refining furnace using combined oxygen and air blow in bath consisting of

hot metal, pre-heated solid scrap and fluxes.

Submerged oxygen blow reacts with carbon from hot metal, generating CO bubbles, further

oxidized to CO2 by oxygen through atmospheric air injections by supersonic lances.

Sensible heat in the off gases is used for pre heating of scrap, located above the furnace roof.

Salient Features of EOF are summarized below:

i. No electrical energy is utilized for melting of charge.

ii. Maximum heat is utilized from the chemical reactions.

iii. Liquid steel produced is of highest purity with very low phosphorous and sulphur.

This is due to continuous flushing of slag during blowing and slag free tapping.

iv. Low tramp elements in steel due to virgin Liquid Metal route.

v. About a third of oxygen is used for blowing the bath and two thirds facilitates post-

combustion.

vi. Greater flexibility of metallic charge mix, solid addition of scrap up to 40% is possible.

However, DRI usage up to 5%. is possible.



vii. Combined oxygen blowing as submerged and post combustion in atmosphere.

viii. The solid scrap is pre heated by outgoing waste gases.

ix. Especial submerged tuyeres for oxygen blowing with longer life.

x. Blowing time is about 30 minutes and tap-to-tap time less than an hour.

xi. The productivity of an EOF is similar to that for a state of the art EAF but it has relatively

low capital cost because of elimination of the electrical supply equipment.

xii. Efficient pollution control operation under slightly negative pressure, hence no

secondary dust emissions.

xiii. De-slagging and double slag practice possible during oxygen blowing

xiv. Highest productivity

3.4.4.4 Induction Furnace (IF)

The option of Induction Furnace (IF) based steel making is limited to relatively smaller

capacities with limitations of refining steel with slag as is possible in BOF, EOF and EAF

processes.

Among the four steelmaking processes, EOF is considered the most suitable. Major advantages

of EOF are:

i. There is no electrical energy required for melting. The entire operation consumes 30-35

KWH/T of electrical power.

ii. Maximum utilization of all reaction energy, outgoing flue gases

iii. Quality requirement of steel produced especially for low ‘P’ up to 0.025 (max) is best

achieved through EOF. The process is very effective because of de-slagging during oxygen

blowing.

iv. Cost of production is lowest as compared to any other process.

v. Pollution control equipments are cheaper and the route is environment friendly.

3.4.5 Liquid Steel to Refined Liquid Steel

Having manufactured Liquid Steel of the required composition from the LD Convertor, the next

step is to further refine this to the exact chemical composition and other metallurgical

requirements as per the required steel grades.

Technologies available for refining the liquid steel are;

i. Ladle Refining Furnace (LRF)



In the LRF, liquid steel in deoxidized and de-sulphurised with the help of slag metal reactions

and addition of fluxes. Argon in bubbled to facilitate reactions through stirring. Steel temperature

is raised by arcing with the help of three graphite electrodes. LRF performs the following

operation:-a

Raising the temperature to desired levels (1620oC for mild steel) with perfect soaking of

ladle shell and refractory.

Floatation of non-metallic inclusion making steel clean.

Homogenization of temperature and chemistry.

Presently, LRF is the only process available and hence recommended.

ii. Vacuum Degassing

Vacuum Degassing means removal of harmful dissolved gases from LM. This is a requirement

from end users like Automobiles industry. Depending on the selection of equipment, vacuum

degassing can be carried out in two ways;

Tank VD

In this process ladle with LM is placed inside a tank, the tank is covered and then subjected to

high vacuum. The Tank may be fixed or mounted on a moving car.

RH Degasser

This technology is an improvement over the tank degasser. In RHD, two snorkels of the

refractory lined vacuum vessel are lowered into the ladle with liquid metal. LM is sucked

through one snorkel and returned through the other. LM comes in intimate contact with vacuum.

Efficiency of this process in reaching low gas levels is better than tank degasser.

Both VD & RH degasser are desired for producing alloy steels & specialty steels. These are not

required in the present stage of the project.

RH degasser is suitable for heat sizes of 50 T or above. For smaller heat sizes, like this project,

tank degasser is the best choice and recommended.

3.4.6 Refined Liquid Steel to Semis3.4.6.1 Continuous Casting Machine (CCM)Continuous casting is the process to solidify molten steel into a semi finished billet, bloom, or

slab for subsequent processing. Prior to introduction of the continuous casting practice in

1950s, steel was poured into stationary molds to form ingots. But continuous casting has

substantially added to improved yield, quality, productivity and cost efficiency.



Steel from the LD Convertor -LRF is tapped into a ladle and taken to the continuous casting

machine. The ladle is raised onto a turret that rotates the ladle into the casting position above the

tundish. Liquid steel flows out of the ladle into the tundish and then into water-cooled copper

mold. Solidification begins in the mold, and continues through the first zone and strand guide. In

this configuration, the strand is straightened, torch- cut and then discharged for intermediate

storage or hot charged for

finished rolling. The melting /casting/ rolling processes are linked while casting a shape that

substantially conforms to the finished product. The complete chain from liquid metal to finished

rolling can be achieved within two hours. End-use dictates quality, grade and shape of the cast

product (billet, bloom, slab, beam blank, and/or round).

To start a cast, the mold bottom is sealed with a dummy bar head attached to dummy bar. The

dummy bar is held in place hydraulically by Straightener Withdrawal units. This head prevents

liquid steel from flowing out of the mold. The steel poured into the mold is partially solidified,

producing a steel strand with a solid outer shell and a liquid core. In this primary cooling area,

once the steel shell has sufficient thickness, about 10–20 mm, the straightener withdrawal units

are started. The moving dummy bar starts to withdraw the partially solidified strand out of the

mold along with the dummy bar.

Liquid steel continues to pour into mold to replenish the withdrawn steel at an equal rate. The

withdrawal rate depends upon the cross-section, grade and quality of steel being produced, and

may vary widely depending upon section, quality and machine design parameters. Casting

times are typically matched with the EOF tap-to-tap time.

Upon exiting the mold, the strand enters a roller containment section and secondary cooling

chamber in which the solidifying strand is sprayed with water to promote solidification. This

area preserves cast shape integrity and product quality. Larger cross-sections require extended

roller containment. Once the strand is fully solidified and passed through the straightener

withdrawal units, the dummy bar is disconnected, removed and stored. Following the

Straightener, the strand is cut into individual pieces of required length and discharged for

further processing.

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPA integrated SteelPlant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill , Oxygen Plant & WHRBAt Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka


3.5 Process DescriptionSandur Manganese & Iron Ores Limited is planning to setup an Integrated Steel Plant Facility for

production of about 8,00,000 tpa Pig Iron & about 1,00,000 Liquid Steel & further Rebars. Following

is the brief description of Technological Equipments being set up at Proposed Plant.

Proposed expansion comprises of following major units:

Blast furnace,

Pig Casting Machine,

Coke Oven plant and WHRB,

Sinter Plant,

Energy Optimization Furnace (EOF)

Ladle Refining Furnace (LRF) and Vacuum Degasser (VD)

Continuous Casting Machine (CCM)

Rolling (Rebar Mill)

Oxygen Plant

3.5.1 Blast Furnace

The size requirement of the 2 Mini Blast Furnace has to be decided based on the capacity requirement

of the finished product and has been worked out to be 350-400 m3. The furnace will conform to the

following main features:

3.5.1.1 Main Features of the BF Installation

The salient features of the BF installation are envisaged as enumerated below:

To ensure enhanced smelting rate in the furnace, the materials charged in the furnace will undergo

before charging: Screening, weighing and automatic balancing of weight for variation in

moisture to improve accuracy of input materials and fuels for stable blast furnace operation and

increased output.

High top pressure for enhanced output and coke saving through better heat exchange between

charged solid materials and the generated gases.

Energy saving and environmental protection: In blast furnace design, a series of energy saving &

environmental protection technologies are adopted, such as reclamation of used heat from the flue

gas of the hot blast stoves for preheating the combustion-supporting air.

BF with 350-400 m3 effective volume shall have one tap hole and 12-14 tuyeres. However the

vendor can decide the number of tuyeres based on the design considerations.



Furnace Profile and dimensions shall be selected taking into consideration, the

characteristics of available raw materials and modern trends in Blast Furnace technology to give

high productivity, low energy consumption and longevity of the furnace.

The selection of refractory materials at various sections of BF will ensure a long campaign life

>10 years, keeping the investment cost at an appropriate and reasonable level.

An efficient BF cooling system shall be adopted to ensure longevity of the blast furnace at

optimum coal injection of 120-150 Kg/thm. In addition to the Stave Coolers of appropriate

design in various parts of BF body walls, the BF bottom shall also be water cooled.

Belt Conveyor Charging and Bell-Less top system shall be provided to ensure proper distribution

of charge inside the BF.

Three (3) nos. top combustion hot blast stoves will be provided to meet the high blast temperature

requirements of ~ 12000C. BF gas shall be used for all the stove burners along with combustion

air, both preheated to ~150-2000C in separate recuperators installed in exhaust flue duct of

stoves.

Dry Bag type gas cleaning is proposed to ensure higher cleaning quality of 5 mg/Nm3 and

achieve higher blast temperature in hot blast stores.

A hydraulic Mud-Gun and a tap hole Drill Machines of appropriate capacity shall be installed at

the cast house.

Slag Granulation Plant shall be of Filter Bed Type. The water supply system shall be of re-

circulation type. Granulated Slag shall be sold to cement factories.

BF gas shall be used for Hot Blast Stoves heating, Hot Metal Ladles Preheating, Sinter Plant and

surplus gas shall be utilized for electric power production.

Pig Casting Machine having a capacity of about 121.12 TPD is proposed to ensure production of

Pig Iron.

Sinter and Coke shall be screened before charging to BF. Charging shall be done through Weigh

Hoppers with load cell weighing system.

One (1) working + one (1) standby Electric Motor Driven Air Blowers with BPRT (BF gas

pressure recovery turbine) facility is not envisaged for this small furnace size. The electric supply

for these motors shall be at 11 KV, 50 c/s, 3-Phase. To utilize the available pressure and

temperature of BF gas. One gas turbine will be connected with electric blower through clutch



with this system about 40% power will be saved for normal running of electric blower. The BPRT

is not envisaged as the Power output of the unit is not viable w.r.t the investment made.

Pneumatic Pulse Jet Cleaning Bag Filter Type De-dusting unit shall be provided to cater to all

the dust generating points in material handling system.

EOT Cranes / Hoists shall be provided for maintenance of the various equipment.

Table 3.2 Technical parameters of Blast Furnace

No Name Unit Indicator Remarks

1. Blast furnace volume m3 350-400

2. B.F. working volume m3 295

3. Productivity t/m3/day >3.0

4. Coke ratio Kg/thm <450

5. Coal ratio Kg/thm ~120

6. Ore grade TFe % 61-63

7. Sinter usage % 75 * 25% Iron

Ore/Pellets8. Blast temperature °C ~ 1200

9. Top pressure MPa 0.03- 0.12

10. Slag volume Kg/thm 300-350

11. Oxygen enrichment rate % Upto 4

12. Steam Injection gm/m3 As required

13. Working days of BF days 330 Annual

14. Iron output of BF t/a >400,000 Annual

15. No. of Tuyers Nos. 12-14

16. Tap Hole Nos. One (1)

17. Charging System Type Belt conveyor

with Bell Less

Top



Table 3.3 Specific Consumption of Power & Utilities

NO. TYPE OF POWER UNIT REMARKS

1. Blast rate

1400 Nm3/thm

1250 Nm3/thmWith O2

Air volume infurnace without O2Air volume infurnace with O2

2. Steam 0.020 t/thm

3. Electricity 30 kWh/thmExcluding airblowers

4. Clear circulating water50 t/thm(Approx.)

As perRequirement

5.Turbid circulating waterFrom slag flushing

~3.5 t/thm(Approx.)

As perRequirement

6.Water supplemented forslag flushing

0.7t/thm(Approx.)

As perRequirement

7. Nitrogen ~20 Nm3/thmAs perRequirement

8. Oxygen ~42 Nm3/thmAs perRequirement

9. Compressed air ~10 Nm3/thmAs perRequirement



Figure 3.4 Process Flow Diagram of Blast furnace3.5.2 Pig Casting Machine

Design parameter

Type : : Continuous Double Strand Linear Pig Casting Machine

No. required : One Double Strand Pig Casting Machine

Capacity 1212.12 TPD

Speed 8-12 m/mm

Slope 11 degree (approx.)

No. of Pig 5 per Mould

Weight of each

pig

7.5 kg

Temp. of Liquid

Metal

1400 deg.Cel. at pouring point

Drive A.C>Motor

Lime Sprayer A.C.Motor




Design parameter




Speed 8-12 m/mm



Weight of each

pig

7.5 kg

Temp. of Liquid

Metal


Drive A.C>Motor





Design parameter




Speed 8-12 m/mm



Weight of each

pig

7.5 kg

Temp. of Liquid

Metal


Drive A.C>Motor




Control VVVF

Voltage 415 V +/- 10%, 60 Hz +/- 5%, 3 Phase

3.5.3 Coke Oven Plant

3.5.3.1 Introduction

In view of the plans to set up BF and the present world-wide coal/coke crisis and volatile prices of

Coke, it is necessary for the company to construct coke oven batteries to meet about 400,000 TPA

annual requirement of coke corresponding to 1.0 mtpa capacity planned in future. Availability of BF

coke is likely to remain difficult in future due to increased consumption of coke worldwide.

Developed countries, in general, do not produce coke for outside sale due to stringent pollution

control restrictions.

In the recent past various technologies for improving the quality of coke especially with respect to

strength of coke and environment control have been developed.

Among the various options for Coke oven batteries, it has been found that non-recovery (heat-

recovery) stamp charged type of coke ovens are most economical to build. In China construction of

this type of batteries is very common these days. In India also, several such batteries have been/ are

being installed by companies like Sesa Goa, JVSL, JSW, Neco- Jayswal, etc.

The desired quality parameters can be met by non-recovery type coke ovens. Accordingly, a non-

recovery type coke oven battery is proposed for project.

3.5.3.1 Coking Process

Coal is crushed and fines are conveyed to silos for storage & blending. Crushed coal blend from coal

tower is directly received in a hopper for charging in stamping machine. From the hopper coal is

evenly discharged into stamping box, where coal blend is stamped into coal cake. Bulk density of the

cake is between 1.05 – 1.1 t/ m3. The coal box with ready coal cake are together loaded in coal

charging car and taken to the oven which is ready for pushing. The coke pushing car pushes the coke

out of the oven and coke side is immediately closed. Thereafter, coal cake is pushed inside oven with

the help of charging mechanism and immediately pusher side door is also closed. The coking coal

cake is heated in oven and raw coke oven gas is separated out. Adjustable suction valve on the oven

roof and oven doors allow the introduction of primary air to combustible raw gas. The incomplete

combustible gas goes to coke side descend and then to fire channels on both sides of oven wall and

then goes into fire channel at the oven bottom. The oven bottom fire channels are four linked



arch type. Secondary air is introduced to burn with incomplete combustible gas. Thus, cake base is

heated through heat exchange with oven bottom bricks. Thermo-couples are provided to measure

temperature at the bottom.

After the raw gas is completely burnt in bottom fire channel, the flue gases flows into the ascendant

fire channel into the oven wall on other side and then into uptake at the centre of the oven roof.

All the gases evolved during the carbonization of coal charge including tar etc. are completely burnt

inside the oven. The flue gases from the oven at a temperature of about 900-1000oC pass through

waste heat flue ducts and led to WHRB .The sensible heat of waste gas is recovered in WHRB for

generation of power. The gas is cooled to less than 200°C before it is allowed to pass to exhaust

chimney.

Non recovery or heat recovery coke oven are of two types. One is similar to byproduct type having

vertical oven where heating of coking chamber is done from side wall and another type is horizontal

oven where heating of coking chamber is done from the top. The process of carbonization in oven is

under slightly negative pressure and this result in practically emission free operation of battery.

The company has planned to set up 0.4 MPTA non-recovery vertical type coke oven batteries as a

part of its expansion project to meet its captive requirement of coke for its blast furnace

operations. With power generation from Flue gases of coke oven, the net cost of power generation is

reduced substantially.

3.5.3.2 Coke Oven Complex

The proposed Coke Oven Complex will consist of non-recovery type of 2 Nos of 2 x 28 chamber

coke oven batteries, 1 coal tower in-between. A power plant utilizing the waste heat of flue gases

from coke ovens is also proposed to be built. The capacity of the Coke oven complex shall be more

than 400,000 tonnes /annum of gross coke. In this process, the coal to be charged in oven is first

converted into a cake through stamping process and then coke is charged into oven. The oven will be

provided with self adjusting suction pressure controller for individual oven as well as a changer

controller at chimney base in order to control thermal regime of Coke Oven Battery. The major

facilities envisaged are as under:

Coal Preparation and Proportioning Plant

Coke Oven Battery Proper

Coke Screening Plant



Gas Cleaning Heat Recovery System and Power Plant

Auxiliary production facilities like maintenance shop, laboratory, warehouse etc.

a. Coal Preparation & Proportioning Plant

The prime objective of a coal preparation plant is to feed consistent quality of coal to coke oven

batteries for production of required quality of BF coke. For coal for Coke Oven batteries, a separate

coal yard will be provided near the Coke oven battery. Coal will be received through rail wagons,

self-discharging trucks & tipper system. The capacity of the Coke oven complex shall be 400,000

tonnes/ annum of gross coke.

The unloading and loading system is designed to capacity of 100t/h, while the blending, crushing and

feeding system is designed to capacity of 100t/h.

The cleaned coal shall be fed into the coal hopper. Appropriate number of coal blending hoppers shall

be provided based on the coking coal types, and electronic belt scale shall be provide below the coal

blending hopper for measuring the coal blending proportion. The coal blending hoppers shall be

welded with steel, and electrical vibrator shall be provided on the outer wall to ensure no sticking or

blocking.

Two back-impact plate hammer crushers shall be selected for crushing of raw material coal.

Permanent magnetic iron remover shall be provided before raw materials enter the crusher.

The coal preparation plant is mainly composed of cleaned coal yard, coal receiving and blending

hopper, crusher room and cleaned coal belt corridor, for purpose of stripping, loading, coal

blending, crushing and other tasks so that blended coal of required grain size shall be delivered to the

coal tower of the coke oven.

The coal preparation plant shall be continuously operated to 365days every year and production

personnel shall be allocated to three-shift operations.

The major facilities envisaged are as under:

Supply of coals

3-4 grades of coal Imported are blended to make charge mix shall be mainly from Australia. In actual

practice, coal supply will depend upon actual over all receipt patterns and accordingly blend

composition is to be adjusted keeping in view the qualitative parameters of BF coke required. This

would also require laboratory tests for establishing the most optimum coal blend.

Requirement of coals



For production of 400,000 tpa yearly Gross coke (dry), the requirement of gross coal (including

moisture content & handling losses) is estimated at 540,000 tpa. Receiving coal is classified based on

chemical composition and coking index. Non coking coal and coking coal are stacked separately

.These coals are discharged on a conveyor in proportions based on blend composition and taken to

coal crushing unit. The coal is crushed to -3 mm (>90%) in two stages and transferred to fine coal silo

and from there to stamping machine.

b. Coke Oven Batteries Proper and Equipment

The proposed coke oven battery shall be non-recovery type. The installed capacity of plant will be 0.4

mtpa of the BF Coke. The Coke Oven will be provided with self-adjusting suction pressure controller

for individual oven as well as damper controller at chimney. The coke produced shall be screened in 3

sizes i.e. 20-60 mm (BF coke), 8-20 mm (nut coke) & below 0.8 mm (coke breeze).While the BF

coke and Nut coke will be used for Blast Furnace, coke breeze will be used in sinter making. A power

plant utilizing the waste heat from flue gas is proposed to be built.

c. Brief Description of Structure of Coke Ovens

This design will use Heat-Recycle Stamping Clean Coke Oven, with following main features:

Oven body Structure design:

Oven top: flat-top structure of mechanical coke oven.

Arrangement of coking chamber oven wall flue and bottom combustion flue: main wall thickness

100mm for coking chamber, uniform distribution of rectangular down flues and flame flues on the

oven wall.

There is flanged connection between the branch flue and the gas gathering flue to facilitate

integral replacement.

Coking chamber with small center distance and small wall thickness help to reduce refractories of

coke oven.

The waste heat boiler is provided against the emergency chimney in order to reduce length of the

main flue.

Oven body Material

The part from bottom of the coke oven combustion chamber to the coking chamber top shall be

made of silica brick, while other parts shall be made of common clay brick, diatomite brick or red

brick, etc. depending on the strength and temperature changes as well as insulation effects in such

parts.



Process device

Iron parts for oven protection

Iron parts for oven protection include buckstay, tie rod in length and breadth, spring, oven door

and door frame.

Quenching

In the design, quenching tower is designed for purpose of quenching, which shall be provided

with powered coke setting pond of the quenching pump house, clean water tank, drainage pipe

network and other facilities.

Buttress Wall

Reinforced concrete buttress walls shall be provided on both ends of the coke oven to bear thrust

from individual parts of the coke oven.

Figure 3.5 Process Flow Diagram for Coke Oven Plant



Process device



and door frame.

Quenching




Buttress Wall






Process device



and door frame.

Quenching




Buttress Wall






3.5.4 Waste Heat Recovery Boiler

One no. waste heat recovery Boiler with BF combustion gas capability will be installed for heat

recovery from coke oven flue gas and BF gas firing. Total potential of gas generation from BF &

Coke Oven is 130 TPH. It will be sent to existing 32 MW Captive Power Plant for power generation

replacing coal.

3.5.4.1 Boiler & Auxillaries

One no. waste heat recovery boiler with BF combustion gas capability will be installed for heat

recovery from coke oven flue gas and BF gas firing boiler for generating steam at 140t/h and at a

temperature of ~520oC.

The boiler will consist of gas inlet pipe, super-heaters, economiser, air preheater, integral piping,

draft fans, deaerator and feed water system, boiler feed pumps, air ducts, flue gas duct work,

supporting structures, platforms and walkways etc.

The boiler will be provided with Blast furnace gas combustion firing system with required support.

Drum

The boiler will be provided with one (1) No. steam drum and one (1) No. water drum of fusion

welded construction. The drum will be provided with suitable dished ends with pressed steel,

manhole doors. All plates will be of boiler quality, constructed in accordance with IBR. The steam

drum of the boiler will be provided with suitable internal fittings to ensure steam purity with TDS less

than 0.1 ppm and silica content not exceeding 0.02 ppm.

Boiler Tubes and Manifolds

Heating surfaces of the boiler will comprise membrane water walls of combustion chamber

constructed from carbon steel seamless tubes. The water wall tubes will be arranged to cool the front,

roof, sides and rear walls of the combustion chamber.

Super heater

The boiler will be provided with one (1) super heater. The super heater elements would be divided

into two (2) sections viz. primary super heater and final super heater with an attemperator in between.

Attemperators

Spray type attemperating equipment would be provided for the boiler to control the final steam

temperature within a tolerance margin of + 50C

Blow down Tank



Water which is blown down periodically from the steam drum to maintain the quality of the feed

water in the drum will be collected in the blow down tank.

Chemical dosing System

Chemicals are dosed into the boiler water loop at appropriate points for control of boiler water

quality. Two types of dosing systems are present - the high pressure and the low pressure system.

Each system will contain tanks for solution preparation, pumps and agitators with motors.

De-aerator & Feed water storage tank

The de-aerator shall be of either horizontal or vertical, direct contact, spray cum tray type. The steam

for de-aerator will be drawn from the bleed of turbine during normal operation. Condensate from the

Air Cooled Condenser will be supplied to the de-aerator. The de-aerator will be a constant pressure

unit. The make-up requirement of de-aerator will be from de-mineralized storage tanks. The de-

aerator shall be mounted on a feed water storage tank of approximately 20 minutes hold up capacity.

Boiler feed pumps

It is proposed to install two (2) Nos. of 100% capacity, multistage, electric motor driven boiler feed

pumps, one working and one standby, for catering to boiler feed water requirements. The capacity of

these pumps will be suitable for 110% maximum continuous rating of the boiler output, including

spray water requirement of the attemperator. Feed water will be supplied to the boiler at temperature

of 105 0C.

Supporting Structure

The boilers are bottom supported and will be provided with suitable steel supporting structure of

bolted / welded construction from rolled steel sections and designed with adequate strength for the

loads imposed by the boiler and associated equipment. The supporting structure shall be provided

with mono- rail beams for floors.

3.5.6 Sinter Plant

3.5.6.1 Main desirable features of the sintering machines

i. Sinter plant to have Irish mixer (High intensified mixer) to maximize usage of ultra fines

from the mines.

ii. Fuel preparation system adopts open-circuit crushing consisting of four-roller crushers to ensure

more than 85% fuel particle of size 3-0 mm to reduce fuel consumption and achieve better chemistry.

Flux crushing is close circuit crushing through hammer mill.



iii. Automated weighing dosing is employed to improve dosing accuracy, ensuring

consistent quality of sinter, reducing fuel consumption and achieving stable production.

iv. Linear- bed sintering for economical operation of the process.

v. Circular cooler is used for cooling sinter for its simple structure and ease of operation and

maintenance.

vi. Process gas and plant de-dusting system using dry ESP and bag house respectively.

vii. Sinter size stabilization using Sinter Crushing

viii. Standard air draft device adopted for high efficiency and low power consumption.

ix. Control system:

a. Instruments o f r e l i a b l e a n d a d v a n c e d performance are employed to display,

record, control and automatically adjust process parameters; product quality and energy.

b. Communication facilities like telephone, video display (television) etc are installed at

production, quality control, and dispatch for directive communication.

c. Computer control system is incorporated to monitor and manage the whole plan.

3.5.6.2 Technical Parameters

S.NO ITEM UNIT INDICATOR

1. Sintering machine Type Linear with circular cooler

a No of sintering machines Set 2

b Effective sintering area m2 50

2. Productivity machine t/m2/h > 1.5

3. Operation rate % 90

4. Annual working days day 330

5. Annual output of sinter tonnes >592,950

6. Energy consumption Kw/t <48

7. Coke breeze /ton sinter Kg/t ~65

8. Under-grate suction mm WC >1000

9. Sinter Quality Norms

a TFe % > 55-57



b FeO % 8±1.5

c CaO % ~ 10±0.5

d SiO2 % 5±0.5

e Al2O3 % < 2.5

f MgO % 1.1

g Basicity (CaO/SiO2) % 1.8±0.2

h Product Particle size mm +5 to -60 mm

10. Temperature of CooledSinter

0C Below 100

11. Dust Content of ExhaustGases at Stack

mg/Nm3<50

3.5.6.3 Main plant facilities

Sinter plant proper will consist of the following main technological units:

Receiving Bin Unit

Fuel and Flux Crushing Units

Flux Screening Unit

Proportioning Unit

Mixing and Nodulizing Units

Sintering Unit

Cooling Unit

Sinter Screening Unit

Head & Tail De-dusting Units

Main Exhaust Fan Unit

Plant De-dusting Units

The above units will be interconnected by conveyor galleries and junction houses for conveying sinter

mix. Finished sinter, hearth layer and sinter return fines.

3.5.7 Energy Optimizing Furnace (EOF)

3.5.7.1 Design Basis

No. of Units 2



Annual Liquid Steel Production capacity : 5,28,710 T each

Furnace working availability 330 days

Charge Composition

Hot metal 80 %

Scrap 20%

Tap to tap time 35-45 minute

Oxygen Consumption 50-70 Nm3/TLS

Oil Consumption (Heating of new Bottom)0.5 – 1.0 kg/ Ton

Refractory Consumption Bottom Repair ~ 4 kg/t

Heat/Campaign >700 heats

Bottom Exchange Within 12 hrs-16 hrs

3.5.7.2 Salient Design Features

The EOF proper consists of 2-units of shuttle-type Bottom cars. One bottom car supports the EOF

furnace in operation and the other one supports a second bottom at one or another side for relining.

Both cars are equipped with roll collar tracks to tilt the furnace for tapping or de- slagging. Tilting is

performed by high-speed hydraulic cylinders, allowing slag-free tapping.

Furnace is equipped with refractory lined bottom, split water cooled shell, water cooled roof and

sealing between the furnace and Scrap Pre-heater, hot metal launder, steel tapping launder,

submerged tuyeres, atmosphere injectors and supersonic lance for oxygen blowing, air-fuel burners

for heating-up new bottom.

Scrap Preheaters are placed immediately above the furnace, provided with water-cooled tilting fingers

to support the solid metallic charge which is heated by the furnace off-gas. At the moment of

charging, the fingers tilt, releasing the preheated scrap onto the bottom of the EOF.

EOF is also provided with water-cooled inclined pipe placed below the fingers for additions into the

furnace; air injectors for post-combustion of carbon monoxide; water sprays to control the off-gas

temperature before the scrap layer, off-gas uptake, water cooled sliding door and scrap charging

system, both placed at the Scrap Preheater top.

Submerged tuyeres are designed for optimizing oxygen flow rates to ensure effective bath agitation

and optimum reaction with carbon in the bath while avoiding ejection of hot metal from the furnace.



In a special design of tuyeres, three concentric pipes, enable optimum cooling of the end section

projecting into the furnace. In this way, tuyeres burn-off is limited to less than 2.5 mm per heat.

Design and arrangement of scrap Preheater enables efficient preheating up to 850oC and allows rapid

furnace charging without stopping with no dust exhaust to the building atmosphere and little noise.

Water cooled roof and walls above bath reduce refractory consumption.

3.5.7.3 Brief Description of main equipment

Furnace Proper

- Launder for hot metal charging

- Detachable Bottom with spare

- Shell & Roof with cooling elements

- Burners, injectors and tapping system

- Instrumentation and control

Scrap Pre-heater

- Shell, Fingers, water cooled panels, movable roof, scrap bucket operating system.

Gas Cleaning System (Wet Type)

- Ducting

- Expansion Chamber

- Gas Cooling Tower

- Venturi Scrubber

- Thickener

- Control Valves, I D Fans with control damper

- Flow measurement system for stack

- Water circuit for cleaning including pumps and thickener etc.

Additive And Alloy System

- At EOF building

- Bins, weighed discharging system. Ducting in furnace & steel ladle for gas/fumeextraction.

Hydraulic system- The hydraulic system shall serve the following equipment:- Furnace tilting device, scrap bucket opening



- Fingers and movable roof movements etcCooling water system- Cooling towers, pipes and fittings, pumps, chemical treatment system etc.Gases and fluid system- Oxygen, N2, Fuels, handling system with piping and control panelsElectrical control & instrumentation- Main substation, transformer, switchgear, MCC, motors cables, PLC, software, distribution

substation & illumination.

3.5.7.4 Ladle Refining Furnace

As the specifications for steel are becoming more stringent, the conventional primary steel making

processes are finding it increasingly difficult to meet these requirements. Even if the existing EAFs,

BOFs or EOFs are able to meet these requirements they often do so at the expense of loss in

production or under-utilization of the steel making unit. The shortage and the high cost of energy as

well as the need to conserve it, demand that the remelting or the reheating of the steel be kept to the

unavoidable minimum and large number of processes have been developed to treat liquid steel

outside the primary steel making vessel.

The secondary steel making processes have, therefore, been developed in producing steels

conforming to stringent specifications.

Secondary steel making processes are adopted, primarily to meet requirements, in the following

areas:

1. To achieve extremely low levels of Sulphur, Oxygen, Nitrogen, Carbon, Phosphorus and

Hydrogen

2. Inclusion control to extremely low levels and control of morphology of inclusions

3. Temperature control particularly in case of continuous casting and especially for sequence

casting.

4. Alloying and analysis control for optimum utilization of ferroalloys to achieve desired

properties consistently

5. Improving the fluidity of liquid steel for easy teeming

6. Increased Production rates by decreasing furnace refining times

Basic principle behind secondary refining is to shift the major part of the lengthy refining, de-

oxidation, desulphurization and alloying operations outside the primary steel making units.

When compared with conventional treatment of steel in melting furnace, one achieves, besides



metallurgical advantages, a higher productivity of entire plant, lower direct cost per ton of treated

steel and better operational and environmental conditions.

The main features of the LRF process are:

Liquid steel is tapped from the EOF into the ladle. Bulk Ferro alloys and lime are added into the

ladle during tapping.

Transfer car with ladle is driven from EOF tapping location to the approach of EOT crane.

The ladle is then placed on the transfer car of LRF and then positioned below ladle furnace roof (

after necessary interlocks are satisfied)

Ladle furnace roof is lowered.

Steel temperature is measured and sampling done by means of manual lance through the LRF

door.

Arcing is started in lower taps.

Necessary quantities of calcined lime are added through FAFA system.

Trimming alloys are added as per grade and sample analysis requirement.

Sample is taken for analysis.

Arcing is shifted to higher taps and done as per final aimed temperature.

Wire feeding is done as per requirement.

Arcing is stopped, roof lifted and ladle transferred out from treatment position and lifted by EOT

crane to the VD station or Castor as desired.

The ladle furnaces now, have features for increased process flexibility as well as product range. The

furnace roof is provided with opening for three electrodes, alloy additions, injection devices, fume

extraction, sampling and temperature measurement.

3.5.7.5 Main Features

No. of Units : 2

Annual Liquid Metal Capacity : 5,28,710 TPA

Ladle Capacity : 35 t

Type of LRF : Moving Ladle Car self-propelled complete with

drive and with roof moving up & down

Transformer rating : 7 MVA

Primary Voltage : 33 KV



Secondary Voltage : 8-200 V in min six steps

M/s. The Sandur Manganese & Iron Ores LimitedPre- Feasibility Report for Proposed expansion of existing Ferro Alloys Plant to 1.0 MTPAintegrated Steel Plant comprising of Sinter Plant, Mini Blast Furnace, Coke Oven Plant, Rebar Mill& Oxygen Plant At Danapur, Danayakankere & Hanumanhalli Villages, Vyasankere, HospetTaluk,Bellary District, Karnataka


3.5.8 Continuous Casting Machine

Continuous casting is the process to solidify molten steel into a semi-finished billet, bloom,

or slab for subsequent rolling. Prior to introduction of the continuous casting practice in

1950s, steel was poured into stationary molds to form ingots. But continuous casting has

substantially added to improved yield, quality, productivity and cost efficiency.

Steel from the EOF is tapped into a ladle and taken to the continuous casting machine. The

ladle is raised onto a turret that rotates the ladle into the casting position above the tundish.

Liquid steel flows out of the ladle into the tundish and then into water-cooled copper mold.

Solidification begins in the mold, and continues through the first zone and strand guide. In

this configuration, the strand is straightened, torch-cut and then discharged for intermediate

storage or hot charged for finished rolling. The melting /casting/ rolling processes are

linked while casting a shape that substantially conforms to the finished product. The

complete chain from liquid metal to finished rolling can be achieved within two hours.

End-use dictates quality, grade and shape of the cast product (billet, bloom, slab, beam

blank, and/or round).

To start a cast, the mold bottom is sealed with a dummy bar head attached to dummy

bar. The dummy bar is held in place hydraulically by Straightener Withdrawal units.

This head prevents liquid steel from flowing out of the mold. The steel poured into the

mold is partially solidified, producing a steel strand with a solid outer shell and a liquid

core. In this primary cooling area, once the steel shell has sufficient thickness, about 10– 20

mm, the straightener withdrawal units are started. The moving dummy bar starts to

withdraw the partially solidified strand out of the mold along with the dummy bar.

Liquid steel continues to pour into mold to replenish the withdrawn steel at an equal rate.

The withdrawal rate depends upon the cross-section, grade and quality of steel being

produced, and may vary widely depending upon section, quality and machine design

parameters. Casting times are typically matched with the EOF tap-to-tap time.

Upon exiting the mold, the strand enters a roller containment section and secondary cooling

chamber in which the solidifying strand is sprayed with water to promote solidification.

This area preserves cast shape integrity and product quality. Larger cross-sections require

extended roller containment. Once the strand is fully solidified and passed through the

straightener withdrawal units, the dummy bar is disconnected, removed and stored.

Following the Straightener, the strand is cut into individual pieces of required length and



discharged for further processing by rolling.

3.5.8.1 Main Features

No of Units : 2

Production Capacity : 5,18.135 T each

Days/ Year : 330 days

Grades of steel to be cast : Low and Medium Carbon steel grades

Heat Size : 35 t

Type of ladle ; Bottom pouring with slide gate system and porous plug

Billet/ bloom Quality : internationally acceptable for size surface quality, mechanical and

metallurgical properties.

Product size ; 130 X 130 mm & 110 X 110 mm

Billet length : 6 m

3.5.8.2 machine parameters

Type of Machine - 4 strand, curved mould, bow type

Machine Radius - 9/16m

Method of ladle placement - Rotating turret with independent lifting andlowering of the arms with facilities for Weighment

Strand cooling - Water/air mist

EMS - To be provided

Tundish - Of adequate size & capacity to facilitateSequence casting

Mould level control - To be provided with the mould

Billet cutting - To be provided along with auto operation

Method of discharge - Horizontal discharge roller table

Dummy bar - Flexible / rigid with replaceable heads fordifferent sizes

Casting speed - Variable for various grades

Mould oscillation - Short lever arm, variable frequency and variablestroke of oscillation.



Tundish car - With lift lower and centering device

Withdrawal system - Hydraulically pressurized withdrawal machine withIndividual driven rolls for maintaining straightness of thecast strand

Drives - DC or VVVF Drives for withdrawal straightener,Mould oscillation etc.

3.5.9 Rebar Rolling Mill

3.5.9.1 Design Parameters

No of Units: - 2

Annual Capacity: - 5, 00,000 TPA each

Capacity: - 1515 TPD

Designed Product Mix:-

- TMT Bars : 5,00,000 TPA each in dia 6 mm and 40 mm

Steel grade: - Rebar Quality Mild Steel

Bar Bundles: - 2-4 T, 12 m long, tied at 5 places

3.5.10 Oxygen Plant

To meet the requirement of Oxygen one units of Oxygen plant of 100 TPD in Phase-1

and unit of Oxygen plant of 350 TPD in Phase-II has been considered. There is

practically no difference in cost between high purity oxygen (99.5 percent) plant vis-à-vis

medium purity oxygen (minimum 96 per cent) plant. However, the high purity oxygen

plant produces argon which is not available from medium purity plants. Oxygen (99.5 per

cent purity) will be required mainly for the blast furnace enrichment, lancing in the BOF

converters, ladle furnace, cutting operation in billet casters and scrap etc. and for other

general purpose usages.



Figure 3.6 Process Flo Diagram

3.5.9 Plant Utilities & Other Facilities

It is same as previous ToR.

3.6 Raw material Requirement

Table 3.4 Raw material Requirement




Plant0Blast furnace












Plant0Blast furnace












Plant0Blast furnace





3.7 Water & Power Requirement with its Source

3.7.1 Water Requirement

Water requirement for the project is as follows:

Table 3.5 Water RequirementSl.No.

Plant Unit Water Requirement in m3/HrFresh Water Soft Water DM Water Total in

m3

1 Sinter Plant 10 10 -- 202 BF Shop 95 100 -- 195

3

Pig Casting Machine(Considering 10%Utilization of PCM thewater requirement)

20 -- -- 20

4

EOF +LRF +VD(Transformer, Reactor &H.C. Cable Cooling)

64 60 26 150

5 Coke Oven Plant 70 -- -- 706 WHRB --7 CCM 50 -- -- 508 Rebar Mill 130 -- -- 1309 Oxygen Plant 20 -- -- 20

10Green belt & DustSuppression 20

-- -- 20

11 Miscellaneous Use 10 -- -- 10Total 489 170 26 685

Source of Water

The water requirement will be sourced from Tungabhadra Dam & Bore wells.Power RequirementThe total connected power of the plant is expected to be about 92 MW.

3.8 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for their

Management/Disposal

Table. 3.5 Air Quality Environment & Management (Air Environment – Mitigation

Measures)



SL.

NO.

ITEMS DESCRIPTION POLLUTION CONTROL

1 Sinter plants

Dust Laden

Gases

From the Process Fume extraction & de-dusting plant

2 Blast Furnace (BF)

BF gas (1) From the Process BF gases having calorific value of 750

Kcal/m3 will be used in the plant after

GCP

3 Steel Melt Shop (SMS)

Flue gases From the EAF & LF Fume extraction & de-dusting plant-

Primary

From the top of SMS Shed Fume extraction & de-dusting plant-

Secondary

From the Ladles & CCM Fume extraction & de-dusting plant-

Secondary

From Raw material &

FAFA handling units

Fume extraction & de-dusting plant-

Secondary

4 Continuous Casting Machine

Flue gases

Containing SO2

From the Reheating

Furnaces

To be dispersed as per the CPCB formula

H=14xQ

Where H = Height of chimney, m

Q = Quantity of SO2 generated per hour in

kg.



3.8.1 Waste Water Generation and Treatment

Table 3.6 Waste Water Generation Quantity and Management

SL.

NO.

ITEMS DESCRIPTION QUANTITY POLLUTION CONTROL

1 Blast Furnace (BF)

Sludge From Gas Cleaning

plant (GSP)

0.5 Kg/t of

HM

Solidified sludge from the

thickener to be charged back as

blend mix for sinter production

2 Steel Melt Shop (SMS)

Oil &

Grease

From the direct

Cooling Water at CCM

Scale Pit

0.04 Kg/t of

Billet

To be removed by oil skimmers

& stored in old drums

Backwash

Water

From the pressure filter

cleaning

0.05 Kg/t of

Billet

To be treated at Waste Water

Treatment Plant and discharged

or used for gardeningBlow down

water

From the Water

complex

0.1 Kg/t of

Billet

3 Rolling Mills

Oil &

Grease

From the direct

Cooling Water at RM

Scale Pit

Removed by oil skimmers &

stored in old drums

Blow down

water

From the Water

complex

Treated at Waste Water

Treatment Plant and discharged

or used for gardening



3.8.2 Solid Waste Generation and Utilization

Table3.7 Solid Waste Generation & Management

SL.

NO.

ITEMS DESCRIPTION QUANTITY POLLUTION CONTROL

1 SINTER & PELLET PLANTS

Sinter fines

(< 5mm)

After Screening from Blast

furnace

10% of Sinter Charged back as blend mix

for sinter production

Fine Dust Dust from Bag Filter/

Electro Static Precipitator

0.5 Kg/t of

Sinter

2 BLAST FURNACE (BF)

Slag From the Process 320 Kg/t of HM Disposed to Cement Plants

Flue Dust Dust from Primary dust

catcher

10 Kg/t of HM Charged back as blend mix


3 STEEL MELTING SHOP (SMS)

Slag From the Process 120kg/t of LS Charged back in Sinter

Plant & BF.

CCM Scales From the CCM 10 Kg/t of

Billets

Charged back to sinter

production

Fine Dust From the furnace & LF 13-21 Kg/t of

Billet

Charged back to furnace of

SMS

From the top of SMS Shed 0.5 Kg/t of

Billet

From the Ladles & CCM 0.25 Kg/t of

Billet

From Raw material & FAFA 0.5 Kg/t of



handling units Billet

4 ROLLING MILLS

Mill Scales From the Process 15 kg/t from

each mill

Charged back as blend mix


3.8.3 Noise Levels

The rotating equipment will be provided with necessary arrangements to keep the sound

level at 1.0 m distance at a level of 85 to 90 dB. This includes selection of packaged

equipment with acoustic enclosures, intake and outlet silencers, etc.

The start-up vent, safety valve outlets will be provided with silencers to reduce the noise level

to acceptable limits.

The Hogging Ejector will be provided with silencer. The turbine will be covered with

acoustic enclosure. The buildings where turbines, blowers and bare compressors are

installed will have sound proof walls separating the control rooms.

Measure like use of ear protecting plugs shall be enforced for people who have to

work occasionally very near the mill for checking / inspection during running of the

mill. This is generally required in the vicinity of blowers, Compressors and bar handling

area.

3.8.4 Green Belt Development

A greenbelt development plan will be prepared and implemented along with the project.

The main objective of the greenbelt is to provide a barrier between the plant and the

surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the

noise generated in the plant apart from improving the aesthetics of the plant site.

The Greenbelt will be adequately sized and will have a suitable density so as to mitigate the

effects of emissions from the plant. The treated effluents from the plants will be utilized for

the greenbelt development.

The landscaping of the plant will be carried out. Roads for vehicular movement will be paved

and adequate mitigation measures will be provided to prevent fugitive emissions.



CHAPTER-04SITE ANALYSIS

4.1 General

SMIORE propose to install the aforesaid unit At Danapur, Danayakankere & Hanumanhalli

Villages, Vyasankere, Hospet Taluk,Bellary District, Karnataka

4.2 Connectivity

The site is at 7.1 km West away from nearest town Hospet. National Highway [NH-13] is

550 m towards West and South Western Railway Hospet – Kottur broad gauge railway

line of South Western Railway passes close to the east side boundary of the existing Ferro

Alloy Plant.

The suitability of the project site has been assessed in the report. As the proposed

project shall be located in the existing well developed unit, there shall be minimal

cutting and filling activity. Easy access to raw material.

The following factors were considered while selecting the subject site:

Availability of adequate land free from extensive cultivation and forest for locating

the power plant with provision for future expansion.

Suitability of land from topography and geological aspects.

Location with respect to fuel sources and road/rail linkage.

Availability of adequate supply of water to meet condenser cooling water and other

service water requirements.

Facilities for ash disposal.

Ease of transportation of imported coal from the port

Facility for transportation of power plant equipment and construction materials to site.

Power Evacuation facilities.

Proximity to major load centres in the power system

Environmental aspects

4.2.1 Topography

The topography of the land is gently undulating and well suited for development of industrial

projects. Land for the proposed project is industrial land & Plant is not coming under the

dense forest category land. This area also does not form part of any National Park, Wild Life

Sanctuary and Natural/Biosphere reserve.



4.2.2 Existing Land Use Pattern

The present land is gently undulating and well suited for development of industrial projects.

4.2 Climate Data

May month is usually the hottest with daily maximum of 38 ⁰C and December is the coldest

month with mean daily minimum of 17.2 ºC. The average annual rainfall of the area is 529

mm.



CHAPTER – 05PLANNING BRIEF

5.1 Planning Concept

Technical Concept

The Sandur Manganese & Iron Ores Limited proposes to setup an Integrated Steel Facility for

the production of 1.00 MTPA Steel with finished product of 5.5 to 20 mm diameter wire

rods at Vyasanakere, Near Hospet in the State of Karnataka. The captive power

generation will be to utilize the waste heat from the Coke Ovens and waste gases of Blast

Furnace.

Human Resources

Human Resource is the most valuable asset in any industry. The accelerating pace of

technology advancement and fierce competition in the market has led to the increasing

importance of human resources. Continuous skill updating of the existing human resources

and generating new talents in consonance with the needs of the industry are vital for the

progress of the industry.

5.2 Land Use Planning

Total land required for the plant including existing & expansion is 320.79 Acre (129.81 Ha.).

Total land has already been acquired.



CHAPTER – 06PROPOSED INFRASTRUCTURE

6.1 Industrial and Residential Area

The setting up of the 1.0 MTPA integrated steel plant comprising of Sinter Plant, Mini Blast

Furnace, Coke Oven Plant, Rebar Mill, WHRB & Oxygen Plant along with existing ferro

alloys plant requires 320.79 Acre (129.81 Ha.) of land. Coke plant will be within the existing

Plant premises. All other units shall be installed adjacent area to the existing plant.

6.2 Green BeltA greenbelt development plan will be prepared and implemented along with the project. Total

green belt area shall be of 33% of total area and will be developed in the plant.

Green belt Development plan

Green belt of 33 Acre will be developed in the plant premises as per CPCBguidelines.

10m wide greenbelt will be developed all around the plant.

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

firm, deep rooted. A three tire 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 will act as barrier.

6.3 Others A garland drain around the plant is envisaged to collect surface run-off during rainy

season.

Drinking water facilities will be provided for employees as well as nearby villagers.

Existing road and rail network will be utilized for raw material and final products

transportation.



CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLANNot Applicable as it an expansion project within the existing plant premises.



CHAPTER – 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

In the cement industry, any one of the following three alternate modes of project execution is

adopted:

Turnkey

Semi Turnkey

Packaged procurement mode

In the turnkey mode, there is one implementing agency for the project having the total

responsibility. Hence, the project cost is the highest and at the same time, control on timely

execution is also high. The project cost is minimum in the last mode, also known as shopping

mode, where different items (major machinery or auxiliary; clubbed section wise or type

wise) of the project form the different packages, which are considered for procurement. Thus

control on timely execution is lowest. The semi turnkey mode falls in between the above two

modes, having 4 to 6 packages for procurement and construction & erection and is therefore

the most preferred mode.

Based on the consideration of cost and time, the package procurement mode will be followed,

by clubbing various activities to the extent possible.

Planning of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project. Following activities will be given special attention

Pre Project Activities

Management Approvals.

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups.

Selection of Consultants



Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

Project Activities (Implementation Stage)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of Tender, Evaluation of tenders received and Order placement for

balance machinery

Completion of procurement activities on time

Release of civil drawing for civil construction

Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant

Statutory Clearances

The proposed project will require various statutory approvals and clearances from various

authorities of The Government. Some of these will be required before start of the

construction activities, while others would be required during the course of execution of the

project and upon completion of the project before commencing operations. A list of Plan

sanction authorities is as given in Table 8.1 However other clearances, if any required shall

be identified in due course and necessary action will be taken to obtain the same.

Project Schedule

The commissioning of the plant is 24 months from ordering of main machinery. Following

activities have been considered.

The external agencies such as consultant, machinery suppliers, contractors of civil

construction and equipment will be selected carefully well in advance. An effective project

team shall be formulated with an experienced Project Manager as its leader.



Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely

execution of the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in- house and from external agencies.

A well chosen team of experienced personnel for project execution shall coordinate

the implementation of the project from in-house.

Experienced engineering consultants with proven track records shall be selected for

detailed engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men,

material and tools and tackles, will be engaged for execution of the construction and

erection work.

Effective project monitoring including project planning schedule and monitoring shall

be employed in this project. Timely execution and resources will be monitored using

computer base project monitoring tools. In case of deviations in project progress, all

possible corrective actions such as crashing of network etc. will be carried out.

Effective monitoring and reporting procedure for review of progress and coordination among

various agencies shall be used. At least a monthly coordination meeting, if not earlier, shall

be held to closely monitor the project and take corrective action as required. The schedule

may vary depending on the project status.

8.2 Project Cost

An indicative estimated capital cost of the proposed expansion is Rs. 5300.00 Cr.



CHAPTER – 09ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

9.1.1 Improvements in the Physical Infrastructure

SMIORE has envisaged a lot of infrastructure developmental works in the periphery area.


Strengthening School buildings with playgrounds.

Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure

Social awareness programme will further improve by the local authority such as

sanitation and hygiene, HIV Prevention Program will be improved.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding

area. Sponsor education to Poor Students of the Proposed Area

The proposed project will set up training centre or tie up with Industrial Technical

Institutes to educate local youth as skilled labour.

Provide & conduct Free Eye & Health Check up Programmes.

9.1.3 Employment

The project is going to create substantial employment and income. Due to this project

activity, some person in the project area will be recruited as skilled, semi skilled and

unskilled workers by the company as per its policy. Therefore, substantial amount of

employment and income is likely to be generated for the local people. So, the project will

contribute in a positive manner towards direct employment in the project area. Some

employment potential benefits are given below:

9.1.4 Other Benefits


Strengthening local school buildings with playgrounds.



Improvement in social awareness programme such as sanitation and hygiene, HIV

Prevention Program.

Adult education and female education programmes will be provided to the illiterate

adults and backward females of the villages in the project surrounding area.

Visiontek Consultancy Services Pvt. Ltd.(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : [email protected], [email protected], Visit us at : www.vcspl.org

Committed For Better Environment

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