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OF

FOR

M/s M/s M/s M/s HaHaHaHalllldia Steelsdia Steelsdia Steelsdia Steels Private LimitedPrivate LimitedPrivate LimitedPrivate Limited, , , , UnitUnitUnitUnit ---- IIII

Raturia Industrial Area, Angadpur, Durgapur, PO: Coke Ovens, Dist: Burdwan, West Bengal

APRIL 2018

PRE-FEASIBILITY REPORT

Centre For Envotech and Management Consultancy Pvt. Ltd.

AN ISO: 9001: 2008 and BS OSHAS 18001: 2007 certified company,

Empanelled with OCCL, Govt. Of Odisha, OSPCB as Category “A” Consultant Organization, Recognition by MoEF&CC, Govt. of India, under Environment (Protection) Act, 1986 and accredited by NABL

Accredited b y NAB ET, Qual ity Counc i l o f Ind ia for EIA stud ies

As Category “A” Consultant Organization.

Regd. Off: N5/305, IRC Village, Bhubaneswar, Odisha Tele: 0674 - 2360344, E-mail: [email protected], [email protected]

Website: www.cemc.in

CEMCCEMC

CONTENTS

CHAPTER NO. CONTENTS PAGE NO.

CHAPTER - 1 EXECUTIVE SUMMARY 1

CHAPTER - 2 INTRODUCTION TO THE PROJECT & BACK GROUND INFORMATION 6

2.1 Identification of Project & Project Proponents 6

2.1.1 Identification of Project 6

2.1.2 Identification of Project Proponent 7

2.2 Project Highlights 8

2.3 Need of the Project & Its Importance to the Country & the

Region 9

2.3.1 Need of Ferroalloy Project 9

2.3.2 Estimated Steel Demand and required Crude Steel Capacity,

2011‐12 to 2025‐26

10

2.3.3 Production of Ferro Alloys During 2006-07 to 2010-11 11

2.3.4 Domestic Consumption 11

2.3.5 Installed Capacity and Export/Import Scenario 11

2.4 Employment Generation 12

CHAPTER - 3 PROJECT DESCRIPTION 13

3.1 Type of Project 13

3.2 Location (Map Showing General Location, Specific Location

And Project Boundary & Project Site Layout) with

Coordinates

13

3.3 Details of alternate sites considered & the basis of selecting

the proposed site, particularly, the environmental

consideration gone into should be highlighted

18

3.4 Size or Magnitude of Operation 18

3.5 Project description with process details (a schematic diagram

/flow chart showing the project layout, components of the

project etc. should be given)

19

3.5.1 Project Description 19

3.5.2 Manufacturing Process of each Product with Chemical

Reactions

20

3.5.2.1 Ferro Alloys Plant-Process Description 20

3.5.3 Technology and Process Description-General 22

3.5.4 Mass Balance for each Product 43

3.6 Raw Materials Required along with Estimated quantity, likely

Source, Marketing area of Final Product, Mode of

Transportation of Raw Materials and Final Product

44

3.6.1 Raw Materials Required along with estimated quantity, likely

Source

44

3.6.2 Quantification of Product after Expansion, Marketing Area &

Mode of Transportation

46

3.6.3 Resource optimization / recycling and reuse envisaged in the

project, if any, should be briefly outlined.

46

3.6.4 Availability of Water its Source, Energy / Power Requirement

and Source.

46

3.6.4.1 Water Requirement and its Source. 46

3.6.4.2 Power Requirement and its source. 48

3.6.5 Quantity of waste to be generated (liquid & solid) and

scheme for their management / disposal.

48

3.5.6.1 Quantity of liquid waste to be generated and scheme for

their management / disposal.

48

3.5.6.2 Quantity of solid waste to be generated and management /

Disposal Scheme.

49

3.5.6.3 Source of Air Pollution and Control Measures. 51

CHAPTER - 4 SITE ANALYSIS 53

4.1 Connectivity. 53

4.2 Land from Land Use and Land Ownership. 54

4.3 Topography (along with Map). 54

4.4 Existing Land use pattern (agriculture, non-agriculture,

forest, water bodies, (including area under CRZ), shortest

distance from the periphery of the project to periphery of the

forests National Parks, wild life sanctuary, eco sensitive

areas, water bodies(distance from HFL of the river), CRZ. In

case of Notified Industrial Area a copy of the notification

should be enclosed.

54

4.5 Existing Infrastructure. 57

4.6 Soil Classification. 57

4.6.1 Types of Soil and its distribution in Bardhaman district. 57

4.7 Climate Data from Secondary Sources. 60

4.8 Social Infrastructure available. 61

4.8.1 Educational Facilities. 61

4.8.2 Health Facilities. 62

CHAPTER - 5 PLANNING BRIEF 64

5.1 Planning Concept (Type of Industries, Facilities, Transportation,

Etc.) Town & Country Planning /Development Authority

Classification.

64

CHAPTER - 6 PROPOSED INFRASTRUCTURE 66

6.1 Industrial Area (Processing Area). 66

6.2 Residential Area (Non-processing Area). 66

6.3 Green Belt. 66

6.4 Social Infrastructure. 66

6.5 Connectivity (Traffic & Transportation Road /Rail / Water

Ways, Etc.)

68

6.6 Drinking Water Management (Source & Supply of Water) 68

6.7 Sewerage System. 68

6.8 Industrial Waste Management. 68

6.9 Solid Waste Management. 68

6.10 Power Requirement & Supply / Source. 68

CHAPTER - 7 REHABILITATION AND RESETTLEMENT (R & R) PLAN 69

7.1 Policy to be Adopted (Central/State) in Respect of the Project

Affected Person Including Home Oustees, Land Oustees and

Landless Laborers (A Brief Outline to be given).

69

CHAPTER - 8 PROJECT SCHEDULE & COST ESTIMATES 70

8.1 Likely date of Start of Construction and Likely date of

Completion (Time Schedule for the Project to be given).

70

8.2 Estimated Project Cost along with Analysis in terms of

Economic Viability of the Project.

CHAPTER - 9 ANALYSIS OF PROPOSAL FINAL RECOMMENDATIONS 71

9.1 Financial and Social Benefits with Special Emphasis on the

Benefit to the Local People including Tribal Population, if any,

in the area.

71

PREFEASIBILITY REPORT OF

M/S. HALDIA STEELS PVT. LTD. (UNIT – I)

CEMC Pvt. Ltd. Page 1

CHAPTER - 1

EXECUTIVE SUMMARY

M/s. Haldia Steel Ltd., Unit-I is having a ferroalloy plant in Raturia Industrial Area,

Angadpur, PO: Coke Ovens, Durgapur, Dist: Burdwan, West Bengal. The Ferroalloy plant is

presently manufacturing Ferro Manganese and Silico Manganese. The plant was established

prior to EIA Notification 14th September 2006, after getting Consent to Establish order from

WBSPCB ref. Order No: Sl.No.11116 dated 26.02.2001.Initialy they were operating with 2 X

4MVA and 1X6MVA SEAFs. The promoters requested for capacity expansion to MoEF which

was granted to them vide EC letter No: F J-11011/290//2008-IA(II) dated the 13th June

2008.

The EC was granted for 4 X 7.5 MVA Submerged Electric Arc Furnaces in addition to the

existing 2 X 4 MVA and 1X6 MVA SEAFs and 2 Nos of Induction furnaces of 4 Mt capacity

each. The achievable capacity was for production;

1. Silico Manganese - 4200 MTPA

2. Ferro Manganese - 7200 MTPA

After getting the EC the company, however, has been able to install only 1X 7.5 MVA SEAF

against approved number of four and are not in a position to install any further. As per the

consent to operate letter ref No: C00902162 dt 10/02/2016, the company is permitted

produce as per the following;

1. Ferro Manganese- 1985 MT/month

2. Silico Manganese- 2030 MT/month

Calculated on yearly basis the production capacity translates to

1. Ferro Manganese- 23,820 MTPA

2. Silico Manganese- 24,360 MTPA

As per the practical experience the achievable maximum annual production figures with

good quality raw materials for 21.5 MVA (2X4 MVA+1X6 MVA +1X 7.5 MVA) rating would

be as below.The figures have been caste as per the premises given in the table below.

Ferro Manganese -49,536 MTPA

Silico Manganese -32,589 MTPA




The figures have been caste as per the premises given in the table below.

21.5 MVA Maximum achievable production with best RM

TPD TPM TPA KWH/T

Si-Mn 109 2716 32589 3800

Fe-Mn 165 4128 49536 2500

Fe-Si 49 1214 14,569 8500

Fe-Cr 109 2716 32589 3800 WH/T

As per the figures furnished above, it is observed that the consent to operate production

figures are much higher than the achievable production figure mentioned in the EC. Further

as per the rating the actual achievable capacity would be Fe-Mn 49,536 MTPA and Si-Mn

32,589 MTPA. This has happened due to earlier mistakes furnish in Form 1 submitted prior

to receiving the EC in 2008.

The promoters wanted to have modification of product mix so as to include Ferrochrome

and Ferro Silicon in addition to Ferro Manganese and Silico Msnganese within the existing

capacity of the furnaces. They took note of the Notification of MoEF&CC i.e.S.O.3518 (E)

dated 23rd November 2016 which stated under the heading “7(ii) Prior Environmental

Clearance(EC) process for Expansion or Change of product mix in existing

projects “ c) Any change in product- mix, change in quantities within products or number

of products in the same category for which environmental clearance has been granted shall

be exempt from the requirement of prior environmental clearance provided that there is no

change in total capacity sanctioned in prior environmental clearance granted earlier under

this notification and there is no increase in pollution load. No Increase in Pollution Load

Certificate from the concerned State Pollution Control Board as per the provisions given in

Appendix-XIV”.

Within the frame work of the Notification mentioned above the proponents initiated action

for getting approval for the change in product mix within the approved capacity of

ferroalloy production. However, as the approved capacity mentioned in EC and the capacity

mentioned in Consent to operate given by WBSPCB are at variance the West Bengal State

Pollution Control declined to accord approval.

With back ground as detailed above, the proponents now desire to get the

i) Amendment of Earlier EC reference EC letter No: F J-11011/290//2008-IA(II)

dated the 13th June 2008 in which the production of Slico manganese and Ferro

manganese need to be amended as

1. Silico Manganese: 32,589 MTPA instead of 4200 MTPA

2. Ferro Manganese: 49,536 MTPA instead of 7200 MTPA




II) Approval for change in product mix in the usual process of expansion proposal and

as such the Pre-Feasibility Report is being prepared. The report has been prepared

as per the guideline ref NO-11013/41/2006-IA.II(I)dated the 30th December 2010..

At present the company is having the manufacturing facilities as per the configuration in

the Table No. C1-1. Due to fluctuating trends in the demand for Fe-Mn and Si-Mn, the

manufacture of these products have become uneconomical at the scale and level of

production. The promoters, therefore, propose to use the manufacturing facilities inter alia

for manufacture of Fe-Cr and Ferro Silicon. The market scenario for various ferroalloy

products are given in section 2.2 of this report.

Table No. C1-1: Existing and Proposed Expansion Facilities

Sl.

No.

Facilities Total Existing

capacities

Proposed Capacity Ultimate

capacity

1 Ferro Alloys (Ferro

Chrome /Ferro

Manganese) /Silico

Manganese in Submerge

Electric Arc Furnace

2 X 4 MVA, 1 X 6

MVA and 1X7.5

MVA Submerged

Electric Arc Furnace

The facility is used

for manufacture of

Fe-Mn and Si-Mn

The existing

furnaces will be used

for making Fe-Cr

and Ferrosilicon

4 X 7.5

MVA 1 X 5

MVA and

1X7.5 MVA

Submerged

Electric Arc

Furnace.

Table No. C1-2: Existing Production Range & Capacity per Month

Name of

Existing

Products

SEAF Monthly Capacity/ Identification Total Existing

Production

Capacity (Monthly)

SEAF-1

(4 MVA)

SEAF-2

(4 MVA)

SEAF-3

(6 MVA)

SEAF-4

(7.5 MVA)

Ferro

Manganese 767 MT 767 MT 1152 MT 1539MT 4125 MT

Silico

Manganese 505 MT 505 MT 758 MT 948 MT 2716 MT

Table No C1-3: Proposed Production Range / Capacity per Month

Name of

Products

SEAF Monthly Capacity/ Identification Total

Production

Capacity

(Monthly)

SEAF-1

(4.0 MVA)

SEAF-2

(4.0 MVA)

SEAF-3

(6.0MVA)

SEAF-4

(7.5 MVA)

Ferro


Silico


Ferro

Chrome 505 MT 505 MT 758 MT 948 MT 2716 MT

Ferro

Silicon 226MT 226 MT 339 MT 423 MT 1214 MT

The furnaces will be producing an one of the above products.




The existing plant with 2X 4 MVA and 1X6 MVA Submerged Electric Arc Furnaces (SEAF) was

continuing operation since 2003. Later after getting EC in 2008 the 1X7.5 MVA SEAF was

installed and continued production. The manufacturing facility is located in Raturia Industrial

Area, Angadpur, Durgapur which is a developed Industrial Area. Total land acquired for this

project by M/s. Haldia Steels Pvt. Ltd. is 8.9 Acres. The site is well accessible by rail and road.

i) Nearest Railway Station is Durgapur at a distance of 4km South East of project site.

ii) The industry itself is located within the Durgapur municipal limits.

iii) The district head quarter Bardwan is at a distance of 63Kms South East from project

site.

iv) Nearest National Highway is NH-2 is at a distance of 2.85km from project site.

v) Nearest Airport is at Andal; 12.20Kms North West of project site. Netaji Subhash

Chandra Bose International Air Port at Dumdum is 152kms South East of the project

site.

vi) Nearest Sea Port is at Haldia at a distance of 184kms in South East direction.

vii) The project site is also having good connectivity with other sea ports like Kolkata,

Paradeep and Dhamara.

The site is having advantages of proximity to 2 Coalfields i.e. Ranigunj Coal field of ECL and

Dhanbad coalfields of BCCL. It is located in Durgapur a prominent industrial hub of India.

Chrome Ore can be procured in rake loads from Sukinda, dist: Jajpur, Odisha and unloaded in

nearby railway siding of Eastern Railways at Durgapur.

The cost of the existing project was about Rs 2.70Crores at 2008 cost level. It has the potential

to engage about 15 persons in the permanent set up and 100 contractual persons. No further

construction shall be necessary as the same installation would be used for making Fe-Cr.

The major raw material required for the proposed Ferro alloy plant are Manganese Ore, Non-

coking Coal, Coking Coal, Limestone /Dolomite, Quartz, Chromites ore etc. Most of the minerals

including chromites, limestone/dolomite etc will be sourced from neighboring state Odisha

whereas coal both coking will be sourced from neighboring coal fields of ECL and BCCL.

Technology which have been adopted for various sections are up-to-date technology aiming at

lower energy consumption, less water consumption and zero effluent discharge, recycle and

reuse of solid wastes, etc.

The existing Ferro Alloys plant includes 2 X4 MVA SEAFs, 1 X 6 SEAF, and 1X7.5 MVA. The plant

presently produces Ferro-Manganese, Silico-Manganese and Fe-Mn slag. The approved

production capacity of in respect of Fe-Mn as per the WBSPCB and the proposed production of

Fe-Cr and Fe-Si within the approved capacity are mentioned below:

Ferro Manganese from the furnaces i.e. 2X4 MVA, 1X6 MVA and 1X7.5: 1985 MT/month or

23,820 MT/year.

Silico Manganese from the existing furnaces i.e. 2X4 MVA, 1X6 MVA and 1X7.5 MVA: 2030

MT/month or 24360.




Table No. C1-4: Existing and Proposed Product Mix

Sl.

No.

Description of

Products

Existing Capacity

of all

furnaces(2X4MVA

,1X6 MVA and

1X7.5 MVA) in MT

*Proposed Modified

Capacity of

furnaces(2X4 MVA,1X6

MVA and 1 X 7.5 MVA)

furnace in Tons

Total Capacity

in Metric

Tons/ Annum

(MTPA)

1. Ferro Manganese

(Fe-Mn) *

23820 49536 49536

2. Silico Manganese

(Si-Mn) *

24360 32589 32589

3. Ferro Chrome

(Fe-Cr )*

-- 32589 32589

4. Ferro Silicon

(Fe-Si)*

-- 14569 14569

* Ferrochrome and Ferro Silicon are proposed to be manufactured in the existing

furnaces on campaign basis

The slag generated in Ferro-manganese plant will be used for manufacture of silico-manganese.

Silico-Manganese slag may be used for manufacture of Slag Cement or as road base material.

The slag generated in Ferrochrome plants after TCLP test will be utilized as road base material.

The fresh water requirement will be optimized by taking recycling and cascading measures. The

dust from Air Pollution Control devices of Ferroalloy Plant will be used in briquette making in a

sister unit located at Plasto Park Industrial Estate located in Bankura district at a distance of 9.4

Kms. South East from the plant.

Point source emissions from various manufacturing facilities as well as fugitive emissions are

/will be maintained within statutory limits by installation of bag filters and other pollution control

equipments. Secondary fugitive emission during tapping is controlled by provision of suction

hood and ID Fan arrangement and the fume is will be passed through existing GCP system.

Fugitive dust emission is controlled by providing water sprinklers as well as by providing suction

hoods at all transfer points followed by suitable ducts and pulse jet bag filters. The fugitive

emission from tap holes is arrested by suction hood, suitable ducting and passed through bag

filters before being vented to atmosphere through stack.

The existing infrastructure facilities will be utilized for successful manufacturing of the proposed

products. The manufacture of the proposed products will improve the viability of the existing

Ferroalloy plant as well as will contribute to better performance of group companies by way of

supplying needed input material.

Water requirement for the project will be about 290KL/day which will be sourced from supply

mains of Durgapur Municipal Corporation as it is being done presently. Adequate recycling and

cascading measures will be taken to reduce fresh water consumption. Cooling /bleeding water

will be treated and used for dust suppression.

Green belt development is in progress. Suitable plant species will be planted all along the

internal roads, plant boundary, raw material storage & handling, dust prone areas. It is planned

to plant saplings considering the parameters as type, height, leaf area, crown area, growing

nature, water requirement etc. Green belt will be progressively developed on land.

The various aspects of the Pre-Feasibility Report as per MoEF Guidelines vide O.M. J- 11013

/41/2006-IA.II (I) dt. 30-12-2010 is given in the subsequent sections.




CHAPTER - 2

INTRODUCTION TO THE PROJECT & BACK GROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENTS:

2.1.1 Identification of Project:

M/s Haldia Steels Pvt. Ltd, Raturia Industrial Area, Angadpur, PO- Coke Ovens, Dist.- Burdhwan,

West Bengal is presently operating a Ferroalloy plant having configuration as detailed in Table

No.C1-1.The plant has been established in the first phase prior to the EIA Notification opf 14th

September 2006and subsequently had an expansion after obtaining the EC from the MoEF.

Presently the plant is operating 2X4 MVA, 1X^MVA, and 1X7.5 MVA Submerged Electric Arc

Furnaces (SEAFs). Though the company had obtained EC for installation of 4X7.5 MVA SEAFs,

the have been able to install only 1X7.5 MVA furnace and do not plan to expand any further.

In the EC ref No:F.No. -11011/290/2008-IA(II) dated 13th June 2008 it has been mentioned that

the approved capacity after the expansion with installation of 4X7.5 MVA furnaces would be

Silico Manganese- 4200 MTPA

Ferro Manganese- 7200 MTPA

These figures are very less for the installed capacities and clearly erroneous. On scrutiny of

previous papers it could be understood that the mistake has been made in the Form-I which has

been carried to the EC. As such the company based its maximum output to the Consent to

Operate letter which mentions the production capacity as below.

Ferro Manganese - 1985 MT/Month or 23,820 MTPA

Silico Manganese - 2030 MT/Month or 24,360 MTPA

As per literature and practical experience from such industries, the achievable production

however will be as below:

Ferro Manganese - 4128 MT/Month or 49,536 MTPA

Silico Manganese - 2719 MT/Month or 32, 589 MTPA

The plant is being operated with due permission from West Bengal Pollution Control Board. The

company now proposes to modify the product mix of the existing Ferroalloy plant. There will not

be any capacity enhancement. Since EC has been availed by the company for production of

Silico Manganese and Ferro Manganese for achievable capacity of 4200 MTPA and 7200 MTPA,

i) it seeks amendment of the Environmental Clearance (EC) for the Factory ref

No F. No. -11011/290/2008-IA(II) so as to make the achievable production

capacity of

Silico Manganese -32,589 MTPA

Ferro Manganese – 49,536 MTPA




ii) To modify the product mix to include Ferro chrome and Ferro Silicon the

achievable production figures of which shall be

Ferro Chrome-32,589 MTPA

Ferro Silicon-14,569 MTPA

The Sub-merged Electric Arc Furnaces of 2X 4 MVA, 1X6 MVA and 1 X 7.5 MVA have already

been installed for production of Ferro-Manganese and Silico-Manganese. Due to market

fluctuation for the demand of Fe-Mn and Si-Mn, the plant sometimes remains under shutdown.

The promoters therefore propose to add Fe-Cr and Fero Silicon to the product Mix so as to make

the plant more viable. No additional furnace or enhancement of capacity is envisaged. However,

certain mistakes in respect of capacity production as in existing EC need to be corrected and the

corrected capacity would be higher than the capacity provided in EC dated 13th June 2018 as

clarified above. The existing facility is having adequate pollution control measures in place

which is being narrated in Chapter-3.

The project is set up over an area of 8.9 acres in the Raturia Industrial area which is an

Industrial Estate in Angadpur within the municipal limits of Durgapur. The water demand of the

facility which is about 290 KL/day will be met from the water mains of the Industrial Estate

belonging to Assansol Durgapur Development. The power demand of 24 MVA at 0.8 PF shall be

sourced from DVC grid. The directors along with key persons of the group are confident of better

performance after the implementation of the proposed modification of product mix.

2.1.2 Identification of Project Proponent:

M/s. Haldia Steel Ltd., Unit-I is a company which is part of the well known industrial house of

India namely the Eurasia group and is promoted by them. The Eurasia group is renowned

manufacturer of Sponge Iron (DRI), Ferro Alloys, Steel Billets, Engineering Steel Castings,

Captive Power, TMT Rebars and Organic Darjeeling Tea since last three decades in India. The

group has following manufacturing facilities located at eastern states of India. The group

turnover is more than 20,000 million (INR) and employing more than 3000 people. Mr. Vikash

Bansal and Mr. Satpal Bansal are currently in the Board of Directors of the company.

Table No. C2-1: Company Background

NAME OF COMPANY PRODUCTS FACTORY LOCATION

Brand Alloys Ltd

(An ISO & BIS

Certified, RDSO

Approved “CLASS A”

Foundry & NABL

Accredited)

-Indian Railways Casnub Bogie

& Its Components.

-Indian Railways Cms Crossing, Coupler Components.

-TMT Rebars.

-Steel, Alloy & Stainless Steel

Casting Upto 20 M.T Single

Piece,Machining & Assembling

As Per Customer Drawing, Design & Specification.

Factory: Unit – I

NH-2 Delhi Road

Post : Sreerampur, Hooghly

Pin-712223

West Bengal, India

Factory : Unit – II

Vill.: Murusuan,

Post :Palaspanga

Dist.: Keonjhar, Odrisha, India




2.2 Project Highlights:

The principal features or highlights of the proposed project of M/s Haldia Steels Pvt. Ltd., Unit-I,

under study are as follows:

Table No. C2-2: Project Highlights

Location Raturia Industrial Area, Angadpur, PO:Coke Ovens, Durgapur, District:

Burdwan, West Bengal.

Its geographical co-ordinates are Latitude 230 30’ 46” N and Longitude

870 16’ 54” E with altitude above mean sea level (MSL) of 77m.

Land

requirement

The units are located on a piece of land measuring 8.9 Acres, allotted

by the West Bengal Industrial Development Corporation Ltd. (WBIDCL).

Raw water As per an initial estimate, water to the tune of 290 KL/day will be

-Steel, Alloy & Stainless Steel

Centrifugal Casting Upto 600

Dia & 3000 Mm Length.

-Steel Billets.

-Sponge Iron (DRI).

Haldia Steels Ltd

(An ISO & BIS

Certified Company)

-Ferro Alloys (Si-Mn & Fe-Mn)

-Steel Billets

-Sponge Iron (DRI)

-Captive Power Plant

Factory : Unit – I

Raturia Industrial Area

Angadpur, Durgapur West Bengal, India

Factory : Unit – II

Raturia Industrial Area

Angadpur, Durgapur

West Bengal, India

ISPAT DAMODAR LTD

(An ISO & BIS

Certified Company))

-Ferro Alloys (SiMn & FeMn)

-Steel Billets

-Sponge Iron (DRI)

-Captive Power

Factory

Nabagram P.O-Digha, P.S-

Neturia, Purulia, West Bengal,

India

Sonic Thermal Pvt.

Ltd.

(An ISO Certified)

-Ferro Alloys (Si-Mn & Fe-Mn) Factory

Ghutghoria, Barjora, Dist-

Bankura, West Bengal, India

Brand Steel and

Power(P) Ltd Songe Iron Factory Vill: Murusuan,

Po:Palaspanga,

Block: Keonjhar Sadar, Dist:

Keonjhar, Odisha, India

The Arya Tea

Company Ltd Since

1885

(An IMO Organic, DNV

& Fair Trade Certified)

Organic Darjeeling Tea

Garden Address

Arya Tea Estate

Darjeeling Railway Station

Darjelling (N.F.Railway) , West

Bengal, India




requirement

& source

required for the project. The makeup water will be sourced from Water

Mains of Raturia Industrial Area belonging to Durgapur Municipal

Corporation.

Effluent

generation &

disposal

The plant has been designed as a zero discharge plant.

The water is being re-circulated after cooling and treatment. The entire

wastewater will be recycled for various purposes inside the plant.

Domestic wastewater will be treated in Septic tank & Soak pit system.

Air pollution

control

Adequate control measures like bag filters, dust extraction /suppression

system and stacks of adequate height at relevant points already exist.

Solid Waste

Management

Ferro Manganese Slag is being used for making Silico-Manganese. Ferro

Chrome Slag will be subjected to TCLP test. Silico slag will be used for

land filling. Ferro Slag will be recycled. The dust collected from the bag

filters will be sent to the sister plant at Plasto Steel Park for briquetting

and reuse.

2.3 Need of the Project & Its Importance to the Country & the Region:

The project as identified above aims at production of Ferro-manganese, Silico-manganese,

Ferro-chrome and Ferro-silicon which will be used in production of alloy steels which are vital

inputs for steel manufacture. Following paragraphs justify the need of the project.

2.3.1 Need of Ferroalloy Project:

Ferro Alloys are used in steelmaking which consists of less than one Percent of the total raw

material required for steel production. Despite of being a very low constituent, Ferro Alloys are

vital additives for steel making. The principal function of ferroalloy addition is that it increases

the resistance of steel to corrosion & oxidation, improves its hardenibility, tensile strength at

high temperatures, wear and abrasion resistance and increases its other properties like creep

strength etc. Ferro Alloys are generally used to impart engineering properties to steel. Ferro

Alloys are vital input for producing all type of steel and are used as raw material in the

production of special steels, alloy steels and stainless steel.

Demand Drivers of Ferro Alloys are:

• Crude Steel Production

• Alloy and special steel Production

• Stainless Steel Production

The National steel policy 2005 envisaged a target production of 110 million tones by 2019-2020.

It enunciated important milestones/physical targets and an overarching broad policy framework

to achieve the stated end on an assumed 6.9% growth in steel consumption, 7.3% growth in

steel production and a 23% share of exports in total production by the year 2019‐20.




Since then, however, the Indian economy experienced a paradigm shift with the actual

performance of the economy as well as that of Indian steel industry surpassing the projected

levels of performance. Steel consumption grew by 10% per annum from 2005‐06 to 2011‐12

and production at an annual rate of 7.8% during the same period thereby surpassing the NSP

2005 projections by a significant margin. The NSP 2012 therefore envisages capacity build up of

300 Million Tonnes, a finished steel production of 275 Million Tonnes. Taking growth scenario of

7% and 8% of GDP the policy statement envisages a growth at CAGR of 7.8% and 8.9%

respectively.

The increased in production of steel required increase in Ferro Alloy production. Thus, Ferro-

alloy plant of 2X4 MVA, 1X6MVA and 1X 7.5 SEAFs MT were set up for production of bulk

ferroalloys of Fe-Mn Si-Mn,Fe-Cr and Fe-Si to meet the need of the country. The factory was set

up in Raturia Industrial Area, Angadpur, Durgapur, in Bardhaman district of WB. However, over

the years the demand of products Fe-Mn and Si-Mn showed a decline trend where as the

demand of Fe-Cr and Fe-Si has increased. As can be seen from the Tables below, the indigenous

consumption of Fe-Cr has jumped from 311 kilo tones 2008-09 to 403 kilo tones 2011-12.

Compared to Fe-Cr the market demand of Fe-Cr was not as promising. The Fe-Cr manufacturing

facilities were also less in comparison to Manganese alloy units as can be seen from Table No.

C2-4. The promoters therefore wish to include Fe-Cr anf Fe-Si in the product mix so as to make

the plant viable. Apart from meeting internal needs of the company, the products will also have

good market as many steel plants are located in Durgapur area of Bardhman district of WB.

2.3.2 Estimated Steel Demand and required Crude Steel Capacity, 2011‐‐‐‐12 to 2025‐‐‐‐26

Table No. C2-3: Estimated Steel Demand & Required Crude Steel Capacity (Million Tonnes)

Growth Scenario Projected Demand for Finished Steel

2011‐‐‐‐12

(Actual)

2025‐‐‐‐26 CAGR

(%)

Implicit GDP

Elasticity

GDP Growth at 7% pa (Base Case)* 70.92 202 7.8% 1.11

GDP Growth at 8%* 70.92 233 8.9% 1.11

Crude Steel capacity required to sustain

projected demand in the base case

88.40 244

Note: * The assumed growth rates are average for the years between 2011‐12 and

2025‐26, notwithstanding possibilities of yearly fluctuations /swings within the period.

Source: National Steel Policy 2012.

India has enough scope of Ferro alloy industry as raw materials are available for its production,

there are indigenous demand as well as demand in the export market. The production and

demand figures are given below.




2.3.3 Production of Ferro Alloys During 2006-07 to 2010-11 (Quantity in Metric Tonnes)

Table No. C2-4: Production of Ferro Alloys during 2006-07 to 2010-11

2010-11 2009-10 2008-09 2007-08 2006-07

Bulk Ferro Alloys:

HC Ferro Manganese 390,000 341,883 372,286 364,908 281,013

MC Ferro Manganese 8,000 8,222 8,386 7,704 9,190

LC Ferro Manganese 6,000 6,018 5,775 3,905 6,523

Silico Manganese 1,250,000 1,066,485 889,434 886,325 738,314

MC Silico Manganese 24,000 24,108 24,087 27,106 29,581

LC Silico Manganese 25,000 25,454 22,368 33,576 15,067

Ferro Silicon 117,000 97,682 110,742 96,972 92,632

HC Ferro Chrome

/Charge Chrome

1,030,000 890,916 790,072 964,806 801,138

LC Ferro Chrome 2,000 2,007 1,352 235 230

Total Bulk Ferroalloys 2,852,000 2,462,775 2,224,502 2,385,537 1,973,688

Noble Ferro alloys 33,360 30,858 27,235 29,185 27,763

Total 2,885,360 2,493,633 2,251,737 2,414,722 2,001,451

Growth percentage 15.70% 10.74% (-) 6.75% 20.65% 21.64%

Source: IFAPA

2.3.4 Domestic Consumption

Table No. C2-5: Domestic Consumption of Ferroalloys (in Kilo Tonnes)

Ferro Alloy 2005-06 2008-09 2011-12

Si-Mn 443 589 700

Fe-Cr 375 311 403

Fe-Mn 233 277 292

Fe-Si 174 156 229

Others 83 91 115

Source: IFAPA

2.3.5 Installed Capacity and Export/Import Scenario:

Capacity increase of the Ferro Alloy Industry in general followed the course to meet the planned

target levels of the Steel Industry in the country and to continue to remain potential exporters of

Ferro Alloys in the international market for earning substantial foreign exchange for the country.

After initiation of the liberalization programme, there has been a spurt in the export of Bulk Ferro

Alloys, like all other products. The present scenario indicates that the ferroalloy production in the

country is driven not only indigenous demand but also exports. The installed capacity as well as

the export figures is given in the tables below.




Table No. C2-6: Ferroalloy Capacity in India (2012 estimates)

Ferroalloy Capacity In Million Tonnes

Mn Alloys 3.16

Chrome Alloys 1.69

Ferro Silicon 0.25

Noble Alloys 0.05

Total 5.15

Table No. C2-7: Ferro Alloy Export ( ‘000 MT)

Category 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

Export 517 640 961 960 863 1555 1533

Domestic 1308 1520 1558 1420 1819 1460 1740

Total 1825 2160 2519 2380 2682 3015 3273

Export % 28 30 38 40 32 52 47

Source: IFAPA

Ferroalloy Imports:

Although India is a large exporter of Ferroalloys, due to uncertain economic conditions in the

developed world, many ferroalloy companies (mainly from the CIS, Russia and Kazakhstan)

which restricted themselves to supplying to customers in the developed world (US, EU, Japan)

and to China have started making inroads into India. This has led to stiff rise in imports of

ferroalloys (25% CAGR) for the years as reflected in the table below.

Table C2-8 Growth of Imports of Ferroalloys in India ( ‘000 MT)

Ferroalloy 2005-06 2008-09 2011-12

Fe-Si 74 83 149

Refined Alloys 44 42 66

Fe-Cr 1 2 34

Fe-Mn 5 6 10

Total 124 133 259

2.4 Employment Generation:

As there is no expansion, only modification to product mix is being proposed, there is no

possibility of employment generation.




CHAPTER – 3

PROJECT DESCRIPTION

3.1 Type of Project:

It is an existing Ferroalloy plant which is operating at Raturia Industrial Area, Angadpur,

Durgapur, WB. The proponents want to modify the product mix with inclusion of Ferro-chrome

and Ferro Silicon in addition to existing Fe-Mn and Si-Mn. The modification will be carried at

present existing site at Raturia Industrial Area, Angadpur, PO: Mayabazar, PS: Coke Ovens,

Durgapur, Dist: Burdwan, West Bengal. The modification will render the plant economically

viable. No additional facility will be set up. The existing Ferroalloy plant with pollution control

measures shall be utilized for manufacture of Ferro-chrome as well as Ferro Silicon. The raw

materials for the existing plant are Mn ore, Quartz and Chrcoal. For proposed modification

chrome ore, coke, quartz and lime stone will be used as raw material. The power requirement of

the plant will be sourced from Durgapur Projects Limited. and Water requirement will be met

from the water mains of Raturia Industrial Area belonging to Durgapur Municipal Corporation..

As per EIA Notification 2006 the proposed Ferro Alloy Plant falls under Schedule in serial No. 3

(a) - Metallurgical Industry (ferrous & non- ferrous). Based on general conditions mentioned in

the schedule of EIA Notification, the project is categorized as Category A.

3.2. Location (Map Showing General Location, Specific Location and Project

Boundary & Project Site Layout) with Coordinates:

The project is located in the Raturia Industrial Area, Angadpur, PO: Mayabazar, developed by

the West Bengal Industrial Development Corporation Limited for providing industrial

infrastructure to prospective enterpreanures. The Co-ordinates of Project site are as mentioned

earlier in Chapter 2.

The inclusion of Ferrochrome & Ferro Silicon production will be achieved in the existing industrial

complex the consisting of Ferroalloys Plants of M/s. Haldia Steels Pvt. Ltd Unit I. The site is

already developed and connected to road and rail network. Adequate transportation facilities are

available for transportation of product to important destinations.

By incorporation of Fe-Cr & Ferro Silicon production in the existing factory premises, M/s. Haldia

Steels Pvt. Ltd. is planning to increase the economy of existing plant and to earn greater

revenue by selling ferroalloys, which will be used for manufacturing steel and alloy steel

products, structural steel etc. Hence the proposed modification project will be beneficial and

techno-economically feasible. Hence, no alternative site is analyzed. Financial and social benefits

with special emphasis on environmental consideration and benefit to the local people will be

kept as top priority for the proposed project.

CEMC Pvt. Ltd.

The site selection has been made in view of the fact that the company has existing fac

location, the location is well connect

water. Environmental pollution control measures will be under

below the limits stipulated by CPCB/ WBPCB/ MoEF & CC.

M/S. HALDIA

The site selection has been made in view of the fact that the company has existing fac

location, the location is well connected by road and rail network; proximity to raw materials and

water. Environmental pollution control measures will be undertaken to restrict the pollution

below the limits stipulated by CPCB/ WBPCB/ MoEF & CC.

Fig. No. C3-1: Index Map


ALDIA STEELS PVT. LTD. (UNIT – I)

Page 14

The site selection has been made in view of the fact that the company has existing facility in the

ed by road and rail network; proximity to raw materials and

aken to restrict the pollution




Fig. No. C3- 2: Location Map




Fig. No.C3- 3: Vicinity Map




Fig. No.C3- 4: Google Earth Map




Fig. No. C3-5: Plot Plan

3.3 Details of alternate sites considered & the basis of selecting the proposed site,

particularly, the environmental consideration gone into should be highlighted:

The existing project is located at Raturia industrial area at Angadpur. Durgapur, in the District of

Bardhaman, West Bengal. In view of the fact that the proponents are operating ferroalloy plant

the same location since 2003 and the project is located in the industrial Estate, the

infrastructure is already developed. The modification of product mix shall be carried out in the

same location. Therefore, no other location has been considered for the above proposal.

3.4 Size or Magnitude of Operation:

The configuration of the project has been given Table below;




Table No. C3-1: Project Configuration

Facilities Existing

Capacities

Proposed

Modification

Ultimate Capacity

Ferro Alloys(Ferro Chrome

/Ferro Manganese /Silico

Manganese /Ferro silicon)

SEAF

2X4 MVA,

1X6MVA and

1X7.5 MVA

SEAFs for

manufacture of

Fe-Mn and Si-

Mn allos

2X4 MVA,

1X6MVA and

1X7.5 MVA

SEAFs for

manufacture of

Fe-Mn and Si-

Mn,Fe-Cr and

Fe-Si alloys)

2X4 MVA, 1X6MVA

and 1X7.5 MVA SEAFs

for manufacture of

Fe-Mn and Si-Mn,Fe-

Cr and Fe-Si alloys)

3.5 Project description with process details (a schematic diagram /flow chart

showing the project layout, components of the project etc. should be given):

3.5.1 Project Description:

The proposal is for availing EC for the existing plant which operates a ferroalloys plant of 2X 4

MVA, 1 X 6 MVA and 1X7.5 MVAfor production of Fe-Mn and Si-Mn and proposes to utilize the

furnaces for production of Fe-Cr, and Fe-Si also.

The raw materials will be sourced from neighboring state Odisha as well as local market. The

raw materials as well as finished products will be transported through the existing rail and road

network.

Total land over which the project is located is 8.9 acres. Total water requirement for the

proposed project will be about 290 KLD. Water requirement for the project is being sourced from

Water Mains ofDurgapur Municipal Corporationy. The same source will be adequate for

manufacture of Fe-Cr and Fe-Si also. Electricity requirement will be about 21.5 MVA at 0.8

power factor which will be available from in DVC Grid. The details of various units of the

proposed project with production capacity are given below;

1. Ferro Alloys Plant with capacity of Fe-Mn 49536TPA or Si-Mn 32,589 TPA or Fe-Cr

32,589 TPA or Fe-Si 14,569 TPA.

The manufacturing process technologies are indigenous and well established. The details are

given below:




3.5.2. Manufacturing Process of each Product with Chemical Reactions:

3.5.2.1 Ferro Alloys Plant-Process Description:

Most of the Ferro-alloys e.g. Ferro-silicon, Ferro-manganese, Silico-manganese, Ferrochrome

etc. are produced by smelting process. Smelting of the charged materials is carried out in

submerged electric furnaces equipped with transformer of proper ratings. The process developed

in India during 90s is based on basic process parameters as offered by ELKEM, Norway, in the

past.

Various Indian furnace manufacturers successfully developed furnace design up to 12.5 MVA

electrical ratings for manufacture of different grades of ferro-alloys based on ELKEM Technology.

The process for the manufacture of Ferro Alloys viz. Silico Manganese, Ferro manganese, Ferro-

Chrome and Ferro-Silicon by submersible Arc furnace technology is well established in India. All

the companies manufacturing Ferro Alloys are using the above technology.

a. Submerged Electric Arc Furnace:

A schematic view of typical submerged electric arc furnace design is depicted in Figure No C3-6.

The lower part of the submerged electric arc furnace is composed of a cylindrical steel shell with

a flat bottom or hearth. The interior of the shell is lined with 2 or more layers of carbon blocks.

The furnace shell may be water-cooled to protect it from the heat of the process. A water-cooled

cover and fume collection hood are mounted over the furnace shell. Normally, 3 carbon

electrodes arranged in a triangular formation extend through the cover and into the furnace

shell opening. Prebaked or self baking (Soderberg) electrodes ranging from 76 cm to over 100

cm (30 inches to over 40 inches) in diameter are typically used. Raw materials are sometimes

charged to the furnace through feed chutes from above the furnace. The surface of the furnace

charge, which contains both molten material and unconverted charge during operation, is

typically maintained near the top of the furnace shell. The lower ends of the electrodes are

maintained at about 0.9 to 1.5 meters (3 to 5 feet) below the charge surface. Three phase

electric current arcs from electrode to electrode, passing through the charge material. The

charge material melts and reacts to form the desired product as the electric energy is converted

into heat. The carbonaceous material in the furnace charge reacts with oxygen in the metal

oxides of the charge and reduces them to base metals. The reactions produce large quantities of

carbon monoxide (CO) that passes upward through the furnace charge. The molten metal and

slag are removed (tapped) through one or more tap holes extending through the furnace shell at

the hearth level. Feed materials may be charged continuously or intermittently. Power is

supplied continuously. Tapping can be intermittent or continuous based on production rate of

the furnace.

Submerged electric arc furnaces are of 2 basic types, open and covered. Most of the submerged

electric arc furnaces in India are open furnaces. Open furnaces have a fume collection hood at

least 1 meter (3.3 feet) above the top of the furnace shell. Moveable panels or screens are

sometimes used to reduce the open area between the furnace and hood, and to improve

emissions capture efficiency. Carbon monoxide rising through the furnace charge burns in the

area between the charge surface and the capture hood. This substantially increases the volume

of gas the containment system must handle. Additionally, the vigorous open combustion process

entrains finer material in the charge. Fabric filters are typically used to control emissions from

open furnaces.




Covered furnaces have a water-cooled steel cover that fits closely to the furnace shell. The

objective of covered furnaces is to reduce air infiltration into the furnace gases, which reduces

combustion of that gas. This reduces the volume of gas requiring collection and treatment.

The cover has holes for the charge and electrodes to pass through. Covered furnaces that

partially close these hood openings with charge material are referred to as "mix-sealed" or

"semi-enclosed furnaces".

Although these covered furnaces significantly reduce air infiltration, some combustion still occurs

under the furnace cover. Covered furnaces that have mechanical seals around the electrodes

and sealing compounds around the outer edges are referred to as "sealed" or "totally closed".

These furnaces have little, if any, air infiltration and undercover combustion. Water leaks from

the cover into the furnace must be minimized as this leads to excessive gas production and

unstable furnace operation. Products prone to highly variable releases of process gases are

typically not made in covered furnaces for safety reasons. As the degree of enclosure increases,

less gas is produced for capture by the hood system and the concentration of carbon monoxide

in the furnace gas increases. Wet scrubbers are used to control emissions from covered

furnaces. The scrubbed, high carbon monoxide content gas may be used within the plant or

flared.

The molten alloy & slag that accumulate on the furnace hearth are removed at 1 to 5 hour

intervals through the tap hole. Tapping typically lasts 10 to 15 minutes. Tap holes are opened

with pellet shot from a gun, by drilling or by oxygen lancing. The molten metal and slag flow

from the tap hole into a carbon-lined trough, then into a carbon-lined runner that directs the

metal and slag into a reaction ladle, ingot molds, or chills (Chills are low, flat iron or steel pans

that provide rapid cooling of the molten metal). After tapping is completed, the furnace is

resealed by inserting a carbon paste plug into the tap hole.

Fig. No. C3-6




Chemistry adjustments may be necessary after furnace smelting to achieve a specified product.

Ladle treatment reactions are batch processes and may include metal and alloy additions. During

tapping, and/or in the reaction ladle, slag is skimmed from the surface of the molten metal. It can

be disposed of in landfills, sold as road ballast, or used as a raw material in a furnace or reaction

ladle to produce a chemically related ferroalloy product.

After cooling and solidifying, the large ferroalloy castings may be broken with drop weights or

hammers. The broken ferroalloy pieces are then crushed, screened (sized), and stored in bins

until shipment. In some instances, the alloys are stored in lump form in inventories prior to

sizing for shipping.

Smelting in an electric arc furnace is accomplished by conversion of electrical energy to heat. An

alternating current applied to the electrodes causes current to flow through the charge between

the electrode tips. This provides a reaction zone at temperatures up to 2000°C. The tip of each

electrode changes polarity continuously as the alternating current flows between the tips.

In Haldia Steels-I the furnaces are semi-open type.

3.5.3 Technology and Process Description-General:

The process technology area relates to only ferro alloy production. This plant has been designed

for production of Ferro-Manganese and Silico-Manganese. However, flexibility in furnace design

and operation, electrode operation and transformer design exists for manufacture of

Ferrochrome also.

Four nos. submerged electric arc furnaces having one having 7.5 MVA rating, one furnace of 6

MVA rating and two nos of 4 MVA rating each have been installed in this ferroalloys plant. The

submerged arc process is a carbothermic reduction smelting operation. The reactants consist of

metallic ores (ferrous oxides, silicon oxides, manganese oxides, chrome oxides, etc.) and a

carbon-source as reducing agent usually in the form of coke, low-volatility coal or wood chips.

Limestone may also be added as a flux material. Raw materials are crushed, sized, and in some

cases, dried, and then conveyed to a mix house for weighing and blending. Conveyors, buckets,

skip hoists or cars transport the processed material to hoppers above the furnace. The mix is

then gravity-fed through a feed chute either continuously or intermittently, as needed. At high

temperatures in the reaction zone, the carbon source reacts with metal oxides to form carbon

monoxide and to reduce the ores to base metal.

The process flow diagram is common for all the products which is presented in Fig. No. C3-7.

The process of manufacture consists of the following sections:

• Raw Material Receipt and Storage

• Sizing, Screening and Feeding of of Raw Materials

• Raw Material Batching

• Melting in Ferroalloy Furnace

• Handling of Hot Metal and Slag

• Metal Recovery




ID IDFAN

i) Raw Material Receipt and Storage:

Incoming raw material i.e. Coal, Quartz, Charcoal, etc. will be received by trucks and stacked

separately in the stockyard. The material will be procured in required size range and quality.

Appropriate storage methods shall be adopted.

ii) Sizing, Screening and feeding of Raw Material:

Raw material will be fed to a ground hopper by dumpers. The material will be drawn from

ground hopper to screening plant where fines will be removed. The screened material will be

conveyed to hoppers through skip hoist/bucket elevators. The bunkers will be fed with reversible

conveyors.

Each storage hopper is provided with vibratory feeder. Material from each storage hopper will be

withdrawn and weighed separately in the weigh hoppers and dumped to a common surge hopper

provided with a vibratory feeder through a conveyor.

Fig. No. C3-7: General Process Flow Diagram of Ferroalloy Production

INPUT OF SIZED

AND GRADED

RAW MATERIALS

HANDLING BY

PAYLOADERS

AND DAMPERS

FEED IN DAY BINS

THROUGH BELT

CONVEYORS

BATCH

PREPARATION BY

COMPUTERIZED

WEIGHMENT

TAPPING IN

CAST IRON

LADELS

DISCHARGE OF

MOLTEN

METAL

REACTION IN THE

FURNACE

CHARGING IN TO

FURNACE

HEAT

EXCHANGER

BAG FILTER

NATURAL

COOLING OF

INGOTS

SIZING, GRADING

AND PACKING

DISCHARGE OF

SLAG

METAL

REECOVERY

PLANT

FLUE DUST FOR BRIQUETTING STACK

RECOVERED METAL

INSPECTION DESPATCH

SLAG FOR REUSE

AND/OR ROAD

BASE MATRIAL

CYCLONE

SEPARATOR




The weight of raw materials in required quantity from the surge hopper will be fed to the feed

hopper provided at the top platform. The material from feed hopper will be conveyed to charging

bins and correction bin, which will be located around the circumference of the furnace. These

charging bins will feed the raw material mix through chutes and slide gates into the furnace.

iii) Batching of Raw Materials:

Batching is the most important part of the process. The total process control and quality control

is largely dependent on accurate batching. This is nothing but accurate weighing of different raw

materials in the required proportion and taking simultaneously as a quantum. This is done with

the help of a raw material batching system consisting of vibrating feeders, load cells, weigh

hoppers and conveyors. The total operation is controlled by a PLC. The required proportion of

the raw material mix is determined by means of material balance made by a metallurgist based

on the combination of theoretical calculations and practical assumptions from past experience.

iv) Smelting in Ferroalloy Furnace:

Fe-Mn/Si-Mn/Fe-Cr is produced in submerged electric arc furnace. Details of furnace have been

already discussed earlier in this chapter. The outer & bottom wall of the furnace is made up of

steel sheet, which is water-cooled. The outer shell as well as the bottom is lined with refractory

materials like carbon block, refractory bricks, silicon carbide bricks, tamping paste, castables

and mortars etc. depending on the lining design. Silicon carbide bricks will be used for tap hole

lining The furnace shell along with the refractory lining forms the crucible for holding the molten

metal & slag and provides the space for reactions at very high temperature.

The electrodes are the carriers of electricity in to the furnace. Self-baking continuous Soderberg

electrodes are used in these furnaces. In fact these are the heart of the furnaces. Electric arcing

takes place inside the charge to produce high temperature and provides the necessary heat

energy for endothermic reactions.

The furnace shall be provided with water-cooling system for:

- Cooling of current conducting pipes and contact clamp.

- Cooling of electrode holder ring

- Cooling of electrode shell

- Cooling of supporting framework exposed to heat from furnace top.

For furnace tapping, tap hole arcing device (moving around the furnace) will be provided.

Electrical connection to the arcing device shall be made manually after positioning.

Various raw materials are analyzed. Depending on the composition and specification of metal to

be produced a material balance is prepared. This shows the proportion in which various raw

materials are to be mixed before feeding in to the furnace. Once the materials are fed in to the

furnace in desired proportion it is called the burden. The burden under goes various physical and

chemical changes simultaneously. Various metallic & nonmetallic oxides like MnO,Cr2O3, FeO and

SiO2 get reduced to their elementary form by the reaction of fixed carbon in reductants with the

respective oxides.




For example in case of ferrochrome production, the following reactions will take place in the

furnace.

Cr2O3 + 3C 2Cr + 3CO

FeO + C Fe + CO

SiO2 + 2C Si + 2CO

Al2O3, MgO, CaO and SiO2 are the main oxides, which form the gangue in the ore and

reductants. They combine together along with certain amount of unreduced Cr2O3 and FeO to

form slag. Metal & slag gets accumulated at the bottom of the furnace as a result of smelting

and is tapped out from time to time.

Metal & slag are tapped out simultaneously through the tap hole and collected in different

receptacles like ladle; CI pans etc. metal & slag are separated from each other due to difference

in their specific gravity by the method of decantation or simply by casting in pans. Pure metal is

cast in moulds or beds.

Slag Chemistry:

Formation of a suitable slag is of paramount importance in ferroalloy production, as it not only

determines the stability of operation but the total economy of the process. The slag composition

is determined taking in to account the specification of product, gangue materials present in the

ore and available fluxes. Temperature and fluidity of slag assumes primary consideration. The

temperature of slag is maintained 50 – 1000 C above the metal temperature. The total

temperature profile inside the furnace is maintained by the slag temperature and hence by slag

composition. The slag composition in typical case of ferrochrome manufacture is maintained in

the range as mentioned below;

Slag Composition:

Cr2O3 : 8 - 10 %

FeO : 2 – 3 %

SiO2 : 28 - 30 %

Al2O3 : 22 - 26 %

MgO : 20 - 24 %

CaO : 8 – 10 %

Guiding principle to maintain slag composition:

MgO / Al2O3 : 0.9 – 1.1

Basicity : 1.1 – 1.2




Tapping and Casting:

Metal and slag formed inside furnace as a result of smelting is tapped out at regular interval

from the furnace through tap hole provided in the side lining of the furnace. The interval is

determined based on the power in put and previous tapping condition. Tap hole is cut by oxygen

lancing at the stipulated place to make a way for molten metal & slag to flow out. The molten

metal is collected in a combination of ladle, CI pan and sand bed arranged in cascading manner.

Metal is collected in the ladle and CI pan along with some slag. But the sand bed accommodates

only slag. After tapping the tap hole is closed with the help of plug clay made out of clay and

carbonaceous particles derived from electrode paste. Metal & slag from the ladle are separated

by decantation in the molten state and the pure metal is cast in moulds. After cooling the metal

moulds are sifted to metal handling yards for further handling. The slag is sifted to slag yard for

further processing in metal recovery plant.

Tapping & Casting materials used:

• Oxygen lancing pipe

• Oxygen gas

• MS rods

• Sodium silicate

• Sand

• CI ladles

• Refractory ladles

• CI pans

• Rectangular moulds

v) Technical Specification of Furnace:

There are four nos. of Submerged Electric Arc Furnaces having capacity of 1X7.5 MVA 1X6 MVA

and 2X4 MVA for Production of Ferroalloy products like Fe-Mn, Si-Mn or Fe-Cr and Ferrosilicon.

The technical specification of the furnaces is presented below;

Table No.C3-2: Technical Specifications of Furnace

Parameter SEAF of 7.5 MVA SEAF of 6MVA SEAF of 4MVA

Installed Capacity

Electric Furnace

power

7.5 MVA 6 MVA

4 MVA

Range of

Transformer

secondary voltage, V

90-170v 90 170v




Parameter SEAF of 7.5 MVA SEAF of 6MVA SEAF of 4MVA

Electrode current, kA 32 25.6 17.1

Type of electrode Shoderberg self

baking electrode

Shoderberg self

baking electrode

Shoderberg self

baking electrode

Diameter of electrode

(mm)

900 850

650

Number of electrode 3 3 3

Pitch circle diameter

(mm)

2200 1900

1900

Electrode travel, Hydraulic Hydraulic Hydraulic

Method of Charging

Continuous

charging through

skip, teller hoist

and charging

chutes

Continuous charging

through skip, teller

hoist and charging

chutes

Continuous charging

through skip, teller

hoist and charging

chutes

Method of tap

changing

Automatic Automatic Automatic

Inner dia of shell,(

mm)

6800 6500

6000

Shell height,( mm) 4800 4800 4500

Technical Specification for Each furnace to be obtained:

vi) Metal Handling:

The hot metal tapped from the spout will be collected in a ladle on rails. The liquid metal from

the ladle will be poured into sand moulds with the help of a crane. Manual breaking and packing

will be carried out for dispatch. Metal cakes are handled with the aim of removing slag

contamination and meeting the size specification. The moulds are broken manually to serve both

the purpose. Manual sorting is done to separate out slag. In certain cases chipping is necessary to

separate out sand and slag contamination from the metal surface. As a result of the metal

handling process the following out puts are generated.

• Sized pure metal (sifted to sales yard for dispatch after confirmatory analysis)

• Slag & metal contaminated mixture (sifted to MRP for further processing)

• Undersized metal particles containing small quantity of slag particles (sifted to MRP for

further processing)

CEMC Pvt. Ltd.

vii) Air Pollution Control System for Ferro Alloy Furnace

There are 1X 7.5 MVA, 1X6MVA and 2X4 MVA ferroalloy furnaces. During tapping to control

secondary fugitive emission proper hood and ID fan has been provided and fumes collected are

passed through GCP System. Fixed hoods are provided over the respective ferro allo

capture fumes.

Fumes from furnaces are sucked by a suitable Induced Draught Fan. Captured fumes at a

temperature of around 280 ºC are transported to a water cooled gas cooler. Hot fumes then

pass through the tubes and the water circulating

110 ºC. After heat exchanger the dust laden fumes pass through cyclone where coarse particles

are removed.

It is then passed through a modular Off

woven filter bags where the dusts /fumes will be separated and only clean filtered air will pass

through the filter bags. Clean air having PM level below 150 mg/ NM

through a chimney. Ladder, platform and sampling port have been provid

position as per WBPCB norms.

Collected dusts in the dry form will be taken out of the Bag Filter by a rotary airlock valve

having geared motor drive arrangement. Dry dusts will be disposed off in gunny bags.

Schematic diagram of a pollution control system is given at

Fig

M/S. HALDIA

vii) Air Pollution Control System for Ferro Alloy Furnace:

re 1X 7.5 MVA, 1X6MVA and 2X4 MVA ferroalloy furnaces. During tapping to control


passed through GCP System. Fixed hoods are provided over the respective ferro allo



pass through the tubes and the water circulating system reduces the fume temperature to about


It is then passed through a modular Off-Line Pulse Jet Bag Filter having Polyester needle felt non

n filter bags where the dusts /fumes will be separated and only clean filtered air will pass

through the filter bags. Clean air having PM level below 150 mg/ NM3

through a chimney. Ladder, platform and sampling port have been provid

position as per WBPCB norms.



llution control system is given at Fig. No. C3-

Fig. No. C3-8: Pollution Control Measures



Page 28

re 1X 7.5 MVA, 1X6MVA and 2X4 MVA ferroalloy furnaces. During tapping to control


passed through GCP System. Fixed hoods are provided over the respective ferro alloy furnace to



system reduces the fume temperature to about


Line Pulse Jet Bag Filter having Polyester needle felt non

n filter bags where the dusts /fumes will be separated and only clean filtered air will pass 3 will then be vented out

through a chimney. Ladder, platform and sampling port have been provided at the appropriate



-8: below.

Pollution Control Measures




A. Ferro- Manganese:

Metallurgical Reactions involved during production of Ferro-manganese & Silico-manganese:

• 2MnO2 + C → Mn2O3 + CO

• 3 Mn2O3 + C → 2Mn3O2 + CO

• Mn3O2 + C → 3MnO + CO

• MnO + C → Mn + CO

• Fe2O3 + 3C → 2Fe + 3CO

• SiO2 + 2C → Si + 2CO

• P2O5 + 5C → 2P + 5CO

High-carbon ferro-manganese is made in three phase open or closed top furnace of a power of

7,500-18,000 KVA at a linear voltage of 120-130 V with a current of 33-38 kA, operating at a

voltage of 120-130 V. The charge for making high-carbon ferro-manganese is composed of

manganese ore and coke/coal.

Physico-Chemical Conditions of the Process: High carbon ferro manganese is smelted by a

continuous process with the electrodes submerged deep into the charge. The following

processes take place when making high carbon ferro manganese:

• Pre-heating of the materials;

• Drying and removal of volatiles & moisture from the charge; heating of the charge by

the heat of burning gases which leave the furnace & after-burn at the top;

• Reduction of oxides;

• Melting of the elements reduced with the formation of molten ferro-manganese;

• Formation and melting of slag;

The iron contained in the manganese ore is reduced to a high extent in the process. oxides are

reduced with carbon monoxide and hydrogen at low temperatures. Ferrous oxide is first reduced

with carbon monoxide and hydrogen at 500-600°C temperature and after that with solid carbon

in the deeper zones of the bath.

The reduction of manganese from pyrolusite occurs stepwise:

MnO2 > Mn3O4 > MnO > Mn3C

With a reducing atmosphere in the furnace, the dissociation of manganese oxides can place at

low temperatures. Carbon monoxide and hydrogen can also reduce Mn3O4 to MnO at low

temperatures.




The manufacturing process of ferro-manganese consists of smelting of manganese ore, quartz

and charcoal at 1400-1600 degree Celsius, in submerged electric arc furnace. Manganese ore is

the basic raw material having major constituent of ferro-manganese alloys, i.e. manganese ore

and Charcoal is used as reductant. The body of the furnace is cylindrical in shape, lined with fire

bricks, silicon carbide bricks and carbon tamping paste. Three tap holes are provided at 1200

apart for draining out both the molten alloy and slag. The raw materials are charged into the

furnace manually in specified proportion. The charged material is smelted in the furnace by

electric power delivered through three electrodes. The electrodes are partially submerged in the

charge and are supported on hydraulic cylinders for upward and downward movement to

maintain the desired electrical conditions in the furnace.

As the charge enters the smelting zone, the alloy is formed by reaction of the oxides and the

reductant. The alloy so formed is heavy and gradually settles at the bottom of the furnace. The

furnace is tapped at regular intervals. The tap hole is opened by oxygen lancing pipes and once

tapping is completed the tap-hole is closed with clay plugs.

High Carbon ferro-manganese can be smelted with addition of fluxes or by fluxless process. In the

latter case, a valuable by-product of the process is high manganese low phosphorus slag which is

used in smelting silico-manganese and manganese metal. Manufacturing of high carbon ferro-

manganese may be done through two alternative process:

i) Flux Process

ii) Flux less Process

In the flux process, the charge includes fluxes like limestone to take care of the gangue material

in the charge as is conventional in the smelting process of other ferroalloys. Ferro manganese is

tapped after draining out the slag from the furnace.

In the second process, no flux is added to the charge mix. As a result the manganese recovery

is low and the slag is rich in residual manganese. This manganese rich slag can be used in

recycling through the smelting furnace as a constituent of the charge mix, replacing part of the

manganese ore.

Table No.C3-3: RAW MATERIALS FOR FE-MN AND THEIR CHEMICAL COMPOSITION

Sl. No. Constituents Mn Ore Dolomite Coke

1 MnO 46-48% -- --

2 CaO + MgO -- 55% --

3 Al2O3 5% -- --

4 Fe2O3 5-15% -- --

5 Ash -- -- 20%

6 Fixed Carbon -- -- 60%

7 Volatile Matter -- -- Balance

CEMC Pvt. Ltd.

Charge Composition:

Table No.C3-4: General Charge Composition

Input Material

Mn Ore

Dolomite

Low Ash Met Coke

Fig. No. C3-

M/S. HALDIA

Charge Composition:

General Charge Composition

Amount in Tons per Ton of Product

2.3

0.35

0.6

-9: Process Flow Diagram of Ferromanganese



Page 31

Amount in Tons per Ton of Product

f Ferromanganese




B. Silico-Manganese:

High-carbon Silico-Manganese is made in three phase open or closed top furnace of a power of

5,000-12,000 KVA, operating at a voltage of 90-100 Volt. The composition of different grades of

silico-manganese is given below:

Table No.C3-5: COMPOSITION OF DIFFERENT GRADES OF SILICO MANGANESE

Mn % in different

grades of Si-Mn

Contents (%)

Silicon Carbon Sulphur Phosphorous

60-65 14-18 2.30 0.04 0.30

65-70 15-18 2.00 0.04 0.25

Size: 10-50mm (90% minimum)

Silico-manganese is produced by carbothermic reduction of oxidic raw materials in electric

submerged arc furnaces. The same type of furnaces is used for Fe-Mn and Si-Mn alloys.

Operation of the Si-Mn process is often more difficult than the Fe-Mn process because higher

process temperature is needed.

Standard silico-manganese with 18-20% Si and about 70% Mn is produced from a blend of

HCFeMn slag with about 35 to 45% MnO, manganese ores, quartzite, (Fe) Si-remelts or off

grade qualities, and coke. Sometimes minor amounts of MgO-containing minerals are added, e.g.

dolomite [CaCO3.MgCO3] or olivine [(MgO)2.SiO2].

The discard slag from the SiMn process normally contains 5 to 10% MnO. Low carbon silico-

manganese with around 30% Si is produced by upgrading standard alloy by addition of silicon

wastes from the ferrosilicon industry. Manganese ores normally contain unwanted elements that

cannot be removed in the mining and processing stages. Of special importance is phosphorus

due to the strict demands in respect of this element both in the Fe-Mn and Si-Mn alloys. Iron,

phosphorus and arsenic are reduced more easily than manganese and will consequently go first

into the metal. Their content in the final alloy must therefore be controlled by selection of ores.

The HCFeMn slag is a very pure source of manganese because the easily reduced impurities in

the ores have been taken up by the HCFeMn metal in the preceding process step. The content of

impurities, like phosphorus, in Si-Mn alloys is therefore controlled, not only by the selection of

manganese ores, but also by the relative amounts of manganese ores and HCFeMn slag in the

raw material mix.

A process temperature of 1600 to 1650°C is necessary to obtain metal with sufficiently high

content of Si and discard slag with low MnO. Fe-Mn slag has a relatively low melting

temperature (about 1250°C) compared with Mn-ores. Accordingly, a high share of Fe-Mn slag

will tend to give lower process temperatures. When the Mn-ore starts melting at around 1350°C,

it will contain a mixture of a solid and a liquid phase, where the solid phase is MnO. Further

heating and reduction to 1550°C or more is necessary before the melting ore will mix with the

slag and flow freely. With a high share of Mn-ore in the mix, the surface temperature and

process temperature in the cokebed zone will be higher.




The specific power consumption for production of standard Si-Mn from a mixture of Mn ore,

HCFeMn slag and Si-rich metallic remelts, can typically be 3500-4500 kWh/tonne metal,

dependent first of all on the amount of metallics added to the feed. The power consumption will

increase with the Si-content of the metal produced, and also with the amount of slag per tonne

of SiMn. Each additional 100 kg slag produced will consume additionally about 50 kWh electric

energy. About 100 kWh per tonne of metal and some coke will be saved if the ore fraction in the

charge is reduced to MnO by CO gas ascending from the smelt reduction zone

The charge for making high-carbon Silico-Manganese is therefore composed of manganese ore,

Quartz HC Fe-Mn slag and coke.

Physico-Chemical Conditions of the Process:

The following processes take place when making high-carbon Silico-Manganese:

(a) Removal of volatiles and moisture from the charge and heating of the charge by the heat

of burning gases which leave the furnace and after-burn at the top;

(b) Reduction of iron and ores with simultaneous formation of metal carbides;

(c) Melting of the elements reduced with the formation of molten metal;

(d) Formation and melting of slag;

(e) Reduction of Manganese and silica from the slag.

Table No.C3-6: Raw Materials for Si -Mn and their Chemical Composition

Sl. No. CONSTITUENTS MN ORE QUARTZ COKE

1 MnO 38-40% -- --

2 SiO2 3% 97% --

3 Al2O3 5% 1% --

4 Fe2O3 17% 0.5% 0.5%

5 Ash -- -- 20%

6 Fixed Carbon -- -- 60%

7 Volatile Matter -- -- Balance

Charge Composition:

Table No.C3-7: General Charge Composition

Silico manganese is more stable compounds than manganese carbides. Therefore the higher the

Si content in the Silico manganese less is its carbon content. 20% Silico manganese is used for

smelting of medium carbon Ferro manganese and 30% used for production of metallic

manganese.

Input Material Amount in Ton /ton of finished product

Mn Ore 1.80 T

Fe-Mn Slag 0.60 T

Dolomite 0.35 T

Low Ash Met Coke 0.60 T

Casing Sheet 0.01 T




Silico Manganese is an alloy of silicon, manganese, iron and some other elements in small

percentage. Silicon and manganese are the principal de-oxidants in steel making. Silico

Manganese is used on a large scale as an alloying element in the manufacture of spring /Alloy

steel/ stainless Steel/ tool steel. Silicon has positive effect on mechanical, physical and chemical

properties of steel and is widely used in manufacture of structural, tool grade and special steel.

The production process of transformer grade steel also requires silicon. Manganese has the

additional property of controlling the effect of sulphur by forming Manganese Sulphide, which

floats out of liquid steel. The quality of silico manganese produced is given in following table.

Fig. No. C3-10: Process Flow Diagram of Silico-Manganese

RAW MATERIAL YARD STORE

MANGANE

SE ORE

LAM

COKE DOLOM

ITE

FERRO-

MANGANESE

SLAG

ELECTRODE

PASTE

OXYGEN

MIXING BAY

SUBMERGED ELECTRIC

ARCH FURNACE

SILICOMANGA

NESE SLAG LIQUID SILICO

MANGANESE

POURING BAY

CASHING

SHEETS

SILICO MANGANESE

MOULD KNOCKOUT

FINISHED

PRODUCT STORE

BREAKING TO

PROPER SIZE




C. Ferro-Chrome:

More than 80% of the world production of ferrochromium is used in stainless steel making.

There are four grades of ferrochromium produced commercially, characterized broadly in terms

of their carbon and chromium contents;

• High carbon ferrochromium (Cr : >60%, C : 6-9%)

• Charge chrome (Cr : 50-60%, C : 6-9%)

• Medium carbon ferrochromium (Cr : 56-70%, C : 1-4%) and

• Low carbon ferrochromium (Cr : 56-70%, C : 0.015-1.0%)

The demand for low-carbon ferrochromium, produced by reacting Fe-Cr-Si alloy with a Cr2O3CaO

based slag, has decreased dramatically during the last two decades mainly due to the

commercial development of AOD and VOD processes which allow removal of carbon from

stainless steels with acceptable loss (oxidation) of chromium. These low and ultra-low carbon

ferrochromium grades are used mainly for final adjustments of composition and for super alloys

which are melted in coreless induction furnaces. The ultra-low ferrochromium, produced by

aluminothermic reduction of chrornite, is relatively pure but very expensive and consequently,

not widely employed in the steel industry.

As a result the high-carbon ferrochromium has become the most widely produced and consumed

grade of chromium-containing ferroalloys. The production of high carbon ferrro-chromium is

based on reduction smelting of chromite ore with coke in the presence of silica in a submerged

arc furnace.

Physico- Chemical Conditions of the Process:

The conventional smelting process for producing ferrochromium is carried out in electric

reduction furnaces having Soderberg electrodes submerged in the burden material. To achieve

steady process of the reduction reactions, the gas flow and partition through the burden should

be uniform enough to avoid channeling of carbon monoxide gas produced by the reactions. This

requires the charges to be primarily comprised of lumpy ore with a minimum of ore fines; also,

the ore should not be friable so that excessive degradation of the ore does not occur in the

furnace. However, due to increasing mechanization of the ore mining operations and the

necessity of using ferrugneous friable ores, there is considerable generation of ore fines, with

grain size smaller than 1 mm, which calls for some form of agglomeration (such as pelletizing,

briquetting or sintering) of the feed materials. Another important cost factor of the conventional

technology is the high power consumption which is in the range of 4000-4200 KWh/t-FeCr alloy.




Table No.C3-8: Probable Reactions and Equilibrium Temperatures during

Carbothermic Reduction of Chromite in Fe-Cr Manufacture

Reaction T 0K for P,co = 1 atm

Fe3O4 + C = 3FeO + CO 942

FeO + C = Fe + CO 1001

Cr2O3 + 3C = 2Cr + 3CO 1698

Fe3O4 + 5C = Fe3C + 4CO 983

3FeO + 4C = Fe3C + 3CO 1001

7Cr2O3 + 27C = 2Cr7C3 + 21 CO 1571

SiO2 + 3C = SiC + 2C0 1805

3SiO2 + 2SiC = Si + 4SiO + 2CO 2082

Cr 203 + 3Cr7C3 = Cr23C6 + 3CO 1800

Chromite ores contain iron oxides and gangue which have significant effects on the reduction

reactions in submerged are smelting. Studies on solid-state reduction of chromite have shown

that the iron oxides get reduced more readily than the chromite oxides. Under such conditions,

iron forms only one carbide Fe1C, which can dissolve chromium to form a complex carbide

(Cr,Fe)7C. Thus, an ore rich in iron oxide will have high reducibility at relatively low

temperatures. Accordingly, the reduction of chromic oxide in such ores will also occur at relatively

lower temperatures with the likely formation of a carbon-rich chromite carbide (Cr3C2, or Cr7C3)

known to be stable at lower temperatures.

The gangue present in a chromium ore has a significant effect on the temperature of the

smelting zone thereby influencing the carbon content of the ferroalloy. An ore having a relatively

high MgO content will require a higher smelting temperature. Further, if silica flux addition is

reduced or lime is added, the liquidus temperature of the slag will increase thus promoting high

smelting temperatures. In practice, it has been found that a MgO : AI2O3 ratio close to 1.0 forms

high smelting slag which promotes low carbon levels in ferro alloys.

It has been argued that, because of their high surface to volume ratio, fine ores react readily at

low temperatures forming a product high in carbon. The use of chromite-carbon agglomerates is

reported to have produced high carbon ferro-chromium since they start reacting at lower

temperatures. On the other hand, coarse-sized ores will not be as reactive and thus can survive to

a lower depth in the burden and react with high carbon alloy, thereby, promoting a low carbon

ferro-chromium.

Silicon Content of High Carbon Ferrochromium:

The silicon content of the ferrochromium should be low as it is an undesirable element in

stainless steels. A low silicon content is favored by a low operating temperature, a high carbon

content in the ferroalloy and a basic slag. Other impurities are not. Known to affect the silicon

content significantly. In general, the specifications for ferrochromium call for a silicon level

below 3%. This can be achieved by forming a layer of chromic oxide ore in the lower portion of

the slag which oxidizes some silicon in addition to carbon.




Phosphorous Content of High Carbon Ferrochroinium:

Phosphorous is detrimental to both the mechanical properties and corrosion resistance of

stainless steels. In the submerged arc smelting of chromite ore, a portion of the phosphorus

contained in the charge is vaporized and removed with the off-gas; however, up to 60 percent

can be retained in the alloy.

For low phosphorous levels (<0.02%) in ferrochromium, the phosphorus content of the raw

materials should be as low as possible. Also a relatively low operating temperature will promote

removal of phosphorus into the slag phase, especially under oxidizing conditions. However, due

to the highly reducing and hot conditions in the submerged arc furnace, there are no easy ways

to produce a low phosphorus ferrochromium from high phosphorus ore/coke.

The charge for making high-carbon Ferro-Chrome is therefore composed of Chromite ore, coke &

quartz. The following processes take place when making high-carbon ferro-chrome:

(a) Removal of volatiles and moisture from the charge and heating of the charge by the

heat of burning gases which leave the furnace and after-burn at the top;

(b) Reduction of chromite ores with simultaneous formation of metal carbides;

(c) Melting of the elements reduced with the formation of molten metal;

(d) Formation and melting of slag;

(e) Chrome ores are mostly friable in nature and necessitate some form of agglomeration

before being charged into the furnace along with other raw materials. Most of the

chrome alloy producers in India have adopted the briquetting process towards

agglomeration of fines. M/s Sonic Thermal would adopt briquetting technology for the

friable chrome ores.

(f) Slag: The slag coming out of the smelting process, though it contains a relatively low Cr

in form of Cr203 contains inevitably metallic FeCr. The metallic FeCr in form of ''trapped"

droplets is incorporated inside of the solidified slag. The slag of the process is sent to

the slag treatment line where it is crushed and screened and the fractions rich of FeCr

having magnetic properties are separated from the remaining slag by two magnetic

separators. The magnetic fractions are returned back to the smelting furnaces while the

poor slag is dumped to the slag deposit. Magnetic separation is not the most efficient

way to recover the mechanical FeCr losses within the slag. However, the treated slag

deposited in the dump area is kept to be probably retreated by a more sophisticated and

efficient method in future.




Table No.C3-9: Raw Materials for Fe-Cr and their Chemical Composition

Sl.

No.

Constituents Chromite

Ore Hard

Lump (%)

Chromite

Ore Fines

(%)

Quartz

(%)

Dolomi

te (%)

Magnes

ite (%)

Coal

(%)

Coke

(%)

1 Cr2O3 40-44 min 50-52 max -- -- -- -- --

2 FeO (total) 11 max 13 max 0.6 2.0-2.5 -- -- --

3 Al2O3 10 max 10 max 1 0.8-1.5 -- -- --

4 SiO2 12 max 5 max 98 4.5-5.8 -- -- --

5 CaO 4-6 4-6 0.3 28-30 45 -- --

6 MgO 15-18 10-12 0.2 18-20 -- -- --

7 Sulphur

(as SO3)

0.005 0.005 -- -- -- -- --

8 Phosphorous 0.01 max 0.01 max -- -- -- 0.01 max 0.01 max

9 Cr:Fe 1.8:1-2:1 -- -- -- -- --

10 Ash -- -- -- -- -- 12 max 14 max

11 Fixed Carbon -- -- -- -- -- 50 min 84 min

12 Volatile matter -- -- -- -- -- 38 max 2 max

13 Moisture -- -- -- -- -- 10 max 8 max

Charge Composition and Utility Consumption:

Table No.C3-10: General Charge Composition in Ton per Ton of Finished Product

Raw Material and Utilities Consumption /Ton of Charge Chrome

(Salable Product)

Chrome Ore Hard Lump (+50 mm size) 0.381 T

Chromite Ore briquette 1.9 T

Chromite Ore Friable Lumps 0.127

Quartzite 0.279

Magnesite 0.05 T

Coal 0.293T

Coke 0.501 T

Electricity Around 3800 to 4000 KWH (With

briquette charge without preheating)

For an average of 40 - 42% Cr2O3 content in the blended ore of the charge & a Cr/Fe ratio of 3.0

- 3.2, the specific ore consumption per ton FeCr min. 65% is 2.7 - 2.9 tons.




Metal Recovery from Slag and Mixture:

Some quantity of mixtures gets generated at various point of handling of molten metal & slag.

Manual separation of metal and slag from the mixture is being done.

The same process is repeated for processing of pure slag. Pure slag is not actually pure. It contains

metal content to the extent of 4 – 4.2 % mainly in the form of nodules and entrapments.

After making the fines and chips sized output from metal recovery plant free from non-metallic

contents or reducing it to the desired level they are handed over to sales yard for dispatch after

confirmatory analysis.

Fig. No. C3-11: Process Flow Diagram of Ferrochrome Alloy

STORE

OXYGEN

CHROME ORE

FINES

ZIGGING PLANT

SLAG

BAY

RAW MATERIAL YARD

CHROME

ORE HARD

LUMP

CHROME ORE

FRRIABLE

LUMPS

QUAR

TZITE

COAL

ELECTRODE

PASTE

MIXING BAY

SUBMERGED ELECTRIC

ARCH FURNACE

FERROCHROME

SLAG

LIQUID

FERROCHROME

POURING BAY

FERROCHROME

MOULD KNOCKOUT

FINISHED

PRODUCT STORE BRAKING TO

PROPER SIZE

MAGN

ESITE

COKE




D. Ferrosilicon:

Silicon is a metalloid having an atomic mass of 28.086, density of 2.37 gm/cm3, melting point of

1414°C & boiling point of 2287°C. In its electric properties, silicon is a semiconductor.

Silicon reacts with oxygen to form silica (SiO2), whose melting point is 1710°C. Silica can exist

in several modifications: quartz, tridymite, cristobalite, and silica glass. Ferro-silicon is made in

submerged arc provided with three-phase transformers having power rating of 7,500-9,000 kVA

operating at a voltage of 145-175 V. Generally, Semi- Closed-type stationary or tilting furnaces

are mainly used for manufacturing ferro alloys.

The physical state of the charge is of prime importance for successful operation of a furnace. The

charge materials must have constant moisture content and lumps of coke breeze and quartzite

should have only slightly varying size. The process of making Ferro-silicon produces little slag;

this is tapped together with the metal through the same tap hole.

Physico-chemical Conditions of the Process:

The reaction of reduction of silicon from silica occurs with solid carbon:

SiO2l + 2COg 2CO2g + Sil

2CO2g + 2Cs 4COg

SiO2l + 2C Sil + 2COg

A typical reaction producing ferro-silicon is shown below:

Fe2O3 + 2SiO2 + 7C 2FeSi + 7 CO

During the course of the reaction of silicon reduction is determined by the applied pressure of

carbon monoxide. In an industrial furnace for smelting ferro-silicon, the pressure at the top is

equal to atmospheric and the partial pressure of carbon monoxide that is established in the

reduction zone is slightly above atmospheric pressure. With a constant value of P2CO, the

equilibrium constant for a 45 per cent alloy is lower than that for 75 per cent alloy, which means

that a lower temperature is required for making the former.

During a melt for ferro-silicon, the iron dissolves the reduced silicon thereby removes it from the

reaction zone and thus causes the reaction to be proceeded from left to right. The mechanism of

reduction of silica is not described exhaustively in the above resulting reaction. An intermediate

oxide – silicon dioxide, and silicon carbide can also form in the process. Carbon causes final

reduction of silica. The latter reacts with carbon both at the surface of lumps of coke breeze and

in their core upon having penetrated through pores and fissures.




Samples taken from lower levels in the furnace usually contain much silicon carbide. According

to P. V. Geld, the formation of SiC from the elements can only occur with large kinetic difficulties

and requires a high mobility of atoms, which can only be achieved at temperatures above

1700°C. On the other hand, the reaction is thought to be probable.

Thus, silicon carbide forms as an intermediate product. Solid inclusions of silicon carbide, if

present in the slag, can impair the fluidity of already tough siliceous slags. At corresponding

temperatures, silicon carbide can be destroyed by metals and oxides, its destruction by iron

following the reaction SiCs + Fel = FeSil + Cgr

At high temperatures and in the presence of a solvent (iron with silicon) the aluminium and

calcium, if present in the charge, are reduced by carbon and silicon. Industrial grades of ferro-

silicon can thus contain up to 2 per cent Al and up to 1.5 per cent Ca.

Under the reducing conditions, a great amount of phosphorus from the charge and ash pass to

the melt, while sulphur is volatilized in the form of SiS2.

In operation with rich quartzites, the process occurs with little slag, only 2-6 per cent of the

mass of melt. The slag is formed from the alumina, calcium oxide and magnesia that are

present in quartzite and coke breeze. A typical composition of slag is 35-39 per cent Al2O3, 22-

26 per cent SiO2, 9-18 per cent CaO, 7-13 per cent BaO, 1-3 per cent MgO, 7-14 per cent SiC,

and 0.2-2.0 per cent FeO. The melting temperature of slag is 1650-1700°C, i.e. low enough to

cause slagging of the hearth. In practice, a trend is to operate with silica-rich quartzite and low-

ash reducer in order to minimize the bulk of slag of this composition.

The charge materials, prepared as indicated earlier, should be stored separately in furnace bay

bins. Before supplying to the furnace, they should carefully be weighed and mixed. A dosing

carriage is loaded first with coke breeze, then with turnings and quartzite, and finally with

graphitization wastes.

Table No. C3 – 11: Raw Materials for Fe-Si and their Chemical Composition

Sl.

No.

Constituents Quartz (%) Charcoal (%) Iron Scrap (%)

1 Si O2 98 --- ---

2 Al2O3 1 -- --

3 Fe 0.6 -- 94

4 S & P 0.05 -- 0.05

5 Ash -- 20 --

6 Fixed carbon -- 60 --

7 Volatile matter -- Balance --




Charge Composition:

The general composition of a charge in ton, may be as follows:

Table No. C3 – 12: General Charge Composition in Ton per ton of product

Material FS45 FS75

Quartz 3.00 3.00

Coke breeze 1.41 1.44

Iron turnings/ Mill Scale 170kgs 38kgs

Fig. No. C3-12: Process Flow Diagram of Ferrosilicon

RAW MATERIAL YARD STORE

QUARTZ COKE

BREEZE

IRON

SCRAP

MS ROUNDS ELECTRODE

PASTE

OXYGEN

MIXING BAY

SUBMERGED ELECTRIC

ARCH FURNACE

FE RRO‐SILICON

SLAG

LIQUID FERRO‐

SILICON

POURING BAY

CASHING

SHEETS

FERROSILICON

MOULD KNOCKOUT

FINISHED

PRODUCT STORE BREAKING TO

PROPER SIZE




3.5.4 Mass Balance for each Product:

Table No. C3 – 13:- Mass Balance for Ferro Manganese

For Each Tonne of Product Materials In For Each Tonne of Product Material out

Material In Quantity Tonne Material Out Quantity Tonne

Manganese Ore 2.3 Ferro Manganese 1.0

Dolomite 0.35 Slag 1.3

Low Ash Met Coke 0.6 Gassius Emissions 0.96

Electrode Paste 0.015 Flue Dust 0.005

Total 3.265 Total 3.265

Table No. C3 – 14:- Mass Balance for Silico-manganese


Material In Quantity Tonne Material In Quantity Tonne

Manganese Ore/Pellets 1.79 Silico-Manganese 1.000

Dolomite 0.35 Slag 0.990

Fe-Mn Slag 0.6 Gaseous Emission 1.381

Low Ash Met coke 0.6 Flue Dust 0.004

Electrode Paste 0.025 -- --

Cashing Sheet 0.01 -- --

Total 3.375 3.375

Table No. C3 – 15: Mass Balance for Ferrochrome


Material In Quantity Tonne Material Out Quantity Tonne

Chromites Ore Hard

Lump/ Briquettes

2.2 Ferrochrome 1.00

Chromite Ore Friable Lump 0.13 Slag 1.11

Quartzite 0.28 Gaseous Emissions 1.235

Coke 0.5 Flue Dust 0.09

Coal 0.3 -- --

Electrode Paste 0.025 -- --


Table No. C3 – 16: Mass Balance for Ferro-Silicon (70% Si)


Material In Quantity Tonne Material In Quantity Tonne

Quartz 1.700 Fe-Si alloy 1.000

Charcoal 1.450 Slag 0.060

Mill Scale 0.350 Flue dust 0.165

-- -- Loss as gas 2.275





3.6 Raw Materials Required along with Estimated quantity, likely Source, Marketing

area of Final Product, Mode of Transportation of Raw Materials and Final Product:

3.6.1 Raw Materials Required along with estimated quantity, likely Source

Table No. C3 – 17:

Sl.

No.

Raw

material

Consumption

per T of

Product

Quantity

Required

for

existing

Product

Mix(TPM)

Quantity

Required

for

proposed

product

mix

Source of

Raw

Material

Mode of

Transport

Ferro Alloy – Ferro manganese-Existing Production level 1985 TPM & Proposed

Production Level 4128 TPM

1. Manganese

Ore 2.3 4555.5 9494

OMC

Manganese

mines in

Odisha

By Rail

/Road in

covered

trucks

2 Dolomite 0.35 695 1449

Biramitrapur,

Sundargarh

dist., Odisha

By Rail

/Road in

covered

trucks

3 Low Ash

Met Coke 0.6 1191 1486

Durgapur

Steel Plant

/Coking Plant

of Durgapur

Projects Ltd.

By Rail

/Road in

covered

trucks

4 Electrode

Paste 0.015 30 62

Maharastra

Carbon Ltd.,

Graphite

India Ltd.,

Durgapur

By Rail

/Road in

covered

trucks

Ferroalloy – Silico-manganese - Existing Production

Level 2030 TPM & Proposed Production Level 2716 TPM

1. Manganese

Ore 1.79 3633.7 4861

Manganese

Mines in

Odisha

/Chhatisgarh

By Rail

/Road in

covered

trucks

2. Dolomite 0.35 710 950

Mines in

Odisha,

Chhatisgarh

By Rail

/Road in

covered

trucks

3. Fe-Mn Slag 0.6 1218 1629 Own

Production

--




4. Low Ash

Met coke 0.6 1218 1629

Imported

coal

From

Australia by

Ship & then

by Rail

/Road

5. Electrode

Paste 0.025 51 70

Maharastra

Carbon Ltd.,

Graphite

India Ltd.,

Durgapur

By Rail

/Road in

covered

trucks

6. Cashing

Sheet 0.01 20 27

Steel Plants

Of

SAIL/TISCO

By Road

Ferroalloy – Proposed Ferro chrome-2716 TPM

1.

Chromites

Ore Hard

Lump

2.22 -- 5975

Sukinda,

Jajpur dist.,

Odisha

By rail

/road in

covered

trucks

2.

Chromite

Ore Friable

Lump

0.13 -- 353

Sukinda,

Jajpur dist.,

Odisha

By rail

/road in

covered

trucks

3. Quartzite 0.28 -- 760

Mines in

Bankura, W.

Bengal and

Chhatisgarh

By rail

/road in

covered

trucks

4. Coke 0.5 -- 1358

Local Market By Road in

Covered

Trucks

5. Coal 0.3 -- 815

Nearby Coal

Mines of ECL

& BCCL

By rail

/road in

covered

trucks

6. Electrode

Paste 0.025 -- 70

Maharastra

Carbon Ltd.,

Graphite

India,

Durgapur

By rail

/road in

covered

trucks

Ferroalloy- Proposed Ferro-Silicon:1214 TPM

1. Quartz 0.5 --- 607

Mines in

Bankura, W.

Bengal and

Chhatisgarh

By rail

/road in

covered

trucks




2. Coke breeze 1.5 -- 1821

Durgapur

Steel Plant

/Coking

Plant of

Durgapur

Projects Ltd

By road in

covered

trucks

3. Iron Scrap 0.35 -- 425

Steel Plants

of Sail/Tisco

By Rail

/Road in

covered

trucks

4. Electrode

Paste 0.06 -- 72.84

Maharastra

Carbon Ltd.,

Graphite

India Ltd.,

Durgapur

By Rail

/Road in

covered

trucks

5. Cashing

Sheet 0.005 -- 6.07

Steel Plants

of Sail/Tisco

By Rail

/Road in

covered

trucks

6. MS Rounds 0.027 -- 32.778

Steel Plants

of Sail/Tisco By Rail

/Road in

covered

trucks

3.6.2 Table No. C3 - 18: Quantification of Product after Expansion, Marketing Area &

Mode of Transportation

Sl.

No.

Product Amount, TPA Market Mode of

Transport

1. Ferroalloys 49536 (Fe-Mn), or

32589(Si-Mn) or

32589(Fe-Cr) or

14,569(Fe-Si)

Will be sold to steel

manufacturers in West

Bengal

By Road in

covered trucks

3.6.3 Resource optimization/recycling and reuse envisaged in the project, if any,

should be briefly outlined

• The process selected envisages recycling all the materials collected in the pollution

control equipments thereby ensuring no generation of solid waste.

• Ferro manganese slag generated in the manufacture of Fe-Mn will be used for the

manufacture of Silico-Manganese.

• Cooling Water used in the process shall be recycled

3.6.4 Availability of water its source, energy /power requirement and source

3.6.4.1 Water requirement and its source:

Source: Fresh Water will be sourced from the water mains of Durgapur Municipal Corporation.




Table No. C3 – 19 : Water Requirement

Propose Existing

Water

Consumption

Water Consumption

Break up after change in product mix

Proposed

Additional Water

Consumption

INDUSTRIAL

Process + APCM -- -- --

Boiler -- -- --

Cooling (make-up) 250 250 0

Washing -- -- --

Gardening 20 20 0

Others i.e. Fire

Fighting

-- -- --

Total Industrial 270 270 0

DOMESTIC 20 20 0

NB: Permitted Water consumption as per Consent to operate is 3600 KL/day for industrial

purposes and 20 KL/day for domestic purposes

Water Balance Diagram (with reuse/recycle if any):

Total Make up Water Requirement:

270+20=290 KL/D for four nos. of SEAFs having total load of 21.5 MVA, Domestic use and

sprinkling.

Fig. No. C3-13: Water Balance Diagram

4 Nos. Submerged Arc Furnaces

and 2 Nos. Induction Furnaces

Water Sump

Water from DMC

pipeline 290KL/Day

COOLING TOWERS

Water Treatment Plant

/ Soft Water Plant Intake Tank

290KL/Day

Recycled / ZLD

Overhead

Tank

Drinking Water/ Toilets/

Domestic Uses

Septic Tank

ADDA Drain

Plantation &

Sprinkling

270

KL/Day

20KL/

Day




3.6.4.2 Power Requirement and its source:

Table No. C3-20: Power Requirement and its source

Sl.

No.

Plant Facility Power Requirement

per Tonne of Product

(Kwh)

Annual

Production

(Tonnes)

Total Power

Requirement

(MW)

Ferroalloy Plant:

Fe-Mn

2500 49,536 14.1

Si-Mn 3800 32589 14.1

Fe-Si 8500 14569 14.1

Fe-Cr 3800 32589 14.1

Total 14.1

The Ferroalloys plant is energy intensive process. We have taken ferrochrome production as

basis as the power demand for FE-Cr is high in comparison to Fe-Mn. As such the total

estimated demand of power for the entire project shall be 14.1 MW. Power will be drawn from

the DVC grid as it s being drawn at present.

3.6.5 Quantity of waste to be generated (liquid & solid) and scheme for their

management/ disposal

3.6.5.1 Quantity of liquid waste to be generated and scheme for their management/

disposal

The plant will be designed for a zero effluent discharge. Effluent generated in various units will

be treated so that it can be used for secondary purposed like toilet flushes, floor washing, green

belt development dust suppression etc. In the table below tentative disposal amount and their

treatment and reuse scheme is furnished.

Table No. C3 - 21: Waste Water Generation/Recycle and Reuse

EFFLUENT GENERATION (KL/day) :

Industrial Existing

Industrial

Modified

Industrial

Mode of Disposal & Ultimate

receiving Body

INDUSTRIAL INDUSTRIAL

Process + APCM -- -- --

Boiler -- -- --

Cooling/Bleeding

Water

20 20 Reused for gardening /road dust

suppression /washing or Fire

fighting

Washing 0 0 0

Others 0 0 0

Total Industrial 20 20 Zero Discharge will be maintained

DOMESTIC 16 - Soak Pit




Table No. C3 - 22: Waste Water Management

Sl. No.

Facility Waste water Management

1 Ferroalloy

Plant

There will be no process effluent. Cooling water will be

completely recycled in closed loop with makeup water. 20 KLD

waste water generated from cooling water blow down will be

taken to guard pond after treatment in settling pond and reused

in dust suppression/ green belt development

3 Domestic

effluent

16 KLD will be treated in STP and reused for green belt

development.

• Impact of Waste Water Generation due to proposed change in Product-Mix

There is no enhancement production capacity, no installation of new equipment and the

existing equipments and pollution abatement systems will be alternatively used to cope

up with the new product the cooling load will not have significant variations and the

existing cooling system with be sufficient for the change of product mix. The waste water

generation will not be significantly varry

3.6.5.2 Table No. C3 - 23: Quantity of solid waste to be generated and management/

Disposal Scheme:

Sl.

No.

Description of

Solid Waste

Quantity in TPD Disposal Practice

Existing

Plant

After Proposed

Modification of

Product Mix

I. Ferroalloy Plant

1 * Slag from ferroalloy plant

Fe-Mn slag 84.5 214.5 Used as raw material for Si-

Mn

Si-Mn slag 66.33 108 Used as road construction

material

Fe-Cr Slag -- 121 TCLP test will be conducted

and subject to passing the

test, the slag will be used in

road making. Otherwise the

slag will be to HW

authorized recyclers or

disposers. A

Fe-Si slag 2.94 Used as road construction

material




* The ferroalloy furnaces can be inter alia used for manufacture of Fe-Mn, Si-Mn,

Fe-Si, or Fe-Cr. In that case the maximum of the slag produced has been shown.

* All the solid wastes will be subjected to TCLP test to ascertain that they are non-

hazardous before their disposal.

Hazardous Waste Generation:

Table No. C3 - 24: Hazardous Waste Generation

Sl.

No.

Type of

Waste

Category

(As per

Schedule)

Generation per

Year (No Change)

Source of

Generation

Mode

of

Storage

Mode of

Treatment

& Disposal Existing Proposed

1 Used

Oil/Used

Lubricants

Schedule-I

5.1

500 L

per

year

500 L

per year

Transformer

Oil /Used

bearing oil,

engine oil, etc.

Stored

in

drums

Will be given

to authorized

re-processor

2 Used Oil

Filters

Schedule-I

3.3

20 nos. 20 nos. Oil Filters of

Vehicles and

DG Set.

Stored

in

Drums

Will be given

to authorized

re-processor

3 Empty

Barrels of

hazardous

materials

Schedule-I

33.1

8 nos. 8 nos. Empty barrels

of lubricating

oil &

transformer

oil

Stored

drums

Will be given

to authorized

re-processor

4 Contaminate

d cotton rags

Schedule-I

33.2

5 kg 5 kg Maintenance

of

machineries

Stored

in

drums

Will be given

to authorized

re-processor

5 Bag Filter

dust of

Ferrochrome

Manufacture

Schedule-

II A4

-- 2933 Flue dust

from FeCr

Manufacture

Stored

in bags

Will be

dispatched to

sister unit at

Barjora Plasto

Park Area for

briquetting

2 Dust from APC

devices of Fe-Mn

production

0.325 0.825 Recycled back to Briquetting

Plant

Dust from APC

devices of Si-Mn

production

0.268 0.436 Recycled back to briquette

plant

Dust from APC

devices of Fe-Cr

production

-- 9.81 Recycled back to briquette

plant

Dust from APC

devices of Fe-Cr

production

-- 8.065 Recycled back to briquette

plant




3.5.6.3 Source of Air Pollution and Control Measures:

Table No. C3-25: Source of Air Pollution and Control Measures

Sl.

No.

Source of Pollution Pollutants Measures adopted for control

1. Submerged Electric Arc Furnace

I Smelting Particulate

Matter

• Dust extracting system with

hooding connected to Ambient

Air Cooler, Cyclone Separator,

Bag Filter and stack

• Water sprinkling system

II Taping

III Product Handling

IV Unloading of Raw

Materials

V Tapping of gases Dust • Fume extraction systems such

as canopy hooding/other

tapping hoods duly ducting the

emissions from various sources

connected to Bag filter

• Water sprinkling system

a. Exposed Metal

b. Slag Surfaces

c. Cast Handling

d. Refining

e. Product Crushing

and Cleaning

Table No. C3 - 26: Details of Bag Filters & Stacks

Furnace Bag Filter Capacity No. of Bags Stack Height (m)

F1-4MVA 75 KW 2X110 45

F2-4 MVA 75 KW 2X110 45

F3-6MVA 90 KW 6X80 45

F4-7.5 MVA 90KW 6X80 45

Table No. C3 - 27: Sample Stack Emission Data of Existing Project

Date of

Measurement

Particulate Matter Emission mg/NM3

Stack No. 1 of

4MVA furnace

Stack No. 2 of

4 MVA furnace Stack No. 3 of

6MVA furnace Stack No. 4 of

7.5 MVA

furnace

28/05/2009 22.51 22.51 109.98 --

04/03/2010 -- 23.85 -- 9.25

10/11/2010 5.14 -- -- 128.40

19/05/2011 17.52 -- -- 15.42




M/s. Haldia Steels Pvt. Ltd.

At: Angadpur, PO: Mayabazar, PS: Coke Ovens, Durgapur, Dist: Burdwan, West Bengal.

FACILITIES:

Ferroalloys Plant

WATER REQUIRED:

Amount: 290 Kl/day

Source: River

Damodar-through

Durgapur Municipal

Corporation Pipes

Land: 8.9 acres

of allotted plot in

Plasto Steel Park

Industrial Area,

Bankura, WB

RAW MATERIALS:

- Non coking Coal

- Met Coal

- Dolomite

- Chromites Ore

- Manganese Ore

- Quartzite

ENVIRONMENTAL IMPACT ASSESSMENT-ATTRIBUTES

Air:

Process

emission,

Fugitive

emissions,

Vehicular

emossions.

PM2.5,

PM10,

SO2, NOx

Water: CT

blow down,

Soft water

regenerati

on, pH,

TDS, TSS

Noise:

Noise

generating

Machines,

Vehicles

Soil:

Excavation,

Seepage/

drainage

from

material

storage

area

Bio-

diversity:

Impact due

to noise, air

pollution,

water

pollution

and loss of

habitat

R&R:

Evacuati

on due

to land

acquisiti

on

Solid

Waste/HW:

Ferroalloy slag,

Bag filter dust,

HAZ WASTE:

Used Oil, Used Oil

drums, Used oil

filters, Oil

contaminated

waste

AIR:

Bag

Filter

WATER:

ETP,

Recycle

and

Reuse

NOISE:

Green Belt,

Pads,

Insulation,

Silencers,

Enclosures,

PPE

SOIL:

Plantation,

Water

Sprinkling

BIO-

DIVERSITY:

Conservation

of Flora and

fauna. No Wild

life sanctuary

within study

area

R&R:

Land

already

procured.

No R&R

action plan

SOLID WASTE:

Disposal in solid

waste dump

yard, reused/

recycled.

Hazardous waste

disposed in

secured land fill,

used oil sent to

authorized re-

processers

ENVIRONMENTAL MANAGEMENT PLAN

Fig. No. C3-14: Schematic Diagram of EIA & EMP Process of the Project




CHAPTER – 4

SITE ANALYSIS

4.1 Connectivity:

a. This product mix modification project is already existing at village Namabandh-

Sitarampur, PO:Ghutgoria, PS:Bajira, Dist. Bankura, WB in the Plasto Steel Park-an

industrial Estate Developed by the West Bengal Industrial Development Corporation. The

site is having advantages of proximity to 2 Coalfields – i. e. Ranigung Coal field of ECL

and Dhanbad coalfields of BCCL.

b. Nearest Railway station is at Durgapur on Eastern Railway which is about 14 Km N-E of

the project site.

c. Nearest sea port is at Haldia at a crow-fly distance of 274 KM in S-E direction of the

project site.

d. Other sea ports like Kolkata, Paradeep and Vishakhapatanam are also well connected by

road and rail.

e. Nearest Air Port is at Andal at a distqance of 15 Km N-W and Netaji Subhas Chandra Bose

Airport at Kolkota is at an aerial distance of 150 KM East of project site.

f. Nearest National Highway NH 2 is at a distance of 18 KM and NH 60 (State Highway) is at

2Km.

g. Within the city private mini‐buses are the cheapest and most convenient mode of transportation.

They operate from Prantika to Station terminus, via different routes through the city. Some of them

operate to other termini from Prantika, like Nadiha, Madhaipur, Kasba, Sillyaghat, etc. CNG auto‐

rickshaws ply between City Center, Benachity, Railway Station and other parts of the city in a number

of routes. They are non‐polluting, environment friendly, convenient, less time‐consuming, and cheap

mode of transport. Cycle‐rickshaws are available for travelling smaller distances, as a preferred

commute. Pre‐paid taxis are available in the city from Station and City Center Terminus. From 2015,

OLACABS, the country's most popular App‐based luxury cab app, has also started operating within the

city boundaries as well as from the city to the Durgapur Airport. A new auto rickshaw service provider

Autowale have also started in the city.

Location Advantages:

The location of the project at Namabandh-Sitarampur, District-Bankura has the following

advantages:

a. Proximity to Coal mines of ECL & BCCL which will ensure easy supply of coal at reduced

cost of carriage.

b. Mn Ore and Chrome ore can be procured in rake loads from mines in Odisha (SE railway)

and unloaded in nearby railway siding of E Railway near Durgapur.

c. Proximity to Durgapur Projects Ltd which is the source of power for the project.

d. Location of the site near in Durgapur, and its proximity, to Asansol Bardhamann will

provide for adequate social infrastructures.

e. Location of the site close to National Highway No. 60 and NH 2 gives easy access and

convenience for transportation.




4.2 Land form Land Use and Land Ownership:

The study area comprises of different land forms like river bodies, reserve forests, hills, water

reservoir etc. The distance of such land forms from project site are mentioned below;

Table No C4- 1: Location of Water bodies, Reserve Forests & Hill from Project Site

Location Distance Direction

From Project Site

Water Bodies

Damodar River 1.2 km SW

Barjor Nala 4.8 km S

Tartari Nala 7.6 km SW

Tamla Nala 1.1 km N

Reserve/Protected Forests

Beliator P.F. 7.2 km SW

Gobindapur P.F. 8.3 km SE

4.3 Topography (along with Map):

Durgapur is in the Paschim Bardhaman district of West Bengal, on the bank of the Damodar

River, just before it enters the alluvial plains of Bengal. The topography is undulating. The coal-

bearing area of the Raniganj coalfields lies just beyond Durgapur; some parts intrude into the

area. The area was deeply forested till recent times, and some streaks of the original Sal and

eucalyptus forests can still be seen.The average elevation of Durgapur is 65 m AMSL.

Durgapur subdivision is surrounded by Asansol Sadar subdivision on the west, Purba Bardhaman

district on the east, Bankura district across the Damodar in the south, and Birbhum district

across the Ajay River to the north.

4.4. Existing Land use pattern (agriculture, non-agriculture, forest, water bodies,

(including area under CRZ), shortest distance from the periphery of the project to

periphery of the forests National Parks, wild life sanctuary, eco sensitive areas, water

bodies(distance from HFL of the river), CRZ. In case of Notified Industrial Area a copy

of the notification should be enclosed:

No forest land is involved in the Plant area. The wildlife map showing the distance of the project

site from the National Park / Sanctuaries and Elephant /Tiger Reserve and their corridors is

given in Fig. No. C4-1.




Fig. No. C4-1: Map showing National Parks, Wild Life Sanctuary




Fig. No. C4-2: Land Use Land Cover Map




The land use map of 10km radius of the project area is given above, which shows the land use

pattern in the surrounding of the plant area. The land use / land cover of the region can be

divided into 9 categories. The categories of land use/ land cover for the proposed study area are

shown in the following table;

Table No. C4-2: Land Use Classification

Sl. No. Land Use Category Area Statistics (in sq.km.) Area in %

1. Urban Area 84.12

26.79

2. Industrial area 20.87 6.65

3. Settlement 15.18 4.83

4. Plantation 0.85 0.27

5. Agriculture Land 143.01 45.54

6. Waste Land 1.38 0.44

7. Sandy Area 8.62 2.75

8. Forest cover 12.47 3.97

9. River/Water body 27.5 8.76

Total 314.286 100

4.5 Existing Infrastructure:

The Ferroalloy plant is already operating. The industrial area is well developed with well

connected road and rail network. The social infrastructure is also well developed.

4.6 Soil Classification:

4.6.1 Types of Soil and its distribution in Bardhaman district:

Soils of Bardhaman district can be classified into three categories; namely Gangetic alluvium,

Vindhyan alluvium and Laterite red soil. Gangetic alluvium occurs along the Ganga River,

Vindhyan alluvium is found in the area between Ajoy and Damodar rivers in the central and

eastern parts of the district and the third type of soil is found to occur in the undulating and coal

field areas in the western part of the district. The chemical characteristics of these soils are

given in Table 2.1.

Bardhaman district is included in the western tract of West Bengal.In the case of western tract,

the soils are formed by many principal rivers and their tributaries viz., Damoder Kangsabati,

Silabati, Ajoy, Mayurakshi etc. and hence to put them under a common name, they are called as

Vindhya alluvium since the catchment areas of all these rivers lie in Rajmahal hills and

Chhotanagpur plateau, which may have some physiographic similarity or continuity of the

Vindhya range (lying further west).Soil of Durgapur region corresponds to the Vindhya Aluvium

type.




Extensive stud has been carried out about the soil type of West Bengal. According to a study is

available in the web, the soil of the region belong to Taxonomic group called Ochraqualfs-

Haplaquepts-Eutrochrepts. The description of this class of soil is given below for deOchraqualfs-

Haplaquepts-Eutrochrepts.

This unit consists of three important group of soils. Jagadishpur, Banpara and hanrgram group

with inclusion of other soil groups.

Jagadishpur Soil:

Jagadishpur soils (B. M. soils of India 1982) have developed in granite alluvium on nearly level

to very gently sloping old flood plains of the Dwaraka river in Birbhum district at an elevation of

30 to 50 m above MSL. They are very deep clayey, imperfectly drained soils and have light

brownish gray to pale olive strongly acid to slightly acid silt loam to silty clay a horixon and gray

medium acid silty clay loam to silty clay Bt horizon is more than 100 em. The climate of the area

is tropical moist subhumid with mean annual air temperature of 26.5°C and mean annual rainfall

of 1,422 mm. The CEC ranges from 18 to 28 meq per 100 gm of soil. The moisture retention

capacity is high. The lands are usually terraced, but susceptible to erosion if the terraces are not

properly maintained. This soil is cultivated for rice in the kharif season and crops like wheat,

pulses and oilseeds with irrigation in the rabi season. Their productivity potential is medium. I

Banpara Series Soil:

Banpara series (NBSS-1984) which represents Banpara soil group have developed on old alluvium on nearly level to very gently sloping lower alluvial plain at an elevation of 40 to 50 m

above MSL in Burdwan district. They are very deep, imperfectly drained and have light brownish gray to olive gray, slight acid, sandy loam to loam A horizon, light gray to olive gray neutral sandy clay loam to clay loam B horizon and gray neutral clay loam to clay C horizon. The soils

have aquic moisture regime and so have the inherent problem of poor aeration. The climate is tropical moist sub-humid with mean annual air temperature 26.6°C arid mean annual rainfall 1,529 mm. The CEC ranges from 8.0 to 16.0 meq per 100 gm soil. The soils are suited only for

paddy kharif season. They can support climatically adapted crops, pulses, etc. on conserved soil moisture. The productivity potential of the soils is high. Banpara group soils have been classified as Haplaquepts as per USDA soil taxonomy in great group level. The same Banpara group soil

was classified earlier as Vindhya flat lands (DA, WB- 1965) • Totpara soil series also belongs to this soil group and is intensively cultivated for rice crop.

Hanrgram Series Soil:

Hanrgram series (B. M. soils of India - 1982) a representative of Hanrgram soil group was

originally established in Burdwan district. These soils have develo.ped in alluvium on old flood plain of river Damodar on· nearly level to level lands at an elevation of 20 to 30 m above MSL. The soils are deep, imperfectly drained and have high gray to olive brown, strongly to slightly

acid, clay loam to clay A horizon and gray to grayish brown, slightly acid, clay loam to clay B horizon whi~h are distinctly mottled with strong brown to olive brown in colour. The climate is tropical moist sub-humid with mean annual air temperature of 26.6°C and mean annual rainfall

of 1,400 mm. The soil cracks one em wide up to about 30 em depth. CEC ranges from 18 to 28 meq per 100 gm soil, Hanrgram soils are subjected to flooding and water stagnation during rainy season. Hence, they are suitable only for growing rice. However, lentil and gram may be

grown in winter on conserved moisture and wheat with supplementary irrigation. Product! Vity potential of this type of soil is medium, Hanrgram soil group have been classified as Eutrochrepts as per USDA soil taxonomy at great group level. In earlier time Hangram group soil

has been classified asDamodar flat lands. Ochraqualfs-Ustochrepts-




Table No. C4-3: Chemical characteristics of different types of soil (Source: Gupta, 2009)

Types of soil

Ca Free CaCO3

Clay P2O5 K Org. Matter

Gangetic

alluvium

Rich High from

surface

downward

Fairly

high, illite

dominant

clay

mineral

Medium Medium Low to

medium

Vindhyan

alluvium

- - - Low

Medium

Medium to

medium

high

Low

Lateritic

and red

soil

Low Some

time

present

Some

time

present,

kaolinite

main clay

mineral

Low - Low

Most of the soils are low in nitrogen content and the soils are mostly acidic in reaction

Fig No. C4 – 3 Types of soil and its distribution of Burdwan district, West Bengal (Source:NATMO MAP)




4.7 Climate Data from Secondary Sources:

Climatologically, the district enjoys in general, a moderate climate, divisible into short, mild winter, hot,

humid summer and a protracted rainy season. However, in the western part of the district i.e. in

Durgapur‐Asansol area, the summer is very severe, when hot Western Winds blow and temperature

occasionally shoots up to about 450C. The general temperature range, however is much lower and it is

recorded at 37 0C (in summer) to about 13 0C (in winter), but winter temperature as low as 6 0C is also

recorded. The district receives reasonable amount of rainfall normal being given 1350 mm. the town of

the Burdwan registers as much as 1528.6 mm. and Asansol has about 14710 mm of Rainfall. An isohyetal

map of the district shows that rainfall increases towards west, as also in the south western part around

Burdwan town (Figure 2.4). The area between Mankar and Mangalkot has rainfall less than 130 mm. in a

year and the areas of Katoya, Monteswar and Kalna have rainfall less than1400 mm. yearly. The area of

the district falling under D.V.C. irrigation system has been studied in respect of its evaporation rate and

it was found to be about 150 cm/yr. The annual data in respect of temperature and rain fall and cloud

cover averaged for different months of five years from (1998‐2002) for the district is presented in

Table No: C4 – 4 .

Durgapur experiences a somewhat transitional climate between the tropical wet and dry climate of Kolkata

and the more humid subtropical climate further north. Summers are extremely hot and dry, lasting from

March to the middle of June, with average daily temperatures near 32 °C. They are followed by the monsoon

season with heavy precipitation and somewhat lower temperatures. Durgapur receives most of its annual

rainfall of around 1321 during this season. The monsoon is followed by a mild, dry winter from November to

January. Temperatures are quite moderate, with average daily temperatures near 20 °C. There is a short

autumn at the end of October and a short spring in February, both of which have relatively moderate

temperatures of around 25 °C. The Köppen-Geiger climate classification is Aw. The driest month is

December, with 2 mm of rain. The greatest amount of precipitation occurs in July, with an

average of 309 mm. The lowest average temperatures in the year occur in January, when it is

around 19.4 °C.

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

10.558 28.1778 22.5108 44.7484 107.1212 211.9114 220.596 307.4928 250.9422 128.2542 12.6058 0.3022 Rain

Fall

12.595 16.4924 20.3584 24.7976 26.1326 26.341 25.7682 25.8222 25.3668 23.5538 18.3934 13.729 Min T

C

26.1456 29.1264 34.4132 38.4606 38.1838 35.3414 32.3778 32.1034 32.2186 32.2522 29.8132 26.6938 Max

TC

19.35 22.78 27.37 31.62 32.13 30.83 29.06 28.95 28.77 27.89 24.08 20.19 Av TC

21.4 27.2 33.2 29.46 43.69 67.45 76.72 74.86 68.05 44.7 24.92 23.09 Cl

Cover

Table No. C4-4: Monthly Weather Averages Summary




Fig No.: C4 – 4 Climate of Burdwan district, West Bengal (Source: NATMO MAP).

4.8 Social Infrastructure Available:

4.8.1 Educational Facilities:

Table No. C4-5: Educational Facilities in Burdwan District

Sl. No. Type of Educational Facility Number

1. Sishu Sikha Kendras 1085

2. Adult High Schools 1

3. Rabindra Mukta Vidyalaya Centres 7

4. Sanskrit Tols 64

5. Blind, Physical & Mentallly Handicapped Inst. 10 6. Non-Formal Education Centres 850

7. Anganwadi (Education) Centre (under ICDS) 4838

8. Social Welfare Homes under MEE Deptt. 3

9. Others 67




4.8.2 Health Facilities:

Table No. C4-6: Health Facilities

Sub-division

Blocks/ Municipality/ Municipal

Corporation

Hospitals Health Centres

Clinics*

Dispensaries

Total Total beds

Doctors**

Asansol

Salanpur 1 3 13 1 18 173 28

Barabani 1 5 17 1 24 83 16

Raniganj 3 2 21 3 29 137 15

Raniganj(M) 4 - - - 4 235 40

Jamuria 2 3 14 2 21 103 13

Jamuria(M) - 3 22 1 26 22 5

Asansol(MC) 7 6 10 1 24 1722 205

Kulti(M) 3 3 - 2 8 374 63

Total of Sub-Division 21 25 97 11 154 2849 385

Burdwan (North)

Burdwan-I - 3 20 2 25 23 4

Burdwan-II - 3 21 1 25 16 4

Burdwan(M) 3 1 - - 4 1189 167

Ausgram-I - 4 21 1 26 35 8

Guskara(M) - - - - - - -

Ausgram-II - 6 20 2 28 39 7

Bhatar 1 6 38 3 48 82 11

Galsi-II - 3 24 1 28 29 6


Burdwan (South)

Memari-I 1 3 31 3 38 86 11

Memari-II - 4 25 2 31 32 6

Memari(M) - - - - - - -

Jamalpur - 5 38 2 45 45 8

Raina-I - 4 26 2 32 31 4

Raina-II - 6 21 5 32 39 6

Khandaghosh - 4 26 2 32 29 6


Durgapur

Galsi-I 1 3 27 2 33 53 10

Andal 3 2 34 - 39 171 25

Faridpur

Durgapur - 4 15 1 20 33 4

Pandabeswar - 2 14 - 16 12 3

Kanksa - 5 26 3 34 39 7

Durgapur(MC) 6 1 - - 7 1104 196





Sub-division

Blocks/ Municipality

/ Municipal

Corporation

Hospitals Health

Centres

Clinics*

Dispensar

ies Total

Total

beds

Doctors**

Kalna

Purbathali-I 1 3 23 2 29 44 7

Purbasthali-II - 5 25 3 33 33 7

Kalna-I - 4 26 1 31 41 6

Kalna-II - 5 21 2 28 40 7

Kalna(M) 1 - - - 1 150 24

Monteshwar - 4 32 2 38 37 6


Katwa

Mongolkote 1 5 38 3 47 81 11

Ketugram-I - 3 24 1 28 21 5

Ketugram-II - 3 18 3 24 29 5

Katwa-I - 4 25 3 32 28 5

Katwa-II - 3 20 1 24 25 5

Katwa(M) 1 - - - 1 250 31

Dainhat(M) - - - - - - -


TOTAL OF BURDWAN DISTRICT

40 133 776 64 1013 6715 997




CHAPTER – 5

PLANNING BRIEF

5.1 Planning Concept (Type of Industries, Facilities, Transportation, Etc.) Town &

Country Planning /Development Authority Classification:

The proposed project is located at Raturia Industrial Area, Angadpur, Durgapur which is a

developed Industrial Area. Already an alloy steel Plant with 2X 4 MVA, 1X6 MVA and 1X7.5 MVA

submerged Electric Arc Furnaces are operating for manufacture of Fe-Mn and Si-Mn with consent

to operate from WBPCB and EC from MoEF & CC. The proponents plan to utilize the facility for

production of Fe-Cr & Fe-Si. As such no additional facility will come up and the existing facility

will be utilized with variations in operational conditioned for manufacture of Fe-Cr & Fe-Si. Main

raw material like manganese ore, chrome ore, Lime stone etc will be brought in rake loads from

the neighboring state of Odisha. Non coking coal will be brought from ECL or BCCL coal fields

which are very nearby. Coking coal will be brought from Raniganj and Jharia Coal fields.

Infrastructure facilities in the area are well developed and the sight has connectivity by road and

rail to almost all industrial and commercial centres in the country. The nearest town Durgapur,

Asansol and Burdwan are 04kms., 34kms and 63kms. away respectively and easily accessible by

road. All facilities such as schools, collages, hospitals and markets are available. Durgapur and

Asansol are bigger industrial towns which offer good market for the products.

(ii) Population Projection:

The Submerged Electric Arc Furnaces are being operated by skilled operators and

experienced engineers. Same set of personnel will operate the plant when the plant

switches from present product range to manufacture of Fe-Cr & Fe-Si. There will not be

any increase in population due to change in the product mix. The development of new

residential facility is not contemplated.

(iii) Land use planning (breakup along with green belt etc.):

The proposed project will be constructed with well developed green belt all around the

boundary of the plots as well as all around the various units. The land use breakup of the

proposed project is given below.

Table No. C5 – 1: Existing Area of M/s. Haldia Steels Pvt. Ltd. (Unit – I)

Sl. No. Item Existing

Area in

acres

1 Plant Built Up area 2.7

2 Raw Material and Finished Product-Storage Yard 1.3

3 Solid Waste Storage 1.0

4 Other Ancillary Area 0.2

5 Water Reservoir & Rain water harvesting 0.5

6 Internal Roads and Administrative Building 0.3

7 Green Belt 2.9

Total Land 8.9




Total land of the proposed project is 8.9 acres and about 2.9 acres land will be converted to

Green Belt. It is proposed to plant 300 saplings every year. Suitable plant species will be planted

all along the internal road, raw material storage & handling, ash/dust prone areas. It is planned

to plant saplings considering the parameters as type, height, leaf area, crown area, growing

nature, water requirement etc. Green belt will be progressively developed on land earmarked for

the purpose.

(iv) Assessment of Infrastructure Demand (Physical & Social):

The road and rail infrastructure are already well developed in the area which are required for the

transport of the raw material from and finished goods to the various part of the country. The

manpower will be mostly sourced from the locality and their social infrastructure is also

developed. The inflow of money in terms of taxes to Gram Panchayats and salaries to the

manpower will further improve the physical and social infrastructure.

(v) Amenities / Facilities:

The following facilities shall be provided in the project site:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

j. Emergency vehicle for shifting the workers during accident etc.

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in Factories Act 1948 and amendments thereof. The above

facilities shall also be adequately furnished and equipped.




CHAPTER – 6

PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area):

The infrastructural facilities are already developed in the premises of the unit as per the

requirement and no additional facilities are required as the proposal is only for modification of

product mix.

6.2 Residential Area (Non-processing Area):

The local peoples are being employed for the proposed project. The development of residential

area is not needed.

6.3 Green Belt:

Green belt development work will be undertaken on area of 2.9 acres. About 600 saplings will be

planted per acre. The details of existing Green Belt and Development of Green Belt Plan for the

proposed project are given below. The existing plantation has been done alongside the boundary

wall and in the vacant land earmarked for the purpose. The plants in the existing green belt

include Devil Tree (Alstonia scholaris), Mahaneem (Melia azadiracta), Gulmohar (Delonix regia),

Acasia (Acacia auriculiformis), Mango (Mangifera indica), Silk Tree (Albizia procera) with survival

chance of 78%. The future development will also include above local species.

Table No. C6 – 1: Existing & Proposed Plantation

Sl.

No.

Year of Plantation Area (in

acres)

No of

Saplings

Cumulative

Area

% of Total

Area

1 Existing Plantation 1.0 600 2 11.3

2 1st after availing EC 0.5 300 3 5.7

3 2nd year 0.5 300 4 5.7

4 3rd year 0.9 500 5 10.3

Total 2.9 1700 33.0

6.4 Social Infrastructure:

The social infrastructure in the region is well developed due to the proximity of the location to

Durgapur and Assansol. Further development will be undertaken through CSR activities. Details

of CSR activities already done during last five years are mentioned below. The company is

poised to futher take up CSR activities for social upliftment of the area. and proposed to be

carried out are detailed below.




Table No. C6 - 2: CSR Activities Taken Up During Last Four Years

DURING THE YEAR 2016-17

S/N Details of Projects/activities under taken

Fund utilised during the year for periphery development & CSR

activities

Field

1

Free medicines for (Anti cholera, viral fever, acidity, & etc) are regularly being provided to the people of villages in the vicinity experienced pharmacist.

1.5 lakhs Health

2 Water tankers are dedicated to villagers for providing drinking waters.

1.8 Sanitation

3

Puja/Religious Festivals / Cultural Programme etc:M/s Haldia Steel Ltd. ordinates with different peoples of area and tries to promote their various cultural programmes & futher cop up with them in similar activities to an extent.

1.5 Religious

4

Ambulance Facility : Expenses of Ambulance vehicle for the villagers of this area as a means of conveyance from village

0.7 Health

5

Training & Education: Numbers of teachers have been sponsored to various schools of nearby villages by the management of M/s Haldia Steels Ltd.

2.2 Education

6 Promotion of sports activities to for provide exposure of students of the nearby area

1.8 Skill Development

The company will continue to do CSR activities in future. It is proposed to install tube wells in

the water scarcity areas in future. CSR activities will be finalized after consultation with the

villagers as per demand in public hearing. The annual budgetary provision will be made as per

MoEF norms.




6.5 Connectivity (Traffic & Transportation Road /Rail /Water Ways, Etc.)

The connectivity in terms of traffic, transportation road is already developed and good. There

are well connected roads in the area. Nearest National Highway is NH2 (connecting Kolkata to

Delhi) is at a distance of 2.85Kms from project site from the project site. The nearest railway

station and railway siding is at Durgapur at a distance of 4Kms from project site.

6.6 Drinking Water Management (Source & Supply of Water):

The water for the factory will be sourced from the water header of Raturia Industrial Area of

Durgapur Municipal Corporation. Part of the same water will be use for sanitation and drinking

purpose after proper treatment. For the adjoining areas in the buffer zone of 10 km radius, tube

wells will be dug in water scarcity areas.

6.7 Sewerage System:

Domestic Sewage will be passed through septic tank and Soak pit.

6.8 Industrial Waste Management:

Industrial effluent generated from proposed project will be treated in Settling Pond and ETP. The

treated effluent will be utilized for Green Belt development.

6.9 Solid Waste Management:

Dusts collected in pulse jet bag filters will be reused in manufacture of briquettes in a sister unit

located at nearby Barjora Plasto Steel Park. Majority of solid wastes will be utilized for briquette

manufacture. The solid waste generated in Ferromanganese plant will be used for silico-

manganese. Slag generated in Ferrochrome manufacture will be under go TCLP test. Subject to

passing the test the same will be utilized for the construction of the roads and balance quantity

will be disposed of in landfill. If the slag will be found to be hazardous, then it will be given to

hazardous waste re-processors.

6.10 Power Requirement & Supply/Source:

The power requirement of about 9.0 MWH will met from DVC Grid.




CHAPTER – 7

REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to be Adopted (Central/State) in Respect of the Project Affected Person

Including Home Oustees, Land Oustees and Landless Laborers (A Brief Outline

to be given):

The rehabilitation and resettlement (R & R) is not required for the proposed modification of

product mix as it is an existing plant located in a developed industrial area.




CHAPTER - 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely Date of Start of Construction and Likely Date of Completion (Time

Schedule for the Project to be given):

This is a modification proposal for product mix which envisages production of Ferrochrome in the

existing facility. Therefore no construction job will be carried out.

8.2 Estimated Project Cost along with Analysis in terms of Economic Viability of the

Project:

The gross capital investment of the project is about Rs.2.70 Crores at 2008 level. There will not

be any extra facility addition to the existing plant. The economic viability is good due to

availability of raw materials, market and infrastructural facilities.




CHAPTER - 9

ANALYSIS OF PROPOSAL FINAL RECOMMENDATIONS

9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local

People Including Tribal Population, If Any, in the Area:

The proposed modification of product mix will have good financial and social benefits to the local

people.

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