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PRE-FEASIBILITY REPORT
ON
ENVIRONMENTAL ASPECTS
OF
PROPOSED
5,00,000 TPA M.S. ROLLED PRODUCT
CONSISITING OF SPONGE IRON / INDUCTION FURNACE / ROLLING MILL / WHRB / AFBC
February 2018
Survey # 91 to 95 & 97 to 103 of Amirthamangalam Village
Gummidipoondi Taluk, Thiruvallur District.
PRE-FEASIBILITY REPORT, JR Metal i
CONTENTS
1.0 EXECUTIVE SUMMARY ................................................................................ 1
2.0 INTRODUCTION / BACKGROUND INFORMATION .......................... 4
3.0 PROJECT DESCRIPTION ............................................................................... 7
4.0 SITE ANALYSIS ............................................................................................. 25
5.0 PLANNING BRIEF ........................................................................................ 32
6.0 PROPOSED INFRASTRUCTURE ................................................................ 34
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN .................... 35
8.0 PROJECT SCHEDULE & COST ESTIMATES ............................................ 35
9.0 ANALYSIS OF PROPOSAL ......................................................................... 35
Fig 1.0 Topo Map ……...………………………………………………………….8
Fig 2.0 Administrative Set-up Map………………………………………………9
Fig 3.0 Plant Layout …………………..…………………………………………10
Fig 4.0 Process Flow Diagram – Steel Division …………………………….…12
Fig 5.0 Process Flow Diagram – Captive Power Plant ……………………….19
Fig 6.0 Water Balance Diagram………………………………………………….22
Fig 7.0 Physiography Map …………..………………………………………….26
Fig 8.0 Land use Map ……….………………………….……………………….28
Fig 9.0 Drainage and Water Bodies Map…………………….………………….29
Fig 10.0 Soil Classification Map ………………………………………………….31
Pre-feasibility Report 1 J R Metal - Amirthamangalam
1.0 EXECUTIVE SUMMARY
1.1 Proposed Project
The proposed project is a Greenfield Sponge Iron Plant with Steel Rolling Mill
including billet plant, and also WHRB/AFBC based power generation.
1.2 Project Location
The proposed project will be located at Survey Nos. 91 to 95 & 97 to 103 of
Amirthamanagalam Village, Gummidipoondi Taluk, Thiruvallur District, Tamil
Nadu and is devoid of any notified Eco-Sensitive within 10 kms radius of plant site.
1.3 Project Proponent
M/s. J.R. Metal Chennai Limited a company with 2-decade long experience in Steel
Making and Marketing Business with its registered office at No.3, Manali Express
Road, TKP Nagar, Thiruvottiyur, Chennai – 600 019.
1.4 Manufacturing Process
The Iron-Ore domestically sourced, and though DRI Process is converted to Sponge
Iron. Then M.S. Scrap alongwith Sponge Iron is melted and cast into billets. The
billets are the rolled into M.S. Rolled Products. The waste heat emanating from
Sponge Iron Kilns is used to generate power in WHRB and dolochar / coal is used to
generate power from AFBC.
1.5 Production Capacity
Products Production Details (TPA)
PHASE – I PHASE - II PHASE – III
Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --
Intermediate Product – M.S. Billets Induction Furnace with Billet Caster (2 x 40 T & 1 x 30 T)
-- 4,50,000
1,50,000
Re-Rolled Steel Products (M.S. Rounds, Flats, Angles, etc.,) 1 No x 40 T Reheating Furnace
-- 5,00,000 --
Power Plant – AFBC (65 TPH) -- 16 MW --
Waste Heat Recovery Boiler (WHRB) 8 MW 8MW --
Pre-feasibility Report 2 J R Metal - Amirthamangalam
1.6 Proposed Equipments
List of Equipment Quantity
Induction Furnace 2 x 40 Tons
1 x 30 Tons
Rotary Kiln 2 x 350 Tons
Reheating Furnace 1 x 40 T
Captive Power Plant – AFBC (65 TPH) 1 x 16 MW
WHRB 2 x 8 MW
1.7 Raw Water Requirement
The raw water requirement will be 325 KLD. About 148 KLD will be recycled, and
about 177 KLD will be sourced from Borewell within the plant site.
1.8 Source of Water
Raw water will be sourced from Underground sources/Rain Water Harvesting.
1.9 Land Requirement
The total land area envisaged is 42.8 Acres, of which 27.1 Acres will be required for
Plant and utilities, and about 10.0 Acres will be earmarked for greenbelt
development.
1.10 Solid Waste Generation & Method of Disposal
The solid waste generated will be slag from melting and dolochar from sponge iron
plant.
Flyash and Bottom ash will be generated from AFBC Boiler.
The quantity of solid waste that would be generated from the Proposed Plant are as
follows
Pre-feasibility Report 3 J R Metal - Amirthamangalam
S. No. Description Quantity Generated
(T/D)
Mode of Disposal
1. Slag 130 Ground slag will be Sold to
Cement manufacturers
2. Fly ash 27.65 Sold to Cement
manufacturers
3. Bottom ash 6.91 Sold to Brick manufacturers
4. Dolochar 57 Will be used in AFBC Boiler
1.11 Man Power Requirement
About 200-employees would be needed for the operation of the proposed plant.
1.12 Air Pollution Control
The proposed plant will incorporate all air pollution control equipments including
ESP/Stack for Sponge Iron Kilns, Wet Scrubber / Stack for Electric Induction
Furnace, Wet Scrubber / Stack for Reheating Furnace & ESP/Stack for AFBC Boiler.
1.13 Estimated Project Cost
The total project cost for proposed plant is ` 350 Crores.
1.14 Pollution Control Cost
The total pollution control cost for proposed plant is ` 15 Crores.
Pre-feasibility Report 4 J R Metal - Amirthamangalam
2.0 INTRODUCTION / BACKGROUND INFORMATION
2.1 PROJECT & PROPONENT
J.R. Metal Chennai Limited (J.R. Metal) is a part of J.R. Group and is a continuously
performing company with more than two decades of experience in the field of
steel/metal trading, manufacturing and marketing. J.R. Metal Chennai Ltd is a
privately owned company.
J.R. Metal is already producing M.S. Rolled Products through its group entities to a
tune of 1,00,000 MT/Annum of Rolled Products.
J.R. Metal sells its Rolled Product both domestically and overseas. A substantial
portion of its existing production is exported.
Now, it is proposed to install a separate green field unit to produce
Products Production Details (TPA)
PHASE – I PHASE - II PHASE – III
Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --
Intermediate Product – M.S. Billets
Induction Furnace with Billet Caster
(2 x 40 T & 1 x 30 T)
-- 4,50,000
1,50,000
Re-Rolled Steel Products (M.S. Rounds, Flats,
Angles, etc.,) 1 No x 40 T Reheating Furnace
-- 5,00,000 --
Power Plant – AFBC (65 TPH) -- 16 MW --
Waste Heat Recovery Boiler (WHRB) 8 MW 8MW --
Each of the manufacturing / processing centres of JR Metal conforms to total
commitment in controlling the de-gradation of the environment by Controlling
Pollution, & maintaining green- belt, and open space around the manufacturing/
processing complexes.
Pre-feasibility Report 5 J R Metal - Amirthamangalam
2.2 NATURE OF PROPOSED PROJECT The proposed project is a Greenfield Steel Mill consisting of Primary Sponge Iron
Plant, and Secondary Plant to produce Ingots/Rolled Products.
The proposed project will consist of Rotary Kilns to process Iron-ore to produce
Sponge Iron. The Sponge Iron, and M.S. Scrap will be melted in Electric Induction
Furnace. The molten metal is cast into billets, and the billets are then rolled into
products.
2.3 NEED FOR THE PROJECT
Government of India has approved the National Steel Policy (NSP) 2017, as it seeks
to create a globally competitive Steel Industry in India. NSP 2017 targets 300 million
tonnes (MT) Steel making capacity, and 160 kg/capita steel production by 2030.
Huge Scope for growth is offered by India’s Comparatively low per capita steel
consumption, and expected rise in consumption due to increased infrastructural
construction and thriving transport industry. Government of India focus on
infrastructure, and restarting road projects is aiding boost in demand for steel.
Further, likely acceleration in rural economy and infrastructure is expected to lead
growth in demand for steel.
India is at present third largest producer of steel, and is all set to be the second
largest producer of steel by 2021. The growth in Indian Steel Industry is largely
driven by domestic availability of raw material such as Iron-ore, and cost effective
labour.
Further, remedial measures taken by Government of India to promote domestic steel
production, such as anti dumping duties, safeguard duties, and temporary
introduction of minimum import price, notified quality control order etc.
The Policy of Government of India also stipulates adoption of energy efficient
technologies, to improve overall productivity and reduce energy intensity.
Pre-feasibility Report 6 J R Metal - Amirthamangalam
The Government of India has also announced a policy for providing preference to
domestically manufactured Iron and Steel products in Government Procurement.
This Policy seeks to accomplish PM’s Vision of “Make in India” with objective of
Nation Building and encourage domestic manufacturing and is applicable on all
Government Tenders.
India has now emerged as a net exporter of finished steel products. India has
emerged as a top exporter of steel to Vietnam, Bangladesh, Myanmar, Sri Lanka,
Nepal and other European / American Markets. The demand for Indian Steel
Products from overseas market is set to increase, owing to slowing down of Chinese
production, overall.
2.4 EMPLOYMENT GENERATION
Employment generation is one of the important objective of any development
activity. Employment is closely linked to eradication of poverty. Unemployment,
and under employment had been the chronic feature of the Indian Economy.
Steel Industry employs people with many different skills and diverse knowledge.
Steel Industry employs unskilled, semi skilled and skilled workforce of various
nature. The workers required will be right from handling of raw material, to
processing of production, and finally handling of finished products. Apart from
main activity, workers are required for maintenance and operation of utilities.
Indirect generation of employment also entails in the form of logistics, supply chain
and related commercial activities.
JR Metal will employ about 200 – direct workers and generate large scale indirect
employment in the transportation, and related commercial activities.
Pre-feasibility Report 7 J R Metal - Amirthamangalam
3.0 PROJECT DESCRIPTION
3.1 TYPE OF PROJECT The proposed plant is a green field steel manufacturing unit. The project upon
completion envisages production of rolled products using Sponge Iron and M.S.
Scraps as raw materials. The plant also will have a facility to produce Sponge Iron
using iron Ore.
The Proposed Plant will consist of 16 MW (2 x 8 MW) WHRB, 2 x 40 T & 1 x 30 T
Electric Induction Furnace, 1 x 40 T Reheating Furnace, 2 x 350 TPD Rotary Kiln
and16 MW AFBC based on Dolachar.
3.2 PROJECT LOCATION The proposed project of M/s. J.R. Metal is to be located at Survey Nos. 91 to 95 & 97
to 103 of Amirthamangalam Village, Gummidipoondi Taluk, Thiruvallur District,
Tamil Nadu.
The Latitude and Longitude of the project site is as follows.
The project location is as shown in Fig.1.0 – Topo Map, and Fig.2.0 Administrative
Setup Map and Fig.3.0 Plant Layout.
Pre-feasibility Report JR Metal - Amirthamanagalam
11
3.3 PRODUCTION CAPACITY The details of production capacity of the proposed project are as follows.
Products Production Details (TPA)
PHASE – I PHASE - II PHASE – III
Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --
Intermediate Product – M.S. Billets Induction Furnace with Billet Caster (2 x 40 T & 1 X 30 T)
-- 4,50,000
1,50,000
Re-Rolled Steel Products (M.S. Rounds, Flats, Angles, etc.,) 1 No x 40 T Reheating Furnace
-- 5,00,000 --
Power Plant – AFBC (65 TPH) -- 16 MW --
Waste Heat Recovery Boiler (WHRB) 8 MW 8MW --
3.4 MANUFACTURING PROCESS Sponge Iron Plant The plant consists of raw material preparation unit where iron ore and non-coking
coal are crushed and screened to obtain the required sizes. These required sizes are
conveyed to stock house for storing in the respective bins. No crushing is envisaged
for dolomite/limestone, as it is received mostly in 0-4 mm size form. This limestone
is conveyed to its respective bins. The sized materials stored in bins at stock house
are charged in rotary kiln with predetermined feed rates with the help of weigh
feeders and volumetric feeders and also conveyors.
The iron ore is preheated and reduced to sponge iron in the rotary kiln at the
required and controlled temperatures and pressure. Carbon and volatile matter in
coal is utilised and converted into char. Dolomite is used for desulfurisation and in
the process becomes dolochar. Sponge iron, char and dolochar travel from kiln to
cooler and are cooled to about 80ºC by indirect cooling, using water as medium.
The material cooled and discharged from the cooler, is conveyed to product
separation system. A junction house is provided in between cooler & product
Pre-feasibility Report JR Metal - Amirthamanagalam
12
separation system, to take care of any eventualities occurring due to the breakdown
of the product separation system, which may happen due to breakdown of
equipment etc. The cooler discharged material is screened and separated with the
help of magnetic separators. Sponge iron lumps and sponge iron fines are taken to
their respective bins. Dolochar and char which are non magnetic are taken to a single
bin.
The schematic manufacturing process of Steel production is given in Fig.4.0.
Fig 4.0 Manufacturing process of Steel division
TMT bars, Wire rod coils, Rounds, Structural products
Pre-feasibility Report JR Metal - Amirthamanagalam
13
Steel melting Shop
The Steel Melting Process can be subdivided into the following stages:-
Stage 1: Production of Liquid Metal from Induction Furnace.
Stage 2: Transfer of Liquid Steel to the Ladle Furnace
Stage 3: Continuous Casting.
Induction Furnace Scrap and Direct Reduction Iron (DRI) are the main raw materials for melting in the
Induction Furnace. The scrap and DRI will be brought into the steel plant premises
by Tipper / Dumpers / Trucks and unloaded either in the open scrap yard where it
will be intermittently stored or directly into the scrap bay, whereas, Sponge Iron is
produced within the Plant at Sponge Iron Plant. The usage of scrap and DRI in the
Steel Melt Shop is in the ratio of 56:44.
Raw Materials
Qty. in % fed in charge
Recovery
Qty. fed TPA for 6,00,000
Scrap + Cast iron Pieces
56% 96%
3,36,000
DRI 44% 82% 2,64,000
The capacity in the scrap bay of scrap and DRI will be in the same ratio. The scrap
bay will store the scrap and DRI in bins. In the scrap bay the trucks will be unloaded
by EOT cranes and the tippers will tip the scrap / DRI into the bins directly.
From the bins in the Melting Bay EOT cranes will load the scrap in to a scrap bucket
which will be charged in to the Induction Furnace by EOT Crane. The first charge will
be of light scrap + cast iron pieces of about 3 T followed by DRI to be fed in 2-3
installments. The balance of heavy scrap is charged towards the end of the heat.
Pre-feasibility Report JR Metal - Amirthamanagalam
14
Fe metal C Si Mn P S
92.1% 0.25% 0.35% 0.5 % 0.03% 0.04%
The DRI will be mainly Coal based and will be in lumps with size range of 3 mm to 20 mm with a bulk density of about 2100 kg/ cum. The typical chemical composition of coal based DRI is:
Metallization Fe Total P S C Si
92% 94% 0.045% 0.02% 0.1% 1.8
The Induction Furnaces are Melting Units. The heat and stirring in a coreless
Induction Furnace is caused by magnetic forces which result from the interaction of
the electrical current flowing in the induction coil and in the molten bath itself melts
the metal and can increase the bath temp. to required temperature of 1600°C to
1650°C. Slag formed is taken out in the process.
The first charge of 3 t will consist of scrap and cast iron pieces only. DRI will be fed
in two or three installments. Frequent deslagging will be done to take the slag out. A
mechanical poker is provided to compact the scrap during feeding and to avoid the
formation of a bridge. The scrap mix used is shredded scrap, HMS, Cast Iron and
coal based DRI. Induction Furnace liquid steel output quality is dependent on the
quality of charge mix.
There will be 2 x 40 T Electric Induction Furnaces and 1 x 30 T Electric Induction
Furnace. The tapping temperature is maintained to approx. 1620°C.
Pre-feasibility Report JR Metal - Amirthamanagalam
15
The final chemistry of Liquid Metal from the induction furnace is:
C P S Temp.
0.30 max. 0.070 max 0.05 max. 1620 Deg.C
One heat in one Induction Furnace is estimated to take about 120 minutes on an
average. There will be two Induction Furnaces of 40T capacity + 1 No. of 30 T. The
Melting Bay has to therefore handle 48 heats every 24 hours.
Slag handling
The slag generated during melting will be to the extent of 10%. De-slagging will be
done by tilting the IF forward during the process while the power is reduced to a
minimum for 1-2 min. During the process of deslagging by forward tilting will be
done 5 - 6 times every heat. The slag will fall into in a slag box parked below the
Induction Furnace. The slag pot capacity will be 10 T to take care of the slag of each
heat. The slag pot will be lifted by the EOT crane and either be emptied in a dumper
or at the end of the bay. From there the slag will be taken to the slag dumping area.
Billet Casting
Liquid steel from ladle furnace is now placed in the Turret of the Continuous
Casting Machine. The Turret shall be moved and positioned over the tundish into
which the liquid steel will flow. From the tundish the liquid steel will flow into the
mould which shapes and forms the billet. The required starting ladle temperature
for the manufacture of billet for TMT rebars, wire rod, rounds, structural / grade at
the CCM is about 1650° C.
The hot billet goes through a water spray cooling chamber and comes to a
straightening cum withdrawal machine which is a set of individually driven rollers
with hydraulically pressed rollers.
Pre-feasibility Report JR Metal - Amirthamanagalam
16
The withdrawal machine also varies the speed of the billet to keep the level of the
mould constant as the steel flow into it varies as the metering nozzle erodes with
time. After the withdrawal machine is the oxy-fuel cutting machine which cuts the
billets into 6 m / 12 m length.
The billet by the time it reaches the cutting machine has no liquid core. The billets of
the 2 strands then come out onto a run out roller table and go into the run-in roller
table of the cooling bed. The transportation of the billets together from the run-in
roller table onto the cooling bed is done by an over head cross transfer for further
pushing of by a billet pusher on a skid Bank cooling bed.
A non-sequence casting cycle is as follows:
Placement of ladle on the Ladle turret : 2 min.
Moving the turret on position : 2.min.
Opening of the slide gate to start flow of : 1 min.
steel into the tundish
Opening the tundish metering nozzle : 1 min.
Start and end of casting including
slow start /slow finish : 25 min.
Total : 31 min.
Machine preparation : 20 min. After every sequence the CCM will have to be prepared again. The final output from
the CCM is 200 mm sq. billets in 6 m/ 12 m length.
Rolling Mill
The DRI – IF – CCM – RM route is considered for the integrated plant under
consideration, which is suitably supported by the Captive Power Plant. The main
technological facilities in different processing steps for production of rolled products
Pre-feasibility Report JR Metal - Amirthamanagalam
17
in DRI-SMS-RM route are as follows.
S.No Processing step Technological facility
1. Iron making Direct Reduction Plant
2. Steel making Induction Furnace
3. Casting Billet Caster
4. Rolling of Billets/ Blooms Rolling Mill
The Billets from Steel Melting Shop after Quality inspection are charged into
reheating furnace and at discharge end uniformly heated billets at a temperature of
about 1050OC – 1250OC (depending upon grade of Steel being rolled) are discharged
by an Ejector.
The heated billets are fed to different rolling mills to produce required size of
finished products.
The rolled product after last stand is transferred to Turnover Cooling Bed and cut to
specified length and after Quality inspection and requisite Color Coding, bundling
etc. is shifted to dispatch section.
Pre-feasibility Report JR Metal - Amirthamanagalam
18
Captive Power Plant Process Description
The process of sponge iron making by the DRI route produces a large quantity of
flue furnace gas. About 3500 N.Cu.m of flue gas with a calorific value of 900
K.Cal/N.Cu.m will be generated per ton of hot metal produced. It is estimated to
generate about 15 tons per hour of steam, which inturn generates about 8000 KW
power per kiln, and Hence total Power Generated for 2-kilns together will be 16
MW.
In addition to above, it is proposed to make use of the Dolachar generated in Kilns
alongwith some quantity of coal in the FBC boiler to generate additionally 16MW of
power, thus resulting in a total of 32MW power generation.
The Power plant will consist of a boiler house, steam turbine and generator along
with accessories such as condensers, deaerators, boiler feed pumps, controls and
instrumentation.
Process flow sheet for captive power plant is as shown in Fig 5.0.
Pre-feasibility Report JR Metal - Amirthamanagalam
19
Fig 5.0 Flow Diagram for Captive Power Plant
WHR / FBC BOILER
FLUE GAS
FROM ROTARY KILN & DOLACHAR/COAL
STEAM TURBINE
GENERATOR
AIR
PREHEATER
AIR
WATER
FLUE GAS
AIR
AIR COOLED CONDENSOR WATER OUT
DEAERATOR FLUE GAS TO CHIMNEY THROUGH ID FAN
32.0 MW
STEAM
Pre-feasibility Report 20 J R Metal - Amirthamangalam
3.5 RAW MATERIAL REQUIREMENT
Annual requirement of raw materials on the basis of achievable production is as follows:
FOR SPONGE IRON PLANT
Sl. No.
Raw Material Quantity (TPA) Source
1. 2. 3.
Iron-Ore Coal Dolomite/Limestone/ Quartz
5,40,000 2,70,000 14,900
Indigenous Imported/Indigenous Indigenous
FOR INDUCTION FURNACE / (BILLET)
Sl. No.
Raw Material Quantity (TPA) Source
1. 2. 3. 4.
Sponge Iron Melting Scrap Ramming Mars Refractories
2,15,000 4,32,000
1,200 620
Captive Indigenous/Imported Indigenous Indigenous
FOR RE-ROLLING MILL
The Billet produced by the Steel Melt Shop will be the Raw Material for Re-Rolling Mill
Sl. No.
Raw Material Quantity Source
1.
2.
Coal for Producer Gas Furnace Oil
23,000 TPA
4 KL/day
Imported/Indigenous Indigenous
FOR POWER PLANT
Sl. No.
Raw Material Quantity
1. Imported Coal 384 TPD
Pre-feasibility Report 21 J R Metal - Amirthamangalam
3.6 WATER / ENERGY REQUIREMENT 3.6.1 RAW WATER REQUIREMENT
The raw water requirement for the operation of the proposed plant will be as
follows, and will be sourced from ground water within plant site.
Description Qty (KLD)
Boiler Feed Make-up 20
DM. Plant Regeration 15
Induction Cooling make-up 60
Rotary Kiln Cooling make-up 160
Concast Cooling make-up 30
TMT Cooling make-up 30
Domestic Consumption 10
Total 325
The Fresh Water drawn from ground will be only 177 Cu.m/day after recycling of waste
water.
The detailed Water Balance Diagram is as shown in Fig 6.0.
Pre-feasibility Report 22 J R Metal - Amirthamangalam
Fig 6.0 Water Balance Diagram
All values are in KLD.
Raw Water 325
Induction Furnace 1 & 2 Cooling
Concast Cooling
Rolling Mill Cooling
Boiler Water Make-up (AFBC)
Boiler Water Make-up (WHRB)
Rotary Kiln Cooling
Evaporation Loss – 40
Evaporation Loss – 20
Evaporation Loss – 18
60
30
30
10
10
160
12
10
20
9
9
Green Belt
Cooling Pond I
Cooling Pond II
170
Guard Pond
Evaporation Loss – 1
Evaporation Loss – 50
110
Coal Dust Suppression /
Ash Dyke
7
D.M. Plant Regeneration
15 15
Domestic Consumption
10 9
STP 9
37
Rec
ycle
d
14
8
Har
vest
ed R
ain
Wat
er/
Bo
rew
ell
17
7
325
Neutralization Pit
RO Plant
185
RO Reject
148
30
15
Pre-feasibility Report 23 J R Metal - Amirthamangalam
3.6.2 ENERGY CONSUMPTION
The required power for the project will be met captively, and about 20 MW power
will be drawn from TNEB Grid
3.7 QUANTITY OF LIQUID & SOLID WASTES 3.7.1 LIQUID WASTE MANAGEMENT
Description of effluent generated Qty (KLD)
Boiler Blow Down 18
DM. Plant Regeration Waste 15
Induction Cooling Blowdown 20
Rotary Kiln Cooling Blowdown 110
Concast Cooling Blow Down 10
TMT Cooling Blow Down 12
Sewage 9
Total 194
The blowdowns from plant will be taken to 2- consecutive Cooling Ponds, and then
to Guard Pond after neutralization. Further the treated water from Guard Pond
taken to RO Plat for further treatment and then about 148 KLD will be recycled for
make-up water. From RO Reject about 30 KLD used for green belt and about 7 KLD
will be used for coal dust suppression and ash dyke. Hence, 177 KLD of Fresh Water
will be required for process after recycling of waste water.
The domestic sewage will be treated in Sewage Treatment Plant and about 9 KLD
discharged on land within the plant premises for green belt development.
3.7.2 SOLID WASTE MANAGEMENT
The solid waste generated will be slag from melting, and dolochar from sponge iron
plant.
Flyash and Bottom ash will be generated from Power Plant.
Pre-feasibility Report 24 J R Metal - Amirthamangalam
The quantity of solid waste that would be generated in the proposed plant are as
follows
S.
No.
Description Quantity Generated
(T/D)
Mode of Disposal
1. Slag 130 Ground slag will be given to
Cement manufacturers
2. Fly ash 27.65 Will be given to Cement
manufacturers
3. Bottom ash 6.91 Will be given to Brick
manufacturers
4. Dolochar 57 Will be used in AFBC Boiler
Pre-feasibility Report 25 J R Metal - Amirthamangalam
4.0 SITE ANALYSIS
4.1 CONNECTIVITY The proposed plant will be located at Amirthamangalam Village, Gummidipoondi
Taluk, Thiruvallur District, Tamil Nadu. The project site is located at distance of 8.00
km from Gummidipoondi Railway Station, Plant site is well connected from
Chennai Road NH-5 (Chennai – Kolkata Road), about 8 km East.
The plant site is then accessible through State Highway SH-52 from NH-5 ie the
Kaverapettai – Sathyavedu Road.
The project site is predominantly industrial area, and well connected by the Road.
4.2 LAND FORM, LAND USE & LAND OWNERSHIP The total area of the Project Site is 42.8 Acres which is Dry unclassified land. The
Land is barren unused at present. The said land is entirely owned by J R Metal
Chennai Limited.
The entire land is at present owned by J.R. Metal. 4.3 TOPOGRAPHY Topography is Plain. The Topography of the proposed project site is as shown in
Fig.7.0 Physiography Map.
Pre-feasibility Report 27 J R Metal - Amirthamangalam
4.4 EXISTING LANDUSE PATTERN The Existing Land is Dry and unclassified land. The Land for the proposed project
site is barren and unused at present.
There is river/steam crossing within the 10 km radius of the site viz., Araniyar River
in South East at a distance of 6.0 km.
Also, the Plant Site is located within 10 km of Inter State Boundary (Tamil Nadu –
Andhra Pradesh).
There is the Palavakkam Reserve Forests at a distance of 2.5 km in South from the
project site. There are no national park, wild life sanctuary, or eco sensitive areas
within 10 kms of project site.
The Landuse of the proposed project site is as shown in Fig.8.0 Landuse Map and
the Drainage and Water Bodies Map is as shown in Fig.9.0.
Pre-feasibility Report 30 J R Metal - Amirthamangalam
4.5 SOIL CLASSIFICATION The soils in general are characterized by sand/clay content, poor nitrate and
phosphorus contents. The fertility status of the lands, mostly under rain fed
agricultural use, is generally medium except in some pockets where the soils are
fertile.
The Soil Classification of the proposed project site is as shown in Fig.10.0 Soil
Classification.
Pre-feasibility Report 32 JR Metal-Amirthamangalam
4.6 CLIMATIC DATA The climate of the project site is dry and arid coastal climate. The Max. dry & wet
bulb temperature is 42.1 / 38.7.8°C respectively and Min. dry & wet bulb
temperature 19.6 / 15.8°C respectively. The predominant wind direction in the
region W followed by SE. Average annual rain fall of this region is about 1200 mm.
The average maximum wind speed in this region is about 11 km/hr. The annual
Maximum Humidity is 100% and minimum humidity is 25%.
5.0 PLANNING BRIEF
The Plant Site is located in an area which is outside the classification regulation of
Department of Town & Country Planning.
The Revenue Classification is a dry rain fed agricultural land. The area is now dependent on the industries for their overall development and
livelihood. The area within 10 kms radius of plant site is dominated by small,
medium and large scale industries.
Some of the Large Scale Industries in the area are Michelin India Pvt. Ltd, (Automobile Tyres)
SKI Carbon Black (India) Pvt. Ltd, (Carbon Black)
SRF Limited, (Nylon 6.6)
Suryadev Alloys & Power Pvt Ltd, (1,00,000 MTPA Steel Plant & 2 x 80 MW Power Plant)
OPG Power Generation Pvt Ltd, (3 x 80 MW & 1 x 160 MW Power Plant)
Tulsyan NEC Limited, (2 x 35 MW Power Plant)
TCP Limite, (63 MW Power Plant).
Kavery Power Generation Chennai Pvt Ltd, (2 x 180 MW Power Plant)
Bhatia Coke & Energy Ltd, (Cove Oven Plant)
ARS Metals Pvt Ltd, (Steel and 1 x 60 MW & 1 x 135 MW & 1 x 350 MW Power Plant)
Tulsyan NEC Ltd (Steel Plant)
Pre-feasibility Report 33 JR Metal-Amirthamangalam
And the area also houses 2 – SIPCOT Complexes, one in Thervoy Kandigai which is
SW at 6 Kms, and the other at Gummidipoondi which is NE at 5 Kms.
The total land requirement for the proposed project is 42.8 Acres. The Land usage and Break-up are as follows.
Sl.
No.
Description Land Area
(in Acres)
1. Induction Furnace & Rolling Mill 10.0
2. AFBC Captive Power Plant 3.1
4. Rotary Kiln & WHRB 1.8
5. Switch Yard 1.6
6. Greenbelt 10.0
7. Iron Ore Stock Yard 0.4
8. Coal Storage 2.4
9. Ash dyke 2.0
10. Slag Storage 4.7
11. Scrap Yard 1.1
12. Road 1.4
13. Open Area 4.3
Total Land Area 42.8
The green belt development will be initiated even before commencement of
project activities.
Pre-feasibility Report 34 JR Metal-Amirthamangalam
6.0 PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA About 42.8 Acres of land is required for implementation of the proposed project.
The Plant Site would require
A Industrial Shed to house 2 x 40 T & 1 x 30 T Induction Furnace, Concast
Machine, Reheating Furnace and Rolling Mill.
Offsite facility such as Cooling Tower, Scrubber, Water Treatment Plant and
Other Utilities.
A Storage Yard for Scrap Storage.
Facility for Installation of Coal Crusher, Rotary Kiln and Sponge Iron
Screening Facility of Sponge Iron Plant.
Facility for WHRB, Turbine & Turbine Hall, Air Cooled Condenser etc.
Facility for Boiler, Turbine, Generator of 1 x 16 MW CPP.
Air Cooled Condenser, D.M Water Plant etc for CPP.
Coal Storage Shed
The entire Plant Boundary will have 2 m width green belt.
The existing transport infrastructure will be used and there will be no new
transport infrastructure required.
6.2 RESIDENTIAL AREA J.R. Metal does not propose to have any residential accommodation within or
outside the plant area. Most of the work force requirement will be met from local
availability.
However, workers rest room, cafeteria, and canteen facility will be provided within
the plant, predominantly for the labourers.
Pre-feasibility Report 35 JR Metal-Amirthamangalam
6.3 GREEN BELT About 10 Acres of Land will be developed as Greenbelt, and will be initiated at the
project stage. More-over species selected will be in consultation with the local forest
officer, and will be predominantly consist of local species.
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN
The proposed plant will be located in an area of 42.8 Acres, which is Dry unclassified
land. The Land is barren unused at present. Topography is Plain. It is vacant land,
and there are no rehabilitation and resettlement or land oustees, as the land is fully
owned by M/s. J. R. Metal.
8.0 PROJECT SCHEDULE & COST ESTIMATES
8.1 TIME SCHEDULE The construction of proposed plant will take around 18 months from date of
obtaining Environmental Clearance. So, the proposed plant will be commissioned
during the September 2020.
8.2 PROJECT COST
The total project cost will be Rs.350 Crores, which is inclusive of Rs. 15 Crores for
pollution control activities.
9.0 ANALYSIS OF PROPOSAL
9.1 FINANCIAL & SOCIAL BENEFITS Social benefits results in evaluation of project from society point of view. Proposed
steel plant will involve not only construction of the plant, but also construction of
Pre-feasibility Report 36 JR Metal-Amirthamangalam
intermediaries, which are basically facilities to the workers but will also offer
economic benefit to the local population.
Pollution from plant may cause degradation of the environment, which is the cost or
price locals have to pay for economic benefits accruing because of the proposed
project.
The significance of economic development cannot be underplayed especially in a
underdeveloped area, and Government also recommends investment in projects to
contribute in well being of the Society.
The proposed project of M/s. J.R. Metal Chennai Limited would result in increased
revenues to Government of Tamilnadu, and Government of India, in terms of
cumulative tax, both indirect taxes, and direct taxes.
The proposed project of M/s. J. R. Metal Chennai Limited will also result in
augmentation of the social infrastructure, more-over investments in various
environment conservation measures will result in better living condition.
M/s. J.R. Metal Chennai Limited will invest about 0.2% of the project cost in thrust
areas for CSR activities such as income generation program, health and hygiene,
empowerment through self help groups, and water supply to near by villages.
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