coal washery in india

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EIA Report

Greenfield Integrated Steel Plant

Raigarh, Chhattisgarh______________________________________________________________________________________

1

CHAPTER 1 : INTRODUCTION

1.1 Purpose of the Report

M/s Visa Steel Limited (VISA) proposes to set up a Greenfield 2.5 Million Tons Per Annum (MTPA)

Integrated Steel Plant and 559 MW Captive Power Plant near Kotarlia, Kotmar and Patrapali villages,

District Raigarh in Chhattisgarh State. The location map is shown in Figure 1.1. About 400 hectares land

has been identified for the project. The site is on the east of Raigarh town and north of Kotarlia railway

station. Raiway siding for transportation of raw materials and finshed products will be taken from this

railway station. The site is approachable from Raigarh - Mauhapalli Oriisa Road.

The name and capacity of the units is given in Table 1.1.

Table 1.1 Name and Capacity of Units of the Integrated Steel Plant

Name of Units Capacity

Iron ore Beneficiation & Pellet Plant 2.4 MTPA

Blast Furnace, 2 x 900 m3

1.764 MTPA

Coal Washery, 2 x 2.5 MTPA 5.0 MTPA

DRI Plant, 8 x 500 TPD 1.2 MTPA

Sinter Plant, 2 x 120 m2

2.4 MTPA

Coke Oven, Non Recovery type 0.8 MTPA

Oxygen Plant 1000 TPD

SMS, (2 X 130 Tons EAF) 2.5 MTPA

Rolling Mill 2.5 MTPA

Power Plant 559 MW

This Environmental Impact Assessment Study report discusses the proposed project site, its

surroundings, regulatory scoping, manufacturing process, pollution mitigation measures, impact

predictions, and environmental management and monitoring plan. The Terms of Reference for the EIA

study was presented before the Ministry of Environment & Forests, Government of India and approval

was obtained vide letter No.J.11011/842/2008/IA-I dated 23rd

January 2009. This draft EIA report has

been prepared as per the TOR issued by MOEF for public hearing.


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FIGURE 1.1 LOCATION MAP


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1.2 Project Proponent

M/s VISA Steel Limited is the Indian flagship company of VISA Group having turnover of Rs. 4000 Crores at

present. M/s VISA Steel is in the Iron and Steel Sector for the last eight years. M/s VSL have spreaded over

their business across India, China, Australia, Indonesia, Switzerland, UK and Hong Kong.. The VISA group of

companies has been promoted by Shri Vishambhar Saran who has successfully established stable and profit

making entities in the areas of iron and steel, minerals beneficiation, etc. As a corporate entity M/s VISA Steel

Limited is a board-led company, which believe in the basic principles of enlightened management,

meritocracy, transparency and accountability.

1.3 Nature & Size of the Project

This proposal includes iron making, steel making and rolling facility integrated with coal washery, pellet

plant, sinter plant, coke oven plant and oxygen plant. Captive power plant will provide the electricity to

the integrated steel plant. In Coal Washery Run of Mine coal containing high ash will be cleaned /

beneficiated to produce clean coal containing low ash. In Pellet Plant iron ore fines will be converted to

pellets, suitable for use in DRI plant and Blast furnace. Sinter plant will utilize the iron bearing dust and

mill scales generated from other units to form sinter. The coke oven will produce coke using non-

recovery process. Blast furnace gas will be utilized in various furnaces. Coke oven gas and DRI kiln gas

will be used to generate steam and power. The slag generated from blast furnace will be granulated and

used in cement making.

The project cost is Rs.9625 crores. The proposed project activity is large and falls under Category A

Serial 3 (a) of EIA Notification 2006.

Raw Material Handling Complex, Product Handling Complex, Railway Siding, Oxygen Plant, Air

Compressors, Demineralization Plant, Steam Boilers, Laboratory, Workshop, Wagon Repair Shop, DG

Sets, Air Condition Unit, Ventilation System, Water Reservoir and System and Fire Fighting System are

the utilities proposed for the integrated steel plant complex. .

The steel plant will need development of right of way for transporting water from Sapnai river, railway

siding from Kotarlia station to carry the raw materials and finished products and approach road for traffic

entry.

The proposed 2.5 MTPA Integrated Steel Plant at Raigarh (CG) will be consisting of the following units:


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1. DRI-I-------------------------------- 8 X 500 TPD

2. Coal Washery -------------------- 2 X 2.5 MTPA

3. Blast Furnace ------------------ 2 x 900 Cum

4. Sinter Plant ----------------------- 2 x 120 SQM5. Pellet Plant-------------------------- 2 x 1.2 MTPA

6. Steel Melting Shop (EAF Furnace) ------2 X 150 t

7. LRF ----------------------------------------------2 X 150 t

8. Concast------------------------------2 X 6 Strand Billet Caster

9. Captive Power Plant ----------- 559 MW

10. Bar & Wire Rod Mill------------ 1.25 MTPA

11. Section Mill -------------------------1.25 MTPA

12. Non-Recovery Coke Oven ------- 0.8 MTPA

13. Other Infrastructure facilities as required for Plant.

Product-mix: The proposed product-mix envisaged for the plant is indicated below.(All Figures in TPA)

Sl Product Total

1. Bar & Wire Rod Mill ProductsMS BilletsTMT Bar 5 mm-63 mmPlain Round BarsRCS 40-63 mm

Angles 50-100

4,00,000 t3,00,000 t3,00,000 t2,50,000 t

Total 12,50,000 12,50,000

2. Section Mill ProductsHeavy Beams>350 to 600Light & Medium BeamsHeavy Channels >200 to 400Light & Medium Channels 100 to 200FLATS

2,00,000 t2,00,000 t2,00,000 t3,00,000 t1,50,000 t1,00,000 t1,00,000 t

TOTAL 12,50,000 12,50,000

Technological Considerations and Process Selection: As envisaged in the product-mix, the plant

configuration and finishing process has been selected to produce billets with the use of sponge iron and

hot metal. A number of mini Blast Furnaces and DR Kilns have also been installed with

indigenous/Chinese design. Hence, the steel complex to be installed is based on the less capital-

intensive indigenous DR and BF technology so that DRI and hot metal forms the main metallic charge

constituents during steel making.


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Continuous casting technology has now been established as conventional process for casting liquid

steel through extensive development and automation and is in a position today to cover most of steel

grades. With the technology of continuous casting of steel having been fully mastered and keeping in

view the advantages of continuous casting in terms of higher yield, lower energy consumption, lowerinvestment cost due to absence of primary mills, etc. the continuous casting of steels has been

envisaged for the proposed Steel Plant.

For effective utilization of DRI for liquid steel production, as one of the major metallic input, the

technology for steel making will be so selected which utilizes optimum quantity of DRI in charge-mix.

Metallic charge for EAF process usually consists of steel scrap and or DRI/HBI in varying percentage

depending on their availability and market price. In order to reduce the total electrical load of the plant

usage of hot metal in electric arc furnace has been envisaged. In recent years, many plants have started

using hot metal as a part of metallic input in EAF to take the advantage of lower power consumption and

increased annual production. The use of hot metal in EAF is more relevant in a country like India where

the availability of electric power is scarce and tariff is very high. Use of hot metal also brings down the

requirement of scrap whose availability and quality is quite erratic in the country.

Typical operating parameters with or without use of Hot metal in EAF is shown in Table below:

Parameter Without Hot Metal With Hot Metal

Scrap Mix Scrap : 5-10%Pig Iron : 10-15%

DRI : 70-80 %

Scrap : 5-10%Hot Metal : 50-60%

DRI : 55-40 %

Total Capacity 375000 TPA 920000 TPAHeats 11 heats / day 27 heats /day

Tap to Tap time 125 min. 50 min.

Power Consumption 850 KWH/ TLS 325 KWH / TLS

Electrode Consumption 4.5 kg/ MT 2.9 kg / MT

Refractory Consumption Rs.570 / MT Rs.350 / MT

Oxygen Consumption 18 Nm3/ MT 60 Nm

3/ MT

Considering above benefits, EAF process has been finally considered for steel production. Thus, an

Integrated Steel Plant of medium size could operate at much higher capacities coupled with blast

furnace. The S.I & H.M, depending on available site conditions, could vary from 30% to 70%. This has

already given a boost to many site-specific steel-making capacities between 50,000 tons to 3.0 million

tons.

To meet the secondary refining needs of the envisaged product-mix, ladle furnace has been considered

having facilities for arc heating, injection and stirring.


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The options available for hot metal production are namely EPIF, COREX, large blast furnace and mini

blast furnace. Taking into account the merits and demerits, the status of technology, flexibility of

operation, availability of indigenous raw materials, quality of hot metal requirement, capital investment

and economics of operation with respect to small plant capacity, mini BF process has been envisagedfor production of hot metal. The Chinese and indigenous developed mini blast furnaces is energy

efficient due to adoption of a number of design development like use of kalugin shaftless stoves, higher

top pressure, PCI, oxygen enrichment of blast, etc., which will be installed in the proposed plant.

A desulphurization plant will be installed for removal of sulphur from hot metal. The hot metal will be

further refined in a Ladle Furnace. Addition of Ferro alloys like Fe-Si, FC-Mn and Si-Mn will be done to

attain desired chemical composition & temperature as per requirements. Process gases like oxygen,

nitrogen will be blown through tuyeres provided in the furnace.

1.4 Schedule of Implementation

The project will apply Good Industry Practice at all levels, which means the exercise of the degree and

skill, diligence and prudence and those practices, methods, specification and standard of equipment,

safety and performance, as may change from time to time and which would reasonably and ordinarily be

expected to be used by a skilled and experienced operator engaged in construction, development,

operation and maintenance of facilities, equipment or system of the type and size similar to the Project.

The construction work will start after obtaining environmental clearance from MOEF and Consent to

Establish from CECB. The project will require 48 months to complete construction and start production.

Approximately 1000 people will get employment for 60 months during the construction of project. About

4000 people will get direct employment during the operation of the project. The project will be

implemented on turnkey basis for the major production unit and civil works. The peak construction

intensities are very high; hence high degree of mechanization is essential. It will be necessary to ensure

selection of capable and reputed construction and erection agencies and mobilization of requisite

resources of men, materials and construction machinery and expertise. It will also be essential to ensure

timely availability of site infrastructure in terms of water, electricity, site office, housing, etc for work

execution.

1.5 Description of Project Site and Surroundings

No ecologically sensitive habitats like national parks, biosphere reserves, wildlife sanctuary,

wetlands, migratory corridor of wild animals and notified archaeological monuments, health resorts

and defence installation is present within 10 km radius of the site.


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Forests present within 10 km radius of the site are given below.

1. Patrapali PF 1 km N

2. Boirdar RF - 3 km NW3. Sambalpuri PF 3.5 SW

4. Kumbahai PF 4.5 km NE

5. Jhariadipa RF 3 km NE

6. Saraipal PF 3 km E

7. Mahuapali PF 2.5 km SE

8. Kukurda RF 4 km SE

9. Chuhapai PF 4.5 km E

10. Sukhadongri RF 7.5 km E

11. Kolaibahai PF- 7.5 km E

12. Gajmar RF 4.5 km S

13. Balbhadrapur PF 9 km NE

The nearest railway station is Kotarlia on the Mumbai-Howrah rail line. The site is approachable from

Mahapalli road. The nearest river is Sapnai River, located about 1 km. away from the site. Kelo river

flows about 7-8 km from the site in west direction.

Raigarh town is located about 8 km on west side. The nearby villages are Kotmar 1 km east

direction, Patrapali 1 km northwest direction and Saraipali 2 km south direction.

The big industries present in the study area are Ind Synergy (Steel Plant) at Kotarlia and MSP Ispat

Ltd (Steel Plant) at Jamgaon. Other industries are Maa Shakambari Steel, Mangala Ispat, Shiv

Shakti Steel (Sponge Iron Plants) and R.R.Energy Ltd (Small biomass based power plant).

Map showing surrounding topographical features within 10 km radius of project site is shown in Figure

1.2. The project boundary marked on the toposheet 64 O/5 is shown in Figure 1.3.


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FIGURE 1.2 TOPOMAP SHOWING 10 KM RADIUS AROUND PROJECT SITE

Latitude : 21o

53 N L in i tude : 83o

28 E


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Figure 1.3 Map Showing Project Boundary

1.6 Importance of the Project

World production of crude steel in March 2008 rose by 5.8% to 119.5 million tonnes, the highest monthly

total in over 15 years. The total of the 3 months to date was 340.7 million tonnes, 5.6% higher than the

January to March period in 2007.

Overall, Asia produced 66.9 mmt of crude steel in March 2008 compared to 61.5 mmt in March 2007, an

8.8% increase in crude steel production. The IISI estimated crude steel production for its 67 member

countries to be 1.322 billion tones in 2007, 7.3% up on the year 2006 total of 1.232 billion tonnes.

However, China accounted for 37% of this total, and the total excluding China rose by only 3.2%

compared to 2006.

SITE


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This total represents the highest level of crude steel output in history. 2007 is also the fourth consecutive

year in which crude steel output has been above 1 billion tons. MEPS is now forecasting world wide

crude steel making in 2008 at in excess of 1.4 billion tones. The oxygen/blast furnace process continued

to lift its share of manufacturing - rising by 11 percent in 2006 and almost 7 percent in 2007 to 873 and932.5 million tonnes, respectively.

India is now the 5th

largest producer of steel with an annual production of around 53.9 million tonnes.

Steel production has jumped since the economic liberalization. The economic indicators are all favorable

for Growth. Massive investment in infrastructure planned will step up demand for steel. In the last

financial year (2007-2008), the country's crude steel production stood at 53.9 million tonnes, of which

about 5 million tonnes were exported. To bridge the demand-supply mismatch, India had to import nearly

7 million tonnes of steel. As per official figures, the country's finished steel import went up by over 300

per cent from 1.6 million tonnes in 2002-03 to nearly 7 million tonnes in 2007-08 (provisional). India had

emerged as a net importer of steel for the first time in 2007-08 and the situation is going to worsen in the

next two to three years.

It is reported that Indian government is concerned over the increasing gap between demand and supply

of steel in India, and sees that the situation is going to become worse in nex t few years. All estimates

regarding consumption and production had gone haywire. While consumption was estimated to grow at

3% and production at 7%, it had been seen that consumption growth had outstripped demand. The

annual demand for steel in India has been rising by about 13 per cent against estimated 3%, production

is growing by over 6 per cent only, according to official sources.

In view of the growing demand, the government plans to scale up steel production to touch 124 million

tons by 2011-12.and over 290 million tonnes by 2020. By 2015-16, India will emerge as the number two

steel producers in the world.

The economic indicators are all favorable for sustained growth. Massive investment in infrastructure

planned will step up demand for steel. India will become the fastest growing economy out of 34

developed and emerging markets and 2nd largest economy by 2020. Current GDP per capita is USD

2500 and expected to be USD 5000 in 2020. India is fast emerging as a global hub and in future FDI is

bound to increase by leaps & bounds. The wide gap in relative consumption of steel indicates that the

potential ahead for India in raising its steel consumption and prospects for development of the Indian

steel industry to sustain the growth momentum is quite rosy.


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The steel industry is buoyant due to strong growth in demand particularly in the following sectors, which

are the key drivers to the steel demand.

Infrastructure development Housing and urban development

High degree of urbanizations

High demand in the auto sector

Capacity building in steel making

8.5 % GDP growth targeted in 2008-09 - second only to China; aspirational 10 % growth looks possible.

Chhattisgarh, endowed with abundant natural resources, is a 21st century state. It is the endeavour of

the State Government to work towards rapid economic growth with regional balance so as to take the

state to the category of "developed states". To bring about prosperity to the people of Chhattisgarh, it is

necessary that the present rate of industrial growth increases substantially. Therefore, creation of a

favourable investment environment for increasing industrial production and creating employment

opportunities is one of the priority areas of the State Government.

The main objective of the new industrial policy of Chhattisgarh Government is to add maximum value to

state's abundant natural resources within the state itself, and create maximum employment opportunities

by setting up industries in all its districts across the state. To attract industrial investment in the state, the

policy attempts at providing necessary infrastructure for investment, reducing the cost of production for

the investor and ensuring an investor friendly administration. Towards this end, special importance has

been given to private sector participation.

Under the free market condition only those steel plants will survive, which are installed with lower capital

cost, capable of producing quality products at low cost. Chhattisgarh has a storehouse of huge mineral

deposits. Due to easy availability of these resources and the huge level of support given by the State

Government, it has immense potential for setting up of Integrated Steel Plants to realize above

objectives.

VISA shall be using its core competence to produce steel and power in a cost effective manner. The

proposed plant will add value to mineral reserve of the country and bridge the demand-supply gap of

steel and power in the country. The project shall also provide additional revenue to state government

and direct and indirect employment opportunities to the local people. The site near village Kotmar and

Patrapali selected for establishing the plant fulfills the guidelines prescribed by the Ministry of


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Environment and Forests (MOEF), Govt. of India for siting an industry. The proposed location and

technological features of the project makes it environmentally compatible due to the following reasons.

Location Features

1. The proposed site maintains the following distances from the areas listed below, as stipulated by

Ministry of Environment and Forests (MOEF):

Ecologically or otherwise sensitive areas (like historical places, archaeological monuments,

wetlands, hill resorts, beach resorts, health resorts, biosphere reserves, national parks and

sanctuaries, migratory corridors of elephants or tigers). - None within 15 km radial distance.

Flood plain of river - More than 500 m away from flood plain of river system. Kelo and sapnai rivers

are located more than 1 km away from the site hence, there is no flood plain within 500 m distanceof the plant

Coastal area - More than 500 m away from high tide line of coastal zone. The site does not involve

any coastal zone regulations.

Transport system - More than 500 m away from highway. The plant facilities are located more than

500 m away from highway.

Major settlements - More than 25 km away from any major settlements above 3.0 lakhs population.

There is no major settlement involving 3 lakhs population within 25 km area of the project site.

2. The proposed site involves no forestland.

3. The layout of the plant has been designed in such a manner that the aesthetics of the surroundings

are improved. Adequate greenbelt will be developed around the plant premises.

Technological Features

4. The adverse impacts of the project are amenable to technological control and can be foreseen and

minimised through necessary preventive and control measures and finally through effective

environmental management of the operating units.

5. The project technology is proven and such plants are operating all over the world. The efficacy of

pollution control technology is also validated and national discharge standards are available for

pollution control stipulations.


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6. The project is optimised in terms of energy and raw water conservation. The specific raw material

consumption, including raw water, is optimised for superior yield. Water required for direct and

indirect cooling purposes are re-circulated to the maximum extent possible through cooling towers.

7. The project is based on zero wastewater discharge and the entire wastewater generated from the

project will be adequately treated and recycled to the maximum extent possible and the balance will

be reused for greenbelt, greenery development and dust suppression measures .

8. Pelletisation of iron ore fines to convert into lumps is clean technology. The furnaces of the plant will

be fired using blast furnace gas, instead of liquid fuel. Such process comes under recognized clean

technology.

9. The project involves power generation using DRI kiln waste gas, flue gas of coke oven by using

WHRB technology. The char generated from DRI plant will be mixed with coal fines and used for

power generation using FBC technology. These are covered under clean development mechanism

entailing reduction of greenhouse gas emissions and eligible for CDM benefits.

1.7 Scope of EIA Study

The purpose of Environmental Impact Assessment (EIA) study is to determine as precisely as possible,

within the present limits of knowledge and expertise, the likely environmental impacts of the projectactivity. VISA entrusted the work of carrying out the EIA study of the proposed project to M/s EMTRC

Consultants Private Limited and Envirotechno Consultants, whose profiles are given in Chapter 10. The

Terms of Reference for the EIA study was presented before the Ministry of Environment & Forests,

Government of India and approval was obtained vide letter No.J.11011/842/2008/IA-I dated 23rd

January

2009. Pointwise compliance to the TOR is given in Appendix 1.

The generic structure of the EIA Report is discussed below:

1. Introduction (This chapter describes the purpose of the report, Identification of nature, size and

location of the project and its proponent, Schedule for approval and implementation, Description of site

and surrounding environment, Location maps, Importance of project to the country and region and the

Scope of the EIA study)


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2. Project Description (This chapter describes the project, land requirement, technology and

process description. flow diagram, layout of project showing boundary, water requirement, description of

mitigation measures to meet the environmental standards)

3. Description of the Environment (This chapter describes the study area, period of study,

components and methodology, establishment of baseline data for valued environmental components

and base maps, description of environmental component namely Topography, Meteorology, Ambient air

quality, Ambient noise quality, Hydrology and water quality, Landuse, Agriculture, Soil quality, Ecology,

Demography, Occupational pattern and Socio-economics

4. Anticipated environmental impacts and mitigation measures (This chapter describes the details

of investigated impacts during construction and regular operation, mitigation measures considered for for

minimizing and / or offsetting adverse impacts, possible accidents and rosk mitigation measures,

Assessment of significance of impacts [criteria for determining significance, Assigning significance].

Modeling for air emissions shall be done using ISCST3 Model (recommended by US-EPA), and Traffic

by Caline4 Model.

5. Additional Studies (This chapter describes the Risk Assessment and proposed risk mitigation

measures, Rehabilitation and Resettlement issues).

6. Environmental Monitoring Plan (This chapter describes the technical aspects of monitoring the

effectiveness of mitigation measures including measurement methodologies, frequency, location, data

analysis, reporting schedules, emergency procedures)

7. Environmental Management Plan (This chapter describes the recommeded mitigation and

administrative aspects of ensuring that mitigation measures are implemented and their effectiveness

monitored after approval of the project).

8. Project Benefits (This chapter describes the benefits derived from the project in terms of

improvement in physical infrastructure, Improvement in social infrastructure, employment potential of

skilled, semi-skilled and unskilled persons, other tangible benefits)

9. Summary and Conclusion (This chapter describes the overall justification for implementation of

the project, and Explanation of how adverse affects have been mitigated)

10. Disclosure of Consultant Engaged (The name of the consultant engaged with brief resume and

nature of consultancy rendered will be provided as appendix)


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Methodology

The baseline environmental quality within 10 km radius of the project site has been assessed usingsecondary data collected from various sources supplemented by primary data generated within the study

area. Potential sources of pollution owing to the project have been identified to quantify the pollution

load. Potential environmental impacts have been assessed qualitatively and quantitatively. The changes

in the quality of the environment have been predicted based on simulation models and professional

judgement.

Land: It includes land utilization, surrounding land use, sensitive locations within the study area for

drinking water sources, other water bodies, archaeological monuments, monuments of cultural and

historical importance, places of scenic beauty, biosphere reserves, national park and wildlife

sanctuaries, defense installation and ecotones / migratory corridors. Land use pattern of the study area

is based on secondary information collected from district statistical records and satellite imagery

obtained from Google Earth.

Meteorology: Site specific met data has been generated for one season. Met station was established at

village Kotmar, which is near to the plant site. The station was equipped to generate hourly data on wind

speed, wind direction, relative humidity and ambient temperature. Mixing height and Stability class

values has been obtained using SODAR data. Historical weather data for past 30 years has been

collected from Climatological Tables of IMD.

Ambient Air Qual ity: The measurement of ambient air quality of the study area is important because

the ambient air quality after the project commissioning can be predicted only if the baseline information

on the existing air quality is available. For this, air quality was measured at selected locations around the

site. The locations were selected based on impacted areas due to the air emissions from the project.

The monitoring was conducted as per CPCB procedure. At all locations, concentrations of suspended

and respirable particulate matter, sulphur dioxide and nitrogen dioxide were monitored.

Ambient Noise Qual ity: The baseline noise levels were collected from locations where air monitoring

was done. Noise readings were taken using noise meter once during the study period as per CPCB

procedure.

Water Quality: Both surface and groundwater samples from the study area were collected from

locations based on the drainage pattern and water utilization. Parameters recommended by CPCB / IS


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10500 were analysed following the standard methods (APHA). Samples of surface water and

groundwater were taken once during the study period. In regard of water, two aspects one the water

availability for the project and second is the quantity and quality of wastewater that will be generated and

re-circulated will be considered. The concern will be to minimise the use of fresh water. The water that isbeing re-circulated will be, as far as possible, segregated and treated before it is reused. The treated

wastewater will meet the standards set by CPCB. Proper plan for the disposal of the sludge generated

from the water treatment plant will be considered.

Soil: Soil sampling was done at eight agriculture field locations. The samples were analysed for

parameters namely texture, moisture, organic matter, conductivity, pH, bulk density, water holding

capacity, NPK and Infiltration rate.

Flora and Fauna: The list of flora and fauna has been obtained from the Working Plan of Raigarh

Forest Division and observations noted by Ecology Experts during field visits.

Green Belt Development: A green belt development plan has been prepared to enhance the aesthetic

quality of the environment and also attenuating air and noise pollution levels. The green belt design is

based on CPCB guidelines. Indigenous species and those having long-term economic value have been

recommended for green belt development.

Socio-economic Environment: The existing quality of life of the people in the study area was

assessed. Demography, occupational pattern, health and educational facilities and infrastructure

facilities were noted from District Statistics Handbook

Occupational Health and Safety: Based on standard procedures prescribed by the National Safety

Council and provisions mentioned in the Factories Act, occupational health and safety aspects of the

cement plant was identified and assessed.

Environmental Management Plan: EMP has been drawn up to maintain and enhance the

environmental quality in and around the project area. In case the quality of the environment is expected

to deteriorate beyond acceptable limits, additional strategies were suggested. Such strategies include

wastewater treatment and reuse, more efficient air pollution control devices, noise reduction measures

and solid wastes utilization and disposal. EMP has been designed to achieve the following objectives:

Reduction of adverse environmental impact due to the project activity

Improvement of environmental quality of the surrounding area


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Waste minimization, reuse and resource recovery

Waste segregation to make the treatment and disposal cost-effective

Establish proper monitoring mechanism with adequate infrastructure mechanism

The plan earmarked specific staff, instruments and finances for routine environmental management and

monitoring including collection, collation and examination of various environmental data. A post-project

monitoring plan is suggested to monitor the changes in the environmental quality after implementation of

the project.


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CHAPTER 2 : PROCESS DESCRIPTION

2.1 Project Outline

The name of proposed units and its capacity is given in Table 2.1: The process flow of the project is

shown in Figure 2.1. The process description described below is based on preliminary information about

plant process and equipment / machineries obtained from the VISA.

Table 2.1 Name and Capacity of Proposed Units

Name of the Unit Product Capacity(MTPA)

1 Iron ore beneficiation cum pellet plant Iron ore pellets for DRI and

blast furnace

2.4

2 Coal washery Washed coal for DRI plant 5.0

3 DRI plant (8 x 500 TPD) Sponge iron for steel making 1.2

4 Sinter plant (2 x 120 sq.m) Sinter nodules for blast

furnace

2.4

5 Coke oven (Non recovery type) Coke for blast furnace 0.8

6 Blast furnace (2 x 900 cu. m) Hot metal for steel making 1.764

7 Steel Melting Shop (EAF + LRF 2 x

130 tons + Billet Caster 2 x 6 strand)

Steel 2.5

8 Rolling Mill Bar and Wire Rod Mill (1.25)Section Mill (1.25)

2.5

9 Oxygen Plant Oxygen for blast furnace and

SMS

1000 TPD

10 Power Plant 154 MW using WHRB

405 MW using CFBC

559 MW

The project will apply Good Industry Practice at all levels, which means the exercise of the degree and

skill, diligence and prudence and those practices, methods, specification and standard of equipment,

safety and performance, as may change from time to time and which would reasonably and ordinarily be

expected to be used by a skilled and experienced operator engaged in construction, development,

operation and maintenance of facilities, equipment or system of the type and size similar to the Project.


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2.2 Land Requirement

About 400 hectares land for this integrated steel and captive power plant project has been identified

Most of the land is single crop agriculture land. 20 small houses (huts) present inside the identified landneed to be relocated. Most of the land has been purchased through Chhattisgarh State Industrial

Development Corporation. Compensation for land acquisition has been already paid for 118.51 acres out

of the CSIDCs allotted 146 acres and 23 acres land out of 36.44 acres land. Application has been

submitted for 788.39 acres land to State Investment Promotion Board. Out of this 766.39 acres land,

248.956 acres land comes under revenue forest land, for which separate clearance will be obtained.

R&R plan as per State and Central Government Ploicy will be implemented. The land details are given

below (all values in acres):

Descript ion Kotmar village Patrapali village Total (acres)

Land allotted by CSIDC 83.09 62.91 146.0

Additional land to bepurchased directly (landbetween the allotted area)

18.69 17.75 36.44

Total 101.78 80.66 182.44

Fresh land acquisition applied 341.51 446.88 788.39

Total Project Area 443.29 527.54 970.83 acres(say 400 hectares)

The land area statement of the proposed project is given in Table 2.2. The preliminary plant layout is

shown in Figure 2.2.

Table 2.2 Land Area Statement of the Integrated Steel and Power Plant

Name Land Requirement, ha

1 Steel Plant Complex 90

2 Power Plant 80

3 Raw Material Yard 20

4 Oxygen Plant 2

5 Coal Washery 8

6 Water Reservoir 4

7 Ash Pond and Dump Yard 50

8 Administration Block and Buildings 4

9 Utilities 10

10 Greenbelt and Greenery 132

Total 400 hectares


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2.3 Water Requirement

Water requirement for the project is about 3550 kl/hour, which will be taken from Sapnai river, located

about 1 km away. Water will be taken from the stop dam constructed by Water Resource Department.The WRD has already given permission to draw 1003 kl/hour water (8.78 MCM) from the stop dam. This

water quantity will be adequate to run the initial units. Application has been submitted to WRD for

balance water. Water will be transported by means of pipelines buried underground. Right of Way will be

taken for laying the water pipeline.

The project design encompasses optimum water consumption through the concept of recycling and

reuse. Storm water drains will be kept separate from wastewater drains. The storm water will be

disposed into nearby nalas. The wastewater generated from various units will be taken to Effluent

Treatment Plant for treatment to meet the stipulated standards / norms. The treated wastewater will be

100% reused within the plant and no wastewater will be discharged outside the plant premises. The

water balance is shown in Table 2.3.

: Table 2.3 Water Balalnce for the Integrated Steel Plant

Name of Unit Fresh Water Requirement,kl/hour (Make-up)

Wastewater GenerationKl/hour

1 Sponge Iron Plant 150 15

2 Blast Furnace 300 Nil

3 SMS and Rolling Mill 650 65

4 Sinter Plant 25 Nil

5 Pellet Plant 25 Nil

6 Coke Oven 25 Nil

7 Captive Power Plant 1700 340

8 Coal washery 25 Nil

9 Plant domestic use 10 8

10 Utilities and Misc uses 40 10

Total 3550 438

2.4 Construct ion Power

The requirement will be approximately 1 MW, which will be taken from the State Electricity Board. DG

sets (2 x 500 KVA) will be installed to meet the emergency power requirement.


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2.5 Raw Materials

The raw materials required for the project, the source and transportation is shown in Table 2.4. The

quantity of raw materials required for each unit is given in the material balance and integrated processflow sheet of the steel and power plant.

The receipt, storage and handling system will include all facilities for receipt of raw materials like iron

ore, coke, non-coking coal, limestone, dolomite, etc. for both DRI and Blast furnaces, Sinter Plants,

Pellet Plants, NR Coke Ovens, storing these raw materials and subsequent reclamation for sending to

various consuming units. A railway network will be developed for unloading the full rake of Wagons and

for loading the finished products into the wagons. It is desired that for ensuring uninterrupted & uniform

supply of iron ore/iron ore fines and non-coking coal, an iron ore block of 500 Million tonnes and a coal

block of about 1200 Million tonnes should be allotted for captive mining to ensure the efficient functioning

of DRI plants, Blast Furnace, Sinter Plants and Pellet Plants for 30 years.

Table 2.4 Name and Quantit y of Raw Materials for 2.5 MTPA Integrated Steel Plant

Lum

p

Iron

Ore

for

Blast

Furn

ace

&

DRl

Plant

: Iron

Ore

will

be

avail

able

in Singhbhum Region. The following quality of iron ores has been envisaged for the proposed project.

Lump(DR) Lump(BF)

Sl. No. Total Requirement, t/yr.

1. Hard-Coking coal 5,60,000

2 Soft Coking Coal. 5,60,000

3 Non Coking Coal DRI 16,80,000

4 Coal for CDI 2,64,600

5 Coal for Pellet Plant 96,000

6 Coal for Power Plant 40,82,400

7. Iron Ore

7a - DR grade sized 20,40,000

7b - BF grade lump 2,99,880

7c - SP Grade Iron ore Fines 18,20,450

7d - Pellet Grade Iron ore Fines 24,79,200

8. Limestone BF 2,59,310

9. Dolomite BF 93,450

10. Limestone SP 2,89,300

11. Dolomite SP 1.34,100

12. Flux for DRI 482,000

13. Flux for Pellet Plant 72,000

14. Bentonite for Pellet plant 38,400

15. Manganese ore 35,28016.. Quartzite 88,200

17. Purchased lime SP 45,620

18. Purchased lime SMS 77,760

19. Scrap 1,65,850


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Fe, % 65. 64 - 66

SiO2 % 1.5-2.0 2.0-2.5

AI2O3, % 1:5-2.5 2.0-2.5

Iron Ore Fines for Sinter Plant: The following quality of iron ore fines have been envisaged for the Sinter

Plants.

Chemical Composition (%)Name

TFe Fe2O3 FeO Al2O3 SiO2 CaO MgO P LOI

Size

mm

Iron ore fines 64.5 2.8 2.5 2 8-0

Iron Ore Fines for Pellet Plant: The following quality of iron ore fines have been envisaged for the Sinter

Plants.

Chemical Composition of the Ore : Tfe > 65% (Al2O3 + SiO2) -


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SiO2 % - 3-6

Non-coking Coal (DR grade): The quality of non-coking coal envisaged for use in DR plant in the

proposed project is as indicated below.

Fixed carbon 40% (min) (on wet basis)Ash 24% (max)VM 28-32%S 0.8% (max)Reactivity 2 cc of CO/gm of carbon/sec.

Initial Ash fusion 1250 C (min) temp. underreducing atmosphere

Caking index 3 (max)Size, mm 3-20

M/s VSL will consider taking mining blocks in suitable locations subject to approval from concerned

authorities.

Coal for Pellet Plant: Low sulphur and high calorific value coal shall be used as fuel in pelletisation, coal

consumption per ton pellet is determined as 40 kg standard coal, with following specification.

Ash content : < 12%, VM : 17%, S < 0.5%, H2O : 10-15, Ash Fusion Temp: 1400 centrigrade, CV : >

7000 kcal/kg

Coking Coal: The hard coking coal required for coke oven operations has been assured to be imported

from China / Australia. The total requirement of coking coal for 8 lac t/yr will be 10,80,000 t/yr. It is also

proposed to blend soft and semi-hard coal in suitable proportion based on their availability in the region.

Further, it is also proposed to obtain suitable coal block for captive consumption and a provision for

coking coal washery is contemplated.

Bentonite: To improve granularity of green ball and increase strength of green ball and dry ball, a certain

proportion of bentonite is to be mixed with the input and specific consumption of bentonite is 16 kg/t

pellet

Raw Material Receipt, Storage And Supply System: The receipt, handling and storage system will

consist of the following.

Receipt of all the raw materials like iron ore lump, iron ore fines, coking coal, non-coking coal, limestone,

dolomite will be by railway. Storing of lump iron ore, Iron Ore Fines, and coal for DRI kiln, coking coal for

coke oven after washing (if require) and materials in different stock piles. Reclaiming of the various


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materials from the respective storage and sending to various consuming units

Receipt of Major Raw Materials: Receipt of major raw materials like coal for Non Recovery Coke Ovens,

DRI Plants, Power Plant, Pellet Plants, PCI for BF , iron ore and iron ore fines for Sinter Plant, BlastFurnace, DRI Plants, Pellet Plants, Flux Materials like Limestone & Dolomite for Blast furnace, DRI

Plants, Pellet Plants and Sinter Plants will be by rail in full rakes . It is estimated that on an average

around 20 rakes of materials will be received daily. To unload these huge quantities, three wagon

tipplers with side arm chargers and one track hopper has been planned along with all the associated

facilities i.e network of rail tracks, rail weigh bridges, yard master office, dust suppression facilities,

railway signaling system,, power distribution, electrics, instrumentation & automation, illumination,

telecommunication, all utilities & services, in-plant road networks, drainage systems, landscaping, fire

detection & alarm system, administrative & welfare building, area repair shop, sub-store, fire fighting

pump house, as required, for complete & trouble free operation of Raw Material Handling System in an

integrated manner.

The materials will be unloaded in wagon tippler buildings and conveyed to Central Raw Materials

Storage yard by system of belt conveyors. The capacity of the belt conveyor system will be 1600 TPH.

Storage of Raw Materials: All the major raw materials unloaded at the Wagon Tippler Buildings and the

track hoppers will be received in the Central Raw Materials Storage Yard and stored in different stock

piles by 4 nos. of twin Boom Stackers, In all 14 nos. of storage beds have been planned to stack

different materials. The storage of different materials in the yard is shown below:

S NO. MARERIAL Daily

Requirement

Storage Provided No of Days

Storage

Mode of

receipt

A Coal

1 COKING COAL A 775 16000 21 By rail

2 COKING COAL B 775 16000 21 By rail

3 COKING COAL C 775 16000 21 By rail

4 COKING COAL D 775 16000 21 By rail

5 Non Coking Coal DRI 7471 30000 8 By rail

6 Coal for CDI 537 10000 19 By rail

7 Coal for Pellet Plant 398 10000 25 By rail


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8 Coal for Power Plant 22593 120000 5 By rail

B Iron Ore

9 DR grade sized 8467 90000 11 By rail

10 BF grade lump 830 15000 18 By rail

11 SP Grade Iron ore Fines 5037 90000 18 By rail

12Pellet Grade Iron ore

Fines10290 90000 9 By rail

C Flux

13 Limestone BF 718 15000 21 By road

14 Dolomite BF 259 9000 23 By road

15 Limestone SP 801 15000 19 By road

16 Dolomite SP 371 9000 24 By road

17 Flux for DRI 199 6000 30 By road

18 Flux for Pellet Plant 199 6000 30 By road

19 Bentonite for Pellet plant 159 6000 38 By road

20 Manganese ore 97 3000 31 By road

21 Quartzite 244 6000 25 By road

22 Purchased lime SP 125 By road

23 Purchased lime SMS 273 By road

D Scrap 454 In house

2.6 Energy Requirement

The power consumption by individual units of the integrated steel plant is shown in Table 2.5.


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Table 2.5 Power Consumption by Individual Units

Name of Unit Capacity Total Load (MW)

1 Sponge Iron Plant 1200,000 TPA 26

2 Blast Furnace 1764,000 TPA 22

3 SMS (EAF, LRF, Auxiliaries) 2500,000 TPA 240

4 Rolling Mill 2500,000 TPA 35

5 Sinter Plant 2400,000 TPA 8

6 Pellet Plant 2400,000 TPA 10

7 Coke Oven 8000,000 TPA 15

8 Coal washery 5000,000 TPA 8

9 Oxygen Plant 1000 TPD 70

10 CPP (Auxiliary Power) 55

12 Utilities & Misc (plant lighting, RMH yard, water system, HVAC, etc) 25

Total 514

2.7 Infrastructure Development Work

Following the EPC route, through private contractors, VISA will carry out all construction activities related

to the plant, associated facilities and infrastructure development. Reputed parties will be short listed and

finally selected through competitive bidding process to supply the plant equipment, machineries, civil

work, etc. Asphalt plant, Raw Mix Concrete Plant and Stone Crushers required during the construction

period would be established either by VISA or the Contractor. The production capacity depends upon the

specific contract and contractors requirement and will be finalized during the detailed engineering stage.

Labour colony will be developed for temporary stay of construction workers. The contractor(s) will

undertake all steps necessary for pollution control and mitigation, as per the requirement of local law and

regulations.

Dust pollution, increase in noise level, wastewater generation and solid wastes disposal are the

nuisance that are expected during the construction activities. The impacts are short term and reversible

in nature. The labour colony and township will generate sewage and garbage that will be treated anddisposed as per the local regulations. Sewerage and sewage treatment facility will be developed for

collection and treatment of domestic sewage. The treated sewage, conforming to irrigation standards,

will be reused for gardening purpose. Containerized garbage collection facility will be installed. The

garbage will be segregated at the source. Garbage will be transported and disposed either by VISA or by

the local body to the nearest landfill site (owned by the local body).


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2.7.1 Pollut ion Mitigation Measures

The pollution mitigation measures necessary for implementation during the construction stage of

infrastructure development will be embedded in the work-specific contract document. The construction

procedure of the named activities is more or less similar; hence single mitigation plan is considered

adequate. The contractor will control and mitigate pollution levels that may result from construction

activities and bring them to acceptable level. The contractor will designate its employees for pollution

control. The contractor will designate one officer who will report to the Head of Environment

Management Department of VISA (EMD), submit the action plan for pollution mitigation with targets for

implementation / taking corrective measures, and submit monthly monitoring reports and action taken

reports.

2.7.1.1 Air Pollut ion Contro l Measures

General Control Requirements during Transport of Material: The Contractor will take precautions to

minimize visible particulate matter (dust and muck) from being deposited upon public roads as a direct

result of his operations. Precautions include removal of particulate matter from equipment before

movement to paved street or prompt removal of material from paved streets onto which such material

has been dropped. Any deposition of material on public streets by construction equipment will be

removed by sweeping in a prompt manner.

The Contractor will ensure that vehicles with an open load carrying area used for moving potentially

dustproducing materials will have properly fitting side and tailboards. Materials having the potential to

create dust will not be loaded to a level higher than the side and tail boards, and carried in vehicles fitted

with cover lids or clean tarpaulin cover in good condition. The tarpaulin will be properly extended beyond

side / tail board and secured properly.

Control Requirements at Dumping Sites: The Contractor will place excavated materials only on the

designated storage / dumping areas inside plant premises. The Contractor will place material in a

manner that will minimize dust production (orientation of stock piles with respect to predominant wind

direction). Material will be stabilized by watering or other accepted dust suppression techniques. The

heights from which materials are dropped will be kept minimum (practical height to limit fugitive dust

generation). The Contractor will stockpile building materials at locations designated by VISA by creating

suitable slopes. During dry weather and windy conditions acceptable dust control methods like wind

breakers by making tall boundary wall (with tin / iron / asbestos sheet), covering stockpiles with plastic

sheet or tarpaulin, making asphalt roads, regular sweeping and cleaning of work areas, water sprinkling,


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greenery development of boundary, etc will be used to prevent any dust from bowing away and pollute

the surrounding environment. The contractor will provide water storage tanks, pumps, pressure gauge,

pipeline network with water sprinklers at strategic points for dust suppression. Sufficient equipment

spares, water for dust suppression and trained personnel will be kept by the contractor at the dumpingsite.

The contractor will spray water as required to suppress dust during handling of excavation soil or debris

or demolition of temporary structure created by him. Effective water sprays will be used during the

delivery and handling of all raw sand and aggregate and other similar materials, when dust is likely to be

created and to dampen all stored materials during dry and windy weather. Interior areas within the sites

where there is a regular movement of vehicles will have hard / stabilized surface that will be kept clear of

loose surface material. If conveyors are used, conveyor belts will be fitted with covers and transfer point

and hopper discharge area will be enclosed to minimize dust emission. All conveyors carrying material

that have the potential to create dust will be fitted with belt cleaner. The contractor will restrict speed of

all motorized vehicles to 15 km/hr inside the work site and confine haulage and delivery vehicles to the

designated roadways inside the site

Control Requirement for Construction Plants: Asphalt plant, Raw Mix Concrete Plant and Stone

Crushers are required during the construction period, the plant capacity and volumetric requirement

cannot be determined at this preliminary level. Asphalt plant, Raw Mix Concrete Plant and Stone

Crushers have potential to create air pollution, which will be prevented, controlled and mitigated as per

the requirement of applicable Indian Environmental Standards. Water pollution or solid waste generation

issues are considered insignificant.

.

2.7.1.2 Water Pollut ion Contro l Measures

Water Reservoir will be created inside the project area during the construction stage, where rainwater

and surface water runoff will be collected and stored. Groundwater used during the construction stage

will be drawn after obtaining permission from CGWB. Drainage network will be constructed to drain off

all surface water form the work site into the reservoir. The drainage will be maintained, removed and

reinstated as required. Precautions will be taken for avoidance of damage by flooding and silt (by

constructing sedimentation pits at strategic points to be identified later). The contractor will collect the

wastewater arising from site offices, canteens and other washing facilities in a pit and reuse it for dust

suppression. Oil separator / interceptor will be provided near vehicle parking site, workshop and canteen

to prevent the release of oil and grease into drainage system. The oil and grease separators will be

cleaned on regular basis.


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Sewage generated from the labour colony will be treated in Sewage Treatment Plant complete with

sewerage network for collection of raw sewage. The treated sewage water will be reused for gardening

and horticulture purpose.

2.7.1.3 Noise Pollut ion Contro l Measures

The contractor will make and bring into use reasonable efforts to minimize construction noise levels.

Truck loading, unloading and hauling operations so as to minimize noise impact near surrounding

villages will be properly scheduled. Vehicular movement during night-time will be avoided. Machinery

that emits noise in one specific direction would, where possible be oriented in a direction away from

noise sensitive receptor. Silencers and mufflers on construction equipment, wherever required, will be

properly fitted and maintained.

2.7.1.4 Solid Waste Management

The contractor will make inventory of all types of solid waste that are expected during the construction

activity before starting the work. The transportation of construction spoil will be allowed only to

designated dumpsites. Careful design, planning and good site management would minimize waste of

materials such as concrete, mortars and cement grouts. Construction waste will be segregated as much

as possible at site itself to increase the feasibility of recycling concrete and masonry as filling material

and steel pieces as saleable scrap. Litter disposal and collection points will be established around the all

construction work sites.

Domestic garbage @250 g/person/day will be generated during the construction and operation stage.

The garbage will be collected in containers and segregated at source. Biodegradable material (organic

waste) will be used for composting. Recyclable material (metal, plastic, glass, paper, packaging material,

etc) will be given to recyclers.

2.8 Coal Washery : Manufactur ing Process

There will be two coal washery; each washery is designed to wash 2.5 million ton of coal per year. The

washed coal will be used in DRI plant. The coal washery is based on Heavy Media Cyclone technology,

which is a wet process and is most suitable for cleaning coal that contains higher amount of Near Gravity

Material. Sized raw coal of +10 mm to 50mm, from intermediate storage bunker is transported to the

washery building through belt conveyor. Coal is fed into Coal Wetting Launder where water is added.

The slurry then flows through launder to a set of Desliming Sieve Bend and Screens where 1 mm coal


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fines is removed from the coal. The coal slurry collected in Desliming Sieve Bend box and Screens is

conveyed to fine coal sump using pipelines. The desired sized coal (coarser fraction of 50 to + 10 mm)

is taken to the Screen Oversize Launder. Magnetite media of required specific gravity is added at the

back of the Launder that gets mixed with the coal. The mixture of magnetite & coal slurry is pushed intothe central column of the Heavy Media Cyclone feed tank. The HM cyclone has overflow and underflow

system. The clean coal along with magnetite media is received as over flow from the HM cyclone and

fed to Clean Coal Sieve Bend. It is collected in the screens dense under pans. The carried away

Magnetite with some coal particles is removed by water spaying in the discharge part of the screens.

The magnetite removed from coal is collected in the dilute catch pan.

The rejects / middlings along with magnetite media shall be received as underflow from the HM cycone

and fed to sieve bend and rinsing screen. The magnetite collected at the dense catch pan is circulated

back to the system. The magnetite collected from the dilute catch pan is taken to dilute media tank. The

drain and rinsed clean coal is dried in a horizontal basket centrifuge and then transported using belt

conveyor for further crushing / use. The rejects / middlings from the drain and rinsing screen is

transported to a bunker from where it is taken to power plant for use in CFBC boilers of the captive

power plant.

The fine coal slurry collected in the fine coal tank is pumped into a set of classifying cyclone. The

underflow of classifying cyclone is dewatered in Hi-Frequency Screen while the overflow from cyclone is

fed to a thickener. The thickened slurry is dewatered in a Multi Roll Belt Press Filter. Anionic and cationic

flocculants are used in thickener and belt press to facilitate quick settling and dewatering. The discharge

from Hi-Frequency Screen and Multi Roll Filter Press is placed on flat surface through a belt conveyor.

The entire water circuit in coal washery is closed cycle. The entire wastewater is clarified and reused for

coal cleaning.

2.8.1 Process Flow and Material Balance

The process flow of coal washery is shown in Figure 2.3. The material balance of coal washery is shown

in Table 2.6.

Table 2.6 Material Balance of Coal Washery

Product Input, TPA Output , TPA

ROM Coal 5000000

Washed Coal 3000000


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Fines & Middlings 2000000

5000000 5000000

Magnetite

coal coarse coalwater

Underflow Overflow

Recirculating water circuit water water water

Figure 2.3 Process Flow of Coal Washery

2.8.2 Pollut ion Mitigation Measures

2.8.2.1Air Pollut ion Control Sys tem

Air pollution from coal washery is in the form of uncontrolled coal dust emission. Dry fog type and watersprinklers type dust suppression system will be provided to control fugitive dust generated during coal

handling and crushing. The coal crushing and screening unit shall be provided with enclosures along

with dry fog type and water sprinkler type dust suppression system. Moveable truck mounted water

sprinklers will be provided for control of re-suspended dust generated from roads during vehicular

movement. Internal roads inside washery will be asphalted.

2.8.2.2 Noise Pollut ion Contro l System

The crushing and other vibrating equipment may generate noise level of 85 dB(A) at the boundary. The

crushing and vibrating equipment shall be housed in a covered shed that will contain the noise. Workers

exposed to noise levels more than prescribed standards will be provided with earplugs. Greenbelt will be

developed around the steel plant that will attenuate the noise from spreading outside plant area. .

Coal Wetting

Launder

Screens LaunderHeavy Media

Cyclone Tank

Fine Coal

Sum

Middlings

Clean Coal


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2.8.2.3 Water Pollut ion Contro l System

Coal washing is wet process. The washing circuit is closed type, hence no wastewater is discharged

from the plant. The water circuit comprises of thickening cyclones, thickeners, hi-frequency screen and

belt press filter for recovery of fines from water. The water after recovery of fines will be re-circulated.Emergency-settling pond of 5000 m

3capacity will be constructed to store the wastewater during

emergency situations.

2.8.2.4 Solid Waste Generation

Middlings and fines generated from the coal washery are used as fuel in the CFBC Boilers.

2.9 Pellet Plant : Manufactur ing Process

Pellet making process involves receiving iron ore slurry from identified iron ore mines and beneficiation

plants, filtration of concentrate and filtrate, mixing with additives, balling, indurating, segregation,

stockpiling and dispatch. To meet the iron ore requirement of DRI plant and blast furnace, Pellet Plant of

2.4 MTPA will be established (2 pellet plants, each of 1.2 MTPA capacity). In pellet making technology

iron ore fines are converted into small pellets suitable as burden to DRI plant and blast furnace. Iron ore

fines and additives (like limestone, coke breeze and bentonite) are grounded in a Grinding Unit. The

grounded material is transported pneumatically to mixer. The mixed material is conveyed to balling disc

for making green balls, where water is added. The green balls are called pellets, which are screened to 9

-16 mm size in a double deck roller screen. Oversize and undersize material are returned to mixed

material bins for reuse. The pellets are fed by conveyor to the traveling grate of indurating furnace for

heat hardening. Mixed gas (blast furnace / coke oven gas) or producer gas is used as fuel to achieve

temperature of 1300oC. Producer gas plant is also considered to supply the gaseous fuel requirement of

pellet plant. Heat provides recrystallization, bonding and imparts strength to the pellets. The indurated

pellets are air-cooled using a fan. The cooled pellets are taken to stockpile by belt conveyors after

separation of hearth and side layers in the hearth layer separation bin. The hearth and side layers are

reused in the furnace.

Slurry receiving and filtration: The iron ore will be received by pipe line in slurry form in slurry

receiving tanks and filtered in high efficient pressure filters. The iron ore is dewatered (called

concentrate). The filtrate is clarified and reused in the pellet making process.


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Mixing: The iron ore concentrate is mixed with additives like coke fines, limestone powder, and

bentonite in high intensity mixer and with required quantity of water for ideal moisture for next stage of

process called balling

Balling: The homogeneous feed is fed to balling discs. Green balls are formed in an inclined pan of 7.5

m diameter, driven by variable frequency drives.

Induration: The green balls are converted to pellets by fired in the indurating furnace. In this process,

the wet pellets are dried, preheated, indurated, and cooled on a continuous moving grate without

intermediate transfers. The indurating burners will be fired with coal gas. The process air introduced for

pellet cooling will be circulated from the cooling zone of the grate in a multipass manner to the other

process zones. The heat transferred to the air in the cooling zone will be transferred to the zones for

drying and preheating of the green pellets. The indutaring furnace divided in to five zones. The zones

are up draft drying, down draft drying, preheating, firing, cooling zones. The indurating temperature is

around 1300 deg C. Fans circulate the process air and then taken to ESP.

Product Handling: Pellet is discharged from end of the machine and screened to remove materials that

are recycled to the hearth layer. The pellets are screened and taken for storage.


The process flow and material balance of pellet plant is shown in Figure 2.4 and Table 2.7.

Table 2.7 Material Balance of Pellet Plant

Input TPA Output TPA

1 Iron ore fines 2400000 Pellets 2400000

2 Coke breeze 18000 LOI 36000

3 Limestone 72000 Dust 90000

4 Bentonite 36000

Total 2526000 2526000

2.9.2 Pollut ion Mitigation System

2.9.2.1 Air Pollut ion Control System


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Indurating process off gasses from updraft drying hood exhaust and wind box exhaust shall be cleaned

using electrostatic precipitators (ESP). The outlet dust concentration will be limited to 50 mg/Nm3.

Fugitive dust from hearth layer bin, machine discharge areaand hearth layer extraction area will be

collected using suction ducts and cleaned in Bag Filters. Fugitive dust generated from Raw MaterialHandling, Bentonite Grinding, Lime and Coal Grinding and Bentonite Transfer points will be collected

using suction ducts and cleaned in Bag Houses. Dust collected from the bentonite and lime stone

systems and other systems will be returned to their respective storage bins. Collected dust from ESP's

and Bag Filters will be reused.

2.9.2.2 Water Pollut ion Contro l System

Pellet making is a dry process, where no water is used in the process / reaction. Make-up water is

required for equipment / machine cooling to compensate the evaporation loss. The cooling water is re-

circulated through cooling tower, to reduce the consumption. Blowdown from the cooling tower is

collected in settling tank, which is re-used for moistening the raw materials and mixing additives with iron

ore in pellet plant.

2.9.2.3 Noise

Noise from pellet plant will be confined within the respective sheds.


Dust collected from ESP and Bag filters and hearth layer of the main furnace comprises solid wastes

from pellet plant. The entire dust will be collected and reused in pellet making process. The hearth layer

is also reused. There will be no solid waste disposal from the pellet plant.


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Figure 2.4: Process Flow of Pellet Plant

2.10 Direct Reduced Iron Plant

1.2 MTPA Direct Reduced Iron (DRI) plant has been proposed. The direct reduction iron plant will

comprise of 8 modules, each having a rated capacity of 500 TPD. The plant will be suitably designed for

conveyor transportation as well as storing system for both iron oxide feed, DRI product as well as by

product like product fines. The utilities system design will include distribution network for utilities like

nitrogen, oxygen, water, electric power, etc.

The process converts lump iron ore, iron oxide pellets or pellet/ lump ore mixtures into highly metallised,

passivated iron product. The product is in the form of pellets/lumps and contains a variable and

controlled percentage of carbon. This is an ideal feed material for quality steel making in EAF. The

presence of Fe3C assures that the product is passivated i.e. non-pyrophoric even without briquetting and

allows easy, safe handling and transport.

When the temperature reaches a value of about 500 - 600 deg C, the haematite (Fe2O3), in presence of

CO, begins to transform itself into magnetite (Fe3O4). When the burden reaches the lower zone of the

furnace and comes in contact with hotter and richer gas, the magnetite is reduced to wustite (FeO). The

reduction of wustite to metallic iron is the slowest stage of the whole reduction process. It requires high

temperatures and gas with high reduction potential and these conditions are reached in the reducing gas

injection zone. The overall reduction process is represented by the following reactions:

Fe2O3 + 3CO2 Fe + 3CO2

Mixing unit Balling Screens Indurating

furnace

coolingScreening

Iron Ore fines

Crushed

limestoneBentonite

Coke breeze

Green balls

Water

Oversize &

undersize

Green balls

9-16 mm

Sinter

SinterSinter

Hearth layer for

recycling


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Oxide material handling: The iron oxide material i.e. lump iron ore (sized) will be collected and

conveyed for screening in the oxide screening station and then sent to oxide day bins for storage. The

iron ore pellets received from the adjacent pellet plant will be directly sent to the oxide storage bins. Two

bins will be earmarked for pellet storage while one bin will store the iron ore lump. About two shiftsstorage capacity has been planned. A series weigh feeders at the bins bottom; delivers the pellets and

lump ore in the pre-determined ratio to a belt conveyor. The iron ore pellets received from the adjacent

pellet plant will be directly sent to the oxide storage bins.


The process flow and material balance of DRI plant is shown in Figure 2.5 and Table 2.8.

Table 2.8 Material Balance of DRI Plant

Input Quantity, TPA Input Quantity , TPA

1Iron Ore 1,920,000 DRI 1,200,000

2Coal 1,440,000 LOI 1,650,000

3Dolomite 45,000 Dust & fines 120,000

Char 435,000

Total 3,405,000 3,405,000

Fig.2.5 Process Flow of DRI Plant


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2.10.2 Pollut ion Mitigation System

2.10.2.1 Air Pollut ion Contro l System

Three separate product handling dedusting systems has been considered to minimize the escape of

dust from Product cooler, Product silos and Bottom seal gas (hot discharge system). Two separate iron

oxide handling dedusting systems has been considered to minimize the escape of dust from oxide

screen and day bins. The dust collection systems consist of exhaust fan, scrubber, stack and associated

ducts and hoods. For each dust collection system, dust laden air is collected and conveyed at a

sufficient velocity to prevent settling and accumulation within the ducts. The dust laden air enters a bag

filter. Cleaned air is pulled from the dust collection system by the exhaust fan and discharged into the

atmosphere through 30 m tall stack. The outlet dust concentration from each point will be limited to 50

mg/Nm

3

.

Hot flue gases coming out of after burning chamber of Kiln will be taken to Waste Heat Recovery Boiler

for power generation. After completion of required passage of the flue gases through boiler, these gases

will be taken to an ESP for trapping the dust in the gases before leaving into atmosphere. The outlet of

the ESP will be connected to a stack of 80 m height. The ESP will be designed to achieve particulate

matter emission of 50 mg/Nm3.

2.10.2.2 Noise Pollut ion Contro l System

Noise generated from material and product handling, machines and equipment of DRI plant will be

located inside shed, that will contain the noise level.

2.10.2.3 Water Pollut ion Control System

DRI making is a dry process where no water is consumed in the process / reaction. Make-up water is

required for equipment / machine cooling to compensate the evaporation loss and for flue gas scrubbing.

The cooling water is re-circulated through cooling tower, to reduce the consumption.


Dust from ESP, bag filters and char comprises solid wastes from DRI plant. Accretions are generated

only when the kiln stops. The ESP and Bag Filter dust contains substantial iron content, which will be

reused in sinter plant. Accretions will be used for landfilling and road making purpose. Char will be


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mixed with coal washery middlings and fines and used as fuel in the AFBC Boiler for steam and power

generation.

2.11 Sinter Plant

The sinter plant complex will consist of two sinter machines, each of 120 m2

grate area along with

associated services facilities. The plant capacity has been selected as 2.4 MTPA for charging about 70%

sinter in BF burden. The sinter plant complex will consist of the following units

1. Storage and proportioning unit2. Combined mixing and balling unit3. Sintering and cooling unit4. Waste gas dedusting unit5. Main exhaust fan unit

6. Cold sinter screening unit7. Plant dedusting unit

The above units will be interconnected by conveyor galleries and junction houses for conveying raw mix,

finished sinter, hearth layer and sinter return fines. All the iron bearing materials (iron ore fines, flue

dust), 100% BF return fines, 80% of total requirement of limestone, 80% of total requirement of dolomite,

80% of total requirement of coke breeze are blended in the base blending yard. Blended mix and

corrective additions of limestone (20% of total requirement), dolomite (20% of total requirement) and

coke breeze (20% of total requirement) are received from the raw material blending yard to the sinter

plant proportioning building. Burnt lime will be carried by lime tanker and fed to lime bin by pneumatic

lime transportation system. A brief description of major facilities proposed for the sinter plant complex is

given below.

Proportioning unit: Suitable capacity of storage and proportioning bins has been envisaged for the

sinter plant. The bunkers for blended mix and return fines will have single outlet while bunkers for

corrective additions of crushed limestone, crushed dolomite and crushed coke breeze will have twin

outlets. All the bins will be suitably lined except return fines bin, which will be self lined. The blended mix,

corrective additions and in-plant returns will be fed to the common collecting conveyor by electronic belt

weigh feeders, whereas, lime will be fed to common collecting belt conveyor by loss in weigh feeder and

ESP dust from ESP dust bin. Proportioned material from belt weigh feeders below respective

proportioning bins shall be transported to a combined mixing and nodulising drum by a common belt

conveyor.

Combined mixing and nodulising unit: Material from belt weigh feeders below respective

proportioning bins will be transported to a combined mixing and nodulising drum by a belt conveyor


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where the various raw materials will be moistened and mixed by 4.6 m dia. x 21 m length drum mixer

installed in the building. Lime from lime bins is discharged onto common collecting conveyor through

lime dosing equipment. A fixed quantity of water of about 60% of requirement will be added in the mixing

part and the rest variable quantity will be added in the nodulising part depending on requirement. Theraw mix discharged from mixing and nodulising drum will be transported to sinter plant main building by

a belt conveyor. Water addition will be done in the nodulising section to maintain the desired moisture

level in raw mix.

Sinter plant main building: The sinter plant main building will mainly consist of hearth layer and raw

mix feeding units, ignition furnace, sinter machine proper, hot sinter breaker. The sintering machine will

comprise charging and discharging sprockets, drive unit, spring loaded pallet cars with high chrome cast

steel grate bars, rails, curved guides at charging and discharge ends, grate bar cleaning device,

automatic lubrication system, provision for thermal expansion, wind boxes, wind main with dust hoppers

and double cone dust valves, machine spillage hoppers, sinter machine support structures. The hearth

layer (15 - 25 mm) will be spread onto the sintering machine first, followed by sinter mix. The height of

the sinter mix bed onto the machine will be 650 mm including 50 mm protective hearth layer height. The

hearth layer is provided for the following reasons.

Prevent plugging of the passage between grate bars

Prevent the scaling and overheating of the grate bars

Prevent the adhesion of fused sinter to grate bars

Ensure uniform gas distribution through the sinter mix bed

The ignition furnace with post heat hood and pre-heating (before ignition furnace) will be installed just

after the sinter mix drum feeder. The ignition furnace will have suitably located energy efficient type gas

firing burner designed for 2000 kCal/ Nm3

of mixed gas. Gas mixing station and gas boosting station will

be located outside sinter plant battery limit. Approx. 250 to 350 deg C hot air for the combustion is

supplied from waste heat recovery system of sinter cooler. Multicyclone will be provided at inlet of

combustion air fan to supply clean hot air from discharge of cooler. The hot air for combustion will have

control by having intake in cold air. The ignition temperature will be 1200 1300 deg C. Pilot burners will

be provided for start up and safety. Hot air from waste heat recovery system of sinter cooler will also be

used for preheating of raw material before ignition furnace and post heat hood after ignition furnace. The

recovered waste heat from cooler will be utilized for ignition, post ignition and preheating of raw-mix. For

suction of air through sinter mix bed on the sintering machine two numbers of exhausters will be

provided.


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Raigarh, Chhattisgarh____________________________________________________________________________________

coal washery in india

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