Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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PROJECT REPORT
PELLET PLANTat
village : Pur, Dist: Bhilwara(RAJASTHAN)
Jindal Saw Limited,12, Bhikaji Cama Place
New Delhi-110066
NOVEMBER 2014
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Table of Contents
Chapter Title Page
1.0 Executive Summary 3
2.0 Introduction of the Project 13
3.0 Project Description 18
4.0 Site Analysis 33
5.0 Planning Brief 37
6.0 Proposed Infrastructure 39
7.0 Rehabilitation and Resettlement (R & R) Plan 43
8.0 Project Schedule & Cost Estimates 44
9.0 Analysis of Proposal 45
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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1.0 EXECUTIVE SUMMARY
M/s JINDAL SAW LIMITED (JSL) has installed and operating 1.2 MTPA pellet plant at
village Pur, District Bhilwara (Rajasthan) using captive iron ore concentrate.
Rajasthan State Pollution Control Board given Consent to establish by order no 2012 –
2013 /MUID/881 (File no (MUID) / Bhilwara (Bhilwara) /2(1)/2010-2011/3687-3689)
and consent to operate by order no 2013 – 2014 /MUID/1172 (File no (MUID) /
Bhilwara (Bhilwara) /2(1)/2010-2011/384-386 .Rajasthan State Pollution Control Board
vide letter no F.14/Tech Bhilwara (11) RSPCB/MUID/3707 dated 7th October 2014 has
directed to apply for TOR & EC as per directive of MOEF.
Environmental clearance for 7 MTPA iron ore mining and 2.5 MTPA iron ore
concentrate using Beneficiation Plant had been obtained from Ministry of Environment
and Forests, Government of India.
Pellet plant, purpose, location, capacity and use of finish productsJindal saw is having mining reserves of low grade magnetite ores with Fe content varying
from 28-38 %.The ore is being made usable for iron making process by beneficiation
(grinding-magnetic separation) process. The concentrate fraction size after beneficiation is
100-350 mesh. These super fine materials can be utilized for iron making by pelletizing
process.
After assessing the potential of Pelletizing of iron ore in India, Jindal Saw Ltd. (JSL)
installed pellet plant of 1.2 MTPA near village- Pur, District- Bhilwara in the State of
Rajasthan.
The pellet plant is utilizing available iron ore concentrate to produce pellets. The pellet
plant is installed at a location adjoining to existing mining lease area of JSL’s Dhedwas
Iron Ore, Copper and Associated Minerals Mine. The unit size and production capacity
of pellet plant is as below:-
Name of Unit Size & Production Capacity, Product
1 Pellet Plant 1.2 MTPA Pellet
2 Supporting Utilities RMH Yard, Nitrogen Plant, PCI, Laboratory, FuelComplex
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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The finished product detail of the pellet plant is as below:-
Product Capacity Use of finished product
Pellets (MT/Annum) 1.2 MTPA Captive use and sale to
Market
Land Requirement and Land type of project area:
The Pellet plant is located adjoining to the Dhedwas Iron ore and associated minerals
mine of JSL at village Pur, District Bhilwara, Rajasthan. No forest land is involved in
the project site. The transportation infrastructure is already available and maintained
in the existing mining lease area. NH 79 is at a distance of 2 km from project site in
East direction. Nearest railway station (Bhilwara) is at a distance of 10.0 km from
project site towards East direction.
Jindal Saw Limited already purchased 88.76 acres of industrial land. Out of
88.76 acres, 40.76 acres land has been covered by pellet plant and other facilities.
Land allotment papers are attached as Annexure #2.
Water Requirement –Quantity and source for industrial and domestic use
The water required for the pellet plant is supplied from treated sewage in the
Company’s STP at Kewara, near Bhilwara Town. The total domestic water demand is
25 KLD. The domestic water is supplying from tube well. Actual water consumption of
pellet plant is given in below table:
Sr. No. Month Pellet Plant Water Consumptions (KL/Month)1 Apr-13 02 May-13 2991(Trials)3 Jun-13 4196 (Regular Production)4 Jul-13 39015 Aug-13 47376 Sep-13 51157 Oct-13 48608 Nov-13 49929 Dec-13 4768
10 Jan-14 574111 Feb-14 345012 Mar-14 2267
Total FY 13-14 47018
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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1 Apr-14 28312 May-14 51853 Jun-14 60254 Jul-14 54705 Aug-14 55536 Sep-14 56027 Oct-14 6609
Power Requirement
Power for the pellet plant is available from RVVNL, Rajasthan, by existing transmission
line from GSS grid to the site.
Actual data of power consumption:-
Sr.No. Month Power Consumption
1000 Unit/Month1 Apr-132 May-133 Jun-134 Jul-13 16955 Aug-13 21426 Sep-13 22177 Oct-13 25328 Nov-13 25899 Dec-13 2428
10 Jan-14 280211 Feb-14 268112 Mar-14 3233
Total FY 13-14 223191 Apr-14 28032 May-14 25853 Jun-14 29114 Jul-14 28135 Aug-14 28616 Sep-14 30597 Oct-14 3139
Total 6 months 20172
Manpower requirement at construction and operation phases
Construction Manpower - NA
Current operational manpower of pellet plant is given below:-
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Type of employment Skilled Un-Skilled Total
Direct 149 27 176Indirect 20 86 106Total 169 113 282
Employment has been generated for local people in surrounding villages and only
highly skilled manpower is sourced from outside area.
Type and Quantity of solid and liquid waste generated and its management
Actual generation of solid waste is given as below
Sr.No.
Month ESP dust(Ton)
Broken Pellets &Fines(Ton) Use
1 Apr-13
Reuse in the preparation ofpellet by dispatching toproportioning room(100 %recycle)
2 May-133 Jun-13 89 6194 Jul-13 145 19195 Aug-13 158 11506 Sep-13 170 5967 Oct-13 227 11098 Nov-13 239 11879 Dec-13 229 316
10 Jan-14 284 63011 Feb-14 258 189912 Mar-14 339 2284
Total FY 13-14 2137 1171013 Apr-14 266 357014 May-14 236 708515 Jun-14 274 262816 Jul-14 280 187717 Aug-14 248 197718 Sep-14 295 136619 Oct-14 314 826
Total FY 14-15 1915 19329
Other types of wastes generated from the project are shown below:Actual data of other waste generation is as below
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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S.N MONTHUSED OIL
GENERATED(Liter)
IN-HOUSE REUSE/ CONSUMPTION
(Liter)
BALANCEAVAILABLE
(Liter)
DISCARDEDCONTAINERS
/BARRELSDETAILS(Nos)
IN HOUSEREUSE
BARRELS(Nos)
1 Apr-13 NIL NIL NIL NIL NIL2 May-13 NIL NIL NIL 5 53 Jun-13 NIL NIL NIL 5 54 Jul-14 NIL NIL NIL 10 95 Aug-13 NIL NIL NIL 1 26 Sep-13 1500 500 1000 3 27 Oct-13 800 300 500 2 28 Nov-13 140 28 112 1 29 Dec-13 140 28 112 1 2
10 Jan-14 140 28 112 1 211 Feb-14 140 28 112 1 212 Mar-14 140 28 112 1 2TOTAL FY 13-14 3000 940 2060 31 351 Apr-14 425 25 400 2 12 May-14 44 30 14
12
3 Jun-14 44 22 22 24 Jul-14 44 25 19 15 Aug-14 296 30 266 2 16 Sep-14 44 25 19 1 1TOTAL FY 14-15 897 157 740 6 8
DATA FOR HYDRAULIC OIL 68 IN PELLET PLANT
S.NO MONTH USED OIL GENERATED(Liter)
IN-HOUSEREUSE/CONSUMPTION
(Liter)
BALANCEAVAILABLE
(Liter)1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 50 NIL 506 Sep-13 75 25 507 Oct-13 64 20 448 Nov-13 33 15 189 Dec-13 33 15 18
10 Jan-14 33 15 1811 Feb-14 33 15 1812 Mar-14 33 15 18
TOTAL FY 13-14 354 120 234
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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1 Apr-14 5 Nill 5
2 May-14 Nill Nill
3 Jun-14 6 Nill 6
4 Jul-14 5 Nill 5
5 Aug-14 5 Nill 5
6 Sep-14 8 Nill 8
TOTAL FY 14-15 29 0 29
DATA FOR GREESE CG -10 IN PELLET PLANT
S.N MONTH USED GREESE GENERATED(Kg)
IN-HOUSEREUSE/CONSUMPTION
(Kg)
BALANCEAVAILABLE
(Kg)1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 220 90 1306 Sep-13 220 90 1307 Oct-13 168 90 788 Nov-13 168 90 789 Dec-13 168 90 78
10 Jan-14 168 90 7811 Feb-14 168 90 7812 Mar-14 168 90 78TOTAL FY 13-14 1448 720 7281 Apr-14 350 Nill 3502 May-14 350 Nill 3503 Jun-14 350 Nill 3504 Jul-14 350 Nill 3505 Aug-14 350 Nill 3506 Sep-14 350 Nill 350TOTAL FY 14-15 2100 0 2100
DATA FOR GREASE HT IN PELLET PLANT
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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S.NO MONTH USED GREESE GENERATEDIN MONTH(Kg)
IN-HOUSEREUSE/CONSUMPTION
(Kg)
BALANCEAVILABLE
(Kg)
1 Apr-13 NIL NIL NIL2 May-13 NIL NIL NIL3 Jun-13 NIL NIL NIL4 Jul-14 NIL NIL NIL5 Aug-13 155 60 956 Sep-13 155 60 957 Oct-13 89 60 298 Nov-13 89 60 299 Dec-13 89 60 29
10 Jan-14 89 60 2911 Feb-14 89 60 2912 Mar-14 89 60 29TOTAL FY 13-14 844 480 3641 Apr-14 313 Nill 3132 May-14 313 Nill 3133 Jun-14 313 Nill 3134 Jul-14 313 Nill 3135 Aug-14 313 Nill 3136 Sep-14 313 Nill 313TOTAL FY 14-15 1878 0 1878
Green belt development program
JSL planted 1500 saplings in project site area. The green belt development progress is
continuing. Around 13.0 acre land has been allocated for green belt development .It is
proposed to plant more than 600 trees per Acre of land area. The schedule of plantation
as given in below Table will be followed.
Year Area (Acre)Present
No. of trees to bePlanted
2014 2.4 1500
2015 2.65 1600
2016 2.65 1600
2017 2.65 1600
2018 2.65 1600
Total 13.0 7900
The name of trees planted / being planted are as below
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Sl. No. Common Name Scientific Name
1. Neem Azadirachta indica2. Dhanbaher/ Amaltas Cassia Fistula3. Kumat Acacia Senegal4. Jand Prosopis Spicigera5. Khaira Acacia Catechu6. Karir Capparis deciduas7. Jungle jalebi Inga dulcis8. Imli Tamarindus Indica9. Ber Zizyphus jujube10. Babul Acacia Arabica11. Peepal Ficus Religiosa12. Vilayati babul Prosopis juliflora13. Khejri Prosopis cineraria14. Bargad Ficus benghalensis15. Gulmohar16. Amaltas17. Ashok
Rehabilitation and Resettlement Plan
The pellet plant is within existing industrial land owned by JSL. No human settlement
exists on the identified land. No agriculture activity is done on the identified land. The
land does not belong to private ownership. Hence no Rehabilitation and Resettlement
is required.
Project schedule and cost of Project
Pellet plant is already is in operation from June, 2013The Pellet plant projected cost is as below:
The total project cost of the pellet plant is Rs. 322.63 crores. The summarized project cost isgiven below:
Particulars Rs. (in crores)
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Land and Site development 0.59
Building 20.88
Plant and Machinery 246.26
Preliminary and Pre-operative expenses 54.90
TOTAL 322.63
Financial and Social Benefits
The low grade iron ore deposit of Pur-Banera Belt of Rajasthan has remained
unexploited so far even though it was explored by Geological Survey of India, way
back in the year 1969-70. Jindal Saw Ltd with their innovative ideas and international
exposures have thought of upgrading iron ore from 35% Fe to 65% Fe by way of
magnetic separation and other separation methods as the Ore is mostly magnetite
along with magnetite quartzite. The Concentrate is palletized in pellet plant and sold to
the DRI producers and steel plants for production of sponge iron and steel. Jindal saw
ltd is in process of establishing integrated steel plant for long product production.
The opening of the mine and beneficiating the ore has provided employment to some
1000 persons, besides paying royalty to State Govt. to the tune of Approximately Rs.
25.00 crore per year. It will increase to about Rs. 50.00 crore per year as the production
increases. Pellet plant helped the nearby areas to get quality pellets locally instead of
getting from Orissa, Karnatika etc. Apart from this the pellet plant provided employment
to additional 282 persons and in-direct employment to 300 persons in transport,
upkeep & maintenance, ancillary units. The pellet plant is generat ing
Approximately Rs 100 crore per year indirect tax revenue.
Actual royalty and tax data are shown as below (in INR):
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Month Royalty Excise duty Service Tax CST Entry Tax WCT Total
2011-12 1,288,766 1,288,766
2012-13 33,294,580 8,221,424 12,345,164 53,861,168
2013-14 246,323,213 745,953,797 73,204,538 128,086,477 7,227,570 15,648,073 1,216,443,6682014-15 -
Apr-14 29,405,092 108,712,418 6,054,604 19,229,693 509,426 27,519 163,938,752
May-14 26,565,796 90,679,959 7,576,260 16,127,423 411,933 882,734 142,244,105
Jun-14 28,611,410 108,372,150 8,453,265 19,443,900 220,369 466,912 165,568,007
Jul-14 27,310,605 98,973,295 9,504,262 17,859,796 1,022,982 396,125 155,067,065
Aug-14 29,509,812 92,082,383 6,613,863 16,741,730 995,229 769,929 146,712,946
Total 422,309,275 1,244,774,002 111,406,792 217,489,019 18,608,934 30,536,456 2,045,124,478
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 Identification of project and project proponent
2.1.1 Project proponent
M/s Jindal Saw Limited is a company incorporated in the year 1985 under the
Companies Act, 1956 and is pioneer in manufacturing and supplying of large diameter
pipes, seamless tubes and pipes, ductile iron and cast iron pipes.
Jindal SAW Ltd. is a part of the O.P. Jindal Group, Country's one of the topmost
industry houses and the foremost indigenous steel producers and exporters. It is the
first company in India to manufacture Submerged Arc Welded (SAW) Pipes using the
internationally acclaimed U-O-E technology.
Jindal SAW Ltd. is in a commanding position in Indian market, being the undisputed
leader with a turnover in excess of Rs. 7500 Crore.
With integrated facilities at multiple locations and an ever expanding market
opportunity, Jindal SAW Ltd. has diversified from a single product company to a multi-
product company, manufacturing large diameter submerged arc welded pipes and
spiral welded pipes for the energy transportation sector; carbon-alloy and stainless
steel seamless pipes and tubes manufactured by conical piercing process used for
industrial applications; and Ductile iron (DI) pipes for water and sewage/wastewater
transportation. Besides these, the company also provides various value added products
like pipe coatings, bends and connector castings to its clients.
JSL has been granted a mining lease for Iron Ore, Copper and Associated Minerals
over an area of 1556.7817 Ha near Dhedwas Village, Bhilwara District Rajasthan for 30
years starting from 8th December’10.
Jindal Saw Limited is currently operating a 2.5 MTPA capacity Iron Ore Beneficiation
Plant and 1.2 MTPA Pellet Plant at Bhilwara (Rajasthan).The pellet plant is using the
iron ore concentrate produced from its own Beneficiation Plant located at the same site.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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2.1.2 Identification of project
PROJECT AT A GLANCE
Project proponent M/s JINDAL SAW LTD, Bhilwara, Rajasthan
Company Name M/s JINDAL SAW LTD
Type of project 1.2 MTPA pellet plant
Category of Project Category A , Sector 8 , Schedule 3a – Pellet plant
S.No in the schedule as perEIA notification, 2006
Schedule 3,Pellet Plant
Total area 40.76 Acre
Location Bhilwara district ,Rajasthan at Captive mine head
Village Pur
Khasra numbers 6711, 9697/6711
District Bhilwara
State Rajasthan
Latitude 250 18’ 56.32” to 250 19’ 13.70” N
Longitude 740 32’ 16.07” to 740 32’ 29.93” E
Near by Features
Highways-NH-79-Approx.2.2 km- East Railways-Bhilwara Railway Station-Approx 10 km-East
Airport- Dabok Airport-Approx 150 km-South West
Village /Town-Pur Village-Approx.2.0 km-South
Distance to nearest Protectedarea
No protected area within 10 km radius
2.2 Brief Description of Nature of the project
The plant is purported to make iron ore balls of 8 to 16 mm size from the concentrated
iron ore power by adding about 0.94% bentonite with some water and heating. These
balls are first dried by hot air and then preheated up to 1100 °C and after preheating
are fed to rotary kiln for indurations. In indurations at about 1200°C the bentonite gets
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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fused, making the bonding of iron ore grains and the balls become firm and compact
attaining compressive strength of about N2500 per pellet. These hot balls are
discharged from rotary kiln to annular cooler for cooling. From there the hot air is
recovered and sent back to Rotary kiln, preheating chambers and drying chambers.
Pellet plant consisting of Raw material system,6 nos ball and disc, coal pulverized
system, travelling grate, rotary kiln, annular cooler,stacker,ESP,120 meter height stack
etc.
Detail plant description with process details is given in point no 3.5.
2.3 Need of the Project and its importance to the country and or region
Need of the Project
The Company has two mining leases (area 1556.78 ha and 451.00 ha) in Bhilwara
District covering a part of the area earlier prospected by Geological Survey of India. The
exploration report of GSI reveals that the Ore body consists of magnetite, the average
content of Fe to be 35 %. The Company has installed to beneficiation process for the ore.
Considering the iron ore to be of poor grade (on an average 35% Fe) and base metals of
poor grade as well as low tonnage, it was never been considered viable to be
economically exploited.
Jindal Saw Ltd. with their innovative ideas and international exposure has proposed to
upgrade the iron ore, from 35% Fe to about 65% Fe by way of magnetic separation and
other beneficiation methods as the ore is mostly magnetite along with magnetite quartzite
and as per prospects of GSI the reserves are adequate to last for 30 years.
It has been studied that if the BMQ is ground to – 100 mesh size there is total liberation
of magnetite and quartzite. Based on the exploration done so far, sufficient reserves of
iron ore have been established and its beneficiation tests have confirmed the reserves to
be viable.
The mined iron is first ground and processed in 3 stages to -200 mesh. The processed -
200 mesh magnetite concentrate is used for manufacturing of pellets in 1.2 million tons
per annum capacity pellet plant near village - Pur, District-Bhilwara, Rajasthan.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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2.3.1 Importance of the Project to the Country
Considering the recent trend in production and consumption of steel globally and in
India, the National Steel Policy, 2005 had projected 110 MTPA steel making capacity in
India by 2019-2020 at 7.3% growth rate. It was noted subsequently in year 2006-07
that domestic production grew at 10.9% and domestic consumption by 11%.
Emboldened by buoyancy of the Indian economy, the Ministry of Steel, Govt. of India,
has revised the goal and projected a capacity of 180 MTPA by 2019-20. This creates
huge opportunity for investment in steel industry with high returns. This pellet plant
proved that low grade iron can be used for pellet production and it will certainly
contribute to the growth of steel industry.
2.3.2. Importance of the Project to the Region
The iron ore deposit of the region was explored by GSI in the year 1969-70. It remained
unexploited due to its poor grade. The opening of the mine and beneficiating the ore
has provided employment to some 1000 persons, besides paying royalty to State Govt.
to the tune of approximately Rs. 25.00 (FY 13-14) crore per year. It will increase to
about Rs. 50.00 crore per year as the production increases. Pellet plant is helping local
industry to get quality pellets locally instead of getting from Orissa, Karnataka etc. Apart
from this the pellet plant has provided employement to 282 persons and in-direct
employment to 300 persons in transport, upkeep & maintenance, ancillary units. The
pellet plant is generat ing Rs 100 (97 crore in FY 13-14) crore per year indirect tax
revenue. This pe l le t p l a n t i s t he first pellet plant in the state of Rajasthan and it
will also supply the quality pellets to our upcoming steel plant and DRI plant.
Actual Data of Royalty and Taxes Paid
Month Royalty Excise duty Service Tax CST Entry Tax WCT Total
2011-12 1,288,766 1,288,7662012-13 33,294,580 8,221,424 12,345,164 53,861,1682013-14 246,323,213 745,953,797 73,204,538 128,086,477 7,227,570 15,648,073 1,216,443,6682014-15 -Apr-14 29,405,092 108,712,418 6,054,604 19,229,693 509,426 27,519 163,938,752May-14 26,565,796 90,679,959 7,576,260 16,127,423 411,933 882,734 142,244,105Jun-14 28,611,410 108,372,150 8,453,265 19,443,900 220,369 466,912 165,568,007Jul-14 27,310,605 98,973,295 9,504,262 17,859,796 1,022,982 396,125 155,067,065
Aug-14 29,509,812 92,082,383 6,613,863 16,741,730 995,229 769,929 146,712,946
Total 422,309,275 1,244,774,002 111,406,792 217,489,019 18,608,934 30,536,456 2,045,124,478
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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2.4 Demand – Supply gap
Jindal Saw is the only company who installed pellet plant in Rajasthan. This pellet
plant filled vacuum of quality pellets in Rajasthan and nearby areas.
2.5 Import vs Indigenous Production
Pellet plant is meeting the Indigenous demand of quality pellets and reduced the import
requirement of pellets.
2.6 Export Possibility
Presently we are supplying pellets to domestic market and will explore the possibilities ofexport in near future.
2.7 Domestic/ export markets
Presently we are supplying these pellets mainly to Gujarat, Maharashtra etc .In future
major quantity of these pellets will be consumed in our upcoming steel and DRI plant.
2.8 Employment generation (Direct and Indirect) due to the project
The total man power presently employed in the pellet plant is 282 persons as detailedbelow:-
Type of employment Skilled Un-Skilled Total
Direct 149 27 176Indirect 20 86 106Total 169 113 282
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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3.0 PROJECT DESCRIPTION
3.1 Type of project including interlinked and interdependent projects, if any
Pellet plant is interlinked with mining and beneficiation plant for which EC has already
been obtained & commercial production already going on.
3.2 Location with coordinates
Location (Google map showing general location, specific location, and project boundary
and project site layout) is shown in below Google map. The location of site with type
of land and boundary coordinates is as below:
Feature Description
Site Village: Pur, District: Bhilwara, Rajasthan
Type of land/ land
use
Existing Industrial land
Latitude and longitude of plant site
Latitude Longitude
250 18’ 56.32” to 250 19’ 13.70” N 740 32’ 16.07” to 740 32’ 29.93” E
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Location Map and Images of Pellet Plant Site
Pellet plant Layout is attached as Annexure #1
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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3.3 Details of alternate sites considered and the basis of selecting the proposedsite, particularly the environmental considerations gone into should behighlighted
The Pellet plant site is adjoining company’s existing beneficiation plant where iron ore
concentrate is being produced, which is the main raw material for the pellet plant. Jindal
Saw is already in possession of 88.76 Acre (143.14 Bhiga) industrial land from which
40.76Acre land has been used by this pellet plant and other facilities (Beneficiation
plant).No alternate site was considered as developed infrastructures was already
available there.
3.4 Size or Magnitude of Operation
The company has installed 1.2 MTPA pellet plant unit and supporting utilities.
Actual Production details are shown in below table:
Sr. No. Month Month wise Pellet Production(Tons)
1 Apr-13 02 May-13 03 Jun-13 301014 Jul-13 411695 Aug-13 433526 Sep-13 489567 Oct-13 685288 Nov-13 822309 Dec-13 75862
10 Jan-14 10140011 Feb-14 9537012 Mar-14 121020
Total FY 13-14 7079881 Apr-14 1040602 May-14 901503 Jun-14 1059104 Jul-14 1030205 Aug-14 910506 Sep-14 1146307 Oct-14 112200
Total FY 14-15 721020
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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3.5 Project Description with Process Details:
Process Flow and Layout of Pellet plant
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Pellet Plant Process Details
Mixing & BallingIron Ore Concentrate containing + 65% Fe, is received from Dhedwas Mine
Beneficiation Plant of the Company is mixed with Bentonite and Water and transferred
to Φ 6.0m balling disc rotating with adjustable angle, frequency and speed for higher
degree of balling. Some 0.5% to 1.5% water is added by regulating valve during the
process of balling to achieve the optimal moisture of the mixed material for balling.
Drying and Pre HeatingThe green ball produced by the balling disc is sent to the green ball distribution system
in Traveling Grate room by belt conveyor. The undersize (-8 mm) and oversize
(+16mm) balls is separated and sent back to the balling room via return system. The
green balls of 8 to 16mm size range, called qualified balls, are passed on to the grate
bed of Travelling grate. The thickness of the material (balls) bed on the grate will be
kept 185mm. The green balls will pass through 4 zones of the grate viz. drying zone-I
and II, preheating zones I and II.
The temperature of these zones is 300°C, 500°C, 700°C and 1100°C respectively.
The green ball is dried and preheated on the Travelling grate of 4.0 X 42m size for
about 23.3 minutes. After preheating, the green balls attain enough strength, they are
discharged into Kiln through discharging plate and large chutes.
Induration in Rotary KilnThe preheated balls discharged into the Rotary Kiln of Φ 5m X 35m size and 4.25%
slope and is indurated for about 35 minutes while rolling, mainly due to heat radiation
of the flame produced by burning of pulverized coal. The induration temperature of
1200º to 1250ºC is attained in the Rotary Kiln. The Kiln is Φ 5m X 35m, inclined at
4.25%, operating at about 1 R.P.M. The speed of the Kiln is adjusted according to
variation of the raw material to determine retention time and consequently the quality
of the pellet. The indurated pellet is discharged to the receiving hopper of the annular
cooler through Chute and fixed screen in the Kiln head hood.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Annular Cooler
The Annular Cooler receives the red-hot-pellet with temperature upto 1230ºC
discharged from the Kiln, its particle size being 8-16mm. The pellets are distributed on
the pallet bed in the annular cooler, up to 760mm thickness. The annular cooler is
provided with 3 air blowers. The pellets are cooled in 3 stages, from 1230º C to 900ºC,
from 900º to 550ºC and from 450 ºC to 90-105 ºC. The discharged hot air from annular
cooler is used for drying, pre-heating and indurating sections, thus most of the heat
generated during pellet cooling is effectively utilized in the pellet production process.
The pellet discharged from annular discharge hopper after cooling is stacked in the
finished Pellet Storage yard.
Main workshopMain process workshops of this project include: proportioning room, mixing room, balling
room, feed distribution system, grate-kiln, rotary kiln and annular cooler system, product
system, and main induced draught system. The main facilities in this project include: general
layout and transportation within the plant limit, power supply and distribution facilities, water
supply and drainage facilities, gas flow facilities, ventilation and dedusting facilities.
Auxiliary facilities of this project include: laboratory, repair facilities and spare parts
warehouse.
Proportioning roomQualified iron ore concentrate fine is transferred into 5 numbers of iron ore concentrate
bunkers in the proportioning room. Bentonite is carried to 2 numbers of Bentonite bins
in proportioning room for proportioning by pneumatic conveying pipeline. The collected
dust by the multi-cyclone and ESP of main induced draught system is sent to one dust
bin in proportioning room for proportioning through pneumatic pipeline. Pressure type
bag de-duster is adopted at bin top. Load cell is set up in each ore bin to measure ore
level and control material charging system, the setting value of proportion is controlled
and adjusted by PLC (Programmable Logic Controllers). Steel structure is adopted for
ore bins. Wear-resisting lining plate is fixed inside the concentrated Iron ore bin.
Vibrator is set up inside the concentrated Iron ore bins and bentonite bins to prevent
from material clogging.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Mixing roomThe mixing room is equipped with one continuous type heavy duty mixer. Mixed material is
conveyed to the balling room by belt conveyer. Moisture detector is provided on belt
conveyer to detect the moisture of the mixed material to control the water addition on the
mixer.
Balling roomMixed material is conveyed to the upper part of the balling room by belt conveyor and
discharged respectively to 6 mixed material bins by plough tripper on the belt conveyer. Six
sets of Φ 6m balling discs are provided under bins. Stock level display is provided in mixed
material bin of balling room to control the discharging position of the belt conveyer. Roller
belt weighing system is provided under bin. Rotating speed of the disc feeder is controlled
by interlocking with constant weighing feeder to feed the mixed material constantly to the
balling disc. The rotating speed and inclination of the balling disc can be adjusted to ensure
the pellet quality. Adequate water is added during the process of balling to achieve the
optimal moisture of the mixed material for balling. Regulating valve is adopted for water
addition. Water addition is regulated on time manually according to the moisture of the
mixed material. Green ball produced by the balling disc is sent to the green ball distribution
system in Travelling grate room by material collecting belt and 0-1 belt conveyer.
Green ball distributing systemDistribution system is consisted of swing belt conveyor, big ball roller screen, wide belt
conveyor and roller distributor. Green ball from balling room is sent to the distribution
system by belt conveyer. Swing belt conveyor discharges green ball to the big ball roller
screen. During its swinging, unqualified green ball bigger than 16mm will be separated
and sent back to balling room via return system; green balls smaller than 16mm are
distributed on the wide belt conveyor. The wide belt conveyor is VWF type, through
which green ball is sent to the roller distributor. Roller distributor screens out residual
unqualified small ball less than 8mm and distribute qualified ball of 8~ 16mm to the
grate bed of the Travelling grate. Unqualified green balls are returned to balling room by
belt conveyer.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Induration systemInduration system consists of three main machines, i.e. travelling grate, rotary kiln and
annular cooler. Green balls are dried and preheated on the Travelling grate, hardened
and indurated in the rotary kiln and cooled in the annular cooler.
Travelling grateTravelling grate is 4.0x42m. Distributing thickness is 185mm. Traveling Grate has 4
zones, up-draught drying zone I of 9m, down-draught drying zone II of 9m, preheating
zone I of 9m and preheating zone II of 15m. Process features of each zone of the grate
are as follows:-
Up-draught drying zone IThe decrepitating temperature of green ball is relatively low. In the up-draught drying zone
I, recovered off-gas from heat resisting fan at the lower part of the preheating zone II mixed
with hot gas from annular cooler zone III (1500) to reduce the fume temperature to below
2500 to 3500 will be blown. The up draught from the bottom of bed make green ball fully
dewatered and dried, so that the green ball can resist temperature above 3500C in the
drying zone II without decrepitation.
Off-gas from wind box of up-draught drying zone I is exhausted to the atmosphere by the
main induced fan through ESP after dedusting and meeting the environmental requirement.
Up-draught drying zone is 9m long and equipped with 4 wind boxes.
Down-draught drying zone II350-4000 C recovered off-gas from heat resisting fan at the lower part of the preheating
zone II is downdraught from top of the bed layer to further dewater and dry the green ball,
so that the ball can resist temperature above 7000C in preheating zone I without
decrepitation. Off-gas from wind box of down-draught drying zone II is also exhausted to the
air by the main induced fan through ESP after de-dusting and meeting the environmental
requirement. Down-draught drying zone is 9m long and equipped with 4 wind boxes.
Preheating zone IIn preheating zone I, hot air flow of above 6000C come through bed layer to further dewater
and dry the green ball to ensure that the pellet can resist the high temperature of above
1050-11000C in the preheating zone II.
The main heat source of preheating zone I come from hot off-gas from zone II of annular
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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cooler, and mixed with some hot air flow of 11000C from preheating zone II. This hot air flow
is introduced in preheating zone I at 7000C through preheating zone I and II partition hole
between hood. Hot off-gas of preheating zone I through header at the both sides of the
wind box together with hot off-gas from down-draught drying zone will be exhausted to the
air through ESP, main induced fan and stack, and then discharged after meeting the
environmental requirement. Preheating zone I is 15m long, 5 wind boxes.
Preheating zone IIAt the pre-heating zone II, the heat source is mainly the hot flue from 950° to 1050° C from
the tail of the rotary Kiln. Temperatures of hot air flow is further heat the pellet and impart
complete/ partial consolidation function to ensure that the pellet has attained required
strength to bear the impact force when falling from grate to the kiln and not get broken
during the rotating in the kiln.
Preheating zone II is 15m long with 7 wind boxes. Relief stack and relief valve is provided
on the top of hood of preheating zone II for furnace preheating and emergency
operation.
Green balls are dried and preheated on the Travelling grate. After preheating, green
ball has enough strength and are discharged into kiln through discharging plate and
large chute. Leakage of discharging plate shall not be more than 3%.
Dry revert systemSpillage from dust hopper of the Travelling grate and discharging end of rotary kiln is
returned to kiln through 1# dust bin and special bucket elevator for pellet. Dry return
from dust leg of grate wind box is collected to the return conveyer by dust belt conveyer
and sent to the balling system together with mixed material.
One electrical single beam overhead crane is shared by distribution system and
Travelling grate building for maintenance. An electrical hoist is installed on the head of
Travelling grate for maintenance of driving unit of the Travelling grate.
Rotary kilnSpecification of the rotary kiln is Φ 5m X 35m, inclination is 4.25%, operating rpm is
about 1, two points supported. Compound lining of high alumina brick and high strength
insulating pouring composite lining are adopted, which has a good property of anti-heat
shock, anti-impacting and anti-wearing as well as insulating to extend operating life and
reduce out surface temperature of the kiln. After preheating on the Travelling grate, pellets
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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are discharged to kiln tail end through discharging plate and chute. Kiln head is equipped
with specially designed double adjusting moving burner (Pulverized coal injecting gun), and
the shape and length of the flame can be controlled and adjusted by movement of the
burner and the adjustment of primary wind volume. Pellet in the kiln is indurated while
rolling; mainly due to the heat radiation ~ achieve uniform strength. Indurating temperature
is 12000 ~ 1250°C. Temperature of hot air flow in the kiln depends on the quantum of the
coal injected. Speed of the kiln can be adjusted according to variation of the raw material to
determine the retention time and consequently the quality of the pellet.
Kiln head hood and tail hood adopts new type sealing device and is equipped with structural
cooling fan.
A combination of infrared radiation thermometer-bicolor pyrometer-fixed thermocouple is
adopted for detection to adjust and control the Indurating of the pellet in the kiln.
Indurated pellets are discharged to the receiving hopper of the annular cooler through chute
and fixed screen in the kiln head hood.
Annular cooler(1) Effective area of the annular cooler is 69m2, intermediate diameter is Ф12.5m, width
of the pallet is 2.2m. Normal operation output is 151.5t/h. Cooling time is 44.4 min, bed
layer thickness is 760mm. The annular cooler is composed of rotary part, wind box,
driving unit, frame and upper hood. 3 blast cooling fans and 1 structural cooling fan are
provided. Annular cooler receives red hot pellet with temperature up to 12300C
discharged from the rotary kiln, its particle size is 8~16mm. The kiln may discharge
large lump once in a while due to the high temperature operation. The lumps are sorted
out by the fixed screen in the kiln head hood and discharged by the lump discharge
chute. Pellets are distributed on the pallet in the annular cooler by distributing device,
and distributing thickness is 760 mm which is maintained by AC variable frequency
speed control of the annular cooler according to discharging amount of the kiln.
(2) There are total 9 wind boxes, with one blower for 3 wind boxes. The annular cooler
fume hood is divided into three parts: in 1st cooling section, the 900-1100'C hot air
stream directly returns to rotary kiln through kiln head hood above receiving bucket and
parallel duct, which is applied to increase the kiln inside temperature and be used as
the secondary combustion air for pulverized coal firing ; in 2nd cooling section, the
5500C hot air stream goes through hot blast pipe to Travelling grate I section fume
hood, which is used for pellet drying and preheating; in 3rd cooling section, the 1200C
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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waste gas is discharged mostly to the up-draught drying zone I and some directly to
the stack of annular cooler with the density of less than 100mg/m3. The annular cooler
blower is use wind gate to regulate cooling wind volume automatically and control
return hot air temperature. Through the process, most of the hot air generated during
pellet cooling can be effectively utilized in the three-dimensional pellet production
process.
(3) Under annular cooler discharging bucket, one surge bin will be provided.
The electro-hydraulic feed gate can control uniform discharging. The pellet ore
temperature goes down under 1200C in annular cooler, discharged to belt conveyer
through discharging bucket and then stored in product storage yard. Under annular
cooler, 18 duct buckets are supplied with one electric double-layer dust discharging
valve for each bucket. A hand operated car is used to collect bulk material, which is
sent to belt conveyer and transported out with product ore. The belt conveyer is
equipped with an electronic belt scale for measuring the finished pellets.
Main induced draught systemThe waste fume is collected from the wind boxes of travelling grate preheating section-I,
draught drying section I & II, dedusted by electro static precipitator to reach the
standard, and induced by main induced fan to be discharged by chimney. In future we
will install a de sulphurising unit to further treat the sulpher in waste gases after ESP is
need arises. The Electro-Static Precipitator is 170m2 with four electric fields. The fume
flow rate is 0.98m/s. The precipitator is provided with temperature, pressure and flow
rate measuring devices with dust content measuring holes arranged at incoming &
outgoing duct. The collected dust is pneumatically transported from duct channel,
through duct and to dust bin in proportioning room.
The designed wind flow for main wind induced fan is 60x104 m3/h, with negative pressure of
5.5 kPa. The dust content discharged from electric precipitator, main induced fan and
chimney is ≤50mg/m3. The inner diameter for chimney outlet is < Φ3.2m; the flow rate
is designed as 19.50m/s; the chimney height is 100m. The inner lining of chimney is
wear-resisting anti-corrosive type.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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PCI systemRaw coal is constantly fed to the middle speed grinding mill through sealed electrical belt
weighing feeder for grinding. Ground coal fine (-200 mesh > 85%) is carried by hot fume
through rising pipe directly to the coal fine collector in which air and solid is separated. Coal
fine is sent to the coal fine bin through deposit hopper and discharging valve. Tail gas is
filtered by bag and discharged into atmosphere with discharging density <50mg/m3. An
exhaust fan is installed at the end of pulverizing system as the power source for the
whole system. A silencer is installed at the exit of the exhaust fan to reduce the
noise of the system to <85 db (A).
Raw coal needs hot fume for drying during the grinding. Hot fume is generated by the
furnace and come into the grinding mill through pipeline. Adjusting valve and flow meter is
provided in the pipeline to control fume flow.
Root’s fans (one in operation, one standby) are adopted to transfer coal fine to the kiln
head. Pressurized air generated by Root's fan is mixed with coal fine after the flexible
air lock device and send the coal fine to the kiln head coal burner. Two Root's fans and
two sets of ring balance weighing devices, through switching of valves in the
connecting pipeline realized alternating standby of the coal transfer and coal feeding
equipment to ensure the continuous supply of coal fine to the kiln head.
Finished product system
The pellet discharged from annular discharge hopper after cooling is carried
into 2# transfer station via belt conveyer, and is sent to heavy discharging
wagon via belt conveyer to discharge at finished yard and stored in the open
air or is sent into auto discharging bins.
Material balanceThe raw material for the pellet plant is concentrated magnetite of the percentage of about
65% Fe. The same is added with bentonite powder as per below material balance table:-
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Material Balance
Input Output
Material Ton/Annum Proportion% Material Ton/Annum Proportion
%Iron
concentrate 1204635 95.9%Final
Pellets 1200000 95.5%
Bentonite 10842 0.9%PelletFines 24490 1.9%
Lime 1205 0.1% Dust 3614 0.3%
Dust 3614 0.3%BurntLoss 28330 2.3%
Coal 36139 2.9%Total 1256434 Total 1256434
3.6 Raw Material required along with estimated quantity, likely source,marketing area of final products, mode of transport of raw materials and finishedproducts:
Actual production and corresponding Raw material consumption is shown in below
table
Sr.No. Month Production
(Tons)
Concentrate (Filter
cake)(Tons)
Concentrate(Purchase)
(Tons)
MillScale
(Tons)
Bentonite(Tons)
Coal(Tons)
1 Apr-13 02 May-13 0 03 Jun-13 30101 31593 0 0 331 8244 Jul-13 41169 43226 0 0 552 13465 Aug-13 43352 44554 0 2244 633 14606 Sep-13 48956 45828 0 3577 580 15747 Oct-13 68528 57968 4345 4609 819 21028 Nov-13 82230 67294 12015 3638 1032 22149 Dec-13 75862 64178 11281 297 1140 2120
10 Jan-14 101400 90846 11122 0 1536 262911 Feb-14 95370 87984 10523 0 1499 238812 Mar-14 121020 109845 11077 0 2009 3134
Total(FY13-14) 707988 643316 60363 14365 10131 197911 Apr-14
104,060 85471 13480 169 1685 2662
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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2 May-1490,150 70538 14964 5866 1037 2364
3 Jun-14105,910 91181 11631 4265 1143 2745
4 Jul-14103,020 83113 15004 5210 1111 2803
5 Aug-1491,050 78557 11179 2302 1187 2482
6 Sep-14114,630 99096 11716 2655 925 2950
7 Oct-14112,200 88956 19586 3800 839 3143
Total (FY14-15)up to Oct’14 721020 596912 97561 24267 7927 19149
The Captive Iron ore concentrate is transporting to pellet plant by conveyor and
bought out material like purchased iron, Bentonite, coal and lime is transporting to
plant by road. All conveyors are covered with dust suppression system at transfer
points.
Details of finished product, market area and mode of transport
S.No.Name OfFinishedProduct
Market Area Mode oftransport
1 PelletsSales within Rajasthan, MP,Gujrat, UP, Haryana ,Maharashtra, Export
By Road/Rail/sea
3.7 Resource optimization / recycling and reuse envisaged in the project
100% dust collected from ESP is reused in the process.
3.8 Availability of water, its source, Energy / Power requirement andsource
Availability and source of water
Jindal Saw has already established Bhilwara city Sewage Water Treatment plant
(STP) and treated water is being supplied by pipelines to its Mining & pellet plant.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Availability and source of electricity
Power has being sourced through the existing 220 KV substations.
3.9 Quantity of wastes to be generated (Liquid and solid) and scheme for theirManagement/disposal
100% dust collected from ESP is reused in the process. No wastewater is generated fromthe process.
Type and Quantity of actual liquid and other waste generated and its management
No wastewater is generated from the process.
Other types of wastes generated from the pellet plant are as follows:
Waste generated Quantity Disposal planUsed / Spent oil 10.0 KL/annum 3.0 KL Re-used and balance sent to
registered recyclerUsed / Spent Greese 10 Ton/annum 2.0 Ton Re-used and balance sent to
registered recyclerEmpty /ContaminatedDrums
300Nos /Annum Re-Using for storing of used oil and surplusdrums sold to registered recycler.
Cotton waste / Oilsoaked cloths
0.8 MT/ Year sending to registered recycler
Burnt / UsedRefractory
100 MT/Annum
Sale to refractory manufacturer for Re-cycle, / Landfill
E-Waste - sending to registered recycler
3.10 Schematic representations of the feasibility drawing which gives informationof EIA purpose
The pellet plant does not generate any solid wastes or liquid wastes from the
process. So there is no disposal issue. Dust collected from air pollution control
equipment are 100% reused in pellet making process. Air pollution is controlled
using ESP and Bag Filters.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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4.0 SITE ANALYSIS
4.1 Connectivity
The connectivity of the project site with the major road/ railways/ ports and human
settlement is as given in table
Description Distance
TransportationRoad : ~ NH79 –approx 2.2 KM (East)Rail : ~ Bhilwara railway station approx 10 km(East).
NearestTown/City
Bhilwara town-approx 7 km north east
NearestVillage
Pur-approx 2 km south
4.2 Land form, land use and land ownership
The Pellet plant is located adjoining to the Dhedwas Iron ore and associated minerals
mine of Jindal Saw Limited at village Pur, District Bhilwara, Rajasthan. No forest
land is involved in the proposed project site.
The total industrial land covered by pellet plant and other utilities (Beneficiation plant) is
40.76 Acre Jindal Saw Limited has already purchased 88.76 acres of industrial land
from Government of Rajasthan. The land ownership documents are attached as
Annexure II
4.3 Topography
The project region shows undulating topography, elevation of the study area was in the
range of 399-547 m. above mean sea level. The nearest habitation to the project site is
the Pur village, which is located at a distance of two kilometers towards South. Nearest
Railway Station from p e l l e t plant site is in Bhilwara at 10 km (East). NH-79 is at
02 km (East) and SH-12 is 2.3 km South from Project site. The Kothari River is flowing
from West to East through the North (7.7 km from the project location. There are ponds,
and irrigation Canals present within study area.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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4.4 Existing land use pattern
The land for the pellet plant is a part of notified industrial land allotted by Government of
Rajasthan. The land allotment letter from Government of Rajasthan is attached as
Annexure -II.
4.5 Existing Infrastructure
The company is operating currently Iron ore beneficiation & pellet plant at the site.
Following infrastructure facilities are available at site
- Roads
- Water Reservoir
- 220 KV Electric sub station
- Drainage
- Communication system
- Emergency staff hostel
- Laboratory
- Stores
- Weighbridges
- Offices, canteen, IT Infrastructure.
- OHS (Occupational Health Center)
4.6 Soil classification
The pellet plant area soil texture was found to be loam characteristics which were
determined by correlating the results of soil samples. The soil is in Brown to Blackish
Brown colour. The Gravel (<0.2 mm) was in the range of 3.2 % by weight to 46.8 % by
weight. The pH of the soil samples was in the range of 6.64 to 9.80, which show that the
soil nature in between the neutral and alkaline. The Moisture Content in the soil
ranged from 5.18% to 10.4%. The Organic Matter and Organic Carbon in the soil
varied from 0.67% to 1.43% and 0.39% to 0.83%, respectively. The Available
Phosphorous, Potassium and Total Kjeldahl Nitrogen (TKN) varied from 14.9 mg/100gm
to 30.4 mg/100gm, 0.47 to 1.56 mg/100gm and 0.14 % by mass to 0.3 % by
mass, respectively.
The Calcium, Magnesium and Sodium in the samples ranged from 8.34 mg/100gm to
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
Page 35
16.0 mg/100gm, 3.9 mg/100gm to 6.89 mg/100gm, 0.68 mg/100g to 1.48 mg/100g,
respectively. The Sodium Absorption Ratio (SAR) in the soil varied from 0.71 to 1.47,
which signifies that the soil is non-saline in nature.
4.7 Climate data from secondary sources
There are four prominent seasons in the pellet plant area, Summer, South
West Monsoon, Post Monsoon and Winter. The summer season is from March to
June and is followed by South West Monsoon season, which lasts till the mid
September. The period from mid September to November constitutes the post
monsoon season. The winter season is from December to February. The historical
met data (30 years average) from IMD Bhilwara is given below
Month Temperature(deg C) dailyMax Min
RelativeHumidity, %Max Min
Rainfall(mm)
Windspeedkmph
Predominantwinddirection(from)
January 24.0 7.4 60 30 4.2 4.0 NE, N
February 27.2 10.4 51 23 4.1 4.8 NE, N
March 32.5 15.4 38 17 5.7 5.5 SW, NE
April 37.9 21.7 29 18 1.6 6.5 SW, W
May 40.8 25.9 34 17 5.4 9.1 SW, W
June 38.6 26.2 57 35 58.5 11.2 SW, W
July 33.6 24.8 77 61 207.4 10.0 SW, W
August 31.4 23.6 83 71 231.9 7.8 SW, W
September 32.9 22.2 75 54 112.8 6.1 SW, W
October 34.0 18.3 54 32 9.5 4.4 SW, W
November 30.0 13.2 54 33 12.5 3.4 NE, N
December 25.5 8.9 61 34 4.4 3.6 NE, N
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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4.8 Social infrastructure available
The basic amenities and facilities within the study area, as per Census of India, 2001 are given
in below Table shows the basic amenities and facilities at different location in the study area.
Pur, Samodi, Dhedwas, Lakhshmipura, Malikhera, Dariba , Salampuira
Basic Amenities and Facilities in the Study Area
Sl.No. Habitation
Basic Amenities and Facilities(As Per Census of India, 2001)
1. Dhedwas School: Primary School = 1,Drinking Water Facility: Tank Water, Tube WellElectricity: Available
2. Dariba School: Primary School = 2, Middle School = 1, Secondary School = 1Medical Facilities: Not AvailablePost Office = 0, Telephone Connection = 0Drinking Water Facility: Tap water, Wells, Hand PumpElectricity: Available
3. Samodi School: Primary School = 1Medical Facilities: Family Welfare Centre = 1Post Office = 1Telephone Connection = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available
4. Pansal School: Primary School = 2, Middle School = 1, Secondary School = 0Medical Facilities: Health Centre = 1Post Office = 1Telephone Connection = 10Drinking Water Facility: Tap water, Wells, Hand Pump, Tube WellElectricity: Available
5. Lakshmipura
School: Primary School = 1, Drinking Water Facility: Tube WellElectricity: Available
6. Salampura School: Primary School = 1Medical Facilities: Family Welfare Centre = 1Post Office = 1Telephone Connection = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available
7. MaliKhera#
School: Primary School = 1Drinking Water Facility: Wells, Hand PumpElectricity: Available
8. PurVillage#
School: Secondary and Senior Secondary School = 10 -12Medical Facilities: Govt. Dispensary = 1, Vet nary Hospital =1, AyurvedicHospital = 1Drinking Water Facility: Wells, Hand Pump, Tap Water, Tube WellElectricity: Available
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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5.0 PLANNING BRIEF
5.1 Planning concept (type of industries, facilities, transportation etc) Town andcountry planning/ Development authority classification.
The proposed project is brown field project and the state government has allotted it as
industrial land after conversion of waste land. Also the industrial area and the related
facilities are already developed hence no planning is envisaged.
Also, due to the presence of industries including The Rajasthan State Industrial
Development& Investment Corporation- RIICO (located about 4.5 km in the North East
direction from the project site), which are located near to the proposed project site, has led
to conducive infrastructural facilities like paved roadway and electrical substation, for
establishing an Industry.
5.2 Population projection
There is no significant increase in the population of surrounding area as the workers
for the pellet plant operation come from the local residents in the surrounding
villages. No major influx of people in the area due to pellet plant. Only highly skilled
manpower is taken from outside which is not available in the nearby area.
5.3 Land use planning (break up along with green belt etc
The detailed land use planning and the area break up is as given in the table
TOTAL AREA 164946 (40.76 Acre)
PELLET PLANT AREA 18920(4.67 Acre)
ROADS AND DRAINS 22864 (5.65 Acre)
OPEN AREA/STORAGE YARD 68712 (16.98 Acre)
GREEN BELT 54450 (13.45 Acre)
GREEN BELT 33%
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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5.4 Assessment of infrastructure demand (Physical & social)
As the pellet plant is within the existing industrial premises the basic infrastructure like
water, Electricity and road are available at the plant site.
5.5 Amenities/Facilities
Following facilities are available in the existing industrial premises:-
Canteen
Bachelors Hostel
Sanitation Medical
Safety department with all safety training facilities
Fire Tender & Fire fighting services
Conveyance for staff and workers
Rest rooms for workers
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial area (Processing area)
Jindal Saw Limited purchased 88.76 Acres of Industrial land out of which 40.76 Acres
of land is used for the Pellet plant and other facility.
6.2 Residential area (Non processing area)
No labour colony is envisaged for this pellet plant. Pellet plant site is very near to the
Pur village and Bhilwara city so Residential colony is not required.
6.3 Green belt
JSL planted 1500 saplings in project site area. The green belt development progress is
continuing. Around 13 Acre of land has been allocated for green belt development. It is
proposed to plant more than 600 trees per Acre of land area. The schedule of plantation
as given in below Table will be followed.
Green Belt Development Implementation Schedule
Year Area (Acre) Present No. of trees to be Planted
2014 2.4 1500
2015 2.65 1600
2016 2.65 1600
2017 2.65 1600
2018 2.65 1600
Total 13.0 7900
The list of plant species, which is proposed to be used for the green beltdevelopment is given in below.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Sl. No. Common Name Scientific Name
1. Neem Azadirachta indica2. Dhanbaher/ Amaltas Cassia Fistula3. Kumat Acacia Senegal4. Jand Prosopis Spicigera5. Khaira Acacia Catechu6. Karir Capparis deciduas7. Jungle jalebi Inga dulcis8. Imli Tamarindus Indica9. Ber Zizyphus jujube10. Babul Acacia Arabica11. Peepal Ficus Religiosa12. Vilayati babul Prosopis juliflora13. Khejri Prosopis cineraria14. Bargad Ficus benghalensis15. Gulmohar16. Amaltas17. Ashok
The pit size for the plantation of saplings is about 1 m × 1 m × 1 m. These pits are
filled with soil and manure up to 2/3rd
of its depth, about 5 to 10 days in advance
before plantation. After fifth year, efforts will be taken to replace the dead plants, whichhave been planted during the five years.
6.4 Social infrastructure
The company is bound for the upliftment of social infrastructure in the surrounding area.
Dedicated fund shall be contributed for the development of hospitals, schools and
drinking facilities in the surrounding area.
6.5 Connectivity (Traffic and transportation road/rail/metro/ water ways etc)
The major road/ rail in the area are as given below
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Transportation
Road : - Highway NH-79 , 2 km (east)Highway SH-12 , 2.3 km (south)
Rail : ~ 10 Km (Bhilwara)Nearest Town/City ~ 7 Km (Bhilwara)
Nearest Village Pur (~ 2.0 Km)
6.6 Drinking water Management (Source & Supply of water)
Water required for drinking purpose is about 25 m3/day (25 KLD) and presently it is supplied from tube well.
6.7 Sewerage system
Domestic waste water generated from office toilets is directly discharged through soak pit / septic tank.
6.8 Industrial waste management
No industrial waste is produced from the pellet plant.
6.9 Solid Waste/by product Management
Type and Quantity of actual solid waste generated and its management
Sr. No. Month ESP Dust(Ton)
Broken Pellets &Fines (ton) Use
1 Apr-13
Reuse in thepreparation of pelletby dispatching toproportioningroom(100 %Recycle)
2 May-133 Jun-13 89 6194 Jul-13 145 19195 Aug-13 158 11506 Sep-13 170 5967 Oct-13 227 11098 Nov-13 239 11879 Dec-13 229 316
10 Jan-14 284 63011 Feb-14 258 189912 Mar-14 339 2284Total FY 13-14 2137 11710
13 Apr-14 266 357014 May-14 236 708515 Jun-14 274 2628
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16 Jul-14 280 187717 Aug-14 248 197718 Sep-14 295 136619 Oct-14 314 826Total FY 14-15 1915 19329
6.10 Power requirement & supply/source
Total power requirement of pellet plant is fulfilled from the existing 220 KV feeder.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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7.0 REHABILITATION AND RESETTLEMENT PLAN
7.1 Policy to be adopted (Central/ state) in respect of the project affected persons including homeoustees, land oustees and landless laborers
Not applicable, because no human settlement or agriculture land is involved in the identified project land. The
Pellet plant is within the existing industrial premises.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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8.0 PROJECT SCHEDULE & COST ESTIMATES
8.1 Likely date of start of construction and likely date of completion
The pellet plant was commissioned in June 2013.
8.2 Estimated project cost along with analysis in terms of economic viability of the project
The details cost bifurcation of pellet plant is as below:
Particulars Rs. (in crores)
Land and Site development 0.59
Building 20.88
Plant and Machinery including environmental monitoring andcontrol equipments
246.26
Preliminary and Pre-operative expenses 54.90
TOTAL 322.63
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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9.0 ANALYSIS OF PROPOSAL
9.1 Financial and Social Benefits
Based on the future demand of pellets in the market over the next 5 years, the proximity of the present pellet
plant to iron ore mines is an advantage with respect to price logistics. The financial viability also shows a good
rate of return from the pellet plant. Other financial and social benefits that could be obtained from this
pellet plant are described below:
The plant is generating considerable growth of transport sector in the region.
Providing direct & indirect employment opportunities and development of peripheral /supporting
services and amenities.
Supporting infrastructure development like road, power supply, reality sector.
No environmental significant impacts are envisaged.
Best applicable mitigative measures have been proposed for management of anticipated
environmental impacts.
Community development activities are initiated under CSR programs.
The pellet plant is providing the significant revenue to the exchequer in the form of excise and taxes
etc.
The pellet plant is created opportunity for industrial development in the state.
Jindal Saw Limited has a focus on the all-round development of the communities in and around the plant
and in Bhilwara city and is actively promoting social & welfare activities of the surrounding society. In
past 2 years it has spent Over Rs 5.8 Crore for various social & welfare activities of the nearby society. Over
and above company resources has also been deployed for improving society & welfare programs. Apart
from providing suitable employment for local populations, the key focus of Jindal Saw social & welfare
activities are
- Improving hygiene & sanitary conditions, Drinking water
- Green Belts development & Society parks
- Medical facilities & health awareness
- Education promotion & support- Support for natural calamities & emergencies
- Religious & Cultural activities support, Fodder for animals
Jindal Saw Ltd. has taken an initiative for maintenance of community parks. Presently, more than 80 parks are
being maintained by Jindal Saw Ltd. In addition to that to maintain hygiene and healthy environment in and
around the city, Jindal Saw has also taken a task for community drainage maintenance.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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Jindal Saw ltd works meticulously for the development of schools in villages around the plant. Contribution
has been made towards construction of boundary wall to Government High School in Dhulkhera village,
sponsorship cost for celebrating republic day in Sophia Senior Secondary School, Bhilwara.
Jindal Saw ltd has also undertaken focused initiative for social & religious development, sports & cultural
activities, disaster relief and women welfare in & around villages. Contribution has been made to Vishwa
Hindu Parishad towards the sponsorship for the Tailoring Training Centre for Ladies. Contribution has also
been made to Shree Anand Krishna Gaushala Sewa Samity, Suras village, for providing Fodder to Cattles and
to Sidhudhuni Hathipada Ashram, Pur village, as Sponsorship towards the procurement of Cement Bags for
the construction of temple. Jindal Saw has also contributed in sponsorship towards marriages in the villages,
drinking water facilities and higher education.
Jindal saw ltd. has taken up a cause of health care with considerable commitment and focus. Jindal saw
organized a number of voluntary activities within the area of community health. Regular blood donation
drives are organized at plant site, witnessing enthusiastic participation by Jindalites. Occupational Health
Surveillance Camp was also organized for general health check up and disseminating information on
health care.
Apart from these, a multipurpose Fire Tender is available with trained staff round the clock for attending any
type of fire emergency call in and around the plant site.
Jindal Saw Ltd. constantly strives to move beyond regulatory standards and do more. Jindal Saw is now
building on community development to create a sustainable framework that allows Jindal plant to amplify the
positive impact they have.
In future these social & welfare activities will be continued and few new initiatives like Girl Education, Skill
development & industrial training and Sports promotion etc will be added. In order to access need of nearby
population a systematic “Need Assessment Studies” will be undertaken with help of reputed institutes
and local Government bodies.
CORPORATE SOCIAL RESPONSIBILITY
Along with being a successful Business entity JINDAL SAW LTD. has an active sense of social
responsibility. As a Leading transnational, The Company is committed to be a good corporate citizen wherever
the company is engaged in business activities and interests. The company’s Corporate SocialResponsibility Programme voluntarily integrates Social and Environmental concerns into their operations.
Project Report of 1.2 MTPA Pellet Plant at vill Tur, Bhilwara, Rajasthan
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As a responsible corporate entity JINDAL SAW LTD. shoulders many responsibilities.
To work in tandem with the environment without upsetting the ever-fragile eco-system is our philosophy.
Strict environment management systems for air, water, and waste treatment in and around the plants ensure
stringent procedures and international compliances. The organization attempts to give its workforce a quality
life, hazard free working environment, and drive them to a higher standard of living by providing them access
to amenities like housing, transportation, medical facilities, schools, and other civic infrastructure. As part of
community service, JINDAL SAW LTD. has adopted many villages surrounding the plants. Active
volunteers from the organization undertake regularly literacy drives; organize free health camps, mobile eye-
care units and are continuously striving to make these villages independent and progressive.
For JINDAL SAW LTD. high-quality products and services are inseparably bound with our obligation to
society and environment. “Indeed adding value to all our businesses”.