simhadri pellets india limited - environmentclearance.nic.in
TRANSCRIPT
Simhadri Pellets India Limited In the existing plant premises
M/s Steel Exchange India Limited (SEIL), Sreerampuram Village,
L.Kota mandal, Vizianagaram district
PIONEER ENVIRO
Laboratories & Consultants (P) Ltd 6-3-652, 7-3, Dhruvatara Apartment’, Somajiguda, Hyderabad-500082. E mail: [email protected];
Phone: 040-23314270, 66100103.
APPENDIX I (See paragraph – 6)
FORM 1
Sr. No
(I) BASIC INFORMATION
1. Name of the project SIMHADRI PELLETS INDIA LIMITED
2. S. No. in the schedule 3 (a)
3. Proposed capacity/area/length/tonnage to be
handled/command area/lease area/number of
wells to be drilled
Pellets – 0.6 MTPA
Producer gas – 8500 m3/hr
4. New/Expansion/Modernization New
5. Existing capacity/Area etc. Not applicable
6. Category of project i.e. ‘A’ or ‘B’. A
7. Does it attract the general condition? If yes,
please specify.
No
8. Does it attract the specific condition? If yes,
please specify.
No
9. Location The proposed project will be taken up in the plant
premises of M/s Steel Exchange India Limited.
Total 25.6 acres of land will be taken on lease. A
copy of the lease agreement is enclosed as
Annexure – I
Plot/Survey/Khasra No. 98-2 (P), 99 (P), 100-1, 100-2 (P), 100-3, 100-4, 101-
1, 101-2, 101-3, 101-4, 101-5, 101-6, 101-7, 101-8,
102-10 (P), 102-11, 102-12 (P), 103-2 (P), 103-5,
103-6 (P), 103-11 (P), 103-12 (P), 107-8 (P), 107-11,
107-12, 107-13, 108-1, 108-2, 147-1 (P)
Village Sreerampuram
Mandal L.Kota Mandal
District Vizianagaram
State Andhra Pradesh
10. Nearest Railway station / Airport along with
distance in kms.
Nearest Railway station: Malliveedu (1.5 Kms.)
11. Nearest Town, City, District Headquarters
along with distance in Kms
Nearest Town: Vizianagarm (28.0 Kms.)
Vishakapatnam (29 Kms)
12. Village Panchayats,Zilla Parishad, Municipal
corporation, Local body(complete postal
addresses with telephone nos. to be given)
Sreerampuram Village,
L.Kota Mandal Mandal,
Vijayanagaram Dist.
13. Name of the applicant Simhadri Pellets India Ltd.
14. Registered Address Flat No. 303,
3
My Home Laxminivas Apartments,
Greenlands, Ameerpet,
Hyderabad – 500016
15. Address for correspondence:
Name B.Satish Kumar
Designation(owner/partner/CEO) Director
Address Flat No. 303,
My Home Laxminivas Apartments,
Greenlands, Ameerpet,
Hyderabad – 500016
Pin code 500016
E-Mail [email protected]
Telephone No. 040-23403725
Fax No. 040- 23403267
16.
Details of Alternative sites examined, if any.
Location these sites should be shown on a
topo sheet
No alternative sites have been examined, as the
proposed project will be taken up in the Plant
premises of M/s SEIL
17. Interlinked Projects No
18. Whether separate application of interlinked
project has been submitted?
Not Applicable
19. If yes, date of submission Not Applicable
20. If no, reason Not Applicable
21. Whether the proposal involves
approval/clearance under; if yes, details of the
same and their status to be given.
(a) The Forest (conservation)Act,1980
(b) The Wildlife (protection)Act,1972
(c) The C.R.Z Notification, 1991?
No
22.
Whether there is any a government
order/policy relevant/relating to the site?
No
23. Forest land involved(hectares) Nil
24. Whether there is any litigation pending against
the project and/or land in which the project is
propose to be set up?
(a)Name of the court
(b)Case No.
(c) Orders/directions of the court, if any and its
relevance with the proposed project.
No
4
(II) ACTIVITY
1. Construction, operation or decommissioning of the Project involving actions, which will cause
physical changes in the locality (topography, land use, changes in water bodies, etc.)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate quantities
/rates, wherever possible) with source of
information data
1.1 Permanent or temporary change in land use,
land cover or topography including increase
in intensity of land use (with respect to local
land use plan)
No Present use of the land is Industrial as the
proposed Plant will be established in the
premises of M/s. SEIL by taking 25.6 Acres of
land on lease, under the banner of Simhadri
pellets India Ltd. The topography of the land
is more or less flat without any undulating
nature. No clearance of vegetation is
necessary as there are no trees and shrubs
in the area allocated for the proposed
project.
The Built-up area of the plant is very small
compared to the total area. Moreover
extensive greenbelt will be developed within
the plant premises. This improves the
aesthetics of the area.
Hence there will not be any adverse impact
due to the change in land use pattern due to
the proposed activity.
1.2 Clearance of existing land, vegetation and
buildings?
No No clearance of Buildings & vegetation will
be required in the area earmarked for the
proposed industrial activity.
1.3 Creation of new land uses? Yes No other land use other than industrial will
be created.
1.4 Pre-construction investigations e.g. bore
houses, soil testing?
Yes Bore water & Soil testing are already carried
out.
1.5 Construction works?
Yes Construction activity for the proposed
project will be taken-up after obtaining
Environmental Clearance from MoEF &
Consent For Establishment from APPCB. All
precautions will be taken-up to prevent dust
emission during the construction of the
plant.
1.6 Demolition works? Yes No demolition work will be involved.
1.7 Temporary sites used for construction works No Construction workers will be from local
5
or housing of construction workers? areas. Hence no housing for construction
workers is envisaged.
1.8 Above ground buildings, structures or
earthworks including linear structures, cut
and fill or excavations
Yes Most of the structures in the plant will be
above the ground. However excavations will
be involved for foundations.
The excess cut will be used for land filling.
1.9 Underground works including mining or
tunneling?
No No mining and tunneling will be involved in
the proposed activity.
1.10 Reclamation works? No No reclamation works are essential /
proposed.
1.11 Dredging? No No such work is envisaged.
1.12 Offshore structures? No No offshore structures are envisaged in the
proposed activity.
1.13 Production and manufacturing processes?
Yes Manufacturing of pellets is enclosed as
Annexure – I
1.14 Facilities for storage of goods or materials? Yes Iron ore fines will be stored in covered sheds
1.15 Facilities for treatment or disposal of solid
waste or liquid effluents?
No
Only source of waste water will be sanitary
waste which will be treated in septic tank
followed by soak pit
1.16 Facilities for long term housing of
operational workers?
No No housing colony or township is proposed.
1.17 New road, rail or sea traffic during
construction or operation?
Yes There will be an increase in traffic volume
during construction of the proposed project
activities due to transportation of
construction materials.
Iron ore fines will be transported by railway
wagons up to the site through railway siding.
The existing roads can handle this additional
increase in traffic. Hence there will not be
any adverse impact on road traffic / rail
traffic / sea traffic due to the proposed
activity.
1.18 New road, rail, air waterborne or other
transport infrastructure including new or
altered routes and stations, ports, airports
etc?
No No new road/rail/ air transport infrastructure
is proposed in the activity.
1.19 Closure or diversion of existing transport
routes or infrastructure leading to changes in
traffic movements?
No No closure or diversion of transport routes is
envisaged.
1.20 New or diverted transmission lines or No Not applicable as the water required for the
6
pipelines? proposed project will be supplied by Greater
Vishaka Municipal Corporation (GVMC)
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No No culverting, realignment are envisaged.
There will not be any changes to the
hydrology of watercourses or aquifers.
1.22 Stream crossings? No No stream crossing is involved
1.23 Abstraction or transfers of water form ground
or surface waters?
Yes The water required for the proposed project
will be Greater Vishaka Municipal
Corporation (GVMC). Water will be brought
to the site through dedicated pipelines.
1.24 Changes in water bodies or the land surface
affecting drainage or run-off?
No No changes in water bodies, drainage and
land surface are anticipated as the site is
more or less flat without many undulations.
1.25 Transport of personnel or materials for
construction, operation or decommissioning?
Yes A few vehicles will be provided for transport
of personnel during construction & operation
of the proposed activities. Construction
materials will be transported in contractors
vehicles.
Raw materials like Iron ore fines will be
transported through Railway wagons upto
the site and other raw materials like
Limestone and Bentonite will be transported
in covered trucks by road. The existing road
is capable of handling the additional
vehicular traffic due to the proposed project.
1.26 Long-term dismantling or decommissioning
or restoration works?
No No such works are envisaged
1.27 Ongoing activity during decommissioning
which could have an impact on the
environment?
No No such works are envisaged
1.28 Influx of people to the area either temporarily
or permanently?
Yes Influx of people will be temporary.
1.29 Introduction of alien species? No No such activity is envisaged
1.30 Loss of native species or genetic diversity? No As a part of greenbelt development plan
native species that are suitable to that soil
condition will be developed in consultation
with local DFO as per CPCB guidelines.
1.31 Any other actions? No Nil
7
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or
energy, especially any resources which are non-renewable or in short supply):
S.No. Information/checklist confirmation Yes/No
Details thereof (with approximate quantities
/rates, wherever possible) with source of
information data
2.1 Land especially undeveloped or agricultural
land (ha)
No The present use of the land is Industrial.
26.5 acres of land will be taken on lease
from M/s SEIL. No agriculture land is
involved. 9.8 acres (38% of total area) of
extensive greenbelt will be developed within
the premises.
2.2 Water (expected source & competing users)
unit: KLD
Yes The Water requirement for the proposed
Project will be 500 m3/day. Water required
for the project will be supplied by GVMC. A
dedicated pipelines will be laid upto the site.
2.3 Minerals (MT) Yes Iron ore fines : 663060 TPA
Limestone : 9020 TPA
Bentonite : 6800 TPA
Coal: 21295 MTPA
2.4 Construction material – stone, aggregates,
sand / soil (expected source – MT)
Yes All construction materials will be sourced
from local areas.
2.5 Forests and timber (source – MT) No Not Applicable
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel (MT),
energy (MW)
Yes Fuel
Coal: 21295 TPA
Furnace oil : 8840 KL
HSD : 640 KL
or
Producer gas : 8500 m3/hr.
Power required for the project will be met
from M/s Simhadri Power Limited
Power – 10 MW
2.7 Any other natural resources (use
appropriate standard units)
Not Applicable
8
3. Use, storage, transport, handling or production of substances or materials, which could be harmful
to human health or the environment or raise concerns about actual or perceived risks to human health.
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
3.1 Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna, and
water supplies)
Yes Waste lube oil will be stored in HDPE drums
and will be stored in designated area.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No There will not be any waste water generation
from the project as closed circuit system will
be implemented. Only source of effluent will
be sanitary waste water which will be treated
in septic tank followed by soakpit.
Electro Static Precipitator will be provided
for bring down the particulate matter to less
than 50 mg/Nm3.
Ash and dust generated during the
induration process will be recycled back into
the process to improve the process
efficiency, through pneumatic conveying
system.
Hence no Water borne diseases are
anticipated.
3.3 Affect the welfare of people e.g. by
changing living conditions?
Yes The Population in surrounding area shall get
benefited due to infrastructural and
community development activities. Further,
the project will provide job opportunities.
3.4 Vulnerable groups of people who could be
affected by the project e.g. hospital
patients, children, the elderly etc.,
No High efficiency ESP will be installed to bring
down the particulate matter in the exhaust
flue gas to below 50 mg/Nm3.
Stack of adequate height will be provided as
per CPCB norms to effectively disperse SO2
emissions.
As the nearest habitation is at a distance of
0.5 Km, there will not be any adverse impact
habitations due to the proposed project.
3.5 Any other causes
No Not Applicable
9
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
4.1 Spoil, overburden or mine wastes Yes The dug soil during excavation will be used
for filling of low lying areas.
4.2 Municipal waste (domestic and or
commercial wastes)
Yes Small quantities of domestic wastes shall be
generated and administrative areas, which
will be disposed off in environment friendly
manner as per the stipulated norms.
4.3 Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes Used Oil / Waste Oil, Waste Drums, etc. will
be generated. These wastes will be stored as
per norms in designated area and will be
disposed off to APPCB approved vendors.
4.4 Other industrial process wastes
No Fly ash will be generated due to combustion
of Coal. The ash disposal will be in
accordance with the Ministry of Environment
& Forests Notification on fly ash utilization.
4.5 Surplus product No Not Applicable
4.6 Sewage sludge or other sludge from
effluent treatment
Yes Small quantities will be generated, which will
be disposed off in environment friendly
manner.
4.7 Construction or demolition wastes Yes The construction waste will be disposed off
as per Norms.
4.8 Redundant machinery or equipment No Not Applicable
4.9 Contaminated soils or other materials No Not Applicable
4.10 Agricultural wastes No Not Applicable
4.11 Other solid wastes No Not Applicable
10
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
5.1 Emissions from combustion of fossil fuels
from stationary or mobile sources
Yes The emissions of concern from the proposed
plant will be PM, SO2 and NOx. High
efficiency ESP will be installed to bring down
the particulate matter in the exhaust flue gas
to below 50 mg/Nm3. Stack of adequate
height will be provided as per CPCB norms
to effectively disperse SO2 emissions.
5.2 Emissions from production processes Yes Dust emissions will be controlled by
employing dust extraction systems
5.3 Emissions from materials handling
including storage or transport
Yes Fugitive dust will be generated from raw
material handling. Dust extraction system
with bag filters will be provided in Material
handling areas, transfer points.
5.4 Emissions from construction activities
including plant and equipment
Yes Fugitive dust shall be generated from
construction site due to loosening of soil and
exhaust emissions from construction
equipment. Dust curtains will be provided to
control the dust emission.
5.5 Dust or odours from handling of materials
including construction materials, sewage
and waste
Yes Dust extraction system with bag filters will
be provided at material handling areas and
material transfer points. All wastes will be
disposed off as per norms. Thick Greenbelt
will be developed all round the plant. Hence
there will be not any dust & odor problem
5.6 Emissions from incineration of waste No Not Applicable
5.7 Emissions from burning of waste in open
air (e.g. slash materials, construction
debris)
No Not Applicable
5.8 Emissions from any other sources No Not Applicable
11
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data with source of
information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes The ambient noise levels during operation of
the plant will be in accordance with the
Ministry notification on Noise levels.
6.2 From industrial or similar processes Yes The sources of noise will be mainly Ball
mill, DG set etc. All the machinery will be of
Internationally reputed makes which will
comply with the norms of the Ministry.
6.3 From construction or demolition Yes Some noise will be generated during
construction of the project. Earplugs will be
provided to construction workers working in
the noise prone areas.
6.4 From blasting or piling No Not applicable
6.5 From construction or operational traffic
Yes Due to vehicular movement, there will be
slight increase in the ambient noise level. All
the vehicles used will comply with the
Honorable Ministry norms on noise levels.
6.6 From lighting or cooling systems No Not applicable.
6.7 From any other sources No Not Applicable.
12
7. Risks of contamination of land or water from releases of pollutants into the ground or into
sewers, surface waters, groundwater, coastal waters or the sea:
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
7.1 From handling, storage, use or spillage
of hazardous materials
Yes Good housekeeping practices will be
maintained. This will eliminate any spillages.
All hazardous materials will be handled,
stored in designated area and disposed as
per norms.
7.2 From discharge of sewage or other
effluents to water or the land (expected
mode and place of discharge)
Yes Only source of waste water generation will
be sanitary waste water which will be treated
in septic tank followed by soakpit
7.3 By deposition of pollutants emitted to air
into the land or into water
No The emissions of concern from the proposed
plant will be PM, SO2 and NOx. High
efficiency ESP will be installed to bring down
the particulate matter in the exhaust flue gas
to below 50 mg/Nm3. Stack of adequate
height will be provided as per CPCB norms
to effectively dispersion SO2 emissions.
7.4 From any other sources No Not Applicable.
7.5 Is there a risk of long term build up of
pollutants in the environment from these
sources?
No Not expected as suitable environmental
control measures will be provided to comply
with norms.
13
8. Risk of accidents during construction or operation of the Project, which could affect human health
or the environment.
S.No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
8.1 From explosions, spillages, fires etc from
storage, handling, use or production of
hazardous substances
No Sludge from liquid fuel storage tanks will be
stored in covered HDPE drums and will be
disposed to APPCB approved vendors. Risk
Analysis & Disaster Management Plan will be
prepared and submitted in the REIA Report.
8.2 From any other causes No Not Applicable.
8.3 Could the project be affected by natural
disasters causing environmental damage
(e.g. floods, earthquakes, landslides,
cloudburst etc)
Yes Adequate care will be taken during design
and construction to resist the natural
disaster.
14
9. Factors which should be considered (such as consequential development) which could lead to
environmental effects or the potential for cumulative impacts with other existing or planned
activities in the locality
S. No.
Information/Checklist confirmation
Yes/No
Details thereof (with approximate
quantities/rates, wherever possible) with
source of information data
9.1 Lead to development of supporting
utilities, ancillary development or
development stimulated by the project
which could have impact on the
environment e.g.:
• Supporting infrastructure (roads, power
supply, waste or waste water
treatment, etc.)
• housing development
• extractive industries
• supply industries
• other
No
No impact on environment is anticipated due
to the proposed activities
9.2 Lead to after-use of the site, which could
have an impact on the environment
No Not applicable
9.3 Set a precedent for later developments Yes With the improvement in the socio-economic
status of the people in the area later
developments are expected.
9.4 Have cumulative effects due to proximity
to other existing or planned projects with
similar effects
No No other similar industry exists within the
study area of 10 Kms.
15
(III) Environmental Sensitivity
S.No. Areas Name/
Identity
Aerial distance
(Within 15 km.)
Proposed project location
boundary
1 Areas protected under international
conventions, national or local legislation for
their ecological, landscape, cultural or other
related value
No
Not applicable
2 Areas which are important or sensitive for
ecological reasons - Wetlands, watercourses
or other water bodies, coastal zone,
biospheres, mountains, forests
No Not applicable
3 Areas used by protected, important or
sensitive species of flora or fauna for
breeding, nesting, foraging, resting, over
wintering, migration
Reserve Forest 8.5 kms
4 Inland, coastal, marine or underground waters Under ground
water
available at the site
5 State, National boundaries No Not Applicable
6 Routes or facilities used by the public for
access to recreation or other tourist, pilgrim
areas
No Not Applicable
7 Defense installations No Not Applicable
8 Densely populated or built-up area No Not Applicable
9 Areas occupied by sensitive man-made land
uses (hospitals, schools, places of worship,
community facilities)
Hospitals/schools 0.5 Kms.
10 Areas containing important, high quality or
scarce resources
(ground water resources, surface resources,
forestry, agriculture, fisheries, tourism,
minerals)
No Not Applicable.
11 Areas already subjected to pollution or
environmental damage. (those where existing
legal environmental standards are
exceeded)
No Not Applicable.
12 Areas susceptible to natural hazard which
could cause the project to present
environmental problems
(earthquakes, subsidence, landslides,
erosion, flooding or extreme or adverse
climatic conditions)
No No such presidencies in the
area.
16
(IV). PROPOSED TERMS OF REFERENCE FOR EIA STUDIES
I. BASELINE DATA COLLECTION :
A. AMBIENT AIR QUALITY
Baseline data for the proposed project.
A study area of 10 Km. radius.
8 nos. of sampling stations based on predominant wind direction, upwind direction, cross wind
direction, rural area representation and urban area representation.
Parameters PM10, SO2 & NOX. (As per revised NAAQS standards).
Frequency of monitoring 2 days a week for 3 months.
B. WATER QUALITY
Ground water quality at 8 locations within the study area.
Ground water quality for parameters as per IS : 10500
Surface water quality at two locations and analyzed for various parameters
C. NOISE LEVELS
Noise levels monitoring (day time & night time) at 8 locations within the study area.
D. MICRO METEOROLOGICAL DATA
Wind direction, wind speed, temperature, relative humidity and rainfall fall, cloud cover monitoring on
hourly basis for one season.
E. SOCIO-ECONOMIC DETAILS
Socio economic details of people in the study area
F. FLORA & FAUNA
Collection of list of flora & fauna in the study area.
II. PREDICTION OF IMPACTS
Prediction of GLC’s of PM, SO2 & NOx using Air quality model. The emissions from the other
industries within 10 Km. radius will also be considered.
Finding out the net resultant GLC’s by superimposing predicted incremental rise in concentrations
over the baseline concentrations and comparing them with National Ambient Air Quality Standards.
Prediction of impacts on water environment, land environment, noise environment, Flora & Fauna,
socio-economic environment, traffic etc.
17
PRE-FEASIBILITY REPORT
For
0.6 m TPA Pellatisation unit
of
SIMHADRI PELLETS INDIA LIMITED
2
1.0 EXECUTIVE SUMMARY
Introduction
The national steel policy aims at producing 110 million tonnes (MTs) of finished steel by
the year 2019-2020. To meet that, around 170 MTs of quality iron ore (+63% Fe) is
required. Besides that around 100 MTs of quality lump ore is required to meet the export
commitments. Altogether, 270 MTs of calibrated lump and fines are required which
corresponds to mining of around 400 MTs of Run-Off-Mine (ROM) iron ore every year. At
this rate of mining, the proven reserve may last 32-35 years. It is for this reason the
national steel policy envisages investment in modern mining and beneficiation method s for
value addition and utilization of iron ore fines. In order to increase the resource base, the
options available are either to find new resources or to use the existing resources
judiciously. While the former option in all likelihood will be taken in its own stride, the latter
option calls for detailed scientific characterization and advanced process synthesis for the
utilization of iron ore within the framework of zero waste processing. Low grade iron ore,
iron ore fines and iron ore tailings/slimes accumulated over the years at mine heads and
generated during the existing washing processes, need to be beneficiated to provide
concentrates of required quality to the Indian steel plants. However, these concentrates
are too fine in size to be used directly in the existing iron making processes. For utilizing
this fine concentrate, pelletisation is the only alternative available.
NEED FOR PELLETISATION
Steep rise in the prices of raw materials for DRI & Pig Iron production.
Catering to the iron ore demands of all the DR/ Steel plants in the country.
Good productivity, product quality and reasonable campaign life is very important
amongst fierce competition and low grade iron ore availability.
To meet ever increasing demand for iron ore with the planned growth in Steel i.e.
110 million tones by 2020.
Improved productivity and efficiency of the rotary kiln & Blast Furnace with superior
reducibility behavior of pellets compared to lump ore.
In view of the above Simhadri Pellets India Limited has proposed to install 0.6 MTPA
Pellatisation unit in the premises of M/s Steel Exchange India Limited, in Vizianagaram
district, Andhra Pradesh.
3
Project Highlight
The following are the details of the proposed project
S. No. Parameters Description
1. Proposed project 0.6 mTPA Pellatisation unit
2. Location of the project In the existing plant premises M/s Steel Exchange India
Limited (SEIL),
Sreerampuram Village,
L.Kota mandal,
Vizianagaram district
3. Land required for the
project
Total 25.6 acres of land has proposed to be taken on lease
from M/s SEIL. A copy of the lease agreement is enclosed
as Annexure – I
4. Sy. No. of the land 98-2 (P), 99 (P), 100-1, 100-2 (P), 100-3, 100-4, 101-1, 101-
2, 101-3, 101-4, 101-5, 101-6, 101-7, 101-8, 102-10 (P),
102-11, 102-12 (P), 103-2 (P), 103-5, 103-6 (P), 103-11 (P),
103-12 (P), 107-8 (P), 107-11, 107-12, 107-13, 108-1, 108-2,
147-1 (P)
5. Project cost Rs: 238.9 Crores
6. Process and technology
adopted
Dry grinding with Grate kiln process will be adopted in the
proposed project
7. Main raw materials Iron ore concentrate (hematite or magnetite), binder
(Bentonite), additives (green limestone) and fuel
8. Fuel proposed Coal will be main fuel in the rotary kiln and High Speed
Diesel (HSD) will be used for initial startup of rotary kiln,
Furnace Oil to maintain requisite temperature in the
preheating zone of travelling grate.
9. Quantities of raw
materials required
Raw material Quantity (TPA)
Iron ore fines : 663060
Limestone : 9020
Bentonite : 6800
10. Quantity of fuel required Fuel Quantity
Imported coal : 21295 TPA Furnace oil : 8840 KL HSD : 640 KL or Producer gas : 8500 m3/hr
4
11. Water requirement
a. Water requirement 300 KLD
b. Source of water Water required for the proposed unit will be supplied by
Greater Vishaka Municipal Corporation (GVMC)
12. Waste water generation There will not be any waste water generation as closed
circuit cooling will be adopted in the proposed project
13. Air emissions Emissions from Project will be Particulate matter, SO2 and
NOx
14. Air pollution control
systems proposed
Dry type ESP is proposed as a part of Induration
Plant package
Bag filters in the areas covering drying, ore grinding,
pulverizing units, proportioning system and mixing
unit as a part of dedusting system
ESP is proposed at screening building, travelling
grate conveyors and annual cooler discharge points
Cyclone separators and Electric Detarrer will be
provided in Producer gas units.
15. Noise levels Ambient Noise levels are within the standards prescribed by
MOE&F Notification and its amendments and after proposed
expansion also, similar practice will be followed.
16. Solid waste generation
During the induration process ash and dust is generated.
This will be recycled back into process to improve the
process efficiency through pneumatic conveying system.
As generated from the producer gas unit will be disposed off
to the Brick manufacturers and tar will be given to coal tar
distillation units.
5
2.0 INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION
2.1. Identification of project and Project Proponent
Simhadri Pellets India Limited (SPIL) is part of the Vizag Profiles group. The flag ship Company
Vizag Profiles Limited was promoted by a likeminded group of young hard working technocrat
Entrepreneurs in November, 1997.
The Promoters
2.2 Brief Description of nature of Product
Pellets are manufactured using Iron Ore Fines, Bentonite and Limestone as raw materials. These
Iron ore pellets are used for Iron making in DRI plants and in Blast furnaces along sized lump ore.
2.3 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION
2.3.1 NEED FOR PELLETISATION
Steep rise in the prices of raw materials for DRI & Pig Iron production.
Catering to the iron ore demands of all the DR/ Steel plants in the country.
Good productivity, product quality and reasonable campaign life is very important
amongst fierce competition and low grade iron ore availability.
To meet ever increasing demand for iron ore with the planned growth in Steel i.e.
110 million tones by 2020.
Improved productivity and efficiency of the rotary kiln & Blast Furnace with superior
reducibility behavior of pellets compared to lump ore.
2.3.2 STATUS OF IRON ORE PELLET INDUSTRY IN INDIA
Pelletisation of agglomerated fines has taken a great stride recently in the Karnataka -Goa
region. VSP-NMDC has recently submitted a report on the pelletisation and slime
beneficiation at Donimalai, Karnataka. Ministry of steel has proposed a feasibility report on
the pelletisation plant in Goa, and Tungabhadra Mineral Pvt. Ltd. proposes 1.2 MTPY iron
ore pelletisation plant in Karnataka region. The status of the various commissioned pel let
plants in India are given below
S.No Name Designations
1. Sri B. Satish Kumar
2. Sri B. Ramesh Kumar
3. Sri B. Suresh Kumar
6
2.4 Demand – Supply Gap
The major consumers of pellet (both DR and BF grade) are gas based DR plants, blast
furnaces units & COREX units.
The gas based DR units consume on an average about 750 kg of pellet per tonne of DRI,
which is about 45 to 50% of the total iron ore requirement. Similarly, COREX units
consume about 1 tonne of pellet per tonne of hot metal, which is about 70% of the total
7
iron ore requirement. In the case of blast furnaces, the only agglomerate used at present is
sinter. However, there are plans for use of about 20-30 per cent pellet in the ore burden
with a view to improving blast furnace productivity and hot metal quality. Accordingly,
consumption of pellet per tonne of hot metal by the year 2015 could be in the range of
350-500 kg per tonne of hot metal, depending upon the operational philosophy prevailing
in the different plants at that time.
Based on the above considerations, the likely demand potential for pellet would work out
as follows and presented in the below table
PELLET REQUIREMENTS BY 2015
Total Production,
mtpy
Specific Consumption of Pellet (in
addition to iron ore), Kg
Total Requirement,
mtpy
Gas based DR plants
11-12 750 9
Blast furnaces 50-55 350-500 27.5 COREX units 4.5-5 1,000 5 Total 41.5
In addition to the above consumers, there could be some requirement of pellet by the
sponge iron manufactures and smaller blast furnaces producing both basic grade and
foundry grade pig iron. The requirement of sponge iron manufacturers could be in the
range of 10-11 million tonnes per annum and smaller blast furnaces could be in the range
of 3 to 4 million tonnes per annum. Hence, the total market potential in India by the year
2015 could be in the range of 55-57 million tonnes. Also at present, India is exporting
about 6 million tonnes per annum.
AVAILABILITY OF PELLET
At present there are seven pellet plants in India with an installed capacity of about 21.3
million tonnes. The lists of pellet plants are furnished below:
8
AVAILABILITY OF PELLET
Existing Capacity, mtpy
KIOCL .. 3.5 ESSAR .. 8.0 Mandovi .. 1.8 JSW .. 5.0 BMM Ispat .. 1.2 AISCO .. 1.2 JCL .. 0.6
Total .. 21.3
In addition to the above, some of the existing integrated steel producers and othe r
companies are also planning to set up pelletising capacities. Expected availability of
pellets from the proposed pellet plants are given in below table
EXPECTED AVAILABILITY OF PELLET
Proposed Capacity, mtpy
JSPL .. 5.0 JSPL .. 10.0 Tata Steel .. 6.0 MSPL Ltd, .. 1.2 BSP .. 0.5 XIndia Ltd. .. 2.0 MSP LTD. .. 1.2 Bhushan Energy & Power Ltd
.. 2.5
Total .. 28.4
Therefore, by 2015, total installed capacity for pellet could be in the range of 49 -50 million
tonnes.
From the above, it is evident that there could be a gap in Pellet availability to the tune of
10-12 million tonnes by 2015. Therefore, it is expected that SPIL would have adequate
9
market potential available, for which a new pellet plant can be considered. Also more than
50% of the Pellets produced will be consumed in-house (Captive Consumption) by sister
concern SEIL.
2.5 Employment generation (Direct & Indirect):
The proposed project creates employment to 500 people during construction and 120 people during
operation of the proposed project.
SKILLED
Total skilled employment in the proposed plant will be around 30.
SEMI SKILLED & UNSKILLED
Total Semi Skilled & Unskilled employment in the proposed project will be around 90. Top priority
will be given to local people for Semi skilled & unskilled jobs.
10
3.0 PROJECT DESCRIPTION
3.1 Type of the Project:
The proposed project involves the manufacturing of Pellets using Iron ore fines, Bentonite and Lime
stone as raw materials.
3.2 Location:
Proposed pellatisation unit is planned to be set up in the existing plant premises of M/s Steel
Exchange India Limited situated at Sreerampuram Village, L.Kota Mandal, Vizianagaram District
3.3 Size or Magnitude of Operation:
In view of the current demand of pellets, the company has proposed to put 0.6 mTPA Pellatisation
unit.
3.4. Process Details:
3.4.1 Manufacturing of Pellets
The iron ore pelletising process basically comprises of three major steps , namely grinding,
balling and induration. There is more than one option for each of these steps. These are
reviewed below and options proposed to be adopted for the proposed pelletising plant are
indicated accordingly.
Grinding
Rolling of fines into green balls with sufficient green strength is a prerequisite to
pelletisation process. This, in turn calls for super fineness or pelletisation fineness (85
percent passing through-200mesh) of the raw materials before subjecting them to balling
operations. Raw materials as such do not exist in superfine state. This i s to be achieved
either by direct grinding (as in case of iron ore fines) or a combination of crushing and
grinding as in the case of additives to the desired Blaine number.
Considering the flexibility of operation, especially for the raw materials with h igh degree of
chemical fluctuation, it is recommended to ground all the raw materials separately to
derive the maximum effect. For iron ore, grinding can be carried out dry or wet.
Wet grinding is adopted usually when preceded by beneficiation in wet process. Wet
ground ore in slurry form is then filtered and the filter cake is used for pelletising. One of
the problems of wet grinding is controlling the residual moisture in the filter cake within 10
percent or so which is conducive to good pellet making. To achieve this optimum moisture
level, drying may have to be adopted. One of the difficulties of drying of the moist filter
11
Closed Circuit Dry Grinding System
Closed Circuit Wet Grinding System
cake is that it may result in micro-balling inside the dryer itself which, in turn, affects the
green ball formation process adversely.
Dry grinding is adopted to alleviate the above problem. In case of dry grinding, drying of
ore to 1 percent or less moisture is an essential pre-requisite in order to avoid “coating” of
“grinding media” which is detrimental to efficiency and effectiveness of grinding.
Dry grinding, compared to wet grinding, consumes more power, but consumption of
grinding medium and liner are lower. The lower consumption of power in wet grinding is
largely offset by power required for thickener, slurry pump, vacuum pump for filter, filter
drive etc.
Based on the above analysis, for the proposed plant dry grinding system is envisaged..
12
Balling Disc Circuit
Balling
Balling can be carried out in balling drum or balling disc, the performance of both of which
has been found satisfactory in a number of installations. The green balls produced by a
drum are not uniform in diameter. A significant portion of the discharge (about 70%) is
smaller than target size and must be returned to the drum after screening. It is diff icult to
adjust the drum operation for varying raw material conditions. The operation, however, is
stable for uniform raw material conditions (chemical composition, particle size, moisture,
etc.). Drum Pelletisers usually give 10% capacity advantage, but pellets formed in Disc
Pelletisers are more uniform in size . As a result, the recycle load is much less in disc
pelletisers.
Balling Drum Circuit
13
Further, open design of the disc provides a clear view of operation and permits rapid
adjustment of variables, such as plough position, disc inclination, disc speed etc.
Considering these operational advantages, disc pelletiser is recommended to be
considered in the proposed pelletising plant.
Induration Induration of green balls involves thermal treatment in stages , namely
drying,
pre-heating,
induration /curing and
cooling
These process steps can be carried out in three types of machines, namely Shaft Furnace,
Grate-kiln and Straight Grate.
Shaft furnace system
A shaft furnace is an old system which employs an external combustion chamber to
generate the heat required for indurating and introduces the hot gas into the furnace. The
green balls, charged from the furnace top, make contact with the hot gas as they descend
and exchange heat to increase their temperature. The heated pellets pass a cooling zone
before being discharged outside the furnace. The pellets charged from the furnace top
come into sufficient contact with the hot gas to ensure high thermal efficiency, which is a
feature of shaft furnaces. However, it is difficult to attain a uniform temperature distribution
in the furnaces. This results in non-uniform heating of the pellets, causing them to cluster
and / or to adhere to the furnace wall, leading to difficulty of operation. In addition, the
scale of the plant is limited to about 450 thousand tonnes/ year at maximum, which limits
the cost savings. This technology has become obsolete due to the difficulty of increasing
the furnace size.
14
Straight grate system
A straight grate system emerged in the industry soon after shaft furnaces. The system
comprises a grate which transfers green balls charged onto it. The grate feeds the green
balls sequentially through the steps of drying, preheating, firing and cooling. The
advantage of a straight grate over a shaft furnace exists in the wider range of temperatu re
control for the processing steps of drying, preheating, firing and cooling. This system,
however, suffers from the disadvantage that a change in the grate speed at once change s
all the conditions for the subsequent process steps.
A straight grate machine includes an endless grate car consisting of grate bars with side
walls. A layer (about 100 mm thick) of fired pellets is placed on the grate bars and on the
side walls. Green balls are placed on top of this to form a layer of about 300mm in
thickness. The layer of fired pellets protects the grate bar and side wall from high
temperatures and prevents the green balls from being in homogeneously fired. The green
balls on the grate pass through the zones for drying, preheating, firing and cooling. Each
Shaft Furnace System
15
zone is held at a predetermined temperature, and heat exchange occurs via hot air and/or
combustion gas to fire the pellets.
The straight grate system, consisting essentially of a single unit which moves a static
layer, is easy to operate. However, the system must re -circulate a portion of the fired
pellets to form the layers on the grate bars and side walls to protect the mechanical parts
and prevent variations in pellet quality. Despite this protection, the pellets are subject to
wear when passing through the process steps at elevated temperatures. In addition, as
previously described, this system involves a thick layer (about 300mm), which is prone to
temperature variation between its top and bottom portions. This leads to variations in the
quality of the product pellets.
Grate-Kiln-Cooler System
A grate-kiln-cooler system consists of three major components: a grate, a kiln and a cooler
.The green balls, fed uniformly onto the grate, pass sequentially through the steps of
drying and preheating. The preheating step hardens them to a strength great enough to
endure the tumbling and heating that occur in the subsequent kiln step. The pellets, after
being fired at an elevated temperature inside the kiln, are cooled in the following step to
produce fired pellets.
The basic concept for designing a system including a grate, kiln and cooler consists in
allocating the thermal transfer, occurring at temperatures from ambient to 1,300 0 C or
higher, to each process step so as not to cause any mechanical problems.
The grate is partitioned into drying zones and preheating zones. In these zones, heat
exchanges at relatively low temperatures occur for drying and preheating the green balls.
Forced convection is applied to the heating for high thermal efficiency. The source of the
Straight Grate System
16
heat for drying and preheating the pellets is not only the kiln off gas, but also recoup gas
from the cooler, an arrangement that gives the plant as a whole high thermal efficiency.
A kiln with a relatively short length is connected with the grate at its inlet and with the
cooler at its outlet. The kiln is lined with refractory materials for firing the preheated pellets
discharged from the grate. The firing is conducted at an elevated temperature, and
radiation heating is applied to fire the pellets efficiently and homogeneously. The kiln is
placed at a slight incline to the discharge and rotates at a low revolution. The pellets
tumble inside the rotating kiln to be fired at a predetermined temperature and are
subsequently transferred to the cooler. The tumbling action ensures the homogenous
heating of all the pellets inside the kiln and consistently yields high quality.
An annular-shaped, horizontally rotating cooler decreases the temperature of the fired
pellets to a level suitable for subsequent transportation. This step employs the forced
convection of air blow for cooling. A part of the hot gas collected from the cooler is used as
secondary air for fuel combustion in the kiln. The hot gas is also used for the process
steps of drying and preheating the green balls, making the entire system thermally
efficient.
Selection of indurating machine
The shaft furnace is effective almost exclusively for magnetite ore. The machine is
outdated and has been almost totally phased out in view of technological up gradation in
the field of induration.
Grate Kiln System
17
In Straight-Grate Machine Pellets are relatively at a position of rest in different thermal
zones, once laid on the straight grate.
In the grate-kiln, the transfer of green pellets from grate to kiln and “spiral – roll” tumbling
motion it undergoes inside the kiln, makes the pellet more prone to breakage which results
in larger recycle load. However, the grate-kiln-cooler combination has the advantage of
selecting the three separate thermal units tailored to suit specific requirement, unlike the
straight grate machine, which has to be selected as a whole. Reportedly, grate -kiln
exposes individual pellets to maximum heat in the entire firing zone comparatively more
uniformly, thus resulting in consistent product quality. Fuel and power consumptions are
reported to be low in grate - kiln. In view of the foregoing, grate kiln machine has been
proposed in this present project.
QUALITY OF PELLETS
Acidic and Basic Pellets: The pellets can be either acidic or basic in chemistry,
depending upon the composition of slag additive. Acid pellets have been used most
extensively. Although basic pellets are known to have advantages over acid pell ets in
terms of better reducibility, softening and melting properties, their development has been
slower. One reason for such slow development is that the limestone and dolomite addition
employed requires so much heat for its calcination that the production capacity of the
pelletizing plant is reduced, compared with acidic grade pellets.
Typical analysis of both acidic and basic grade pellets is given in table below:
ANALYSIS OF VARIOUS QUALITIES OF PELLETS
Type Cao/SiO2 Fe, % SiO2, % MgO, %
Compression
Strength,
Kg/Pellet
Acidic
Pellets < 0.15 64-67 2-4.5 <0.2 250-300
Basic
Pellets ~0.8-1.0 62-64 2-4.5 1.3 200-250
18
Proposed Quality of Pellets
Blast furnace charge can typically consist of about 20% pellets, 70% sinter and 10% lump
iron ore. Normally, in Indian Blast Furnaces, Pellets with CaO:SiO2 ratio in the range of
0.15 to 0.8 are being used. The targeted analysis of BF grade and DRI Grade pellets
proposed to be produced are given in table below:
QUALITY/ANALYSIS OF PELLET
Sl.No Property BF Grade DRI Grade
A. Chemical Quality
Fe 65% min 66.5% min
SiO2 + Al2O3 5% max 3.00% max
Al2O3 0.60% max 0.60% max
Na2O 0.05% max 0.05% max
K2O 0.05% max 0.05% max
TiO2 0.10% max 0.10% max
Mn 0.10% max 0.10% max
P 0.04% max 0.04% max
S 0.02% max 0.02% max
V 0.05% max
Basicity (CaO+MgO/SiO2 + Al2O3)
0.40 0.50
B. Physical Quality
Size Distribution
+16mm 5% max 5% max
+16mm, +9mm 85% min 85% min
-9mm, +6.35mm 7% max 7% max
-5mm 5% max 5% max
Tumbler Index(+6.35mm) 94% min 94% min
Abrasion Index (+0.6mm) 5 % max 5 % max
C. Metallurgical Properties
Swelling Index 20% max 20% max
Compression Strength 250 Kg/Pellet min 250 Kg/Pellet min
Porosity 25% min 25% min
Reducibility 60% min 60% min
Metallization - 92% min
Fragmentation - 3.5% max
19
Attainment of these properties will be ensured by providing suitable raw materials/
beneficiated iron ore and also by adopting appropriate process parameters established
through test work before implementation of the project.
3.4.2 Producer Gas Generation
Coal is lifted to the coal storage bin by lifting system; the coal is added in the carbonation stage of
two-stage coal gasifier by a programmable control feeding system. Air is blown in the bottom of
furnace by air blower, at the same time, low pressure steam goes through the blending bin and
blends with air, becomes the gasification agent, which will carry on the gasification reaction with
1200 Celsius degree semi coke in the gasification stage.
Producer gas is made by the gasification agent, which is mixture of steam and air, which goes
through red-hot fixed burning bed. The oxygen content in the air and steam react with the carbon in
the fuel; generating the producer gas which has ingredients like CO, CO2, H2, CH4, C2H4, N2 etc.
Reaction of steam and carbon is endothermic reaction:
C + H2O= CO + H2
When oxygen and carbon react, and then heat output:
2C + O2 =2CO
C + O2 = CO2
Some steam here reacts with carbon monoxide:
CO + H2O = CO2 + H2
In the reducing zone, quick reaction is occurred when the temperature is below 1200 Celsius degree
CO2 + C = 2CO and
H2O + C=H2 + CO
When the coal gas goes through the reducing zone, flammable gas content raises rapidly, carbon
dioxide and steam content decrease. Across the reducing zone, a part of coal gas is withdrawn
through a series of vents in the gasifier walls and is called “DOWN STAGE GAS”.
Its temperature is around 300-400 Celsius degree and container dust and ash particles.
This down stage gas is treated in the cyclone to remove the dust particles, and is then cooled
through a heat exchanger. In this heat exchanger the heat is given to the water in the steam drum.
The gas is further cooled in a wind cooler, where natural air cools the gas to a lower temperature.
20
In the carbonation stage, the coal added in the gasifier are dried, preheated and carbonated,
generate steam, tar and coal gas, exported from the top of gasifier together, this part of gas is called
“up-stage coal gas”, its temperature is around 100-120 Celsius degree.
The temperature of upstage coal gas is about 100-150 Celsius degree, goes into Electric detarrer to
remove tar. Water and tar come from the bottom of Electric Detarrer is sent to the tar tank.
The Upstage and downstage coal gas are mixed in the entrance of indirect cooler, the temperature
after mixing and cooling in the indirect cooler is 35-40 Celsius degree.
The coal gas pressure adder increases the pressure of the coal gas to the desired value and then
connects to the transmitting coal gas pipelines which take the gas to the equipment.
3.5 Raw material required: The major raw materials input for pelletising process are Iron ore concentrate , binder,
additives and fuel.
Quantity and Quality Requirement
Iron ore concentrate requirement for the proposed pellet plant will be about 663060 tons
per annum. Expected Iron ore fines composition for Blast Furnace Grade & DRI Grade
pellets is given in table below:
EXPECTED IRON ORE FINES COMPOSITION FOR BF GRADE & DRI GRADE
PELLETS
Blast Furnace DRI
TFe, % : 64.20 65.60 SiO2, % : 2.00 1.03 Al2O3, % : 1.45 1.10 S, % : 0.005 0.005 P, % : 0.03 0.03 LOI, % : 4.50 4.00
The physical characteristics of the feed are important criteria for design of the plant.
Assumptions in this regard are given in table below:
PHYSICAL CHARACTERISTICS OF THE IRON ORE
Size of ore, mm : -10mm
Specific Gravity : 4.2
Bulk Density, t/m³ : 2.4
21
Angle of Repose, degree : 35
Compressive Strength, Mpa : 350
Bond work Index, kWh per ton : 14
Tumbler Index, % : 0.65
Moisture Content, % 8 Avg. (10 max) LIMESTONE
Limestone requirement will be 9020 tons per annum exclusive of moisture and handling
loss. Typical physical and chemical properties of limestone are given below
PHYSICAL PROPERTIES OF LIMESTONE
Density, kg/m3 : 2.5 - 2.65 Hardness, Mho’s : 3 – 4 Compressive Strength, Mpa
: 177 - 206
Water absorption, % : < 1
CHEMICAL COMPOSITION OF LIMESTONE
SiO2, % (max) : 0.40 Al2O3, % (max) : 0.18 CaO, % : 54.00 MgO, % : 0.87 P, % : 0.08 S, % : 0.04 LOI, % : 42.20
BENTONITE
Bentonite requirement for the proposed plant will be 6,800 tons per annum exclusive of
moisture and handling loss. It is essentially used as Binder material. Typical physical and
chemical properties of bentonite are given below
PHYSICAL PROPERTIES OF BENTONITE
Specific gravity : 2.65 Bulk Density, kg/m3 : 0.8
22
Water absorption, % : ≥ 500 Swelling Index, ml/2g : ≥ 25 Plasticity index, % : 405
CHEMICAL COMPOSITION OF BENTONITE
Fe, % (max) : 13.00 SiO2, % (max) : 50.00 Al2O3, % (max) : 15.00 CaO, % : 1.60 MgO, % : 1.50 LOI, % : 10.00
COAL
Coal requirement for the plant will be 19,200 tons per annum exclusive of moisture and
handling loss. The specification for coal is given below:
SPECIFICATION FOR COAL
Calorific value, kcal/kg : 7000 Volatile Matter, % : 15-16 Ash content, % : 13-14 Fixed Carbon, % : 70-72 Sulphur content, % : ≤ 0.5 Ash melting point, 0C : > 1350 Size (-200 mesh), % : ≥ 85
FUEL OIL
Fuel Oil is envisaged to be used for the pellet plant for preheating, induration and hot air
generation for grinding system. Furnace Oil and High speed Diesel are envisaged as fuel
oil for the above purposes.
Furnace Oil
Furnace Oil requirement for the plant will be 8,840 KL per annum. Furnace oil is mainly
used to maintain requisite temperature in the preheating zone of travelling grate. Also, it is
23
used as main fuel with LPG for pilot heating in the Hot Air Generator of the grinding mill.
The furnace oil specification envisaged is given in Table 5-8 below:
SPECIFICATION FOR FURNACE OIL
Calorific value, kcal/kg : 10,500 Flash Point, oC : 66 Density, g/cm3 : 0.95 (max) Ash content, % : 0.1 Sulphur content, % : 1
High Speed Diesel (HSD)
High Speed Diesel requirement for the plant processes will be 210 KL per annum and
420 KL per annum for earth moving equipment. In the plant, it is requi red to start-up the
Rotary kiln and for emergency requirements in the kiln, flushing the furnace oil pipelines
etc. The HSD specification envisaged is given below:
SPECIFICATION FOR HSD
Calorific value, kcal/kg : 10,700 Flash Point, oC : 32 Density, g/cm3 : 0.86 (max) Ash content, % : 0.01 Sulphur content, % : 0.3
Producer Gas
Producer gas will be also used as backup fuel instead of Furnace oil and HSD. For
generation of producer gas 3 no.s of gasifier’s (2 will be working and one will be standby)
will be installed to meet the requirement of producer gas
CONSUMABLES
Apart from the above raw materials, consumables such as refractory and grinding media
are used in the process. All these are available locally.
24
QUANTITIES OF MATERIALS HANDLED & THE MODE OF RECEIPT
The gross quantities of various raw materials to be handled by the system and the
respective mode of receipt for each material are given in below:
RAW MATERIALS TO BE HANDLED
Materials
Gross quantity (including moisture &
handling loss) Daily
Requirement Mode of receipt
Pellet Plant
Iron ore fines, MT 6,63,060 2,009 Rail/road (by rail and then by tippers)
Imported coal, MT 21,295 65 Rail/road (by rail from nearby port and then by tippers)
Limestone, MT 9,020 27 Rail/road (by rail and then by tippers)
Bentonite, MT 6,800 21 Road (by truck)
Furnace oil, KL 8,840 27 Road (by truck)
HSD, KL 640 2 Road (by truck)
Coal (grade – C) (for gasifier)
16500 50 Rail/road (by rail from nearby port and then by tippers)
Note: (1) Based on the following operating days/years - 330 days and 24 hrs/day for pellet
plant
3.6 Water requirement and its source:
Water required for proposed project will be sourced from Greater Vishaka Municipal Corporation.
Water is basically required for the cooling tower make-up, greenbelt development & domestic
requirements. Total water requirement for the proposed project will be 500 KLD
3.7 Quantity of waste generated:
3.7.1 Waste water generation
There will not be any wastewater generation due to industrial process. Only source of waste water
generation will be sanitary waste water which will be treated in septic tank followed by soak pit.
3.7.2 Solid waste generation
During the induration process ash and dust is generated. This will be recycled back into process to
improve the process efficiency through pneumatic conveying system.
25
Ash generated from the gasifier will be given to the nearby brick manufacturers and tar will be given
to the coal tar distillation units.
Hazardous waste generation will be in the form of used oil, which is categorized as 5.1 in the
Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008. Annual
generation of hazardous waste will be approximately 100 litres.
4.0 SITE ANALYSIS
4.1 Connectivity:
Component Description
Road The project site can will e well approached by Vishakhapatnam to
Araku road
Rail Railway siding facility is available for the existing plant. The same
will be utilized for the proposed project
Air port Nearest Airport is Vishakhapatnam airport located at 28 Kms from
the project site
Sea Port The nearest sea port is Vishakhapatnam port located at a distance
of 30 Kms from the project site
4.2 Land use:
The present use of the land is industrial as the existing plant is already in operation.
4.3 Topography:
The topography of the land is more or less flat without undulations.
4.4 Existing infrastructure:
Infrastructure is available for the existing plant operating at the site. Separate infrastructure will be
developed for the proposed project.
4.5 Soil Classification:
The main soils in the district are Red soils, Sandy loams and Sandy clay and they constitute 96 % of
the total area. The soils in the district are predominantly loamy with medium fertility. There are
mostly red loamy soils, as far as dry lands are concerned and clay loamy in case of wet lands.
4.6 Climatic data from secondary sources:
The climate of Vizianagaram district is characterized by high humidities nearly all the year round
with oppressive summer and good seasonal rainfall. The summer season is from March to May.
26
This is followed by South West monsoon season, which continues up to September, October and
November constitute the post monsoon or retreating monsoon season. December to February is the
season of generally fine weather. The climate of the hill parts of the district is different from that of
the plain.
27
5.0 PLANNING BRIEF
5.1 Planning Concept:
In view of the growing scarcity of high grade Iron ore, the company has proposed to establish 0.6
mTPA pellatisation unit in the existing plant premises of M/s SEIL, situated at Sreerampuram
Village, L.Kota mandal, Vizianagaram district
5.2 Population Projection:
The labour required for the construction of the Project site will be sourced from the nearby villages.
The man power required during the operation of the project will be unskilled and semi-skilled labour.
High priority will be given to the locals for the Unskilled and semi-skilled jobs based the eligibility.
Hence there will not be much increase in population due to the proposed project.
5.3 Land use Planning:
Total land acquired for the proposed Project is 25.6 Acres. As per the MoEF guidelines, 33% of the
total area will be developed with Greenbelt.
5.4 Amenities / Facilities:
Facilities like canteen, rest room and indoor games facilities will be provided in the proposed plant
as basic facilities to workers. No other additional facilities are proposed.
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6.0 PROPOSED INFRASTRUCTURE
6.1 Industrial area:
The pellet plant mainly consists of ten sections, namely:
1. Iron ore handling system
2. Iron ore grinding and humidifying system
3. Limestone preparation system
4. Coal pulverisation system
5. Bentonite storage and handling
6. Proportioning and mixing
7. Balling
8. Green ball distribution
9. Induration
10. Screening, product storage and handling
Iron Ore Handling System
Feed ore stockpile: The iron ore fines of -10mm size will be procured from NMDC mines,
Bailadila or any other private mine in Orissa state and will be stored in stockpile at Pellet plant
area. Since different grades of iron ore are being procured from various mines, it is proposed
to store iron ore having >64% Fe and >65% Fe separately in the raw material storage area.
Receiving Ground Hopper: The ore transported by the Dump trucks or reclaimed from the
stockpile will be dumped into receiving ground hopper. One number of ground hopper has
been envisaged.
Vibrating Feeder: The receiving hoppers will be equipped with heavy duty vibrating feeder to
draw out the material and deliver the same to Iron ore hoppers in the Hopper building through
a belt conveyor.
Iron Ore Hoppers: Belt conveyor will deliver -10mm material to the Iron ore hoppers of two
(2) numbers of capacity 400 tons each to take care of fluctuation in the feed rate and also to
maintain a uniform rate of ore supply to the grinding section.
Iron Ore Grinding & Humidifying System: The ore will be drawn from the iron ore hoppers at
a uniform rate of about 100 tons per hour by a weigh feeder and delivered to a ball mill of
capacity 100 TPH, to grind the same to 85% passing through 200 mesh. Fines dust generated
in the feed end of the
Grinding mill will be collected by a bag filter and sent back to the mill. Fine dust generated in
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the tail end of the Grinding mill after grinding will be passed through a cyclone and bag filter.
The ground iron ore will be transported to a iron ore fines hopper (with storage capacity of
about 2 -3 hours) in the humidifier building through a belt conveyor. The iron ore f ines from
the hopper will be conveyed to a humidifier by means of a weigh feeder, in which the moisture
content of iron ore is increased to 4%-5% by addition of water. The ground iron ore fines after
humidification will be transported to a set of bins in proportioning building by means of a belt
conveyor.
Limestone Preparation System
Limestone will be procured as lumps and stockpiled in a covered storage shed. Limestone
lumps from the stockpile will be fed to a limestone feed hopper and from the hopper it is
conveyed to a jaw crusher through a slide gate and weigh feeder. The Crushed limestone will
be conveyed to a Limestone storage Bin by means of a bucket elevator. From the storage bin,
limestone is fed to an air swept mill through a slide gate. Ground Limestone is taken into a
cyclone collector by means of air where the coarse particles and fine particles are separated.
Coarse limestone particles from the cyclone are recycled back to the mill again through
bucket elevator. Limestone fines from the cyclone are then sent to a Bag Filter. Fines
collected from the bag filter are delivered to a set of bins in the proportioning building by
means of a bucket elevator.
Coal pulverisation system
Coal will be procured as lumps and brought by the railways, wil l be unloaded and stored in
the storage area provided for this purpose in the plant premises, from where it will be
reclaimed by a front-end loader and delivered to the coal pulverizing unit. Covered storage
shed is envisaged for storing coal for about 10 days requirement. Provision for storing coal in
open yard near the coal pulverisation building is also envisaged.
Steel ball type coal mill, grit separator, cyclone collector and gas box pulse collector, hot air
furnace are envisaged in the coal powder preparation system. Roots blower will be used to
inject coal powder. Raw coal enters raw coal bin from the Coal feed hopper through a bucket
elevator and fed into the coal mill to pulverize it to the required size by means of a weigh
feeder. The pulverised coal from coal mill will be sent to a grit separator, cyclone collector and
a bag filter. The cleaned air from the bag filter will be sent to atmosphere with a concentration
of less than 50 mg/Nm3.
Coal powder collected in the cyclone and bag filter falls into a fine coal powder bin directly and
then by means of a screw conveyor, solid flow meter and pneumatic pump and same will be
injected into the rotary kiln. Air required for pneumatic conveying will be supplied by a roots
blower.
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The hot gas required for coal mill pulverisation is supplied by a hot air furnace. From the coal
feed hopper a portion of coal is fed to the furnace for hot gas generation.
Bentonite storage and handling
Bentonite will be procured as powder in plastic bags and will be stacked inside Bentonite
Building. Electric hoist will be provided in bentonite storage room for handling bentonite bags.
Bags are opened with hand in the top of surge hopper. From the Surge Hopper bentonite will
be pneumatically conveyed to the bentonite bin located in the proportioning building.
Proportioning and mixing
There are nine (9) bins in proportioning building. Iron ore fines after humidification are
conveyed into three (3) iron ore bins by means of plough type discharger. Bentonite fines
from bentonite storage area will be pneumatically conveyed to two (2) bins. Similarly two (2)
proportioning bins are proposed for lime stone. Dust collected by Multitube deduster and
Electric deduster is conveyed to two (2) dust bins from dust tank by pneumatic transmission.
Bag filters will be provided on the top of Bentonite bins, dust bins and limestone bins. Wear -
resisting lining plate will be fixed in inner surface of all the nine bins and bin vibrator will be
provided to prevent material from jamming. Thereafter these materials will be drawn out in
requisite proportions by using weigh feeders and fed into a mixing unit. A mixer has been
proposed for mixing iron ore fine, binder and dust in the mixing room. In this unit, mixing of
the feed takes place and desired moisture level of 8% will be achieved by addition of water.
The mixed feed will be then transferred to the balling unit for formation of green balls.
Moisture detector will be provided on belt conveyer to detect the moisture of the mixed
material in line to control the water addition on the mixer.
Balling system
The balling system mainly consists of mixed material bins and Disc Pelletisers. The mixed
material from the mixing building will be conveyed and distributed to the mixed material bins
in the balling room via belt conveyor. Disc Pelletisers will be fed from mixed material bins.
Rotating speed of the weighing feeder will be controlled by Variable Voltage Variable
Frequency (VVVF) drive 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 will be added during the process of balling to achieve the optimal moisture of
the mixed material for balling. Water addition will be regulated manually by means of a
regulating valve, according to the moisture of the mixed material.
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Green balls produced in the balling disc will be sent to the green ball distribution system in
traveling grate area via material collecting belt. A belt scale will be fixed on the belt conveyer
to inspect the quality of green ball and control the material thickness in the traveling grate.
Green ball distribution
Distribution system consists of swing belt conveyor, big ball roller screen, wide belt conveyor
and roller distributor. Swing belt conveyor discharges green balls to a big ball roller screen.
During its swinging, unqualified green balls bigger than 16mm will be separated and sent back
to the balling room via return system; green balls smaller than 16mm will be distributed on the
wide belt conveyor. The wide belt conveyor discharges the green ball to a roller distributor.
Roller distributor takes out residual unqualified smaller balls less than 8mm and distribute
qualified green ball of 8-16mm to the grate bed of the Travelling grate. Unqualified green ball
will be returned to Balling building through a return system via belt conveyor. Belt scale is
fixed on return belt conveyer to inspect the quantity of return and control the material
thickness of traveling grate.
Induration
Induration system consists of three main machines viz. travelling grate, rotary kiln and
annular cooler. Green ball is dried and preheated in the travelling grate, hardened and
indurated in the rotary kiln and cooled in the annular cooler.
Travelling grate: The green pellets from the balling unit will be distributed over a roller feeder
by an oscillating conveyor, from where these will be laid across the full width of the travelling
grate. The travelling grate will be used for the first stage of induration comprising drying and
preheating of green pellets. The grate is divided into 4 zones viz. Drying zone I & II,
Preheating Zone I & II.
Down draught drying Zone I: In the DDD zone, 150-200o C low temperature dry air will be
used to remove water and dry the green ball. Since the temperature of hot air from Preheating
zone II will be about 4000 C which induces the Drying zone I, additional cooling fan is
provided to control the temperature of Drying zone I to about 150-200oC.
Down draught drying zone II: The hot air from preheating zone II of 400
oC will pass through
the bed to remove water and dry the green ball, which induces the Drying zone II to ensure
that the green ball can resist more than 700oC temperature of preheat zone.
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Preheat zone I: The hot air from annular cooler of 400o C will pass through the bed to
remove water and dry the green ball continuously which begins oxide and can resist the
temperature more than 1100o C of preheat zone II.
Preheating zone II: In preheating zone, pellet will be further heated, limestone decomposes
partly, and pellet hardened and indurated partly, which can make the pellet having a certain
strength to resist the impact when it fall from the grate on the kiln and will not rupture during
the rotation of the kiln. Its heat source is from the hot gases coming out from the kiln at
1050oC. The temperature of the pellet in the last layer of traveling grate enter rotary kiln from
traveling grate will be controlled to about 750oC to prevent the grate plate from damaged.
The dust will be transported pneumatically to dust bins in the proportioning building. Green
ball will be dried and preheated on the grate. Preheated pellet with sufficient strength will
enter the kiln through scraper and kiln tail chute.
Dry return system The material collected from the head end of traveling grate and the tail
end of rotary kiln will be returned back to the rotary kiln by means of a special bucket elevator
for hot dust via a dust bin. The return material of other ash box and bellows of traveling grate
will be discharged on to the belt conveyor of humid return system through two belt conveyors,
and will be conveyed to balling room bins for balling.
Rotary kiln: Green pellets preheated by the grate will be discharged to the rotary kiln feed end
by means of a scraper and chute. Adjustable moveable burner (Coal gun) will be installed on
the kiln discharge end. The flame shape and length will be controlled and regulated by
moving the burner and regulating the air flow. Pellet in the kiln will be mainly subjected to
heat radiation and all the pellets get uniformly indurated during the kiln rotation. The
limestone continues to decompose in the kiln. Indurating temperature inside the rotary kiln
will be 1250~1350°C. The rotating speed can be adjusted depending on the pellet feed and
also to adjust the resident time so that the desired quality of pellets can be achieved. The
tumbling actions in the rotary kiln expose all pellets to the set temperature and enable them to
attain the desired characteristics and strength. Sealing devices and cooling fans will be
provided on the hoods of kiln feed end and kiln discharge end. Indurated pellet will be
screened by a fixed screen on the kiln discharge hood to remove any oversized material and
then discharged into the hopper of annular cooler.
Cooling Annular cooler: The indurated pellets from the kiln will be conveyed to the annular
cooler. The temperature of the pellets from the k iln discharge will be about 1200o C with
size range of 8- 16mm. Bed depth on the cooler pallets will be maintained by adjusting the
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rotating speed of the annular cooler by means of VVVF drive according to the level of the
receiving hopper of the annular cooler. Upper hood of the annular cooler is divided into 3
zones. The hot air from cooling zone-I at a temperature of about 850~1100°C will re-enter the
kiln directly through kiln discharge hood. This will also act as second combustion air for coal
to improve the air temperature in kiln. Hot air from cooling zone-II at a temperature of about
450~700°C will return to the preheating zone-I of the travelling grate through recuperated air
duct to preheat pellet; 90~105°C hot air in cooling zone-III will be exhausted directly through
stack on the annular cooler. Temperature of hot recuperated air will be controlled by adjusting
cooling air flow rate by regulating flow control damper. Dust collection hoppers are provided
under annular cooler with dust discharge valves. Pellet cooled to below 120o C on the
annular cooler will be discharged to a belt conveyer through discharge hopper.
Screening, product storage & handling: The hardened and cooled pellets from annular
cooler will be sent to a screening room via belt conveyors. Two sets of vibrating screens (one
for DRI grade and another BF grade) are provided for removal of any minus 8mm pellets
generated during transfer. The undersize product of the screen will be taken to the hopper
then carried by trucks to raw material yard for recycling. The -16 +8 mm pellets obtained will
be conveyed and stored in RCC silos.
6.2 Residential Area (Non Processing area):
Facilities like canteen, rest room and indoor games facilities will be provided.
6.3 Green Belt:
Total 9.8 acres of Green belt will be developed in the Plant premises.
6.4 Social Infrastructure:
Social infrastructure will be developed as per need based in the Villages.
6.5 Connectivity:
Component Description
Road The project site can will e well approached by Vishakhapatnam to Araku road
Rail Railway siding facility is available for the existing plant. The same will be
utilized for the proposed project
Air port Nearest Airport is Vishakhapatnam airport located at 28 Kms from the project
site
Sea Port The nearest sea port is Vishakhapatnam port located at a distance of 30 Kms
from the project site
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6.6 Drinking water management:
The workers at the plant during construction shall be provided with water for their requirement and
for the construction activities. The construction labour will be provided with sufficient and suitable
toilet facilities to allow proper standards of hygiene. These facilities would preferably be connected
to a septic tank and shall be maintained properly to have least environmental impact. Drinking water
required for the workers will be met from ground water resources.
6.7 Sewerage system:
Domestic waste water generated will be treated in septic tank followed by soak pit.
6.8 Industrial waste management:
No solid waste generation is anticipated other ash and dust during induration process
6.9 Solid waste management:
During the induration process ash and dust is generated. This will be recycled back into process to
improve the process efficiency through pneumatic conveying system.
Hazardous waste generation will be in the form of used oil, which is categorized as 5.1 in the
Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008. Annual
generation of hazardous waste will be approximately 100 litres. In addition to that, scrap generated
will be sold to the recyclers and other non-hazardous waste/ garbage will land filled within the
factory premises.
6.10 Power requirement & Supply / Source:
The power required for the project will be met from the M/s Simhadri Power Limited which is under
construction in the plant premises of M/s SEIL.
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7.0 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No rehabilitation or resettlement plan is proposed as there are no habitations in the in the Project
site.
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8.0 PROJECT SCHEDULE & COST ESTIMATES
The total cost of the project has been estimated at Rs.238.9 Crores. The Project Cost estimates
include all expenses to be incurred towards Plant cost, Spares, interest during construction,
contingency, margin money for working capital
Detailed breakup of the Cost is given below.
S.No. Section Project cost (Crore)
1. Land & site development 9.10
2. Civil & structural work 43.93
3. Provision for township 20.0
4. Plant & equipment as erected 156.17
5. Design, engineering & consultancy services 9.7
TOTAL PROJECT INVESTMENT 238.9
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9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
With the implementation of the proposed project, the socio-economic status of the local people will
improve substantially. The land rates in the area will improve in the nearby areas due to the
proposed activity. This will help in upliftment of the social status of the people in the area.
Educational institutions will also come-up and will lead to improvement of educational status of the
people in the area. Primary health centre will also come-up and the medical facilities will certainly
improve due to the proposed project.
9.1. Employment Potential:
The proposed project creates employment to 500 people during construction and 120 people during
operation of the proposed project.
SKILLED
Total skilled employment in the proposed plant will be around 30.
SEMI SKILLED
Total semi-skilled employment in the proposed project will be around 50. Top priority will be given
to local people for unskilled jobs.
UNSKILLED
Total Unskilled employment in the proposed project will be around 40. Top priority will be given to
local people for unskilled jobs.
9.2. Other Tangible Benefits:
The following are the other benefits to the area due to the proposed project.
Educational status will improve in the area
Medical standards will improve due to the proposed project.
Overall economic up liftment of socio-economic status of people in the area.
Ancillary developmental activities will be created due to the establishment of the proposed
unit.
9.3. Socio-Economic Developmental Activities:
The management is committed to uplift the standards of living of the villagers by undertaking
following activities / responsibilities.
Health & hygiene
Drinking water
Education for poor
Village roads
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Lighting
HEALTH & HYGIENE
1. Personal and domestic hygiene,
2. Maintaining clean neighborhood,
3. Weekly health camps offering free-check up & medicines
4. Ambulance services
5. Education & drug de-addiction, aids.
DRINKING WATER
Making drinking water available at centralized locations in the village,
SUPPORTING EDUCATION
1. Providing books to all poor children,
2. Conducting annual sports festival in the village schools,
3. Providing amenities like fans, lavatories,
4. Maintain play ground etc.