Application for Environmental Clearance (EC)environmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2014. 6. 11. · Telephone No. 0771-4082000/ 4082001 Fax No. 0771-4057601

Application for Environmental Clearance (EC)

FORM – 1 & PRE-FEASIBILITY REPORT

for

IRON ORE PELLETIZING PROJECT (Area: 56.64 Acres; Production Capacity 2.1 Million TPA

(0.6 MTPA & 1.5 MTPA)

Location: Village-Siltara Tada, Tehsil- Dharsiwa, Dist-Raipur,

Chhattisgarh

Submitted to

MINISTRY OF ENVIRONMENT & FORESTS

(MoEF), NEW DELHI

PROJECT PROPONENT

GODAWARI POWER & ISPAT LIMITED Hira Arcade, Near Bus Stand, Pandri, Raipur - 492001, Chhattisgarh

Phone No. 0771 - 4082000, Fax No. 4057601

ENVIRONMENT CONSULTANT

POLLUTION AND ECOLOGY CONTROL SERVICES (PECS),

Dhantoli, Nagpur

Phone No. 0712 – 2442363, Fax no. 2459648

June-2014

Application for Environmental Clearance (EC)

FORM - 1


(0.6 MTPA & 1.5 MTPA)


Chhattisgarh

Submitted to

MINISTRY OF ENVIRONMENT & FOREST

(MoEF), NEW DELHI

PROJECT PROPONENT


Phone No. 0771 - 4082000, Fax No. 4057601



Dhantoli, Nagpur Phone No. 0712 – 2442363, Fax no. 2459648

REVISED FORM -1

APPLICATION FOR OBTAINING ENVIRONMENTAL CLEARANCE VIDE

PARA 6 OF S.O. 1533 OF MoEF NOTIFICATION DATED 14.09.2006

(I) Basic Information

Sl.

No.

Item Details

1 Name of the project Iron Ore Pellet Plant

2 S. No. of the schedule As per EIA Notification dated 14th

September 2006, the project activity

falls under Category ‘A’, S. No. 3 (a).

3 Proposed capacity / area / length/

tonnage to be handled/ command area/

lease area/number of wells to be drilled

Production Capacity :

Iron Ore Pellet Plant – 2.1 MTPA

(Two Kilns of 0.6 MTPA & 1.5 MTPA)

4 New/Expansion/Modernization Existing

5 Existing Capacity/Area etc. Iron Ore Pellet Plant – 2.1 MTPA

(Two Kilns of 0.6 MTPA and 1.5 MTPA )

6 Category of the Project i.e. ‘A’ or ‘B’ As per the recent intervention and

judgment of 27th May 2014 of Hon’ble

National Green Tribunal, this project

falls under Category “A”.

7 Does it attract the general condition? If

yes, please specify.

Yes, location of the plant is within 10

Km of severely polluted area

8 Does it attract the specific condition? If

yes, please specify.

No, it does not attract the specific

condition.

9 Location

Plot/Survey/Khasra No. 428/2, Phase-I, Industrial Area

Village Siltara

Tehsil Dharsiwa

District Raipur

State Chhattisgarh

10 Nearest railway station/ airport along

with distance in kms.

Railway Station : Mandhar (3 Kms.)

Airport : Mana, Raipur (30 Kms.)

11 Nearest Town, City, District

Headquarters along with distance in

kms.

Raipur (20 Kms.)

12 Village Panchayats, Zilla Parishad,

Municipal Corporation, Local body

(complete postal addresses with

telephone nos. to be given)

Village Panchayats : Tada - Siltara

Zilla Parishad : Raipur

Municipal Corporation : Raipur

White House, Near Mahila Thana,

Chotapara, Raipur

13 Name of the applicant M/s.Godawari Power & Ispat Limited

14 Registered Address 428/2, Phase-I, Industrial Area,

Siltara,

Raipur - 493111 (Chhattisgarh)

15 Address for Correspondence: Project Proponent

Name T. Bose

Designation (Owner/ Partner/ CEO) Head (Corporate Affairs)

Address Hira Arcade, First Floor, Pandri, Raipur,

Chhattisgarh

Godawari power & Ispat limited Form -I

2

Pin Code 492001

E-mail [email protected]

Telephone No. 0771-4082000/ 4082001

Fax No. 0771-4057601

16 Details of Alternative Sites examined, if

any. Location of these sites should be

shown on a topo sheet

Not applicable as it is existing units.

17 Interlinked Projects No interlinked projects involved.

18 Whether separate application of

interlinked project has been submitted?

No

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?

The proposal does not involve any

approval/clearance under any act as

mentioned in the condition.

No

No

No

22 Whether there is any Government

Order/Policy relevant/relating to the

site?

No Government Order/Policy is issued

relevant for the project site.

23 Forest land involved (hectares)

None.

24 Whether there is any litigation pending

against the project and/or land in which

the project is proposed 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

In the Court of Chief Judicial Magistrate,

Raipur

Case No. 1404 of 2010

Complaint filed by Chhattisgarh

Environment Conservation Board, under

sec. 30, 40, Air (Prevention & control of

pollution) act 1981 read with sec. 43,

44, 47 water (Prevention & control of

pollution) act. 1974 & sec. 34 IPC.

Bail was granted to all the accused.

Recording of evidence before framing of

charge is pending.


3

(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.)

Sr. 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 Iron Ore Pellet Plant exists in the well

established premises of GIPL which is in

industrial use since last years. The

land use planning has been done as per

the regulation. However, Land cover has

been improved with increased green

belt / cover by additional plantation.

1.2 Clearance of existing land,

vegetation and buildings? No

Not applicable, as this is operational

plant

1.3 Creation of new land uses?

No


plant on land which is in industrial use

since last years.

1.4 Pre-construction investigations

e.g. bore houses, soil testing? No


plant

1.5 Construction works?

No


plant

1.6 Demolition works?

No


plant

1.7 Temporary sites used for

construction works or housing of

construction workers?

No Not applicable, as this is operational

plant

1.8 Above ground buildings,

structures or earthworks

including linear structures, cut

and fill or excavations.


plant

1.9 Underground works including

mining or tunneling? No Not applicable

1.10 Reclamation works? No Not applicable

1.11 Dredging?

No Not applicable

1.12 Offshore structures? No Not applicable

1.13 Production and manufacturing

processes?

Yes

The technique of grate kiln technology

was adopted for putting up a 2.1 million

TPA pellet project with 2 Nos. of Kilns of

0.6 MTPA & 1.5 MTPA.

Detailed Process Description and

flowchart are incorporated in the Pre-

Feasibility Report.

1.14 Facilities for storage of goods or

materials?

No


plant. The existing infrastructure in the

plant premises is being used.


4

1.15 Facilities for treatment or disposal

of solid waste or liquid effluents?

No

There is no effluent generated in the

Iron Ore Pelletization Plant. The plant is

designed and equipment was selected

accordingly. The plant is designed as

“ZERO DISCHARGE”.

1.16 Facilities for long term housing of

operational workers? No Not applicable

1.17 New road, rail or sea traffic

during construction or operation? No


plant. The road network is very well

established in the project area.

1.18 New road, rail, air waterborne or

other transport infrastructure

including new or altered routes

and stations, ports, airports etc?

No Not applicable

1.19 Closure or diversion of existing

transport routes or infrastructure

leading to changes in traffic

movements?

No Not applicable

1.20 New or diverted transmission

lines or pipelines? No Not applicable

1.21 Impoundment, damming,

culverting, realignment or other

changes to the hydrology of

watercourses or aquifers?

No Not applicable

1.22 Stream crossings? No Not applicable

1.23 Abstraction or transfers of water

form ground or surface waters? No Not applicable

1.24 Changes in water bodies or the

land surface affecting drainage or

run-off?


plant

1.25 Transport of personnel or

materials for construction,

operation or decommissioning? Yes

Transport of personnel or materials for

construction and operation is being

done by well established transportation

network.

1.26 Long-term dismantling or

decommissioning or restoration

works?

No Not applicable

1.27 Ongoing activity during

decommissioning which could

have an impact on the

environment?

No Not applicable

1.28 Influx of people to an area in

either temporarily or

permanently?

Yes

Influx of people as marginal and

temporary workers/labours is seen and

provided employment in the area.

1.29 Introduction of alien species?

No Not applicable

1.30 Loss of native species or genetic

diversity? No Not applicable

1.31 Any other actions?

No Not applicable


5

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):

Sl.

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


plant

2.2 Water (expected source and

competing users) unit: MGD Yes

Quantity = 1968 KLD

Source = Chhattisgarh Ispat Bhumi

Limited / CSIDC

2.3 Minerals (MT)

Yes

Iron Ore / Fines 23,03,225 TPA

Source:- captive iron ore mines at

Ari Dongri Iron Ore Mines

Boria Tibbu Iron Mines

2.4 Construction material – stone,

aggregates, sand / soil (expected

source – MT)

Yes Not applicable, as this is operational

plant

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

Electricity requirement: 16 MW for both

the Pellet Plants

Source : from captive power plant.

Fuel: Heavy Furnace Oil of 66 KL per

day from local sources/Petroleum

companies

Coal for Gassifier : 365 MT per day

through coal linkage from SECL /

imports.

2.7 Any other natural resources (use

appropriate standard units) No Not applicable

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.

Sl.

No


confirmation

Yes/No




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

The Use, storage, transport, handling is

being done carefully by qualified and

trained persons.

Heavy Furnace Oil (HFO) has been

envisaged as fuel for Kiln and Travel

Grate in Iron Ore Pelletization Plant.

3.2 Changes in occurrence of disease or

affect disease vectors (e.g. insect or

water borne diseases)

No Not applicable

3.3 Affect the welfare of people e.g. by

changing living conditions?

Yes

Operation of the Iron Ore Pellet plant

has significantly contributed to the

social upliftement of the people in the

surrounding area.


6

3.4 Vulnerable groups of people who

could be affected by the project e.g.

hospital patients, children, the

elderly etc.,

No Not applicable

3.5 Any other causes No Not applicable

4. Production of solid wastes during construction or operation or

decommissioning (MT/month)

Sl.

No


confirmation

Yes/No

Details thereof (with approximate

quantities /rates, wherever

possible) with source of

information data

4.1 Soil, overburden or mine wastes No Not applicable

4.2 Municipal waste (domestic and or

commercial wastes)

Yes The source of domestic wastewater is

only from the office toilets of the plant

are being completely disposed off into

the soak pit via septic tank.

During the process, water is recovered

and recycled for process use; hence no

wastewater generation is there.

4.3

Hazardous wastes (as per

Hazardous Waste Management

Rules)

No No there is no hazardous waste

generation in Iron Ore Pellet Plant.

4.4 Other industrial process wastes No Not applicable.

4.5 Surplus product No Not applicable

4.6 Sewage sludge or other sludge from

effluent Treatment No Not applicable.

4.7 Construction or demolition wastes No


plant

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

5. Release of pollutants or any hazardous, toxic or noxious substances to air

(Kg/hr)

Sl.

No


confirmation

Yes/No




information data

5.1 Emissions from combustion of fossil

fuels from stationary or mobile

sources

Yes

The emission of gases (SO2, NO2) may

be accounted due to project activities,

vehicles, etc. the vehicles is being

undergoing regular maintenance; plant

is having appropriate stack height as

per the guidelines of Central Pollution

Control Board (CPCB).

Better maintenance of equipments and

proper mitigation measures has helped

us to reduce and keep pollution level

with in the permissible limit.


7

5.2 Emissions from production

processes

Yes

Emission from the entire process is

being reduced by means of proper

Environmental Pollution Control

measures such electrostatic

precipitators or bag filters, proper stack

height, adequate greenbelt

development, water sprinkling etc

5.3 Emissions from materials handling

including storage or transport Yes

Emission form handling of raw material

is being minimized through water

sprinkling system.

5.4 Emissions from construction

activities including plant and

equipment

No


plant.

5.5 Dust or odours from handling of

materials including construction

materials, sewage and waste

No


plant

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

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sl.

No


confirmation

Yes/No




information data

6.1 From operation of equipment e.g.

engines, ventilation plant, crushers

No

During the operation of the plant, noise

level is expected to be increased and is

maintained at less than 75 dBA at the

plant boundary. Necessary protective

measures have been taken to minimize

the noise level at every points.

6.2 From industrial or similar processes

Yes

There is noise generation due to the

running of the machinery. Proper

mitigation measures has been taken for

the reduction of noise levels, such as

provision of acoustic lagging for the

equipment and suction side silencers,

selection of low noise equipment, dense

greenbelt development, personal

protective equipment, maintenance of

vehicles etc.

6.3 From construction or demolition No


plant

6.4 From blasting or piling No Not applicable

6.5 From construction or operational

traffic No


plant

6.6 From lighting or cooling systems No Not applicable

6.7 From any other sources No

Not applicable


8

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:

Sl.

No


confirmation

Yes/No




information data

7.1 From handling, storage, use or

spillage of hazardous materials

No

The proposed fuel is Heavy Furnace Oil

which is being stored and transported

as per stipulated norms. HFO is being

brought in road tankers and unloaded

by means of pumps. HFO is being

supplied to Kiln and Travel Grate.

Necessary unloading platform, pump

house, unloading header, pumps,

pipelines, etc. has been provided.

Also due care has been taken during its

use for lubrication of external part of

equipment, that nothing falls on ground

to contaminate soil. The Tar generated

during gas cleaning is being sold to

outside authorized chemical industries.

7.2 From discharge of sewage or other

effluents to water or the land

(expected mode and place of

discharge)

No Not applicable

7.3 By deposition of pollutants emitted

to air into the land or into water No Zero waste discharge

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 applicable

8. Risk of accidents during construction or operation of the Project,

which could affect human health or the environment

Sl.No


confirmation

Yes/No




information data

8.1 From explosions, spillages, fires etc

from storage, handling, use or

production of hazardous substances

No Not applicable

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)?

No The project site falls in Seismic Zone –

II.


9

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

Sl.

No


confirmation

Yes/No




information data

9.1 Lead to development of supporting.

facilities, 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

Yes

� Reinforcement of supporting infrastructure like road, transport,

communication, drinking water,

sanitation and other facilities.

� Development of housing infrastructure due to increased

income and employment.

� Development ancillary industry to support to plant requirements.

� Employment opportunities will increase due to the requirement of

workers for the proposed project.

Local people will be preferred for

employment. This will contribute in

raising the socio-economic status

and standard of living of the nearby

villagers.

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 No Not applicable

9.4 Have cumulative effects due to

proximity to other existing or

planned projects with similar effects

No Not applicable

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 None

2

Areas which are important or

sensitive for ecological reasons

- Wetlands, watercourses or

other water bodies, coastal zone,

biospheres, mountains, forests

No None

3

Areas used by protected,

important or sensitive species of

flora or fauna for breeding, nesting,

foraging, resting, over wintering,

migration

No None

4

Inland, coastal, marine or

underground waters

No None


10

S.

No.

Areas

Name/

Identity

Aerial distance (within 15 km.)

Proposed project location boundary

5 State, National boundaries No None

6

Routes or facilities used by the public

for access to recreation or other

tourist, pilgrim areas

No None

7 Defence installations No None

8 Densely populated or built-up area No None

9 Areas occupied by sensitive

man-made land uses (hospitals,

schools, places of worship,

community facilities)

No None

10 Areas containing important, high

quality or scarce resources

(ground water resources,

surface resources, forestry,

agriculture, fisheries, tourism,

minerals)

No None

11 Areas already subjected to

pollution or environmental

damage, (those where existing

legal environmental standards

are exceeded)

Yes

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 None

(IV) Proposed Terms of Reference for EIA studies

The following terms of reference (TOR) are being proposed for environmental impact

assessment:

Introduction

• Purpose of the report.

• Identification of project & project proponent.

• Brief description of nature, size, location of the project and its importance to the

country, region.

• Scope of the study - details of regulatory scoping carried out (as per Terms of

Reference).

Project Description

• Condensed description of those aspects of the project (based on project feasibility

study), likely to cause environmental effects. Details should be provided to give

clear picture of the following:

• Type of project


11

• Need for the project

• Location (maps showing general location, specific location, project boundary &

project site layout)

• Size or magnitude of operation (including associated activities required by or for the

project)

• Proposed schedule for approval and implementation

• Technology and process description

• Project description. Including drawings showing project layout, components of

project etc. Schematic representations of the feasibility drawings which give

information important for EIA purpose

• Description of mitigation measures incorporated into the project to meet

environmental standards, environmental operating conditions, or other EIA

requirements (as required by the scope)

• Assessment of New & untested technology for the risk of technological failure

Description of the Environment

• Study area, period, components & methodology

• Establishment of baseline for valued environmental components, as identified in the

scope

• Base maps of all environmental components

Anticipated Environmental Impacts & Mitigation Measures

• Details of Investigated Environmental impacts due to project location, possible

accidents, project design, project construction, regular operations, final

decommissioning or rehabilitation of a completed project

• Measures for minimizing and / or offsetting adverse impacts identified

• Irreversible and Irretrievable commitments of environmental components

• Assessment of significance of impacts (Criteria for determining significance,

Assigning significance)

• Mitigation measures

Analysis of Alternatives (Technology & Site)

• In case, the scoping exercise results in need for alternatives:

• Description of each alternative

• Summary of adverse impacts of each alternative

• Mitigation measures proposed for each alternative and

• Selection of alternative

Environmental Monitoring Program

Technical aspects of monitoring the effectiveness of mitigation measures (incl.

Measurement methodologies, frequency, location, data analysis, reporting schedules,

emergency procedures, detailed budget & procurement schedules)


12

Additional Studies

• Public Consultation

• Risk assessment

• Social Impact Assessment. R&R Action Plans

Project Benefits

• Improvements in the physical infrastructure

• Improvements in the social infrastructure

• Employment potential – skilled; semi-skilled and unskilled

• Other tangible benefits

Environmental Cost Benefit Analysis

• If recommended at the Scoping stage

Environmental Management Plan

• Description of the administrative aspects of ensuring that mitigative measures are

implemented and their effectiveness monitored, after approval of the EIA.

Summary & Conclusion

This will constitute the summary of the EIA Report

Overall justification for implementation of the project

• Explanation of how, adverse effects have been mitigated

Disclosure of Consultants engaged

• The names of the Consultants engaged with their brief resume and nature of

Consultancy rendered


13

PRE-FEASIBILITY REPORT

(PFR)

Of


(0.6 MTPA & 1.5 MTPA)


Chhattisgarh

Submitted to

MINISTRY OF ENVIRONMENT & FOREST

(MoEF), NEW DELHI

PROJECT PROPONENT


Phone No. 0771 - 4082000, Fax No. 4057601



Dhantoli, Nagpur

Phone No. 0712 – 2442363, Fax no. 2459648

June-2014

Project Feasibility Report of 2.1 Million TPA Iron Ore Pellet Plant

2

TABLE OF CONTENT

1. EXECUTIVE SUMMARY ............................................................................................................................. 5

2. INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION. .......................................................... 6

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ........................................................................................... 6

2.1.1 The current installed capacity of Godawari Power and Ispat Limited is - ............................................. 6

2.1.2 Group Companies .................................................................................................................................. 7

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ...................................................................................................... 9

2.3 PROJECT APPRAISAL: ........................................................................................................................................ 10

2.4 NEED FOR THE PROJECT AND IT’S IMPORTANT TO THE COUNTRY AND OR REGION. ......................................................... 10

2.5 DEMAND SUPPLY GAP. ..................................................................................................................................... 10

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT. ................................................................ 11

3. PROJECT DESCRIPTION .......................................................................................................................... 12

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECT, IF ANY. .................................................... 12

3.2 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATION GONE INTO SHOULD BE HIGHLIGHTED. ......................................................................... 12

3.3 SIZE OR MAGNITUDE OF OPERATION. ................................................................................................................... 12

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS (A SCHEMATIC DIAGRAM/ FLOW CHART SHOWING THE PROJECT LAYOUT,

COMPONENTS OF THE PROJECT ETC. SHOULD BE GIVEN). .............................................................................................. 13

3.4.1 Iron Ore Pellet Plant ............................................................................................................................ 13

3.4.2 Travel Grate Machine – Rotary Kiln Process is Features as:................................................................ 13

3.4.3 Production programme ....................................................................................................................... 14

3.4.4 Description of plant and equipment ................................................................................................... 14

3.4.4.1 Iron Ore grinding System ............................................................................................................................... 14

3.4.4.2 Storehouse of Bentonite/Flux/Coke .............................................................................................................. 15

3.4.4.3 Proportioning Room ...................................................................................................................................... 15

3.4.4.4 Mixing room .................................................................................................................................................. 15

3.4.4.5 Balling Room.................................................................................................................................................. 15

3.4.4.6 Green ball distribution system ...................................................................................................................... 15

3.4.4.7 Baking System ............................................................................................................................................... 16

3.4.4.8 Travel Grate Machine .................................................................................................................................... 16

3.4.4.9 Rotary Kiln ..................................................................................................................................................... 17

3.4.4.10 Annular Cooler............................................................................................................................................. 17

3.4.4.11 Main air suction blowers ............................................................................................................................. 17

3.4.4.12 Finished Product Transportation System .................................................................................................... 17

3.4.5 Rationale for layout ............................................................................................................................ 18

3.4.5.1 Location of various units ............................................................................................................................... 19

3.4.5.2 Salient features of the layout ........................................................................................................................ 19

3.4.5.3 Selection of Technique in Pelletizing ............................................................................................................. 19

3.4.5.4 Process routes and facilities considered ....................................................................................................... 19

3.4.6 Selection of plant capacity and facilities ............................................................................................. 20

3.4.6.1 Plant capacity ................................................................................................................................................ 20

3.4.6.2 Configuration Iron Ore Grinding .................................................................................................................... 20

3.4.6.3 Sizing of Balling Disc Pelletizer ...................................................................................................................... 20

3.5 RAW MATERIAL ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE MARKETING AREA OF FINAL PRODUCTS, MODE OF

TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT. .............................................................................................. 20

3.5.1 Raw materials requirement ................................................................................................................ 21

The material balance is as under: ................................................................................................................ 21

3.5.2 Source of raw materials ...................................................................................................................... 21

3.5.2.1 Iron ore .......................................................................................................................................................... 21


3

3.5.2.2 Bentonite ....................................................................................................................................................... 22

3.5.2.3 Dolomite ........................................................................................................................................................ 22

3.5.2.4 Coke ............................................................................................................................................................... 22

3.5.3 Receipt, Storage and Handling of Raw Materials ............................................................................... 23

General ......................................................................................................................................................... 23

3.5.3.1 Receipt, unloading and storage of raw materials .......................................................................................... 23

3.5.3.2 Reclaiming of raw materials from storage yard ............................................................................................ 23

3.5.3.3 Hoisting and handling facilities ...................................................................................................................... 23

3.6 RESOURCE OPTIMIZATION / RECYCLING AND REUSE ENVISAGED IN THE PROJECT, IF ANY, SHOULD BE BRIEFLY OUTLINED. ....... 23

3.7 AVAILABILITY OF WATER ITS SOURCE, ENERGY / POWER REQUIREMENT AND SOURCE SHOULD BE GIVEN. ........................... 24

3.8 QUANTITY OF WASTE TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT /DISPOSAL. .............. 24

4. SITE ANALYSIS ....................................................................................................................................... 25

4.1 CONNECTIVITY. ............................................................................................................................................... 25

4.2 Land Form, Land use and Land ownership. ............................................................................................ 25

4.3 TOPOGRAPHY (ALONG WITH MAP). ..................................................................................................................... 26

4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER BODIES (INCLUDING AREA UNDER CRZ),

SHORTEST DISTANCES FROM THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FOREST, NATIONAL PARK, WILD LIFE SANCTUARY,

ECO SENSITIVE AREAS, WATER BODIES (DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A

COPY OF THE GAZETTE NOTIFICATION SHOULD BE GIVEN. ............................................................................................... 26

4.5 EXISTING INFRASTRUCTURE. .............................................................................................................................. 26

4.6 SOCIAL INFRASTRUCTURE AVAILABLE. .................................................................................................................. 27

5. PLANNING BRIEF ................................................................................................................................... 28

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION ETC) TOWN AND COUNTRY PLANNING/

DEVELOPMENT AUTHORITY CLASSIFICATION. .............................................................................................................. 28

5.2 POPULATION PROJECTION. ................................................................................................................................ 28

5.2.1 Basis of Planning ................................................................................................................................. 28

5.2.2 Training ............................................................................................................................................... 28

6. PROPOSED INFRASTRUCTURE ............................................................................................................... 29

6.1 INDUSTRIAL AREA (PROCESSING AREA). ................................................................................................................ 29

6.2 RESIDENTIAL AREA (NON PROCESSING AREA). ...................................................................................................... 31

6.3 GREEN BELT. .................................................................................................................................................. 31

6.4 SOCIAL INFRASTRUCTURE. ................................................................................................................................. 31

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/RAIL/METRO/WATER WAYS ETC.) ............................................ 31

6.7 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER) ............................................................................ 31

6.8 SEWERAGE SYSTEM. ......................................................................................................................................... 31

6.9 INDUSTRIAL WASTE MANAGEMENT. ................................................................................................................... 31

6.9.1 Air pollution ......................................................................................................................................... 31

6.9.2 Water pollution ................................................................................................................................... 32

6.9.3 Noise pollution .................................................................................................................................... 32

6.9.4 Pollution control measures ................................................................................................................. 32

6.9.5 Water pollution control ....................................................................................................................... 33

6.9.6 Noise pollution control ........................................................................................................................ 33

6.9.7 Pollution monitoring ........................................................................................................................... 33

6.9.8 Solid Waste Management. .................................................................................................................. 33

6.11 POWER REQUIREMENT & SUPPLY / SOURCE. ...................................................................................................... 34

7. REHABILITATION AND RESETTLEMENT (R & R) PLAN ............................................................................. 37


4

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED PERSON INCLUDING HOME OUSTEES, LAND

OUSTEES AND LANDLESS LABORERS (A BRIEF OUTLINE TO BE GIVEN.) ................................................................................ 37

8. PROJECT SCHEDULE & COST ESTIMATES ................................................................................................ 38

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION (TIME SCHEDULE FOR THE PROJECT TO BE GIVEN.)

.......................................................................................................................................................................... 38

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC VIABILITY OF THE PROJECT. ............................. 38

8.3 QUALITY CONTROL & ENVIRONMENT PROTECTION COST ........................................................................................ 38

9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) ......................................................................... 39

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL

POPULATION, IF ANY, IN THE AREA. ........................................................................................................................... 39


5

1. EXECUTIVE SUMMARY

• This section presents a background of the Iron Ore Pellet Plant and gives the

information related to the components of the project.

• Current combined capacity of the Iron Ore Pelletizing Plant is 2.1 Million TPA. This is

a running plant in two parts having the capacities 0.6 and 1.5 Million TPA.

• State Pollution control board has already given Consent to Operate for both iron ore

pellet plants.

• Iron Ore Pellet Plant of 0.6 Million TPA has received Consent to Operate viz letter no.

2347/TS/CECB/2011 Dated 25/07/2011 Under Water Act, 2349/TS/CECB/2011

Dated 25/07/2011 Under Air Act and is attached as (Annexure-1).

• Iron Ore Pellet Plant of 1.5 Million TPA has received Consent to Operate viz letter no.

6030/TS/CECB/2014 Dated 28/03/2014 under Water Act, 6032/TS/CECB/2014

Dated 28/03/2014 under Air Act and is attached as (Annexure-2).

• Both the pellet plants are located on the free hold land of M/s Godawari Power &

Ispat. The details of the land are enclosed as (Annexure-3)

• The location of the current operational Iron Ore Pellet Plant is within the Survey of

India Toposheet No. 64G11, 64G15 on a scale of 1:50,000 and it lies between

latitude 22004’04.54” N and longitude 710 54’30.14” E .

• M/s. GPIL is running this Pellet plant taking all the statuary permissions from the

state pollution control board of Chhattisgarh.

• The ongoing water requirement of the project is 1968 KLD/day; out of this makeup

water quantity is 1500 KLD/day. The water permission is enclosed as (Annexure-4)

• The power requirement is being met from Captive power plant of GPIL.

• Investment incurred for this Iron Ore Pellet Plant is 742.14 Crores. The capital

budget for environmental protection measure for the Year 2014-2015 is Rs. 112

Lacs.

• There is no National Park, Wildlife sanctuary, defense installation or sensitive area

located within 15 km radius of this running plant.


6

2. INTRODUCTION OF THE PROJECT/ BACKGROUND

INFORMATION.

2.1 Identification of Project and Project Proponent

The company was incorporated on 21/09/1999 with the Registrar of Companies, Gwalior

(M.P.). The promoters of the company are the Hira Group of Industries, which is one of

the largest groups in Central India. Hira Group, integrating its operations by setting up

facilities for forward and backward integration and foraying into higher value added

projects, has diversified into Sponge Iron, Power, Steel, Rolled Products, Ferro Alloys,

Mining, Cement, Crushing, Beneficiation, Pelletization, Renewable Energy, Technology &

Real Estate. In 2013-14, the group’s turnover is about Rs.3500 crores within which the

turnover of Godawari Power & Ispat Ltd is about Rs.2100 crores. The Group has

emerged as one of the fastest growing entities of the Chhattisgarh and also has a

pronounced presence in other states. The Group is poised for vertical and horizontal

growth and having necessary resources, capital and infrastructure for setting up the

projects.

Godawari Power and Ispat Limited (GPIL) is the flagship company of Hira Group of

Industries, incorporated in 1999. The company’s integrated steel manufacturing unit

having a dominant presence in the long products segment of the steel industry, mainly

into mild steel wires. Today, GPIL is an end-to-end manufacturer of mild steel wires. In

the process, the company manufacturers sponge iron, billets, ferro-alloys, power, wire

rods (through subsidiary company) and steel wires.

GPIL has come a long way since it started its operation in Raipur, Chhattisgarh as a

sponge iron manufacturer in the year 2001. Over the last 5 years, the company has

scaled up its capacity fivefold and is today the fifth largest producer of coal based

sponge iron in India and is one of the largest players in the mild steel wires segment.

Not only has the company increased its scale during the aforesaid period, it has also

moved up the value chain.

GPIL successfully completed its initial public offering and its shares got listed on the BSE

and the NSE in April, 2006.GPIL’s first WHRB captive power plant (7 MW) also became

the first one in the world to be registered with CDM Executive Board for entitlement of

carbon credits under the Kyoto Protocol.

2.1.1 The current installed capacity of Godawari Power and Ispat Limited is -

Sponge Iron : 4,95,000 TPA

Steel Billets : 2,00,000 TPA


(Under commissioning stage)

Steel Wires : 2,00,000 TPA

Power (Coal/WHRB/Biomass/Wind): 73 MW

Ferro Alloys or Pig Iron : 15,450 TPA / 33,000 TPA

Oxygen Gas : 12,00,000 M3 per Annum

Nitrogen Gas : 45,00,000 M3 per Annum

Fly Ash Plant : 1,65,00,000 Nos. per Annum


7

Iron Ore Mining : 12,55,000 TPA

Iron Ore Crushing : 12,00,000 TPA

Iron Ore Beneficiation : 10,00,000 TPA

(Under Commissioning Stage)

The company is entered into signing of a MOU with Government of Chhattisgarh for

setting up 2.00 million steel making facilities at Rajnandgaon.

The company is also proposing to set up Cement & Power Plant in Durg district, C.G.

With more steel and power projects in pipeline, the Hira group is poised for exponential

growth in the coming years. GPIL has become the first company in Chhattisgarh to be

awarded the Integrated Management System Certification by Accreditation bodies UKAS

of UK and Swiss Accreditation of Switzerland and certified by SGS India Pvt. Ltd., signify

excellence in different aspects of business.

� ISO:9001:2008 FOR Quality Management System

� ISO:14001:2004 for Environment Management System

� OHSAS ISO:18001:2007 for Occupational Health & Safety

It is worth noting that Godawari Power and Ispat Limited achieved state level recognition

in plantation and stood 2nd in Vriksha Mitra Mahaabhiyan-2008 & 3rd in Open Plantation

Award-2009.

2.1.2 Group Companies

Hira Cements Limited (HCL):

Hira Cement Ltd. is a Cement Grinding Unit set up in 1988 with a current capacity of

42,500 tonnes per annum. The plant is located in Urla Industrial Area, Raipur and has a

good market.

Hira Ferro Alloys Limited (HFAL):

HFAL has set up the first unit in India to commercially manufacture Ferro alloys in small

electric arc furnaces. Our group was the first in India to break this monopoly and

develop in-house technology by own Research and Development to produce Silico

Manganese in a small furnace.

The first unit of HFAL came into production from October 1990 for a capacity of Ferro

Manganese of 8000 TPA. The plant has gone for expansion and the current capacity is

10,500 MT per annum of Ferro Alloys. The second unit of HFAL has a captive thermal

power plant of capacity 20 MW, Biomass power of 8.5 MW, Ferro Alloys of capacity

50,000 TPA and a Fly Ash Brick manufacturing facility of capacity 3,00,000 MT per

annum.

Alok Ferro Alloys Limited (AFAL):

AFAL is the second Ferro Alloys plant of the group. The plant went into production in

March, 1995 manufacturing Ferro chrome & Silico manganese with a capacity of 14,500

MT per annum. AFAL has also set up Captive Power Plant of 8 MW capacity.


8

Hira Steels Limited (HSL):

The group made its first foray into Iron & Steel by setting up a state-of- the-art fully

automatic, high speed wire rod mill & wire drawing unit with an installed capacity to

produce 42500 MT of Wire rods & 20000 MT of wires. The current capacity of the plant is

1,20,000 MT per annum of Wire Rods & 60,000 MT per annum of HB Wires.

Hira Power & Steels Limited

Hira Power & Steels Limited has grown many folds both value wise and volume wise.

This of course would not have been possible without the great support of our group

companies under the banner of Hira Group. Currently the company is having 26 MVA

Furnace, a Captive Power Plant of 20 MW (with Coal linkage), and mines located in

Madhya Pradesh.

HPSL has also acquired seven prospecting rights for Manganese Ore in South Africa.

Three of the Seven Rights are located at close proximity to the world famous Kalahari

Manganese basin. Another 20 MVA Furnace capacity expansion is already on the cards.

R.R. Ispat (A Unit of Godawari Power & Ispat Ltd.):

R.R. Ispat, is a subsidiary company of Godawari Power and Ispat Ltd. was established in

May 1999 and commenced commercial production w.e.f. 29.01.2000.The manufacture

capacity of Wire rods is 1,00,000 tons per annum. The company has also installed a coal

based gasifier plant.

Jagdamba Power & Alloys Ltd (JPAL):

JPAL located at Murethi, Siltara Industrial Area, Raipur is having a capacity of 25 MW

Thermal Power plant. The unit was commissioned in March, 2007 and is selling all its

power to the Electricity Board Grid.

Ardent Steel Limited

ASL is the subsidiary of M/s. Godawari Power and Ispat Limited, a company incorporated

under the Companies Act in April, 2007. The company has established a 0.6 MTPA Iron

Ore Pelletisation Plant in Keonjhar District, Orissa, India. This was a step towards value

addition to the iron ore mines deposits with some soft ore in the Gandhamardhan and

other nearby deposits of Keonjhar district., Odisha.

Godawari Green Energy Limited

The company has recently commissioned the First Concentric Solar Power Project of 50

MW capacity under the Jawaharlal Nehru Solar Mission Phase-I at Village Nokh, Tehsil-

Pokhran, District Jaisalmer, Rajasthan. The unit has successfully started injecting power

to the National grid on World Environment Day, the 5th June, 2013 and subsequently the

commercial operations were started from 19th June, 2013.

Godawari Energy Limited

The group has also forayed into independent power business of 2 x 660 MW supercritical

power project in District Raigarh, Chhattisgarh, India. GEL is a SPV company of M/s.

Godawari Power and Ispat Limited. The project is in development stage.


9

Name and Address of project proponent:

2.2 Brief description of nature of the project

The pelletizing plant of 21,00,000 TPA capacity (with 2 kilns of 6,00,000 TPA &

15,00,000 TPA) is situated at its existing plant premises located at Siltara, Dist. Raipur,

Chhattisgarh is a backward integration for utilization of iron ore fines as pellets in the

sponge iron kilns, having no effect on the total sponge iron capacity of the plant. The

techniques of pelletizing process include: grate kiln, travelling grate and shaft furnace.

The technique of Grate kiln technology is adopted by Godawari Power & Ispat Limited for

2.1 million TPA pellet project.

The company after assessing the market potential of the steel industry thoroughly

decided to go in for iron-ore pellets. The highly encouraging response received on

market survey also ruled favorably for the said project. Promoters are well experienced

entrepreneurs and are well supported by technical personnel experience to run such unit.

Presently, most of the coal based sponge iron plants in India uses iron ore lumps. The

requirement is generally 1.8 t/ t of sponge iron. This high requirement is mainly due to

the fines generated in handling the purchased ore from the source to the plant. This

reduces the kiln campaign length and increases ore fines lost.

Use of pellets with better physical and metallurgical properties for sponge iron

production reduces the accretion formation in the kiln and the pellets consumption is

about1.6 t/t. Further, the production from the kiln is expected to increase by 25% to

30%. It is noteworthy that the operations of M/s Godawari Power & Ispat Limited iron

ore mines at Ari Dongri & Boria Tibbu are in process. Thus, the iron ore fines so

generated are utilized through pelletizing route to DRI.

Efficacy of the Pellet

1) Pellet is a kind of high grade and indispensable B.F. burden. At the end of last century

the iron making technique in West Europe kept ahead in the world due to the technique

of high pellet proportion in the B.F. burden (55~77%). A lot of steel making plants with

grate kiln pelletizing production lines have been built, and the pellet proportion in B.F.

burden will increase to 30%, which results in millions of tons of pellet scarcity. The

reasons are concluded as follow:

Name of the Unit

: GODAWARI POWER & ISPAT LTD.

Date of Incorporation : 21/09/1999

Regd. Office : Plot No. 428/2, Phase-I, Industrial Area, Siltara, RAIPUR (Chhattisgarh)

Plant Location : Industrial Area, Siltara, Raipur

Contact Person : Shri T. Bose

E-mail : [email protected]

Tel No. : 91-771-4082000, 4082736

Fax No. : 91-771-4057601


10

� Metallurgy property and B.F. burden can be optimized under the conditions of

30% pellet proportion and over 1.8% sinter alkalinity. So Pellet is a kind of high

grade and indispensable B.F. burden.

� Low cost: The investment of pellet line is 30% higher than that of sinter line, but

due to half fuel consumption and 0.5~0.8 percent higher in iron grade (under the

same condition of raw material and alkalinity), the cost of pellet line can be

reduced 10RMB/t. So the Efficacy of pellet is higher than sinter.

� Pollution control is easy. Exhaust gas from pellet is only a half compared with that

of sinter, which is easier to control.

� Capability of pellet is stable, and pellet is convenient to be transported and

commercialized.

2) Important material for DRI making is a new process in iron making technique, which

utilizes the green ore with high fuel consumption (1000kg/t). If utilizing the pellet the

fuel consumption will be reduced to 800kg/t. Pellet is kind of important material for DRI

making.

2.3 Project appraisal:

As mentioned in the executive summary this is running project with combined capacity of 2.1 Million TPA of Iron Ore Pellets. Consent to operate is already been given by the State Pollution Control Board of Chhattisgarh. This PFR is prepared for getting Environmental Clearance from Honorable Ministry of Environment and Forest. Recent compliance report of this running plant submitted to the state pollution control board of Chhattisgarh is enclosed herewith as (Annexure-5)

2.4 Need for the project and it’s important to the country and or

region.

Utilization of low grade ore and fines has to play an important role. In India partly due to

the sponge iron sector; the overall percentage of lumps usage in steel making (47%) is

higher than most other countries. As hard ore reserves is depleting day by day, lump

generation suitable for blast furnace operation is coming down resulting in production of

large amount of surplus fines. Alternative iron making processes for production of steel

may lead to changing pattern of use material inputs and feed stock causing significant

shift in respective share of lumps and agglomerated iron ore (pellets) and will also

enable the use of ores which could not be utilized earlier. As fines forms considerable

part of iron ore resources, value addition to the iron ore fines through various activities

such as beneficiation, Pelletization is the need of the hour.

2.5 Demand Supply Gap.

With the rapid development of Infrastructure and manufacturing sector, the Iron and

steel industry is poised for an accelerated growth. Steel demand in the country is

increasing at an average rate of 10% and is likely to remain in 10-12% range at least for

the next decade. In order to meet the steadily growing steel demand in the country,

domestic steel producing capacity is required to be higher than 110 mtpa within next

three years and, 150 mtpa by the year 2016-17. Indian economy is growing at more

than 10% rate, steel demand and supply will grow in the same way. As good quality iron

ore deposits are depleting fast beneficiation technologies will have to be adopted to meet

iron ore demand. Therefore good yield of beneficiation process generally around 70 %

will make this technology economically viable.


11

� Agglomeration technologies such as Pelletization will have to be added to DRI Plant /

Steel Plant so that concentrates can be used as feed material. Recycling of cheaper

raw material (fines) by beneficiation and pelletization process as feed material will

result in better Return on Investment as compared to using Iron ore as feed

material.

� With superior reducibility behavior of pellets compared to lump ore efficiency of DRI

production improves.

� It can be concluded from results obtained by conducting various tests on

manufactured pavement blocks that substitution of iron ore tailings for sand or

quarry dust shows better compressive strength without much change in water

absorption.

With gradual depletion of high Iron Ore reserves, the Iron and Steel sector world over

has been looking at alternatives to utilise the low grade iron ore fines for iron making so

that there is optimal utilisation of the available iron ore resources. Growth of Steel

Industry, especially in China over the years despite the depletion of high grade Iron Ore

has taken place on the strength of technologies of Beneficiation, Sintering and

Pelletisation of Iron Ore Fines, which enhances the productivity of the blast furnaces in

Steel making and hence lowering the cost of steel production.

In the Indian context, by the year 2020, India’s production of steel is expected to touch

110 Million Tonnes and it is imperative that the fines generated in the mining of iron ore

be utilized for the production of steel. The Indian steel industry which predominantly

uses expensive lump ore is gradually moving towards usage of iron ore pellets.

The present Indian raw material scenario offers an opportunistic disposition towards

pellet making owing to the availability of large quantities of sub grade fines, slimes and

blue dust etc. at different mine heads. These materials are not suitable for sinter

making. Pelletization is the only possible route for salvaging these, otherwise waste but

valuable materials. Recent techno-economic studies indicated favorable indices for

installation of pellet plants, both small and large scale. The demand supply analysis also

underlines the need for Pelletization.

2.6 Employment Generation (Direct and Indirect) due to the

project.

The pellet plant is directly employing around 380 workers. It has employed the local population wherever possible in the project activities. There is secondary employment generation due to the running of this project. Wherever possible based on the educational qualification and capacity to undertake the available job, local people has given preference in the employment.


12

3. PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked and Interdependent

Project, if any.

The pelletizing plant of 21,00,000 TPA capacity (with 2 kilns of 6,00,000 TPA &

15,00,000 TPA) is situated at its existing plant premises located at Siltara, Dist. Raipur,

Chhattisgarh is a backward integration for utilization of iron ore fines as pellets in the

sponge iron kilns, having no effect on the total sponge iron capacity of the plant. The

techniques of pelletizing process include: grate kiln, travelling grate and shaft furnace.

The technique of Grate kiln technology is adopted by Godawari Power & Ispat Limited for

2.1 million TPA pellet project.

There are following facilities/projects that are interdependent and interlinked with the

pellet plant. For all the below mentioned projects the statutory clearances has already

been given by the government authorities.

Sponge Iron : 4,95,000 TPA


Steel Wires : 2,00,000 TPA

Power (Coal/WHRB/Biomass/Wind): 73 MW

Ferro Alloys or Pig Iron : 15,450 TPA / 33,000 TPA

Oxygen Gas : 12,00,000 M3 per Annum

Nitrogen Gas : 45,00,000 M3 per Annum

Fly Ash Plant : 1,65,00,000 Nos. per Annum

Iron Ore Mining : 12,55,000 TPA

Iron Ore Crushing : 12,00,000 TPA

Iron Ore Beneficiation : 10,00,000 TPA

(Under Commissioning Stage)

3.2 Details of alternate sites considered and the basis of selecting

the proposed site, particularly the environmental consideration

gone into should be highlighted.

This Iron Ore Pellet project is operational project, necessary permissions and approvals

for this project were obtained from the state pollution control board. Based on the

intervention of the Honorable MoEF and NGT, it has been learnt that the pelletizing units

that are running after obtaining the consent to operate from state pollution control board

only, should approach MoEF and submit their application for obtaining Environment

Clearance. In view of this background there is no alternate site has been considered for

this project since this is well establish and successfully running project.

3.3 Size or magnitude of operation.

The existing pellet plant is in two phases each of 0.6 and 1.5 million TPA/Year capacity,

thus the combine application for obtaining EC for the operation of 2.1 Million TPA iron ore

pelletizing project.

The 2.1 Million TPA pelletizing project is a backward integration having no effect on the

total sponge iron capacity of the plant. It is a backward integration for utilization of iron

ore fines as pellets in its sponge iron kilns. It is situated on the same land for which GPIL


13

having clearances from Gram Panchayat and Town & Country Planning Department,

Government of Chhattisgarh copy of the clearances is enclosed as (Annexure-6)

The company after assessing the market potential of the steel industry thoroughly

decided to go in for iron-ore pellets. The highly encouraging response received on

market survey also ruled favorably for the said project.

3.4 Project description with process details (a schematic diagram/

flow chart showing the project layout, components of the project

etc. should be given).

3.4.1 Iron Ore Pellet Plant In order to make entire technological level, environment protection level advanced stage

and suitable for operation and maintenance, it is designed to have some new material,

new technology, new process, new equipment and new structure, with aim at improving

reliability, reducing investment, extending life campaign, lowering operation cost,

facilitating maintenance and replacement.

� Proportioning system is complete with automatic proportioning process controlled by

computer. AC frequency converter facilities are adopted to increase accuracy of

proportion ration of raw material in the proportioning system.

� Infrared ray water content automatic measurement is adopted to keep water content

of the material mix optimum for Pelletization process.

� Balling discs with tilting angle adjustable, AC frequency convertible facilities of

advanced technology are provided, leading to high percentage of finished pellet

product, small recycle load and high productivity.

� Simplified and reasonable screening and distribution process are adopted and

featured as reliable equipment, high percentage of qualified finished pellet product,

uniform material distribution.

3.4.2 Travel Grate Machine – Rotary Kiln Process is Features as:

� Drying, Preheating, Baking, Cooling and etc are carried on different equipments

including travel grate machine, rotary kiln and annular machine, leading to uniform

quality of product and reliable and simplified equipment.

� Each set of equipment can be controlled individually and adjusted conveniently,

which is strongly adapted for raw material, particularly hematite.

� Good adaptability for fuel. Low fuel consumption, power consumption and low

operation cost.

� Rotary kiln is step-less adjusted by speed reducer and AC frequency converter to

enable operation smooth and stabilized.

� To adopt advanced air flow system, fully recovering sensible heat of high

temperature flue gas generated from annular cooler, making utilization of thermal

energy to the maximum extent, and lowering thermal consumption of pellet.


14

� Main operation process are centralized controlled and adjusted by computer, main

technological process are monitored and administrated by industrious TV with high

automatic control level.

� High attention is put on the protection of environment, which purify the dust

contained waste gas by use of high effective dust catcher to discharge into the air

after reaching standard discharge norm. Dust is collected in centralized manner,

which is fully recovered and utilized.

The Iron Ore Pelletization Plant has the following major units:

1. Iron Ore Yard

2. Raw Material Gentry

3. Iron Ore Grinding

4. Proportionating

5. Mixer

6. Balling Disc

7. Travel Grate

7. Kiln

8. Annular Cooler

3.4.3 Production programme The production program of the Iron Ore Pelletization Plant is 21,00,000 MTPA. The

annual average production hours considered is 7,920 hrs based on three 8 hrs

shifts/day, 7 days/week and 330 d/yr of plant operation. The required production rate is

265 tph.

3.4.4 Description of plant and equipment

3.4.4.1 Iron Ore grinding System

The raw material handled is hematite. The capacity of fine grinding machines is 290 t/h

feeding granular sizes is from 1 to 25mm. Fe content of incoming raw iron ore is around

63.5%. Granular sizes of output of iron ore after grinding is such that not less than 80%

passing though 325 mesh at water content of less than 8%. Preliminary iron ore grinding

is carried out in closed circuit ball mill and Hydrocyclone. Capacity of ball grinding

machine is 290t/h. Closed circuit recycle load is 200%. Overflow of Hydrocyclone product

sizes is such that not less than 80% passing though 325 mesh with concentration of iron

ore solid particle being 55%, which is directly fed into ceramic filter machine where the

iron ore is filtered and discharged into iron ore concentrate bunkers. Whole iron ore

grinding workshop is provided with 2 lines, each of which is equipped with a set of ball

grinding machine, a set of Derick Screens and a set of filter press are equipped.

Technological process water is provided with 2 sets of circulating water pumps and 2

sets of slurry pumps.


15

3.4.4.2 Storehouse of Bentonite/Flux/Coke

The Bentonite is transferred by cars into the storehouse in bags. Then Bentonite is lifted

into the Proportioning bunkers by electric hoist after manually dismantling bags. Under

proportioning bunkers are provided with proportioning weighing scale facilities.

3.4.4.3 Proportioning Room

Proportioning Room is complete with 13 bunkers, out of which, there is 5 iron ore

bunkers, 2 ash bunker, 2 Bentonite bunker, 2 flux bunker and 2 Coke bunker.

Iron ore filter cake is transferred from grinding unit through belt conveyor into the high

level of proportioning room, where the iron ore fines are fed into 5 iron ore bunkers

through belt conveyor into 4 iron ore bunkers. Dust collected from multiple cyclone dust

catchers and ESP is fed into the proportioning ash bunkers through ash channel

pneumatically by air. Bentonite and ash bunkers are installed with 4 discharching holes

for each. Under iron ore bunker is installed with AC frequency convertible disc feeder and

electronic scale belt. Bentonite bunker and dust bunkers are installed with speed variable

quantitative feeder. All bunkers are installed with material level monitoring device by use

of weighing level indicator for measurement of material level in the bunkers and giving

instruction for material supply system. Set value of proportioning ratio is controlled by

PLC and adjusted automatically. Various materials are transferred into the mixing room

through H-2 belt conveyor as per proportioning set ratio.

3.4.4.4 Mixing room

Iron ore fines, Bentonite, flux, coke and dust are all mixed uniformly in a horizontal

intensified mixer. As per water content of material, some certain quantities of water is

added so as to maintain water content before balling process ranged from 9 to 9.5%.

Otherwise, it is not beneficial for subsequent procedures. Mixed material is discharged by

Belt conveyor into balling room.

3.4.4.5 Balling Room

Mixed material is transferred through belt conveyor into the high level of balling room,

where the material mix is discharged through plough-type dumper above belt conveyor

separately into 4 mixed material bunker, under which, 9 sets of Ф6.0m balling disc are

installed. Material mix bunkers in the balling room are installed with material level

indicator which control material discharging from belt conveyor. Under material mix

bunkers are installed with disc feeder (Speed variable and AC frequency converter).

Electronic weighing scale belt interlink is utilized to control rotary speed of disc to feed

material mix into the balling disc quantitatively. In order to assure finished pellet product

quality, rotary angle and tilting angle of the balling disc is adjusted. Certain quantity of

water is added in balling process to keep water content of material mix optimum for

balling process. Balling disc is added with water by regulative valve, which is adjusted

manually as per water content of material mix. Green ball produced from balling disc is

transferred from collective belt conveyor into the green ball distribution system in the

travel grate machine for material distribution.

3.4.4.6 Green ball distribution system

Distribution system consists of head swinging belt conveyor, large ball roll sieve, wide

belt conveyor and roll distributor etc. Green ball from balling room is fed into the

distribution system through belt conveyor. In reciprocating process, head swinging belt


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conveyor feed the green ball into large ball roll screen for screening. Unqualified green

ball of more than 16mm are separated out and then fed back into the balling room

through return material system. Green ball of less than 16mm is fed onto wide belt

conveyor, which transfers the green ball onto roll distributor through AC frequency

converter. Roll distributor sieve out unqualified green ball of less than 8mm, and fed

qualified green ball of 8-16mm onto travel grate machine. Unqualified green ball is

returned into balling room through belt conveyor.

3.4.4.7 Baking System

Travel grate machine, rotary kiln and annular circular machine are designed to formulate

baking system. Green ball are dried and preheated in the travel grate machine, and then

baked, solidified in the rotary kiln, cooled in the annular cooler.

3.4.4.8 Travel Grate Machine

Effective length of travel grate machine is 115 sqm for 0.6 mtpa & 216 sqm. for 1.5

mtpa. Length of wind box is 3m. The travel grate machine is divided into 4 zones each

unit, which are separately for suction drying zone, preheating zone I and preheating

zone II.

� Suction drying zone I & II

In suction drying zone, recoverable hot west gas suctioned by heat resistant fans from

wind boxes in preheating zone II penetrates material layer downward from up, to keep

green ball free of water and dried.

A set of main suction blower is provided to exhaust waste gas from wind box into the air

through ESP.

� Preheating zone I

Hot waste gas flow in the preheating zone I is utilized to keep drying green ball through

material layer, in order to assure pellet to sustain high temperature in Preheating Zone

II.

Thermal source of the Preheating Zone I is generated from waste gas in Cooling Zone II

of annular cooler. Hot gas flow from cooling zone II of annular cooler is directly fed into

flue gas cover in preheating zone I though pipes.

Hot waste gas in preheating zone I is merged through main pipes at a side of wind box

with hot waste gas from suction drying zone to be discharged into air all together

through ESP, Main suction blowers and chimney.

� Preheating zone II

In preheating zone II, pellet is further heated. Pellet is partially solidified and hardened

to achieve certain strength to sustain impact caused by pellet falling from travel grate

machine into the rotary kiln to avoid being crushed in process of rotation of the kiln. Top

of upper cover in the preheating zone II is equipped with bleeding chimney and bleeding

valve for the purpose of heating up furnace and operation while in trouble. Green ball is

dried and preheated on travel grate machine for period of 24.33min. After preheated,

pellet achieves sufficient strength and then is fed into rotary kiln through scrapper and

kiln-end chute.


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3.4.4.9 Rotary Kiln

Sizes of the kiln are Φ4.0X 30m for 0.6 mpta & Φ5.0 X 42m for 1.5 mtpa. The kiln is of

2-gear support. It is internally lined with pre-fabricated bricks and pouring material to

achieve property of excellent anti thermal vibration, anti impact, anti abrasion and heat

isolation leading to extension of life campaign of lining material and lowering

temperature of the kiln shell.

Pellet, after preheated by the travel grate machine, is discharged into the end of the kiln

through scrapper and chute. The kiln is provided with HFO & producer gas spraying gun

in its head.

Pellet, receiving mainly radial heat inside the kiln, is rotated and baked in the same time

to keep baking process evenly and uniformly. The rotary speed of the kiln is variable

with the category of the raw material so as to achieve suitable duration period in the kiln

subject to quality of finished pellet product.

The well baked pellet, is discharged, after large sizes of pellet is sieved out by fixed

screen at the head of the rotary kiln, into the material receiving hopper of annular

cooler.

3.4.4.10 Annular Cooler

Effective area of annular cooler is 50 sqm fpr 0.6 mtpa & 90 sqm for 1.5 mtpa. The

annular cooler consists of Rotary mechanism, Wind Box, Driving Device, Frame, Upper

Cover and etc.

Inside the material receiving hopper of annular cooler is hot pellet discharged from the

kiln. The sizes of the said hot pellet are ranged from 8 to 16mm. As per height of

material inside the material receiving hopper in the annular cooler, by adjusting rotating

speed of the annular cooler through AC frequency convertible device, the material

thickness in the pellets are maintained.

Annular cooler is designed to have 9 wind boxes for each unit. The upper cover of the

annular cooler is divided into 3 parts. Wind volume of blowers of annular cooler is

variable through adjusting gate valve to control the temperature of the return hot wind.

Therefore, most of the heat energy of the gas flow cooling pellet is effectively utilized in

process of the Pelletization plant.

The pellet, after cooled down to below 100 centigrade in the annular cooler, is

discharged outside through discharging hopper.

3.4.4.11 Main air suction blowers

Waste gas from preheating zone I merge with those from Wind Box of Suction drying

zone is discharged through ESP and main chimney into the air. Dust content of waste

gas to be discharged into the air is not more than 50mg/Nm3.

3.4.4.12 Finished Product Transportation System

Cooled pellet, after discharged from material discharging hopper of annular cooler, is

transferred through belt conveyor into the Junction Box, where the cooled pellet 100 to

150 deg C is transferred through metal belt conveyor into the finished product

transportation system.


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3.4.5 Rationale for layout The general layout of the plant has been developed keeping in the view the following

factors.

� Smooth and uninterrupted flow of materials in accordance with the technological requirements.

� Optimum lead for transport of material and for services lines

� Logistic approach in location of technological units as well as services facilities

- Safety clearances and statutory provisions

- Adequate green belt all around the plant


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3.4.5.1 Location of various units

� The respective location of all units has been shown in the general layout drawing.

The Plant layout is enclosed as (Annexure-7)

� The location for storing of major raw material and handling facilities has been

planned in the stock yard adjacent to the Pellet Plant.

� The location of services units and auxiliary facilities, viz. fuel oil facilities, water

supply facilities, compressed air station, sto

Documents

Application for Environmental Clearance (EC)environmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2014. 6. 11. · Telephone No. 0771-4082000/ 4082001 Fax No. 0771-4057601