M/s. KASHVI INTERNATIONAL PVT. LTD. · Visiontek Consultancy Services Private Limited Page 2 1.0 Introduction 1.1 Identification of Project and Project Proponent M/s Kashvi International

PRE-FEASIBILITY REPORT

On

Proposed 0.6 MTPA Iron Ore Pellet Plant & 5 Nos.( 4 W + 1 S ) Producer Gas Plant of Capacity 5000

Nm³/hr each.

OF

M/s. KASHVI INTERNATIONAL PVT. LTD.At-Champadihi, Keonjhar District,Odisha

Prepared by:- SEPTEMBER-2014

VISIONTEK CONSULTANCY SERVICES PVT. LTD(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16,Phone No. : 91-674-2744594, 3250790, Fax: 91-674-2744594

[email protected] , [email protected] us at - www.vcspl.org

TABLE OF CONTENTS

Sl. No. Particulars Page No.

CHAPTER-1

1 Executive Summary 1

1.0 Introduction 2

2.0 Project Description 3

3.0 Site Analysis 5

4.0 Land Use Planning 6

5.0 Proposed Infrastructure 6

6.0 Rehabilitation & Resettlements (R & R) Plan 6

7.0 Project Schedule & Cost Estimates 6

8.0 Analysis of Proposal 7

CHAPTER-2 INTRODUCTION

2.1 Introduction 8

2.2 Identification of Project & Project Proponent 8

2.3 Description of Nature of the Project 9

2.4 Need of the Project & its importance to the Country and/or Region 9

2.5 Demand-Supply gap 10

2.6 Export Possibility 13

2.7 Employment Generation(Direct & Indirect) due to the Project 13

CHAPTER-3 PROJECT DESCRIPTION

3.1 Type of Project 16

3.2 Location & Accessibility 16

3.3 Site Selection 19

3.4 Size of Magnitude of Operation 19

3.5 Project Description 19

3.6 Plant & machinery Source 35

3.7 Raw Materials Requirements 35

3.8 Water & Power Requirement 35

3.9 Pollution Control Measures 38

3.10 Schematic representations of the feasibility drawing which give information of eia

purpose.

42

CHAPTER-4 SITE ANALYSIS

4.1 General 43

4.2 Connectivity 43

4.3 Topography 43

4.4 Existing Land Use Pattern 43

4.5 Existing Infrastructure 43

4.6 Climate Data 44

CHAPTER-5 PLANNING BRIEF

5.1 Planning Brief 46

5.2 Population Projection 46

5.3 Land Use Planning 46

5.4 Amenities & Facilities 47

CHAPTER-6 PRPOSED INFRASTRUCTURE

6.1 Industrial Area 49

6.2 Residential Area 49

6.3 Green Belt 49

6.4 Social Infrastructure 49

6.5 Connectivity 50

6.6 Drinking water Management 50

6.7 Sewerage System 50

6.8 Industrial Waste Management 52

6.9 Solid Waste management 52

6.10 Power Requirement & Supply/ Source 52

CHAPTER-7 REHABILITATION & RESETTLEMENT(R & R) PLAN

7.1 Policy to be adopted for R & R w.r.t Project 53

CHAPTER-8 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule 54

8.2 Project Cost 56

CHAPTER-9 ANALYSIS OF PROPOSAL

9.1 Financial & Social Benefits 57

9.2 Other Benefits 58

LIST OF TABLES

Sr.No PARTICULARS PAGE No.

1.0 Product Profile 4

1.1 Requirement of Raw Materials 4

1.2 Waste Water Generation & Reuse 4

1.3 Solid Waste Generation & Management 5

2.0 Project Profile 9

2.1 Project demand of Indian Iron Ore Pellets 10

2.2 Demand,Availability & resultant gap(-)/surplus(+) for Pellets(MTPA) 11

2.3 Avg. domestic demand of Pellets(SF+DR grade) 12

2.4 World DRI Production by year 12

2.5 Projected demand of Indian Iron Ore Pellets 13

2.6 Domestic/Export Markets 13

2.7 Category wise breakup of Manpower 15

3.0 Production capacity of the Company 19

3.1 Typical Analysis of input raw materials 20

3.2 Consumption Norms of Raw Materials 21

3.3 Comparison of qualities of BF & DR Grade pellets 29

3.4 Storage Details of Major Materials 30

3.5 Requirement of Raw Materials 36

3.6 Water Requirement 37

3.7 Source of air pollution & control Measures 40

3.8 Waste Water Generation & Reuse 40


3.10 Domestic Solid Wastes 41

3.11 Hazardous Wastes 42

4.0 Weather Analysis Report 46

5.0 Land Use Break-Up 48


8.0 Project Cost Break- Up 57

LIST OF FIGURES

Fig. No. Particulars Page no.

3.0 Plant Location 17

3.1 TOPO Map(10 Km Radius) 18

3.2 Process Flow Chart for 0.6 MTPA Pellet Plant 23

3.3 Schematic Diagram 31

3.4 Plant Layout 35

3.5 Water Balance 38

3.6 Schematic Representation 43

M/s Kashvi International Private LimitedPFR Report on Proposed 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant ofCapacity 5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha.

Visiontek Consultancy Services Private Limited Page 1

CHAPTER - I

EXECUTIVE SUMMARY

1 Name of the project Proposed an Iron Ore Pellet Plant of Capacity 0.6

MTPA & 5 Nos. (4w+1s) Producer Gas Plant of

Capacity 5000 Nm³/hr each.

2 Sl. No. in the schedule 3(a)

3 Registered Office Plot No.1234(P), Govind Prasad,Bomokhal,Cuttack-

Puri,Bhubaneswar-751010

4 Name of the promoters Er. Debabrata Behera

Plot No.1234(P), Govind Prasad, Bomokhal, Cuttack-

Puri, Bhubaneswar-751010

5 Present Business Power & Steel

6 Area of Plant 19.62 Acres

7 Topo Sheet No. 73G/5 & 73G/9

8 Latitude

Longitude

210 53’ 23.76”N

850 28’ 47.84”E

9 Proposed Capacity 0.6 MTPA Pellet Plant & 5 Nos(4 w+1s) Producer Gas

Plant of 5000 Nm³/hr each.

10 Cost of Project 22300.00 Lakhs

11 Manpower Requirement 93 People

12 Power Requirement Total power requirement for the project is 5.0 MW,

which will be met from 132/33 KV Sub-station of

OPTCL at Palaspanga.

13 Nearest Railway Station/airport along

with distance in kms.

Nayagarh Railway Station-6 km.

Bhubaneswar Airport-185 km.

14 Nearest town, City, District Head

quarters along with distance in kms.

Jhumpura -12.1 km.

15 Village Panchayats, Zilla Paris

had,Municipal corporation, Local

telephone nos. to be given) body

(complete postal addresses

with telephone no.s to be given)

At- Champadihi

Block & Tehsil- Jhumupra

Village Panchayat-Kutugaon

Zilla Parishad-Keonjhar

District- Keonjhar, Odisha



CHAPTER - I

EXECUTIVE SUMMARY













8 Latitude

Longitude

210 53’ 23.76”N

850 28’ 47.84”E














Jhumpura -12.1 km.






At- Champadihi







CHAPTER - I

EXECUTIVE SUMMARY













8 Latitude

Longitude

210 53’ 23.76”N

850 28’ 47.84”E














Jhumpura -12.1 km.






At- Champadihi





M/s Kashvi International Private LimitedPFR Report on Proposed 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity5000 Nm³/hr At-Champadihi, Keonjhar District, Odisha.


1.0 Introduction

1.1 Identification of Project and Project Proponent

M/s Kashvi International Pvt. Ltd. has proposed to setup an iron ore pellet plant of capacity 0.6

MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each

At-Champadihi, Keonjhar District, Odisha. The Kashvi International Pvt. Ltd (hereinafter referred

to as ‘KIPL’) is and having its Registered office At-Plot No.1234(P), Govind Prasad, Bomikhal,

Cuttack-Puri Road, Bhubaneswar.

M/s Kashvi International Pvt. Ltd. is part of the Kashvi Group of Keonjhar, Odisha having decades

of experience in Iron Ore Fines trading, Iron Ore Lumps crushing & screening, Road Logistic &

Mineral Export Business. The goal of the group is to promote & get stream lined in state's

mission of prosperity through Industrialization by employing its own work force. In the past

business of the company, it has basically employed mostly local professional & work men. It has

specifically emphasized to even employ State's specialized organization for its Projects. The other

associated companies of the promoter are:

M/s Kashvi Power & Steel (P) Ltd.

M/s D.B. Minerals (P) Ltd, (Iron Ore Crushing & Screening Unit).

M/s D.B. Road ways (Road logistic Company).

M/S Hotel Kashvi International (Star category Hotel).

Promoters

The promoters of the project are Mr.Debabrata Behera, who is the Managing Director of the

Company & he has wide experience in multiple business activities, co-promoter of the project is

Mrs. Sushmita Behera who is very apt in relationship business & manages the Hotel & Restaurant

business of the group.

The promoter is a dynamic and resourceful person. He is a Civil Engineer having wide experience

in Construction, Road logistics, Hotel business, Real estate business. Previously he was also doing

trading of Sponge Iron manufactured by Orissa Sponge Iron & Steel Ltd. to different parties in

Odisha and outside Odisha also. He is also a member of All India Sponge Iron Manufacturer

Association (SIMA) & Odisha Sponge Iron Manufacturer Association (OSIMA). The promoter

belongs to a well established business family of Keonjhar. Mr Debabrata Behera is now a day

managing four minerals related Companies through export activities.

Apart from the above mentioned business promoter is having one star category hotel &

restaurant at Keonjhar namely M/S Hotel Kashvi International which is running successfully for

last three years. Mr. Debabrata Behera belongs to Keonjhar and has rich contacts over here due

to operation in the similar business since last fifteen years. He can arrange procurement of raw

materials smoothly. M/S D.B. Roadways is a partnership firm whose main business is



1.0 Introduction


















Promoters



















1.0 Introduction


















Promoters



















transportation in which Mr. Debabrata Behera is also a partner & hence raw material can be

easily transported to any site in the country.

1.2 Employment Generation

It is estimated that the total employment generation due to the proposed project will be 93.

2.0 Project Description

2.1 Location

The proposed Project will be located at Champadihi Village, Keonjhar District of Odisha State

(Ref: Topo sheet 73G/5 & 73G/9). The Latitude and Longitude of the proposed site 210 53’

23.76”N and 850 28’ 47.84”E respectively.

2.2 Site Selection

Site is located at Champadihi, District- Keonjhar in the state of Odisha. The site has following

facilities:

Proximity to the sources of base raw material,

Availability of common Infrastructure facilities / utilities (water / power etc.),

2.3 Technology Selection

Technology selection involves an analysis of past achievements, present status and future

prospects of each technology under consideration keeping in view the following criteria.

Availability of project plant capacity/module.

Suiting to selected product mix & raw materials

Conservation of scarce inputs such as power & water.

Considerations of capital cost & maintenance cost.

Plant is going to utilize Iron ore fines to produce iron ore pellet using combination of producer

gas and furnace oil as fuel in the pellet plant. All units shall be based on Advanced Process

technology.

2.4 Product Profile

M/s Kashvi International Pvt. Ltd. intends to set up an iron ore pellet plant to produce iron ore

pellet of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1S) Producer Gas Plant of Capacity 5000

Nm³/hr each at Champadihi, Keonjhar District, Odisha.








2.1 Location




2.2 Site Selection


facilities:












technology.

2.4 Product Profile











2.1 Location




2.2 Site Selection


facilities:












technology.

2.4 Product Profile






Table 1.0 Product Profile

SI. No. Units Product Configuration Capacity

1 Iron ore Pelletization Plant Iron Ore Pellet 1x0.6MTPA 6,00,000 TPA2 Producer gas Plant Producer gas(Gcal) 5 Nos. (4W+1 S) 5000 Nm³/hr each

2.5 Raw Material Requirement

Table 1.1 Requirement of Raw Materials

SlNo.

Description Quantity Source Mode ofTransport

A. Pellet Plant

1 Iron OreFines

6,48,000 Odisha(KJS Ahluwalia, RP Sao, MESCO Steel,Kalinga Mining)

Road/Rail

2 Bentonite 6,000 Rajasthan Road/Rail

3 Coke 18,000 Rourkela Steel Plant, Rourkela Road/Rail

4 Limestone 18,000 Sundergarh, Odisha Road/Rail

B. Producer Gas Plant

1 Steam Coal 60,000 MCL, Odisha & ECL, Jharkhand Road/Rail

Total 7,50,000

Water and Power Requirement

For the project the water requirement is about 15 m3/hr (4 m3/hr from Baitarani River & 11

m3/hr from ground water). This will be sufficient for the present requirement. Further the River

Baitarani is passing very close to the site. Further the promoters have plan to harvest the rain

water for efficient use of it.

Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Sub-

station of OPTCL at Palaspanga. Further the promoter will have the DG sets to meet the

emergency power requirement.

2.6 Waste Generation and Management

Waste water generated from pellet plant and others is depicted below.

Table 1.2 Waste Water Generations and Reuse

Process Unit Waste water qty(m3/day)

Source Waste watercharacteristics

Waste watermanagement

Pellet No waste watergeneration. Coolingwater will becompletely recycled.

Cooling High Temp Completerecirculation








SlNo.


A. Pellet Plant

1 Iron OreFines


Road/Rail






Total 7,50,000
























SlNo.


A. Pellet Plant

1 Iron OreFines


Road/Rail






Total 7,50,000



















Raw watertreatmentsystem

9.5

14.5

Backwashfrom filtrationunit

Underflow ofclarifier

TSS

TSS

Will be treated insettling tank andtaken to guard pondfor reuse

Domestic 19.0 Domestic usefrom plant

TSS, BOD, Oil &Grease

Will be treated inSTP and reused forgreenbelt

Producer GasPlant

2.50 Gas CleaningSection

Phenol, Ammonia,Cyanide, BOD,COD

Will be treated inETP and treatedwater used in dustsuppression,greenbelt.

Table 1.3 Solid Waste Generation and Management

Units Solid Wastes Qty In TPA Disposal practice

Pellet plant Dust from APC devices 350 Reused in pelletmaking

Broken Pellet 660

Raw water treatment plant Sludge 6 Will be used forlandscaping

Producer Gas Plant Bottom Ash 10,000 Will be used in fillinglow laying areas.

3.0 Site Analysis

3.1 Connectivity

The site is well connected with road. The project site is only 12 km from Kotolposhi and 4 km

away from the village Nahabada. Kotolposhi is on NH-215. NH – 215 is from Panikoili (on NH-

5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance from Kortolpshi to

Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is very close to the site.

Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi.

The railway facility is also available near to the site. The nearest Railway station is Nayagarh in

Joda area and is only 6 km away from the project site. Nearest airport is at Bhubaneswar, 185

Km from proposed project site in its Southern side.

3.2 Topography and Existing Land use Pattern

The topography of the land is generally flat and well suited for development of industrial

projects. Project / Plant is coming under the non- forest category land.




9.5

14.5



TSS

TSS





Producer GasPlant







Broken Pellet 660



3.0 Site Analysis

3.1 Connectivity















9.5

14.5



TSS

TSS





Producer GasPlant







Broken Pellet 660



3.0 Site Analysis

3.1 Connectivity














3.3 Climate Data

The climate of the Keonjhar district is characterized by hot summer with low humidity. During

the summer maximum temperature is 38.20 C. The temperature in the month of December is

lowest i.e. 11.70 C. Sometimes it even drops down to 70 C. The average annual rainfall is 1534.5

mm.

4.0 Land Use Planning

Total land requirement for the proposed unit is about 19.62 acres which is already identified and

acquired.

5.0 Proposed Infrastructure

5.1 Industrial Area

The setting up of the Main Plant Facilities, Raw Material Storage, Ash Storage, Raw Water

Storage Reservoir & Treatment, Auxiliary facilities, viz. Administrative Building, Technical

Building, Workshop, QC Lab, Switch Yard, etc. & Green belt required is 6.49 Acres land out of

which 19.62 acres. Company uses nearest road for goods transportation and equipped with all

other required facilities.

5.2 Green Belt

A greenbelt development plan will be prepared and implemented along with the project. Total

green belt area shall be 33% (6.49 Ac) of total area (i.e.19.62 Ac). The main objective of the

greenbelt is to provide a barrier between the plant and the surrounding areas.

5.3 Others

A garland drain around the plant along boundary is envisaged to collect surface run-offduring rainy season.

Additional drinking water facilities will be provided for employees as well as nearbyvillagers.

6.0 Rehabilitation & Resettlements (R & R) Plan

The proposed project is going to setting up on 19.62 acres area. Total land has already been

identified and acquired. There is no existence of displaced habitants in the identified land. Land

is also devoid of any vegetation. Local people will be engaged for construction and operation

activities and the local area have all the infrastructure facilities. Here no housing

colony/township is envisaged.

7.0 Project Schedule & Cost Estimates

7.1 Project Schedule

The total project implementation schedule is 18 months from zero date, land development. The

external agencies such as consultant, machinery suppliers, contractors of civil construction and



3.3 Climate Data




mm.



acquired.


5.1 Industrial Area






5.2 Green Belt




5.3 Others















3.3 Climate Data




mm.



acquired.


5.1 Industrial Area






5.2 Green Belt




5.3 Others















equipment will be selected carefully well in advance.

7.2 Project Cost

An indicative estimated capital cost of the proposed Plant is Rs. 22300. Lacs, including the pre-

operative expenses, contingency and interest during construction.

8.0 Analysis of Proposal

The socio-economic benefits of the proposed project are as follows:

Improvement and construction of road network in the nearby villages.

Extension & renovation of Local School buildings with playgrounds.

Social awareness programme will further improve the quality of life and standard of living

such as sanitation and hygiene, HIV Prevention Programme etc.

Implementation of adult education and female education programmes in the villages

surrounding the project area.

Financial assistance to talented and poor students for higher

studies.(Management/Engineering/Medical science)

Expected to employment are 93 persons.




7.2 Project Cost

















7.2 Project Cost
















CHAPTER – 02

INTRODUCTION

2.1 Introduction



At-Champadihi, Keonjhar District, Odisha. The Kashvi International Pvt. Ltd is having its

registered office At-Plot No.1234 (P), Govind Prasad, Bomikhal, Cuttack-Puri Road, Bhubaneswar.













Promoters


Company & he has rich experience in multiple business activities, co promoter of the project is

Mrs.Sushmita Behera who is very apt in relationship business & manages the Hotel & Restaurant















CHAPTER – 02

INTRODUCTION

2.1 Introduction

















Promoters


















CHAPTER – 02

INTRODUCTION

2.1 Introduction

















Promoters





















2.3 Description of Nature of the project

M/s Kashvi International Private Limited is going to install 0.6 MTPA Iron Ore Pellet Plant & 5

Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr each. At-Champadihi, Keonjhar

District, Odisha.

Table 2.0 Project Profile

SI.No.

Units Product Configuration Capacity

1 Iron ore PelletizationPlant

Iron Ore Pellet 1x0.6MTPA 6,00,000 TPA

2 Producer gas Plant Producer gas(Gcal) 5 Nos. (4W+1 S) 5000 Nm³/hr each

The object of the process is to transform the finer size iron ore into hardened pellets that can be

used as blast furnace feed or direct reduction kiln feed. The transformation is achieved by the

Grate Kiln. The Grate transfers the green pellets through a series of controlled temperature

zones to produce a preheated pellet at temperature 900-1050°C, which is then feed into the

Rotary Kiln. The Rotary Kiln finishes the Induration Process and operates at 1100-1200°C. The

Indurated Pellets then fed to an Annular Cooler, where the pellets are cooled to a suitable

temperature for transporting on a belt to load out facilities. The gases from the Annular Cooler

are recycled to the Kiln and the Grate, resulting in the Grate-Kiln-Cooler technology being the

most energy efficient system for producing Indurated Pellets.

2.4 Need of the Project and its Importance to the Country and/or Region

Visualizing the demand of iron and steel in the country and to promote maximum value addition

within the state, the state government of Odisha has signed number of MoU for establishment of

steel plants in Odisha. The present reserves of high grade iron ore within the state suitable for

manufacture of Iron and steel is very much limited and will be consumed within coming 20 to 25

years, if all the steel projects will be established as per MoU signed. Therefore, there is an urgent

need for utilization of iron ore fines lying in huge quantity in all the iron ore mines located in

Barbil-Joda sector of Keonjhar district. This iron ore fines is the raw material for the Pellet Plant.

The abundance of iron ore fines in Joda Barbil area led the Management to establish the Iron Ore

Pellet Plant at village Champadihi, Kotolposi,Joda, Keonjhar District, Odisha which will be

ultimately used for steel making through blast furnace/DRI route.









District, Odisha.


SI.No.

































District, Odisha.


SI.No.



























In the light of above the availability of iron ore will continue to be in big concern in future. The

country has abundant reserves of iron ore fines and dumps which can be beneficiated and used

in the production of sponge iron & steel making.

Therefore, there is huge scope of iron ore pellet plant to convert iron ore fines for steel making

which will not only be helpful in enhancement of reserves inventories of desired iron ore grade

but also will be helpful to recover the valuable land, which has been covered under iron ore fines

dumping.

Steel finds wide applications in our day to day life. Various key industries like construction,

transport, communication, agriculture and energy cannot sustain without steel. The

manufacturing process from iron ore to finished product involves production of a large number

of intermediate products. All the intermediate products have a domestic as well as a global

market.

2.5 Demand – Supply Gap

Global capacity and production

The Pellet market consists of a group of sellers controlling a majority of Pellet capacity

worldwide. Long term contracts for supply of Pellets are the norm in the industry. Some of the

largest Pellet manufacturers are from Latin America & Sweden. The market leader in the

industry is CVRD (Brazil) whose prices are generally considered as benchmark price for pellets.

In the export market, the present and future DRI/HBI producers in Southeast Asia, Middle East

and North Africa have given them a definite advantage over the suppliers from Brazil, North

America and Sweden.

The Pellet deficiency in the target market is being currently met from South America (CVRD,

Samarco) and Europe. In view of potential market in South East Asia region and export of iron

ore Pellets by India in the past, a provision of 40% of total anticipated domestic demand of

Pellets is kept for export demand for iron Pellet has been worked out and given in Table.

Table 2.1 Project demand of Indian Iron ore Pellets:

Demand Year2006-07 2011-12

Domestic 13. 26.5Export 5.28 10.6Total 18.48 37.1

* Extrapolated from Demand of Metallic & Compilations from various data sources.









dumping.





market.









America and Sweden.






Demand Year2006-07 2011-12











dumping.





market.









America and Sweden.






Demand Year2006-07 2011-12





Resultant demand-supply scenario

Based on the demand and availability discussed in the previous paragraphs, the

resultant gaps/surpluses of Pellets have been worked out and presented in the following table:

Table 2.2 Demand, Availability and resultant gap (-)/surplus (+) for pellets (MTPA)

Years Demand Total Availability Gaps(-)/surpluses (+)Domestic Export Domestic Export

2006-07 1 13200 5280 +)4800 4800 (+)4800 (-)4802011-12 26500 10600 37100 20800 (-)5700 (-) 16300

From the above table, it may be observed that country is likely to face a shortage of about 5.7

Mt of pellets by 2011-12.With export demand, the gap may further widen. Under the

circumstances, addition of Pellet plant capacity in the country is necessary.

As discussed above Pellet is considered to be a superior feed stock for any primary Iron making

process. While Smelting Reduction Processes and Direct Reduction Processes is currently

utilizing Pelletized ore, Blast Furnace based process still prefers to use sinter as it is produced

in-house. However sinter plants are not very environment friendly, as such it is predicted that

slowly Blast Furnace will start using a part of its burden as Pellet. With increasing trends of

Pellet usage in Blast Furnaces there shall be great demand from steel in next few years. The

steel demand and its growth is as given below:

Steel Demand Forecast by Gross Domestic Products (GDP)

Domestic demand for steel can be related to GDP. Analysis of data for the last several years

shows a very high level of correlation between GDP and steel demand. On conservative basis,

assuming present growth rate of 8% to be constant (as projected by Finance Ministry) the

projected demand with respect to this growth rate is as shown below.

(Sensitivity with Table: Steel Demand Forecast Respect to constant GDP toconstant GDP Growth Rate)

Year Project Demand of Finished Steel (In Million Tones)

2006-07 39.30

2009-10 49.50

2011-12 57.70

Projections are based on base year 2006-07 apparent consumption i.e. 38MT

In India 90% of steel is consumed by 15% of the population while the balance 10% goes to

remaining 85% population. India being a developing country, it is definite that moderate

urbanization of some rural area is to take place in the near future, thereby boosting the








2006-07 1 13200 5280 +)4800 4800 (+)4800 (-)4802011-12 26500 10600 37100 20800 (-)5700 (-) 16300


















2006-07 39.30

2009-10 49.50

2011-12 57.70












2006-07 1 13200 5280 +)4800 4800 (+)4800 (-)4802011-12 26500 10600 37100 20800 (-)5700 (-) 16300


















2006-07 39.30

2009-10 49.50

2011-12 57.70







consumption of steel to a considerable extend. In view of this authors opine that the projected

demand of steel by year 2012 would be around 60 million tones.

Also out of 60 million tonnes of steel it has been estimated that around 45 million tonnes of

steel shall be produced through Blast Furnace route. With a moderate use of iron ore pellet

(20% in burden) the demand for pellet would be around 20 million tones.

Pellet Demand

Considering the projected production of DRI and share of iron ore pellets in iron bearing feed

materials in coal based DRI units, demand of iron ore pellets works out to 0.64 Mt in 2006-07

and 2.6 Mt. in 2011-12.

Anticipated total demand of DR Grade for gas based units as well as coal based units works out

to 7.6 Mt in 2006-07 and 11 Mt. in 2011-12. Aggregate domestic demand of iron ore pellets is

furnished in Table:

Table 2.3 Average domestic demand of Pellets (SF + DR grade)('000 Tons)

Year SF Grade DRI Grade Total

2006-07 5600 7600 13200

2011-12 15500 11000 26500

The world sponge iron production has increased from 0.79 million Mt in 1970 to over 43.2

million Mt in 2000. Worldwide the sponge iron production increased by 2.5% to 43.2 million

tones in 2000 despite a slump in steel market. The increase was due to a number of large DRI

plants started in late 1997 & early 1998 and heavy demand from steel manufacturers. The high

quality of this product is the main factor affecting growth in production of sponge iron.

Table 2.4 World DRI Production by year.

Year Quantity (in Million Tonne.) Year Quantity (in Million Tonne.)

2000 43.3 2006 59.792001 40.32 2007 67.222002 45.08 2008 68.452003 49.95 2009 64.42004 54.60 2010 70.42005 56.99 2011

The sponge iron requirement & its production are increasing day by day due to increase in

metallic requirement for steel making. India became the third largest producer of sponge iron

with the production of 5.40 million Mt in 2000 and the largest producer in the year 2001 with a

production of 5.7 million Mt. Venezuela has been the largest producer of sponge iron in 2000








Pellet Demand



and 2.6 Mt. in 2011-12.



furnished in Table:



2006-07 5600 7600 13200

2011-12 15500 11000 26500








2000 43.3 2006 59.792001 40.32 2007 67.222002 45.08 2008 68.452003 49.95 2009 64.42004 54.60 2010 70.42005 56.99 2011












Pellet Demand



and 2.6 Mt. in 2011-12.



furnished in Table:



2006-07 5600 7600 13200

2011-12 15500 11000 26500








2000 43.3 2006 59.792001 40.32 2007 67.222002 45.08 2008 68.452003 49.95 2009 64.42004 54.60 2010 70.42005 56.99 2011







with production of 6.41 million Mt. Mexico has placed second with 5.90 million Mt production,

India was third with 5.40 million Mt production and Iran was fourth with 4.54 million Mt

production. These four countries are sharing almost 53% of the world's total sponge iron

production.

2.6 Export Possibility

Export Market for Iron Ore Pellets.

In view of potential market in South East Asian region and exports of Iron Ore Pellets by India in

the past, a provision of 40% of total anticipated domestic demand of pellets is kept for export

for the present study. Accordingly, the export demand for iron is pellet has been worked out

and given in Table:

Table 2.5 Projected demand of Indian Iron Ore Pellets (Million Tonnes)

Demand Year2006-07 2011-12

Domestic Export Total 13.205.28

18.48

26.5010.6037.10

Export Possibility.

Competition in exports is mainly from CVRD (Brazil), LKAB (Sweden), GIIC (Bahrain) and Savage

River (Australia). In view of the present situation, FISPL will have two main competitive

advantages viz. -

Proximity to China and other Asian Markets

Customer needs to maintain less inventory

Lower freight costs

Further, supply from Indian Pellet producers will be advantageous to the Customer of lower

lead-time for supplies, lower voyage time and lesser inventory holding costs.

Table 2.6 Domestic/Export Markets

Years Demand

Domestic

Total

Exports

Availability Gaps(-)/Surpluses( +) Domestic With Exports

2006-07 13200 5280 18480 18000 (+) 4800 (-) 480

2011-12 26500 10600 37100 20800 (-) 5700 (-) 16300

2.7 Employment Generation (Direct and Indirect) Due to the Project

Basis of manpower estimate

The manpower estimates have been made taking into consideration the following aspects:






production.






and given in Table:


Demand Year2006-07 2011-12


18.48

26.5010.6037.10

Export Possibility.



advantages viz. -



Lower freight costs




Years Demand

Domestic

Total

Exports


2006-07 13200 5280 18480 18000 (+) 4800 (-) 480

2011-12 26500 10600 37100 20800 (-) 5700 (-) 16300









production.






and given in Table:


Demand Year2006-07 2011-12


18.48

26.5010.6037.10

Export Possibility.



advantages viz. -



Lower freight costs




Years Demand

Domestic

Total

Exports


2006-07 13200 5280 18480 18000 (+) 4800 (-) 480

2011-12 26500 10600 37100 20800 (-) 5700 (-) 16300






a. The proposed organization structure, production processes involved, layout, equipment

with its degree of automation and mode of operation.

b. Additional manpower over and above the daily requirement at the rate of twenty-five

(25) per cent is provided to cater weekly off, holidays, leave, absenteeism etc. for

departments/sections working seven days a week.

c. The operation staff will be required to carry out routine checking of their own plant and

equipment as well as minor repairs and adjustments in addition to plant operation.

Moreover, during equipment shutdown for maintenance, the operation personnel will

assist the maintenance personnel in carrying out the maintenance tasks to maximize the

utilization of manpower.

d. The maintenance personnel will have multi-disciplinary skills; for example, mechanic will

be able to perform simple machining, welding and gas cutting. Implementation of such

concept will optimize the utilization of human resources and thereby will increase labour

productivity of the plant which, in turn, will reduce the cost of production.

e. Implementation of computer systems including local area network (LAN) with standard

user friendly software's in the field of financial management, human resource

management, personnel management, materials management, order scheduling,

sales and marketing management, management information systems (MIS),

production planning and control, maintenance and spares planning, etc. has been

considered to increase work efficiency and to reduce manpower requirement.

f. For security services, canteen and catering services, horticulture and landscaping

services, sanitary services, personnel transport, heavy maintenance and capital repairs,

plant civil maintenance, general cleaning and up-keep of the plant, loading and

unloading of materials, product handling, stores handling, and other miscellaneous

semi-skilled and unskilled job, appropriate external agencies will be employed under

management supervision.

Total manpower requirement

Based on the above, it is estimated that the manpower requirement for the proposed plant will

be about 93 persons, comprising 67 persons for pellet plant and 26 persons for producer gas

plant. The details of manpower estimate for administration and works departments are

presented in Table 2.7





































































Category-wise breakup of manpower

Category of personnel required in each job position for all departments is indicated in Table 2.7.

The category-wise breakdown of manpower for administration and works departments of the

plant is given in Table 2.7.

TABLE 2.7 Category-Wise Breakup of Manpower

Sl.No.

Category Pellet Plant Producer Gas Plant Total

1 Manager 1 1 2

2 Supervisor 4 4 8

3 Skilled Workers 30 9 39

4 Un-skilled Workers 32 12 44

TOTAL 67 26 93

Training

It is presumed that the personnel in the administration departments having requisite

qualification and experience will be available from the local market and they do not normally

require any specific training. It is expected that their recruitment will be progressive depending

upon the requirement during the construction period and will be completed before

commissioning of the plant.

For works departments, most of the key positions in operation and maintenance of the proposed

plant at different categories will be manned by the qualified persons having experience in the

similar field in metallurgical industries and attitude to learn new technologies. However,

depending on the type of equipment/facilities along with the degree of automation

contemplated, the operation and maintenance personnel of the plant so recruited will require

specific need based training which is proposed to be carried out on-site by the respective

equipment supplier during equipment erection, start up and commissioning of different plant

units.








Sl.No.


1 Manager 1 1 2

2 Supervisor 4 4 8



TOTAL 67 26 93

Training













units.








Sl.No.


1 Manager 1 1 2

2 Supervisor 4 4 8



TOTAL 67 26 93

Training













units.



CHAPTER - 3

PROJECT DESCRIPTION

M/s Kashvi International Pvt. Ltd. Intends to set up an iron ore pellet plant to produce iron ore

pellet of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W + 1S) Producer Gas Plant of Capacity 5000

Nm³/hr each At-Chamapdihi, Keonjhar, Odisha

3.1 Type of Project

The proposed project is a Greenfield independent project envisaged to produce BF and DRI grade

iron ore pellet through iron ore pellet plant. Plant shall be based on Advanced Process

technology. The plant will also be equipped with the most efficient auxiliary sub systems,

material handling facilities and pollution control equipment.

3.2 Location & Accessibility

The proposed Project will be located at Champadihi Village in Keonjhar District of Odisha State

(Ref: Topo sheet No. 73G/5 & 73G/9. The Latitude and Longitude of the proposed site 210 53’


a. Road Connectivity: The site is well connected with road. The project site is only 12 km

from Kotolposhi and 4 km away from the village Nahabada. Kotolposhi is on NH-215.

NH – 215 is from Panikoili (on NH-5) to Rajamunda (on NH-23) via Keonjhar, Joda,

Koida etc. The distance from Kortolpshi to Nahabada village is only 8 km. The mineral

rich places like Joda & Barbil is very close to the site. Joda is only 33 km from Kotopshi

and Barbil is only 48 km from Kotolposhi.

b. Rail Connectivity: The railway facility is also available near to the site. The nearest

Railway station is Nayagarh in Joda area and is only 6 km away from the project site.

c. Airport: Nearest airport to the project site is Bhubaneswar at a distance of 185 kms.

d. Seaport: Nearest Seaport at Paradip is located at a distance of about 216 km from the

project site.



CHAPTER - 3

PROJECT DESCRIPTION




3.1 Type of Project



















project site.



CHAPTER - 3

PROJECT DESCRIPTION




3.1 Type of Project



















project site.



Fig 3.0 Plant Location









Fig 3.1 TOPO MAP (10 Km Radius)









3.3 Site Selection

The selection of project site/location has been based on the following considerations.

Proximity to the sources of raw material (iron ore fines),

Availability of Infrastructure like power.

Land for proposed project does not involve any displacement of habitation or any diversionof forest / vegetation.

The site is well connected with road. The project site is only 12 km from Kotolposhi and 4km away from the village Nahabada. Kotolposhi is on NH-215. NH – 215 is from Panikoili(on NH-5) to Rajamunda (on NH-23) via Keonjhar, Joda, Koida etc. The distance fromKortolpshi to Nahabada village is only 8 km. The mineral rich places like Joda & Barbil is veryclose to the site. Joda is only 33 km from Kotopshi and Barbil is only 48 km from Kotolposhi.

Access to high growth domestic steel markets and future industrial and infrastructuredevelopment has been planned.

Availability of water from Baitrani River.

3.4 Size or Magnitude of Operation

Table 3.0 Production capacity of the company

SI.No.



Iron Ore Pellet (1x0.6MTPA) 6,00,000 TPA

2 Producer gas Plant Producer gas(Gcal) 5 Nos. (4W+1 S) 5000Nm³/hr each


3.5.1 Process Description – Pelletization Plant

Design basis: System design of a Pelletizing Plant is carried out on the basis of desired capacity,

quality of raw materials, desired product quality as well as the process parameters established

through appropriate test work. Such test work is yet to be undertaken for the proposed

Pelletizing Plant. Accordingly, suitable assumptions have been made for design of the system

including equipment selection, based on Consulting Engineers' experience in similar projects and

in-house information on the subject.

Plant capacity: The pellet plant will be designed to produce 0.6 MTPA pellet & 5 Nos. (4 w+ 1 s)

Producer Gas Plant of capacity of each unit 5000 Nm³/hr each.

Annual pellet production capacity, million tons : 0.6 MTPA

Producer Gas Plant : 5 Nos. (4 W +1 S) Capacity of each unit-5000 Nm³/hr each

No. of working days per year : 330 days

Working hours per day in 3-shift operation : 24



3.3 Site Selection










SI.No.





















3.3 Site Selection










SI.No.





















Based on the above assumptions, the effective annual working hours amount to 7,920 hours and

pellet production rate works out to about 76 tons per hour.

All equipment shall be selected by keeping a 15 per cent design margin. Also the sizing of

equipment shall take care of other process fluctuations

3.5.1.1 Quality of raw materials

The typical analysis of input raw materials envisaged for the production of pellets are given in

Table below

Table 3.1 Typical Analysis of Input Raw Materials

Raw

Materials

Fe

%

SiO2

%

Al2O3

%

CaO

%

MgO

%

LOI

%

Calorific Value

(Kcal/kg)

Iron ore fines 64.0 3.0 2.1 -- -- 3.0 --

Bentonite -- 45.5 16.0 1.3 1.5 10.0 --

Limestone -- 0.65 0.2 54.5 1.0 42.0 --

Coke -- -- -- -- -- -- >5700

Oxide Feed Stock

Pellets can be made from both hematite and magnetite concentrate. Magnetite concentrate, if

available, is the preferred oxide feed, as use of the same reduces the external energy input

requirement and results in higher productivity. However, the proposed Pelletizing plant is

planned to be based on hematite iron ore mainly available in the region. Source of Iron Ore

concentrate/fines will be from Serajuddin & Co, R.P. Sao, T.P.Sao, KJS Ahluwalia Mines etc. from

Joda and Barbil sector.

Binders

For the formation of green ball of adequate strength and fired pellets of specific quality, it is

necessary to add a suitable binder. Bentonite is the most popular binder in use. Bentonite is a

latticed layered-structure clay material, capable of absorbing large quantity of water. When

water is added, it swells and forms a gel-like mass. This property is the most important

characteristic for its bonding capability.

Coke breeze

Coke/Coal is added to improve the Furnace productivity and overall fuel economy.

Additives

Additives are often used to modify the chemistry of Pellets, specially the slag forming

constituents. Additive generally used is limestone, for basically adjustment as well as for other

likely benefits, such as improvement in pellet strength and porosity.









Table below


Raw

Materials

Fe

%

SiO2

%

Al2O3

%

CaO

%

MgO

%

LOI

%

Calorific Value

(Kcal/kg)

Iron ore fines 64.0 3.0 2.1 -- -- 3.0 --

Bentonite -- 45.5 16.0 1.3 1.5 10.0 --

Limestone -- 0.65 0.2 54.5 1.0 42.0 --

Coke -- -- -- -- -- -- >5700

Oxide Feed Stock







Binders






Coke breeze


Additives












Table below


Raw

Materials

Fe

%

SiO2

%

Al2O3

%

CaO

%

MgO

%

LOI

%

Calorific Value

(Kcal/kg)

Iron ore fines 64.0 3.0 2.1 -- -- 3.0 --

Bentonite -- 45.5 16.0 1.3 1.5 10.0 --

Limestone -- 0.65 0.2 54.5 1.0 42.0 --

Coke -- -- -- -- -- -- >5700

Oxide Feed Stock







Binders






Coke breeze


Additives






3.5.1.2 Fuel

Fuel will be required in Pelletizing plant for heat hardening of green pellets in the Grate and

Rotary Kiln.

In this regard, natural gas and heavy oil have high calorific value, are clean burning, provide

operational flexibility and are convenient for use as fuel. However, natural gas is not available in

the region and heavy oil is costly.

A likely alternative fuel is Coal. There are instances of large plants being run successfully with

coal fired Gasifier. It is also reported that fuel cost could be economized to the extent of about

50 percent by replacing heavy oil with Producers gas for firing the Grate and Rotary Kiln. For

Producers gas based Grate and Rotary Kiln, about 25 per cent of total thermal energy may be

required to be supplied by oil for starting as well as for maintaining requisite temperature profile

in the preheating zone.

However, use of coal makes the Grate, Rotary Kiln and the product vulnerable to ash deposition.

Therefore, it is necessary to be selective about the characteristics of the coal intended to be

used as fuel in a Grate and Rotary Kiln. The desired coal characteristics should generally conform

to the E and F grade having FC little above 45.

Specific requirement of thermal energy for production of one ton of pellet is about 250,000 Kcal.

An advantage of Grate Kiln Technology is that 75% of thermal energy can be provided from low

ash coal for maintaining flame of burner of kiln and the balance 25% from fuel oil for maintaining

the temperature gradient within the Grate. Low Sulphur High Stock (LSHS) oil with calorific value

about 10,000 Kcal per Kg is envisaged for this purpose. Some amount of LSHS oil will also be

required for preheating purpose.

16 liters of oil will be consumed to produce 1T of iron ore pellet.

3.5.1.3 Consumption of input materials

The consumption of raw materials will vary depending upon the grade and basic requirements.

These will have to be computed on the basis of test results. In the absence of test work, suitable

assumptions in respect of consumption rates have been made for the purpose of the report and

the same are given in Table below:

Table 3.2 CONSUMPTION NORMS OF RAW MATERIALS

Sl No. Description Quantity Source Mode ofTransport

A. Pellet Plant

1 Iron Ore Fines 6,48,000 Odisha(KJS Ahluwalia,RP Sao,MescoSteel,Kalinga Mining)

Rail/Road



3.5.1.2 Fuel


Rotary Kiln.




























A. Pellet Plant


Rail/Road



3.5.1.2 Fuel


Rotary Kiln.




























A. Pellet Plant


Rail/Road



2 Bentonite 6,000 Rajasthan Rail/Road

3 Coke 18,000 Rourkela Rail/Road

4 Limestone 18,000 Sundergarh, Odisha Rail/Road


1 Steam Coal 60,000 MCL, Odisha & ECL, Jharkhand Rail/Road

Total 7,50,000

NOTES:

(1) Quantity on dry basis

(2) Quantity excluding moisture and handling losses

(3) To be added depending upon the end use

3.5.1.4 Process Flow Description








Total 7,50,000

NOTES:












Total 7,50,000

NOTES:





M/s Kashvi International Private LimitedPFR Report on Proposed 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000 Nm³/hr At-Champadihi, Keonjhar District,Odisha.


Fig 3.2 Process Flow Chart for 0.6 MTPA Pellet Plant









Major equipment and facilities: The Pelletizing Plant will mainly consist of the followingsections:

A. Iron ore fines storage and handling Grinding

B. Filter press

C. Storage & handling of Filter cake, Binder and Additive

D. Proportioning and Mixing

E. Balling, Induration and Cooling

F. Finished Product Storage

Iron ore fines storage

In coming Iron ore fines will be stored in storage yard.

Grinding Section

At the storage yard the Iron Ore Fines are charged into a hopper which transfers the material to

the ball mill through a conveyor. In the ball mill the incoming iron ore fines which is of -6mm is

grinded (with water) to 45 micron. This material goes to a screen, where 45 micron goes to the

Thickener & +45 micron material goes back to the ball mill. The capacity of the Ball Mill is 100

TPH. The material from the Thickener goes to the Filter Press through an Agitator.

Filter Press

In the Filter Press the moisture is taken out and cakes are formed. The cakes formed can be

directly taken to the Proportioning bins or can be stored in the storage shed.

Proportioning System

There are five bins in the Proportioning building. Two bins for Iron Ore concentrate, one bin for

Bentonite, one bin is for coke and one bin for limestone. Under the bins are belt conveyors and

belt weighers. From these bins required quantity of materials are transferred to the mixture

machine & in Mixture machine iron ore cake, Bentonite & limestone are properly mixed.

Pelletizing Section

The blended materials shall be carried by a belt conveyor to the upper portion of the Pelletizing

building and discharged into two blending bins separately. The blending bin is equipped with a

1.0 meter wide conveyor along with belt weigher from where the material is fed to the

Pelletizing disc, whose speed and tilting angle are both adjustable. Green balls are then

produced & are collected by a belt conveyor and transferred to the system of green ball

screening and distribution.





B. Filter press







Grinding Section






Filter Press








Pelletizing Section











B. Filter press







Grinding Section






Filter Press








Pelletizing Section









Green Ball Screening & Distribution System

It consists of Oversize Roller Screen, Wide belt conveyor, Roll distributor and Belt conveyor

returning fines. The Green balls passes through Over size Roll Screen where the over size (+16

mm) Green balls are separated & collected by a belt conveyor to be conveyed back for reuse.

The under sized (-16 mm) is conveyed by a Wide belt conveyor to the Roller conveyor. In the

Roller conveyor -6 mm are separated & +6 mm to -16 mm is passed on to the Indurating Kiln &

the under sized Green balls (-6 mm) is collected by a belt conveyor & conveyed back to the Disc

Pelletizer.

Induration

The Pellet Induration system mainly consists of three major equipments: Traveling Grate, Rotary

Kiln and Annular Cooler.

Traveling Grate

It consists of Drying and Pre-heating. The main heating source in the drying zone is the waste

gas from the cooling zone and partially from the hot gas from the pre-heating section. The main

heating source in the pre-heating zone is the waste gas from the Feed End of the Rotary Kiln

with temperature of 11000C. Temperature in the Grate for Drying is maximum 9500C to10500C.

Rotary Kiln:

After Pre-heating, the Pellets are discharged to the Rotary kiln where the roasting is done.

Pellets receive heat in the Rotary kiln evenly as Pellets are roasted while rotating. The

temperature in the Rotary kiln is maintained at 1100 to 12500C. Rotation speed of the kiln can

be regulated in accordance with different material so as to determine its retention time and to

determine the quality of Pellet. Discharge end of the kiln is equipped with specially designed

Burner. The Burner can use either Liquid fuel or Producer gas for thermal energy.

Annular Cooler

Hot Pellets with temperature of around 12500C are discharged to the Annular Cooler. Normal

cooling time in the Cooler is 45 to 50 minutes. Cooling of the hot Pellets is done by air from

number of Blowers. Hot gases from the Cooler are recycled back to the Rotary kiln and the

Traveling grate for use.

Finished product handling and storage

The hardened and cooled Pellets will be screened for removal of any -6 mm Pellets generated

during transfer. Undersize material from the screen will be recycled to the plant. The +16 mm

Pellets obtained as oversize fraction of the screen will be conveyed and stacked in a ground










Pelletizer.

Induration



Traveling Grate





Rotary Kiln:







Annular Cooler


















Pelletizer.

Induration



Traveling Grate





Rotary Kiln:







Annular Cooler











stockpile. The same would be reclaimed and dispatched along with the sized product by

conveyor system by conveyor system to the Pellet silos for loading into trucks.

Core Equipment Brief Description

Ball Mill

There are two sets of φ 3.6 X 7.5 mtr Ball mills. Iron ore fines are conveyed into the Ball mill by

belt conveyer. In the Primary Ball mill Iron Ore fines is ground off to 45 micron If required a

secondary Ball mill may be considered for grinding up to 45 micron.

Filter Press

In Filter Press building, there are number of Filter Press Machines. Iron ore slurry materials are

injected to the filter press by Slurry pumps. Iron ore fines are separated from water & Iron ore

fines cakes are formed. Size of the Filter Press is 250M2 discharge 17 T & cycle time is 30

minutes.

Proportioning

There are five bins in proportioning building. One for Bentonite (Capacity: 100 T), one for lime

stone (Capacity: 5 0T), one for coke (Capacity: 100TPH) and two for iron ore (Capacity: 100 T).

Under iron concentrate bins there are belt conveyers and belt weighers. The Bentonite bin is

equipped with a sensor detecting bin level and commanding the operation of material supply

system and therefore the proportion ratio to be set, controlled and regulated automatically.

Bentonite to be transferred into the bin pneumatically, once it is full then transferring pump will

stop. Under bentonite bin there is a variable speed screw feeder and adding dosage of

bentonite is 2% of the concentrate.

Mixer machine

In the Mixer machine Iron ore concentrate, Bentonite, Coke & Limestone are properly mixed.

The capacity for mixer machine is 100 TPH.

Pelletizing Disc

The blended materials shall be carried by a belt conveyer onto the upper part of the pelletizing

building and discharged into 3 blending bins separately, the effective capacity of which is 55M3

for each and under which there are 3 X φ6.0mtr. Disc Pelletizers with capacity of 50 TPH each.

The blending bin is equipped with a 1.0mtr. wide conveyer along with belt weigher from where

the blended materials to be fed onto pelletizing disc, whose speed and tilting angle are both

adjustable.






Ball Mill




Filter Press




minutes.

Proportioning









Mixer machine



Pelletizing Disc






adjustable.






Ball Mill




Filter Press




minutes.

Proportioning









Mixer machine



Pelletizing Disc






adjustable.



Water shall be added during Pelletizing process to ensure the optimal moisture in the mixture.

Green balls formed in the Pelletizing disc are collected by a belt conveyer and transferred to the

system of green ball screening and distribution.

Over size / under size roller Screen

Green balls are collected on a conveyor and transferred to green ball screening and distribution

system. It consists of Over/Under size Roller Screen, Wide belt conveyor, Roller distributor and

Belt conveyor returning fines. The gap of the roller screen is adjustable. The over size (>16 mm)

green balls are collected by a belt conveyor and conveyed back to be reused for balling while

the undersized (<16 mm) are conveyed by the wide conveyor to the roller screen. The speed of

the wide conveyor is -regulated by a frequency modulator. The Roll Screen separates the small

balls of <6mm and at the same time distributes the balls of +6 to -16 mm on to the traveling

grate. The undersized green balls (<6mm) are collected by a belt conveyor and conveyed back to

Disc Pelletizer.

Traveling Grate




with temperature of11000C.

Rotary Kiln






Burner. The Burner can use either Liquid fuel or Producer gas for energy.

Annular Cooler


cooling time in the cooler is 45 to 50 minutes. Cooling of the hot Pellets is done by air from



Dust abatement facilities

The Pelletizing plant comprising various process units, accessories and handling facilities will be

provided with adequate dust suppression and dust extraction facilities to restrict the particulate

emission level within acceptable limits i.e. 50 mg per N cum. The systems will consist of water















Disc Pelletizer.

Traveling Grate





Rotary Kiln







Annular Cooler























Disc Pelletizer.

Traveling Grate





Rotary Kiln







Annular Cooler











spraying facilities, mechanical gas cleaning equipment, dust recycle arrangement and exhaust

stack. Exhaust gas from drying and grinding system will be cleaned using fans, dustings, suction

hoods, cyclones, bag filters, ESPs etc. as applicable. The indurating furnace gas will be made to

pass through electrostatic precipitator (ESP) before being released to the atmosphere. Dust

content in the work zone shall be limited to 5mg/Nm3 over and above the prevailing dust level.

Filtered air supply system has been envisaged for MCC rooms and basements to supply

adequate fresh air to stagnant air zones. The control rooms will be air-conditioned.

The system will be designed in such a way that no solid waste will be discharged outside the

system, the solid waste that is the dust generated in the system will be recycled back to the

system itself.

3.5.1.5 Output of product pellet

The chemical analysis of the pellet computed on the basis of qualities of raw materials and

additives as well as the specific consumption indicated above, works out as given in following

Table:

Expected Chemical Analysis of Pellet

Fe : 64.0%

SiO2 : 3.3 to 3.4%

Al2 O3 : 2.2 to 2.25%

The desired physical and metallurgical characteristics of the pellet to be produced in the

plant are given in following table

Some of the Desired Characteristics of Product Pellet

Property ValueSize distribution+16 mm : 5% max-16 +6 mm : 92%min-6 mm : 3% maxCompressive strength : 230 kg/pelletTumbling index+6 to -16mm : 92%

It is suggested that attainment of the above properties should be ensured by adopting

appropriate process parameters established through necessary test work before

implementation of the project.












system itself.




Table:


Fe : 64.0%

SiO2 : 3.3 to 3.4%

Al2 O3 : 2.2 to 2.25%



















system itself.




Table:


Fe : 64.0%

SiO2 : 3.3 to 3.4%

Al2 O3 : 2.2 to 2.25%










Table 3.3 COMPARISON OF QUALITIES OF BF & DR GRADE PELLETS

CHEMICAL PROPERTIESBF GRADE DR GRADE

PARAMETER SPECIFICATIONFe(t) Below 65% 66.5%

SiO2 + Al2O3 5% Max 3.10% MaxNa2O 0.05% Max 0.05% MaxK2O 0.05% Max 0.05% MaxTiO2 0.10% Max 0.10% MaxMn 0.10% Max 0.10% MaxP 0.04% Max 0.04% MaxS 0.02% Max 0.02% MaxV 0.05% Max --

Basicity (CaO/SiO2) 0.4-0.5 0.5

Moisture (free moisture loss at105 ºC)

4% max (fair season),6% max (monsoon)

4% max (fair season), 6% max(monsoon)

PHYSICAL PROPERTIES

BF GRADE DR GRADEScreen Analysis Specification Screen Analysis Specification-16mm +9mm 85% Min +19mm 5% Max

-9mm,+6.35mm 7% Max -16mm,+9mm 85% Min-5mm 3% Max -9mm,+5mm 5% MinTumbler text (ASTM) -5mm 3% Max

Tumble Index (+6.35mm) 94% Min Tumbler text (ASTM)

Abrasion Index (+0.6mm) 5% Max Tumble Index (+6.35mm)

94% Min

METALLURGICAL PROPERTIES

ParameterSpecification

BF GRADE DR GRADESwelling (JIS) 18-20% Max 20% Max

Compression strength 250 kg/pellet 250 kg/pellet MinPorosity 25% Min 18-25% Min

Reducibility (JIS) 70% Min 70% MinNote: Above is indicative specification only

3.5.1.6 Receipt, unloading & storage of materials

It is envisaged that the Iron Ore fines from storage yards will be carried out by front-end-loader

(FEL) and then the same will be delivered by tippers/trucks of appropriate size for onward

discharge into the plant head receiving hopper. This operation is planned to be taken care by

KIPL or their outsourced agency separately. The battery limit of proposed plant has been

considered from the said receiving hopper onwards.

For limestone, the requirement being in the tune of 18000 tons per annum, the annual

procurement has been considered in several consignments according to the available storage

facility in the Pellet plant. However the said volume will be procured by road logistic from Joda-











PHYSICAL PROPERTIES





94% Min

























PHYSICAL PROPERTIES





94% Min

















Barbil sector of Keonjhar district of Odisha by trucks & shall be stacked in desired stock pile

height of 2.5 mtr.

The other raw material for Pellet plant viz. Bentonite will be transported from their respective

sources and will be received at the Pellet plant by road and stored in the stockpile area

earmarked in the yard (in the pellet plant) in desired stockpile height of 2.5 m through

outsourcing by KIPL.

The storage details of major raw materials are given in Table below:

Table 3.4 Storage Details of Major Materials

Sl. No. Materials Stocking areaL(m) x W(m) x H(m)

Stock quantityNo. of days

1. Ore fines 130 x 130 x 5 152. Bentonite 20x10x2.5 213. Limestone 20 x 10 x 2.5 214. Coke 20x10x2.5 215. Pellet 100x50x2 10

Reclaiming and subsequent dispatch of raw materials to consuming units:

Pellet plant

From Mines, iron ore fines will be carried to plant by tippers. The iron ore fines will stored in a

covered shed & the same shall be loaded by front-end-loaders and transported through tippers

(front-end-loaders and tippers outsourced) to the designated stockpile located inside plant

boundary and having around 15 days' storage capacity. The scheme stated above will be taken

up separately by KIPL and an outside agency will be engaged to carry out the same. Front-end

loader shall be used for reclaiming ore fines from the stockpile and discharge the same to a

reclaim hopper and finally transport to the pellet plant through a conveyor. Lime stone

unloaded manually by outside agency at the side of the designated railway track. From railway

siding, the same shall be loaded by front-end-loaders and transported through tippers (front-

end-loaders and tippers outsourced) to the designated stockpile located inside plant boundary

and having around 15 days' storage capacity. The scheme stated above will be taken up

separately by KIPL and an outside agency will be engaged to carry out the same. Front-end

loader shall be used for reclaiming limestone from the stockpile and discharge the same to a

reclaim hopper and finally transport to the pellet plant through a conveyor. Bentonite shall be

reclaimed from the stockpiles by loader and discharge onto the reclaim hopper for onward

transportation to the pellet plant by a conveyor.

Product pellet




height of 2.5 mtr.











Pellet plant

















Product pellet




height of 2.5 mtr.











Pellet plant

















Product pellet



The product pellet shall be stored through a set of conveyor belts and a non-slewable luffable

stacker. The product pellet shall be reclaimed by a reclaimer and transported to the Wagon

Loading House for loading the same to the wagons. In the Wagon Loading House a set of

conveyors and bins are there for loading product pellet on to the wagons. BOXN types of

wagons have been considered for Pellet dispatch due to space constrain. Review shall be

required for use of wagons other than BOXN type for product Pellet dispatch. It has been

envisaged that total cycle time for loading of a rake of product Pellet shall be five (5) hours.

Weighing has been envisaged through belt scale mounted on the conveyor in the Wagon

Loading House. Metal detectors, DE/ DS system and belt scales will be provided in the system as

per requirements. Hoist will be provided at Junction houses.

3.5.2 PRODUCER GAS PLANT PROCESS

3.5.2.1 GASIFICATION

Gasification is a major & unique element in the development of advance, improved, renewable

energy systems. It is a thermo-chemical process that converts solid coal/bio-coal to a low heat

valve (LHV) gaseous fuel called “producer Gas”. This producer gas is fuel for many different

applications of shaft power or electricity in the equipment like, IC engines, furnaces, kilns dryers,

rolling mills and heat treatment equipment.

3.5.2.2 GASIFICATION PROCESS

The different zones inside the reactor (Gasifier) are clearly shown in the below diagram:

Fig 3.3 Section Diagram of Gasfier















































3.5.2.3 ADVANTAGES OF PYROLYTIC GASIFIER WITH EXTENTED SHAFT OVER CONVENTIONAL FIXED

SHAFT

The produced gas generated in Pyro-Gasifier has higher Calorific Value in the range of 1000-

1400 K.Cal/NM3 which is suitable for getting high flame temperature in the range of 1200-

1400°C as required by most of the thermal processes.

The efficiency of the Pyro-Gasifier is higher by 10-20% than the conventional Gasifier, so to

result in reduction of coal consumption

Tar Content in the gas by pyro-gasification is minimal as the gas temperature is @150°C,

thus delivering gas of higher calorific value to result in higher gasification efficiency and

lower coal consumption rate.

Due to cleaner gas, the chocking and cleaning of the burner and duct pipes is low, which

results in lower down time and increase in productivity and lesser interruptions in the

Process.

Due to consistency of gas quality lesser gas control actions are necessary.

Wide varieties of the coal can be used.

3.5.2.4 FEATURES & ADVANTAGES The Coal Gasifier system is capable of gasifying several types of solid fuel such as Charcoal,

Imported Steam coal, Briquettes at high efficiency.

Minor traces of SC /NOX formation due to low gasification & low flame temperature.

There is no effluent output in the process. The washing of gas is done with hot (70-80° C) re-

circulated phenol water which separates out the Tar in liquid form like FO which can be

burnt in the furnace for giving extra energy to combustion.

Extremely Low Particulates and smoke emission due to the complete direct firing of

Producer Gas & much lesser than prescribed by the PCB.

Much lesser heat losses in flue gases as compare to solid /liquid fuels firing,

Worldwide accepted environment friendly Renewable Energy technology,

Very low Payback period.

Worldwide accepted environment friendly Renewable Energy technology.


3.5.2.5 TECHNICAL SPECIFICATION

Complete up-draft Gasifier system for your thermal application;

COAL GASIFIER SYSTEM (Gas Volume: 5000 Nm3 /hr)

Model : RREDA-P-8000

Installed capacity (Thermal) : 8000 Kilowatts

Thermal Output : 7,425,000 KCal/Hr.

Liquid Fuel Replacement capacity : 500 - 600 Liters/Hr.




SHAFT











Process.


























SHAFT











Process.

























Note: For this project total requirement of 20000 Nm3/Hr of Gas, 4+1 nos.of 5,000 Nm3/Hr.

moduIes of Producer's Gas Plant is selected.

SOLID FUEL CONSUMPTION RATIO (Approx)

Steam Coal - B Grade : 3.00 Kg/Litter Liquid Fuels

Steam Coal - C & D Grade : 3.50 Kg/Litter Liquid Fuels

Steam Coal - Imported : 2.50 Kg/Litter Liquid Fuels

Bio-coal / Briquette : 4.00 Kg/Litter Liquid Fuels

Wood Coal/Charcoal : 1.75 Kg/Litter Liquid Fuels

Wood : 4.00 Kg/Litter Liquid Fuels

SOLID FUEL DATA

Solid Fuel Size : 20-70 mm

Moisture content : < 15 %

Ash content : Up-to 25%

3.5.2.6 CHEMICAL COMPOSITION OF PRODUCER GAS (Approx.)

The Gasifier can convert any type of coal into Producer Gas. The chemical composition of Producer Gas

is as under;

CO (Carbon Monoxide) : 20 ±2%

CH4 (Methane) :03±l%,

H2 (Hydrogen) :18±2%

CO2 (Carbon Dioxide) : 10±2%

N2 (Nitrogen) : Rest

Characteristic of Producer Gas (Approx.)

Calorific value of Producer gas

3.5.3 Plant Layout

The layout of the plant will be developed taking into following considerations:

Process departments will be consolidated into comprehensive production units requiring short

conveying distances;

The major utilities and service facilities will be centrally located in respect to points of high

consumption;

Sufficient space will be provided for ease of operation and maintenance;

The lengths of power cables will be minimized by suitably locating load distribution centres in

respect of process departments;

Outward movements of materials from customers/suppliers will be segregated from internal

plant traffic












SOLID FUEL DATA






is as under;








3.5.3 Plant Layout





consumption;





plant traffic












SOLID FUEL DATA






is as under;








3.5.3 Plant Layout





consumption;





plant traffic



Sufficient space for storage of raw materials and finished products.

Green belt will be provided.

Rainwater harvesting pond will be provided at lowest elevation to collect surface run-off to

maximum possible extent.

Adequate area will earmark for tailings and ash disposal.

Weigh Bridge and administrative block will be located at the entrance.



















Fig3.4 Plant Layout



Fig3.4 Plant Layout



Fig3.4 Plant Layout



3.6 Plant and Machinery Source

All plant and machinery will be sourced through globally reputed and proven suppliers having

vast experience of supply of various equipments required for the steel Industry. All equipment

will incorporate the latest state of the art design and technology, eco friendly and will conform

to global standards of workmanship.

Taking into account, reliability of equipment and matching capacities between the different

sections of the plant, the type of equipment/ installation system and the departmental

capacities at the plant, have been arrived at.

3.7 Raw Materials Requirements


SlNo.


A. Pellet Plant

1 Iron OreFines

6,48,000 Odisha (KJS Ahluwalia, RP Sao, Mesco Steel,Kalinga Mining)

Road/Rail


3 Coke 18,000 Rourkela Road/Rail




Total 7,50,000

NOTE: Based on the following operating days/year: 330 days and 24 hrs/day for pellet plant Fuel

oil will also be required to start-up the rotary kiln and for emergency requirements in the kiln,

flushing of LSHS pipelines etc. Light diesel oil (LDO) conforming to IS: 1460 has been

considered for this purpose. The estimated requirement of LDO during start-up of the kiln and

others will be about 5 KL per day. For meeting the above requirements, suitable capacity bulk

oil storage tanks and day oil tanks are proposed along with unloading and distribution pumps.

3.8 Water and Power Requirement

3.8.1 Water Requirement

Water is required in Pelletizing plant for various equipments cooling as well as wet grinding. In

addition, it is required for drinking and sanitary purposes of working personnel, laboratory,

workshop, office etc. and also for fire fighting and other miscellaneous purposes. Water is also

required for dust suppression of stockpiles of raw materials and also at junction houses to abate

dust nuisance. On study of the various systems, supporting facilities and the corresponding flow













SlNo.


A. Pellet Plant

1 Iron OreFines


Road/Rail






Total 7,50,000


























SlNo.


A. Pellet Plant

1 Iron OreFines


Road/Rail






Total 7,50,000
















figures, it is estimated that the total make-up water requirement for the proposed iron ore and

pellet plant will be around 15M3 per hour. Estimated break up of makeup water quantities is

given in following table.

Table 3.6 Water Requirement

Description Make up water (m3/hr)

Pellet Plant process make-up 4.9

Producer Gas Plant 1.6

Cooling Tower make-up 3.5

Dust Suppression 1.5

Drinking water and Sanitation water for Plant 1.0

Landscaping, greeneries, environmental requirements 1.0

Raw water treatment & conveyance losses 1.0

Fire Fighting 0.5

TOTAL 15.0

The above water requirement will be made from an intake of 4 m3/hr River Baitrani and

remaining 11 m3/hr from ground water source on continuous basis, located at about 0.2 km

away from the proposed site. The static level difference between Plant site and River Baitrani is

approximately 200 mtr.















Fire Fighting 0.5

TOTAL 15.0



















Fire Fighting 0.5

TOTAL 15.0







Fig 3.5 WATER BALANCE

3.8.2 Power Requirement

The estimated power requirements of the plant including utilities and auxiliary facilities are

as follows:

Annual energy consumption : 40 million kWh

15-minute maximum demand : 5 MW

(Considering 0.8 Power Factor)

1-Minute peak demand : 5 MW

Characteristics of plant loads

The loads of the proposed plant will be more or less steady in nature with little variation in load

factor depending on the process requirement.

Source of power


station of OPTCL at Palaspanga. For that promoter has already approached OPTCL and

NESCO authorities. Further the promoter will have the DG sets to meet the emergency power

requirement.






as follows:








Source of power




requirement.






as follows:








Source of power




requirement.



3.9 Pollution Control Measures

3.9.1 Air Environment – Mitigation Measures

Suitable extraction & cleaning system are required to be provided to maintain work zone dust

as well as stack emission to the desired level as follows:

Stack emission :100 mg/Nm3 (Max)

Work zone :Dust content in the work zone shall be limited to 5 mg/Nm3over and

above the prevailing dust level.

The scheme proposed for dedusting and prevention of air pollution are as follows:

i) Extraction of waste gases from the indurations plant after necessary utilization/recovery

of heat in the preheat zone and discharging them to the atmosphere through stack after

cleaning:

Dry type electrostatic precipitators have been envisaged for this system as a part of the

respective plant package. The dust laden air shall be sucked through ductwork and then

cleaned in an Electrostatic Precipitator (ESP) before discharging to the atmosphere

through a fan and self supporting stack.

ii) Extraction of dust for raw material processing area viz. drying, ore grinding, pulverizing

units and other dust generating units as required.

Suitable type and capacities of bag filters have been envisaged for this dedusting system as a

part of the respective packages. The dust laden air shall be sucked through hoods and ductwork

and then cleaned in a bag filter before discharging to the atmosphere through a fan and exhaust

duct/stack.

Electrostatic precipitator and bag filters will be selected based on dust content, moisture

content in gas and gas analysis at the inlets normally encountered for the respective units. The

selection will also consider the dust resistance, dust chemistry, volume of gas to be cleaned and

its temperature and suction flows in the network (normal and maximum).













cleaning:










duct/stack.

















cleaning:










duct/stack.







Table 3.7 Source of air pollution and control measures

Section Source of PollutionAir pollution

controlMeasures

Capacity of APCDevice (M3/hr)

Stack Height(M)

Pelletplant

Raw material Handling(Normally transfer for bunker)

Bag Filter 20000 30

Coke grinding Bag Filter 10000 30

Proportioning system Bag Filter 15000 30

Induration furnace &Traveling Grate kiln

ESP 360000 60

Finished product Handling Bag Filter 15000 30

3.9.2 Water Environment – Mitigation Measures

In the pellet plant there will be no effluent generation from the process. Water will be used in to

maintain moisture in pellets. Further major water will be used for equipments which will be

completely recycled with make-up water. From scrubber waste water will be taken to setting

tank and recycled with makeup water in a closed circuit. Waste water generated from pellet

plant is depicted below.

Table 3.8 Waste Water Generation and Reuse

ProcessUnit

Waste waterqty (m3/day)


Waste water management

Pellet No wastewatergeneration.Cooling waterwill becompletelyrecycled.

Cooling High Temp Complete recirculation


9.5

14.5

Backwashfromfiltration unitUnderflow ofclarifier

TSS

TSS

Will be treated in settlingtank and taken to guard pondfor reuse

Domestic 19 Domestic usefrom plant


Will be treated in STP andreused for greenbelt

ProducerGas plant

2.50 Gas cleaningsection Phenol,Ammonia,Cya

nide,BOD,COD

Will be treated is ETP andtreated water used in dustsuppression and greenbelt.





controlMeasures


Stack Height(M)

Pelletplant


Bag Filter 20000 30




ESP 360000 60









ProcessUnit







9.5

14.5


TSS

TSS





ProducerGas plant


nide,BOD,COD






controlMeasures


Stack Height(M)

Pelletplant


Bag Filter 20000 30




ESP 360000 60









ProcessUnit







9.5

14.5


TSS

TSS





ProducerGas plant


nide,BOD,COD




Raw Water Treatment

The raw water from the river will be suitably treated in water treatment units like clarifier &

filtration unit as per the requirement for cooling process & other requirements.

Waste water treatment

Waste water from RWTP in form of Back Wash will be treated in settling pond and reused in

dust suppression.

STP is proposed to treat the domestic waste water. The treated water will be used for green belt

development, dust suppression etc. the STP sludge will be used as manure for green belt

development.

The project will have its inbuilt system for reuse and recycle of water in the process. Thus, water

requirement from the river will be minimum.

3.9.3 Solid Waste Management

Proposed Plant will generate the following solid wastes from different production processes and

the respective management plans are mentioned against each heads.


Sl.No.

Units Solid Wastes Qty InTPA

Disposal practice

1 Pellet plant Dust from APCdevices

350 Reused in pellet making

Broken Pellet 6602 Raw water treatment

plantSludge 6 Will be used for landscaping

3 Producer Gas Plant Bottom Ash 10000 Will be used in filling low lyingareas.

Table 3.10 Domestic Solid Wastes

Units Solid Wastes Qty In TPA Disposal practiceSTP STP Sludge 2 Will be used as manure for

landscapingCanteen Garbage and food

waste12 Organic and inorganic portion of waste

will be separated, organic waste willbe vermin composted and used forgreenbelt development. Inorganicportion will be given to scrap dealer.



Raw Water Treatment





dust suppression.



development.







Sl.No.


Disposal practice













Raw Water Treatment





dust suppression.



development.







Sl.No.


Disposal practice













Table 3.11 Hazardous Wastes

Hazardous Wastes Quantity Hazardous Wastes Management

Used Oil and Lube Oils 1.0 KL/Annum Collected used oil will be stored on close drums andwill be disposed to authorized re-processors.

Used Oil Filters 30-40 Nos./Annum The used oil-filters are considered a hazardouswaste. The same will be disposed as per hazardouswaste management and handling Rules, 1989 andamendment thereof.

Oily sludge 1.0 TPA Disposed as per hazardous waste management andhandling Rules, 1989 and amendment thereof.

3.9.4 Noise Levels

The major noise prone equipment’s are product screening through crushing, milling, separators,

compressors etc. The noise control will be done in four ways, namely by selecting low noise

prone equipment which would have led level below 75 dB (A) at 1 meter distance;

By selecting low noise generating equipment, which would have below 75 dBA at 1m

distance. This is taken care at the equipment design stage.

By isolating the noise unit from the working personnel’s continuous exposure by

providing acoustic aids for plant personnel.

By administrative & safety measures, providing noise level monitoring, remedial

measures, providing noise safety appliances.

The noise impact on the surrounding environment during the construction phase will be

within acceptable limits. The operation of high noise generating equipment shall be

restricted during the night time.

Various measures proposed to reduce noise pollution include reduction of noise at

source, provision of acoustic lagging for the equipment and suction side silencers,

selection of low noise equipment and isolation of noisy equipment. The plant personnel

in noisy area will be provided with high noise reduction aid such as ear muffler & also the

duration of exposure of the personnel will be limited as per the norms.

Thick green belt development is planned for the attenuation of noise pollution and to maintain

ambient noise quality within the statutory limit.








3.9.4 Noise Levels



























3.9.4 Noise Levels






















3.9.5 Green Belt Development

A greenbelt development plan will be prepared and implemented along with the project.

The main objective of the greenbelt is to provide a barrier between the plant and the

surrounding areas. The greenbelt helps to capture the fugitive emissions and to attenuate the

noise generated in the plant apart from improving the aesthetics of the plant site.

The Greenbelt provided will be 33% (6.49 Ac) of total area 19.62 Ac and will have a suitable

density so as to mitigate the effects of emissions from the plant. The treated effluents from the

plants will be utilized for the greenbelt development.

The landscaping of the plant will be carried out. Roads for vehicular movement will be paved

and adequate mitigation measures will be provided to prevent fugitive emissions.

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE INFORMATION OFEIA PURPOSE.

Fig 3.6 Schematic Representation































CHAPTER-04

SITE ANALYSIS

4.1 General

The proposed site is located at Vill-Champadihi in Keonjhar district of Odisha. The site is at about

35 km away from nearest town Keonjhar. The national highway NH-215 (in eastern side) is runs

at 9.5 km from the site respectively. Nearest airport is at Bhubaneswar, 185 Km from proposed

project site in its Southern side. Nearest river, Baitrani, is 0.2 Km away from the site. About

19.62 acres of land is available in this area of proposed site.

4.2 Connectivity

Road






Rail Linkage


Joda area and is only 6 km away from the project site.

Port

The Paradeep port is the nearest port for this plant site, which is about 216 km away. Nearest

airport, Bhubaneswar, is at 185 Km away from the site.

4.3 Topography

The topography of the proposed land is generally flat and well suited for development of

industrial projects.

4.4 Existing Land Use Pattern

Land of the proposed project is devoid of any vegetation. Plant is not coming under the dense

forest category land. This area does not form part of any National Park, Wild Life Sanctuary and

Natural/Biosphere reserve.

4.5 Existing Infrastructure

Land

Total land requirement for the proposed unit is about 19.62 acres.

Utilities



CHAPTER-04

SITE ANALYSIS

4.1 General






4.2 Connectivity

Road






Rail Linkage



Port



4.3 Topography








Land


Utilities



CHAPTER-04

SITE ANALYSIS

4.1 General






4.2 Connectivity

Road






Rail Linkage



Port



4.3 Topography








Land


Utilities



A. Power


station of OPTCL at Palaspanga. Further the promoter will have DG sets to meet the


B. Water


m3/hr from ground water. This will be sufficient for the present requirement. Further the River

Baitarani is passing very close to the site. Further the promoters have the plan to harvest the

rain water for efficient use of it.

Transport

The plant site is well connected by road NH-215 is at 9.5 km from the proposal plant site.

Nayagarh in Joda area is the nearest board gauge (BG) railway station at about 6 km away from

the proposed plant site.

Communication

Communication facilities such as telephone, tale fax and internet are available in Keonjhar

(Sadar), which is the block headquarter situated near the plant site.

Habitation

Nearest habitation is in village Champadihi, 0.8 Km from the site. The area is sparsely populated.

All basis amenities such as school, hospital, market, etc. are available in 10 Km area.

4.6 Climate Data

Temperature

The climate of the district is characterized by hot summer with low humidity. Summer generally

commences in the month of March. Temperature begins to rise rapidly attaining the maximum

in the month of May. During the summer maximum temperature is 38.20 C. The weather

becomes more pleasant with the advent of the monsoon in June and remains as such up to the

end of October. The temperature in the month of December is lowest i.e. 11.70 C. Sometimes it

even drops down to 70 C. The average annual rainfall is 1534.5 mms.

Rainfall

More than 76 percent of the annual rainfall occurs during monsoon in the period from June to

October. Average annual rainfall is 1534.5 mms.



A. Power




B. Water





Transport




Communication



Habitation



4.6 Climate Data

Temperature







Rainfall





A. Power




B. Water





Transport




Communication



Habitation



4.6 Climate Data

Temperature







Rainfall





Table 4.0 Weather Analysis Report

WEATHER ANALYSIS REPORT

MonthMean daily

max temp in °C

Mean daily

min. temp in °C

Relative Humidity

0830 1730

( in IST )

January 25.4 11.7 62 51

February 28.3 14.4 59 43

March 33.2 18.6 51 36

April 36.9 22.7 53 41

May 38.2 24.6 56 42

June 34.2 24.7 70 65

July 29.7 23.1 82 80

August 29.6 23.6 83 81

September 29.8 22.5 82 81

October 29.2 20.2 77 70

November 27.0 14.8 64 55

December 25.1 11.7 63 54

Annual 30.5 19.4 67 58





MonthMean daily

max temp in °C

Mean daily

min. temp in °C

Relative Humidity

0830 1730

( in IST )

January 25.4 11.7 62 51

February 28.3 14.4 59 43

March 33.2 18.6 51 36

April 36.9 22.7 53 41

May 38.2 24.6 56 42

June 34.2 24.7 70 65

July 29.7 23.1 82 80

August 29.6 23.6 83 81

September 29.8 22.5 82 81

October 29.2 20.2 77 70

November 27.0 14.8 64 55

December 25.1 11.7 63 54

Annual 30.5 19.4 67 58





MonthMean daily

max temp in °C

Mean daily

min. temp in °C

Relative Humidity

0830 1730

( in IST )

January 25.4 11.7 62 51

February 28.3 14.4 59 43

March 33.2 18.6 51 36

April 36.9 22.7 53 41

May 38.2 24.6 56 42

June 34.2 24.7 70 65

July 29.7 23.1 82 80

August 29.6 23.6 83 81

September 29.8 22.5 82 81

October 29.2 20.2 77 70

November 27.0 14.8 64 55

December 25.1 11.7 63 54

Annual 30.5 19.4 67 58



CHAPTER – 05

PLANNING BRIEF

5.1 Planning Concept

M/s Kashvi International Private Ltd proposes to setup an Iron ore pellet plant of capacity 0.6

Million ton/annum & 5 Nos. (4w + 1s) Producer Gas Plant of capacity 5000 Nm³/hr each. High

grade iron ore fines will be used in 0.6 MTPA of Pellet making. Iron ore pellet produce will be

sold to integrated steel plant for utilization in blast furnace and DRI for production of pig iron

and sponge iron.

As the nearest railhead is within 10 kms and NH-215 is within 10km from the site, the

transportation of both raw material as well as product will depend on the roads and rail. As the

site is almost at the confluence of two major national highways, road transportation will not

cause much problem. Existing road connection from the plant site to the NH will be utilized for

material transportation.

Plant should be provided with following facilities:

Transportation facility shall be provided to the executives.

An ambulance shall be provided for the emergency.

Qualified doctor shall be engaged for the regular health check up.

Drinking water and electricity facilities shall be provided.

Greenbelt shall be developed in and around the plant.

Canteen shall be provided with all facilities.

Separate sanitary facilities shall be provided.

5.2 Population Projection

With the set up of proposed project infrastructure and social development will simultaneously

takes place. Project will contribute for raising the population of the locality as it creates job

opportunities and economic upliftment of the area. The company is providing employment to

100-200 persons during construction phase and 93 persons during the operation period of the

proposed project Plant activities will also boost the ancillary industries, business and market

establishments. The whole set will invite both skilled and unskilled from outside. This will result

in increase in the population density due to industry.


Following is the break-up of the land use of the project site/area:



CHAPTER – 05

PLANNING BRIEF






and sponge iron.


























CHAPTER – 05

PLANNING BRIEF






and sponge iron.


























Table 5.0 LAND USE BREAK-UP

Sl. No. Description Area in acre

1. Plant Built-up 5.5

2. Auxiliary facilities 0.76

3. Admn. Building, Offices, Lab, Canteen & First Aid 0.22

4. Roads 2.60

5. Solid waste Disposal Area 1.0

6. Raw material & Product Storage Yard 1.55

7. Water Storage & Rain water harvesting pond 1.5

8. Greenbelt 6.49

Total 19.62

5.4 Amenities & Facilities

To render the necessary repair & maintenance, inventory, quality control related and

administrative services for the proposed pellet plant with slime and associated facilities,

following auxiliary facilities have been considered inside the plant boundary.

Laboratory: Taking into account the quality assurance of iron ore slimes and pellets, it is

proposed to install a laboratory. The role of the laboratory is to carry out physical and

chemical testing of samples. A laboratory will be set up in a building along with the plant

control room located in close vicinity of the plant. Tests will be carried out in the laboratory to

determine physical and chemical properties of the samples as a part of the quality control

activities. The laboratory will be equipped with the sample preparation facilities and testing

devices.

Repair and maintenance shop: It is proposed to set up a local repair shop equipped with

facilities for machining, fabrication, assembly, electrical repairs, instrument calibration/repair

etc. A mobile crane of 10 ton capacity will also be provided for dismantling and mounting of

component assemblies and sub-assemblies of equipment.

Stores: A single-bay building will keep equipment spares, hardware, wearing parts and

consumables. A strong room for keeping valuable item, offices for inventory control, material

receipt section, toilet etc will be suitably provided.

Plant office: An office building will be constructed inside plant premises. The office building will

be complete with separate toilet, conference rooms, computer room, separate executive's room

and other facilities like record maintenance, printing, scanning etc.

Ancillary buildings:

Besides the auxiliary facilities other ancillary buildings with necessary facilities such as canteen,

time office & security offices etc. will also be provided.








4. Roads 2.60




8. Greenbelt 6.49

Total 19.62











devices.





















4. Roads 2.60




8. Greenbelt 6.49

Total 19.62











devices.
















Canteen: A canteen building will be set up near the plant office and a suitable external agency is

proposed to be engaged to service snacks and refreshments to the workers, supervisory and

office staff working in the different plants/facilities and other working area.













CHAPTER – 06

PROPOSED INFRASTRUCTURE

6.1 Industrial Area

The setting up of the Main Plant Facilities, Raw Material Storage, Raw Water Storage Reservoir

& Treatment, Auxilliary facilities, viz. Admn. Bldg., Tech. Bldg, Workshop, QC Lab, Switch Yard,

etc. & Green belt (33%) required 6.49 Acres land. Company will use nearest road and rail facility

for goods transportation and equipped with all other required facilities.

6.2 Residential Area

The area around the site is under development with reasonably good communication facilities.

Around 93 people will be engaged in the plant and Keonjhar town is very close to the project

site and the area around the site is under development with reasonably good communication

facilities. Other social infrastructure like housing, schooling and medical facilities has been

developed and in some area it is underdeveloped. Hence, no residential colony/township is

envisaged for employees.

6.3 Green Belt




Comprehensive greenbelt/plantation program will be undertaken in and around the project. The

species selection will depend upon crown shape, surface of bark and leaves, flower, color,

capacity of growth in the wide variations of ecological conditions etc. A mixture of soil should be

prepared by mixing commercial fertilizer, cow dung, BHC powder in the topsoil.

6.4 Social Infrastructure

KIPL will commence a lot of infrastructure developmental works in the periphery area. Some

glimpses of the developmental activities are presented below:

Improving and building road network in the adjoining villages.

Strengthening School buildings with playgrounds.

Social awareness programme will further improve by the local authority such as sanitation

and hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding area.

The proposed project will set up training centre or tie up with Industrial Technical

Institutes to educate local youth as skilled labour.



CHAPTER – 06


6.1 Industrial Area












6.3 Green Belt





















CHAPTER – 06


6.1 Industrial Area












6.3 Green Belt





















6.5 Connectivity

Proposed project is well connected to NH-215 and also connected to the Nayagarh Railway

station. However the existing road network will be strengthened and new road network will be

built in the adjoining villages.

6.6 Drinking Water Management

Drinking water facilities will be provided for employees as well as nearby villagers. A fresh water

tank will be constructed for this drinking purpose.

A water treatment plant is envisaged for providing potable water to the colony and employees.

After ensuring the drinking water standards prescribed by CPCB water will be supplied for

drinking purpose.

6.6.1 Waste water treatment system

The unit will adopt zero discharge concept as per water balance given above except rainyseason.

There will be no effluent generated from the pellet plant. Water will be used in the process to

maintain the moisture content of 8-10% in the raw material. Cooling water will be completely

recycled in a closed loop. Effluent generated from backwash of filtration plant and clarifier

underflow will be treated in settling tank and will be taken to common monitoring basin. From

common monitoring basin treated effluent will be reused for ash handling, dust suppression and

greenbelt development.

6.7 Sewerage System

A garland drain around the plant is envisaged to collect surface run-off during rainy season.

Separate Internal drainage system will be constructed to collect domestic and industrial

effluent. A common basin will be constructed for the treatment of effluents the plant. The

sewage from the various plant buildings will be taken to a common STP through trenches. The

treated water from the STP will be used for greenbelt development. As the sewage is taken in

trenches the soil will not get contaminated. Sludge from STP will be used as manure for



Domestic effluent from canteen and plant will be treated in STP of capacity 20 m3/day consist of

following units:

1) Bar screen and grit chamber

2) O & G Trap

3) Aeration tank (diffused air aeration system)

4) Secondary settling tank



6.5 Connectivity









drinking purpose.









6.7 Sewerage System










following units:


2) O & G Trap





6.5 Connectivity









drinking purpose.









6.7 Sewerage System










following units:


2) O & G Trap





5) Multi grade filter

6) Chlorination

7) Sludge drying bed (2 nos.)

Domestic effluent after treatment will be reused for landscaping and green belt.

6.7.2 Run-Off Management

The rain water collected from the roof of buildings will be channelized through drains around

the buildings and will be recharged into the ground by providing recharging pits. Overflow, if

any, will be discharged to the nearby plant drainage. Also one rain water collection pond has

been considered in the layout. All the plant storm water drains will be routed to the rain water

collection pond and overflow, if any, from the pond will be discharged to any existing natural

outfall outside the plant area. The rain water collection pond will be unlined.

A Rain Water Harvesting Pond has been contemplated to act as collection basin for rainwater.

The collected water will be 100% reused in the raw water reservoir in dry season. The pond will

be located at the lowest area of the plant so that it can effectively collect all the rainwater by

gravity. The Tank shall be earthen. The pond will be lined at the bottom and sides with two

layers of HDPE lining of appropriate thickness to prevent percolation of the harvested rainwater

in to the ground. Figure below depicts schematically the proposed rainwater harvesting scheme

for the proposed plant. The Rain Water Harvesting Pond is depicted below:

Garland drain will be provided around raw material stock pile area. The run-off collected from

these areas will be treated in adequate settling pond and will be taken to rain water harvesting

pond.

Suitable pump house will be installed adjacent to the rain water collection pond so that the

settled water from the collection pond can be pumped and supplied to the plant for meeting

some of the daily requirement.




6) Chlorination



















pond.







6) Chlorination



















pond.






6.8 Industrial Waste Management

Hazardous Wastes

Majority of the wastes (spend oils, lubricants and oily sludges etc.) will be preferably sold to the

potential users with necessary authorization for reprocess/reuse. The non-hazardous (solid)

wastes at proposed project site are sludges from raw water treatment plant, biological sludge

from STP; and the domestic solid waste from plant area.

The non-hazardous solid waste, i.e. after sludge thicker/centrifuge and sludge drying beds, could

be used as landfill material/manure in greenbelt area or even for reclamation of low lying areas,

however they will be ultimately disposed as per MoEF guidelines in consultation with OPCB.

6.9 Solid Waste Management

The solid wastes include dust from pellet plant. Dust from pellet plant will be recycled and

reused for pellet production.



Pellet plant Dust from APC devices 350 Reused in pellet making

Broken Pellet 660

Raw water treatment plant Sludge 6 Will be used for landscaping

Producer Gas Plant Bottom Ash 10,000 Will be used in filling lowlying areas.

6.10 Power Requirement & Supply/Source

Total power requirement for the project is 5.0 MW, which will be met from 132/33 KV Sub-station

of OPTCL at Palaspanga. Further the promoter will have the DG sets to meet the emergency power

requirement.




Hazardous Wastes














Broken Pellet 660






requirement.




Hazardous Wastes














Broken Pellet 660






requirement.



CHAPTER – 07

REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to Be Adopted For R & R Plan w.r.t Project

The proposed project is going to come up on 19.62 acres area. Total land has already been

acquired. There is no existence of displaced habitants in the area. Land is also devoid of any

vegetation.

Local people will be engaged for construction and operation activities and the local area have all

the infrastructure facilities. Joda Town is just 15 Km away from the site and is well connected

with NH-215, thus, no housing colony/township is envisaged.



CHAPTER – 07





vegetation.






CHAPTER – 07





vegetation.






CHAPTER – 08

PROJECT SCHEDULE & COST ESTIMATES


In this industry, any one of the following three alternate modes of project execution is adopted:

Turnkey

Semi Turnkey

Packaged procurement mode

Planning Of Activities

Careful planning of all the activities is one of the pre-requisite for timely completion of the

project. Following activities will be given special attention.

Pre Project Activities

Management Approvals.

Selection of location

Land acquisitions

Statutory Clearances

Financial Approvals and Tie ups.

Selection of Consultants

Conceptual Design

Preparation of main machinery tender

Evaluation of tenders

Project Activities (Implementation Stage)

Firm up basic design

Main Machinery Order placement

Detailed engineering of the project

Statutory approvals of Building Plans.

Preparation of Tender, Evaluation of tenders received and Order placement for balance

machinery

Completion of procurement activities on time

Release of civil drawing for civil construction



CHAPTER – 08




Turnkey

Semi Turnkey








Land acquisitions




Conceptual Design









machinery





CHAPTER – 08




Turnkey

Semi Turnkey








Land acquisitions




Conceptual Design









machinery





Civil construction

Supply of mechanical & electrical equipment

Inspection of major machinery at supplier’s works

Erection of all plant & machinery

Commissioning of the plant


The proposed project will require various statutory approvals and clearances from various

authorities of the Government. Clearances required for the proposed project shall be identified

in due course and necessary action will be taken to obtain the same.

Project Schedule

The schedule has been developed on the basis of the estimated quantum of work, expected

delivery and installation periods of plant and equipment and the need to commission the plant

facilities in the shortest possible time. The schedule envisages a total project implementation

period of 18 months from the date of 'Go-ahead'. Schedule commissioning of the plant can

only be achieved if construction, delivery and erection periods as shown in the bar chart

can be met by respective suppliers and contractors.

The 'Go-ahead' date for the project implementation has been considered as a date of 'Go-

ahead' given to the Consulting Engineers for detailed engineering. The schedule has been

prepared based on the assumption that the following activities will be completed prior to the

date of 'Go-ahead'.

i. Freezing of adequate project details to enable preparatory site activities to commence on '

Go-ahead',

ii. Finalizing the arrangement for requisite finance as per projections matching with

implementation schedule,

iii. Acquiring all relevant statutory Govt. clearance (environmental, forest, rehab illation etc)

Strategies for Timely Execution of the Project

The following strategies would be adopted for smooth functioning as well as timely execution of

the project:

The task of implementing the project in time shall be achieved by ensuring a well

coordinated project implementation task force in-house and from external agencies



Civil construction









Project Schedule










date of 'Go-ahead'.


Go-ahead',






the project:





Civil construction









Project Schedule










date of 'Go-ahead'.


Go-ahead',






the project:





A well chosen team of experienced personnel for project execution shall coordinate the

implementation of the project from in-house

Experienced engineering consultants with proven track records shall be selected for detailed

engineering of the project.

Reputed and experienced contractors with adequate resources of finance, men, material

and tools and tackles, will be engaged for execution of the construction and erection work.

Effective project monitoring including project planning schedule and monitoring shall be

employed in this project. Timely execution and resources will be monitored using computer

based project monitoring tools. In case of deviations in project progress, all possible

corrective actions such as crashing of network etc. will be carried out.

8.2 Project Cost

An indicative estimated capital cost of the proposed Plant is Rs. 223.00 Crores, including the pre-


A broad break-up of the indicative estimate of the Project capital cost is provided below:

Table 8.0 Project Cost Break-Up

Sl. No. Particulars Amount in Crores1 Land & Land Development Cost 5.002 Building & Infrastructural Facilities 15.003 Steel Structural & Civil Work for Plant &

Equipments50.00

4 Plant & Equipments 110.005 Miscellaneous Fixed Assets 2.006 Provision for Contingencies 5.007 Consultancy Charges 0.608 Pre- Operative Expenses 20.009 Preliminary Expenses 0.40

10 Margin For Working Capital 15.00TOTAL 223.00













8.2 Project Cost






Equipments50.00















8.2 Project Cost






Equipments50.00





CHAPTER – 09ANALYSIS OF PROPOSAL

9.1 Financial and Social Benefits

In order to meet the growing demand of iron ore pellets required as raw material in steel plants,

M/s Kashvi International Private Ltd. proposes to produce iron ore pellets by setting up a pellet

plant of 0.6 MTPA Iron Ore Pellet Plant & 5 Nos. (4W+1 S) Producer Gas Plant of Capacity 5000

Nm³/hr each At-Champadihi, Keonjhar District, Odisha. In view of the increasing demand for

Iron ore pellets, both indigenious and export, the project will be financially profitable and viable.

It will also help in conservation of high grade ores for the future and mitigate the pithead

environmental pollution.

Besides there will be immense social benefits of the project, to the backward region.

9.1.1 Improvements in the Physical Infrastructure

KIPL has envisaged a lot of infrastructure developmental works in the periphery area.



Providing the Drinking Water Facilities.

9.1.2 Improvements in the Social Infrastructure

Employment, direct and indirect for the local predominantly tribal people.


and hygiene, health, immunization etc.



Sponsor the education to Poor Students of the Proposed Area.

The proposed project will set up training centre or tie up with Industrial Technical Institutes

to educate local youth as skilled labour.

Provide & conduct the Free Eye & Health Check up Programmes.

9.1.3 Employment

It is estimated that the total requirement of manpower for the whole organization will be 93.

There will be much larger indirect employment in transport, ancillary, support facilities and

growth in local trades and business. Expected to employ a peak workforce of about 200 persons

(peak demand) and 100 persons (average demand) during construction phase.




























9.1.3 Employment
































9.1.3 Employment







9.2 Other Benefits

Development of the local area in terms of an enlarged market.

Besides above, indirect benefits have also occurred to the region by way of increase in

industrial production.

Thus, the proposed project will usher in the social and economic upliftment of the persons living

in the vicinity of the Project i.e. of society at large.



9.2 Other Benefits








9.2 Other Benefits






Visiontek Consultancy Services Pvt. Ltd(An Enviro Engineering Consulting Cell)

Plot No.-108, District Centre, Chandrasekharpur, Bhubaneswar-16, Tel.: 91-2744594, 3250790, Fax : 91-6742744594E-mail : [email protected], [email protected], Visit us at : www.vcspl.org

Committed For Better Environment

Documents

M/s. KASHVI INTERNATIONAL PVT. LTD. · Visiontek Consultancy Services Private Limited Page 2 1.0 Introduction 1.1 Identification of Project and Project Proponent M/s Kashvi International