ANALYSIS OF ALTERNATIVES (TECHNOLOGY)

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Expansion of Sponge iron plant, Induction furnaces,

TMT Rolling mill & installation of Ferro alloys unit,

Alloy steel billet plant, Rolling mill and Structure mill

At

Village: Heti, Tahsil: Umred, District : Nagpur,

Maharashtra

Project Proponent

M/s Topworth Urja and Metals Ltd.

EIA Consultant

Pollution and Ecology Control Services,

Nagpur

NABET No. 118

I

INDEX

Sr.

No.

Particulars Page No.

Chapter 1- Introduction 1 19

1.0 Introduction 1

1.1 Profile of Project Proponent 1

1.2 Site Selection Criteria 2

1.3 Details of the Project Site 2

1.4 Purpose of the EIA 7

1.5 Need for the Project 7

1.6 Scope of the Study 9

1.6.1 Environmental Impact Assessment 13

1.6.2 Preparation of Environmental Management Plan 13

1.6.3 Contents of the Report 14

1.7 Site Photographs 16

Chapter 2- Project Description 20 - 64

2.1 Plant Layout 20

2.1.1 Project Cost 22

2.1.2 Production Scenario 23

2.1.3 Raw Material Requirement 24

2.1.4 Water Requirement 24

2.1.4.1 Water Treatment Plant 29

2.1.5 Power Requirement 30

2.1.6 Land Requirement 31

2.1.7 Employment potential 32

2.1.8 Transport 32

2.2 Process Details 32

2.2.1 Ferro Alloys Plant for 50000 TPA Capacity 33

2.2.2 4 LAC TPA Electric Arc Furnace Based Alloy Steel Billet Plant 36

2.2.3 Enhancement of Capacity From 240 TPD TO 480 TPD by Installing 2 X 12 48

II

Sr.

No.


Ton Induction Furnace Based Steel Billet Plant and Installation of Ladle

Refining Furnace

2.2.4 TMT Bars Rolling Mill Capacity Enhancement From 66000 to 150000 TPA 53

2.2.5 Proposed 1.5 Lacs TPA Light Section Rolling Mill 56

2.2.6 Proposed 2.5 Lacs TPA Heavy Section Rolling Mill 58

2.2.7 Expansion of Existing Sponge Iron Plant Capacity from 60,000 TPA to

2,91,000 TPA by Installing 2 X 350 TPD Rotary Kilns and other Ancilliary

Units

60

2.3 Fire Fighting System 63

2.4 Health and Sanitation Facilities 64

Chapter 3- Description of the Environment 65 - 127

3.1 Introduction 65

3.2 Climate 67

3.3 Meteorology 68

3.3.1 Wind Speed And Wind Direction 68

3.3.2 Findings 68

3.3.3 Temperature And Humidity 69

3.3.4 Rain Fall 70

3.4 Ambient Air Quality 70

3.4.1 Methodology of Monitoring 70

3.4.2 Frequency for Monitoring 71

3.4.3 Observations 71

3.5 Noise Environment 85

3.5.1 General 85

3.5.2 Locations of Noise Level Monitoring 85

3.5.3 Parameters Measured During Monitoring 87

3.5.4 Method of Monitoring 87


III

Sr.

No.


3.5.6 Ambient Noise Level Standards 89

3.6 Hydrogeology 89

3.6.1 Consolidated Formations 89

3.6.2 Semi-Consolidated Formations 90

3.6.3 Unconsolidated Alluvial Formations 90

3.7 Geology 91

3.8 Water Quality 93

3.8.1 Location of Sampling Stations 93

3.8.2 Methodology for Sampling 94

3.8.3 Analytical Techniques 96


3.9 Soil Quality 102

3.9.1 Location of Sampling Sites 102

3.9.2 Methodology of Sampling 104

3.9.3 Methodology of Analysis 104


3.9.5 Standard Soil Classification 108

3.10 Land Use Pattern 111

3.10.1 Satellite Imagery Based Landuse pattern 111

3.10.2 Census Based Landuse pattern 114

3.11 Socio- Economic Environnent 118

3.11.1 Base line Data 118

3.11.2 Demographic Structure 118

3.11.3 Economic Resource Base 119

3.11.4 Health Status 119

3.11.5 Cultural and Aesthetic Attributes 119

3.11.6 Socio-Economic Survey 120

3.12 Positive and Negative Impact on Demography and Socio-Economics 126

IV

Sr.

No.


Chapter 4 : Anticipated Environmental Impacts & Mitigation Measures 128 - 144

4.1 General 128

4.2 Air Environment 129

4.2.1 Construction Phase Impacts and Mitigation Measures 129

4.2.2 Operation Phase Impacts and Mitigation Measures 130

4.2.3 Simulation Model for Prediction using Industrial Source Complex

AERMOD View

132

4.3 Water Environment 139

4.3.1 Wastewater Generation 139

4.4 Noise Environment 140

4.4.1 Construction Phase Impact 140

4.4.2 Operation Phase Impact 140

4.4.3 Mitigation Measures 140

4.5 Land Environment 141

4.5.1 Source of Soil Pollution 141

4.5.2 Impact and Mitigation Measures 141

4.6 Solid Waste 142

4.7 Socio Economic Environment 143

4.8 Impact on Ecology and Mitigative Measures 143

4.9 Greenbelt Development Plan 144

4.9.1 Effect on Plant 144

Chapter 5 : Analysis of Alternatives (Site & Technology) 145 - 147

5.1 Analysis of Site Selection 145

5.2 Alternate Technology 146

5.3 Conclusion 147

Chapter 6 : Environmental Monitoring Programme 148 - 154

6.1 Environmental Monitoring Programme 148

6.1.1 Environment Monitoring Cell 148

V

Sr.

No.


6.1.2 Environmental Monitoring and Control 148

6.1.2.1 Monitoring Schedule 149

6.1.2.2 Plantation Monitoring 151

6.1.2.3 Health Monitoring 151

6.1.2.4 Action Plan 151

6.2 Monitoring Equipment 151

6.3 Reporting & Documentation 153

6.4 Budget & Procurement Schedule 153

Chapter 7: Additional Studies 155 - 179

7.0 Social Impact Assessment 155

7.1 Ecological Biodiversity 155

7.2 Corporate Social Responsibility 155

7.3 Risk Assessment 155

7.4 Identification of Hazards/Risk 155

7.4.1 Material Hazards 156

7.4.2 Fire and Explosion Index 156

7.5 Consequence Analysis 159

7.6 Conclusions and Recommendations 161

7.7 Risk Mitigation Measures 163

7.8 Disaster Management Plan 164

7.8.1 On-Site Emergency Plan 166

7.8.2 Offsite Emergency Plan 177

Chapter 8: Project Benefits 180 - 182

8.1 Socio Economic Benefits 180

8.2 Benefits to the Infrastructure 181

8.3 Other Benefits 181

8.4 Conclusion 182

Chapter 9: Environmental Management Plan 183 - 216

VI

Sr.

No.


9.1 Introduction 183

9.2 Environmental Management Plan 183

9.3 Details of Environmental Management Plan 184

9.3.1 During Construction Phase 184

9.3.1.1 Air Environment 184

9.3.1.2 Water Environment 185

9.3.1.3 Solid Waste 185

9.3.1.4 Noise Environment 185

9.3.1.5 Land Environment 186

9.3.1.6 Ecology 186

9.3.1.7 Socio-Economic 186

9.3 During Operation Phase 187

9.3.1 Air Environment 187

9.3.2 Water Environment 193

9.3.3 Solid Waste 194

9.3.4 Noise Environment 196

9.3.5 Land Environment 197

9.3.6 Biological Environment 197

9.3.6.1 Green Belt Development Plan 197

9.3.7 General Considerations 204

9.4 Occupational Health and Safety 205

9.4.1 Hazards and health 205

9.4.2 Physical Hazards 206

9.4.2.1 Noise 206

9.4.2.2 Heat Stress 208

9.5 Environmental Organization 211

9.6 Action Points Under CREP 213

Chapter 10: Summary and Conclusion 217 - 225

VII

Sr.

No.


10.1 Project Description 217

10.2 Description of Environment 217

10.3 Anticipated Environmental Impacts and Mitigation Measures 220

10.4 Environmental Monitoring Programme 223

10.5 Additional Studies 224

10.6 Project Benefits 224

10.7 Environment Management Plan 225

Chapter 11: Disclosure of Consultant 226 - 227

VIII

LIST OF TABLES

Sr. No. Particulars Page No.

1.1 Details of the Project 6

1.2 List of the Industries Around the Project Site 9

1.3 Applicable Acts and Guidelines for the Proposed Project 11

2.1 Breakup of Proposed Investment 22

2.2 Existing and Proposed Production Capacities 23

2.3 Utility Requirement 23

2.4 Raw Materials Requirements & Sources 24

2.5 Water Balance 26

2.6 Power Consumption 31

2.7 Break-up of Land Use 32

3.1 The schedule of Environmental Monitoring Programme 66

3.2 Monitored Parameters and Frequency of Sampling 71

3.3 Description of Ambient Air Monitoring Stations 72

3.4 A to I AAQ Observations 74 - 81

3.5 A to B Summarized report of Ambient Air Quality 82

3.6 National Ambient Air Quality Standards 83

3.7 Details of Sampling Stations of Noise Level Measurement 85

3.8 Measured Noise Levels at Monitored Stations 88

3.9 National Ambient Noise Level Standards 89

3.10 Surface and Ground Water Sampling Stations 93

3.11 Standard operating procedure (SOP)for water and wastewater sampling 95

3.12 Methodology for sampling and analysis of water & wastewater 96

3.13 Analysis Report of Surface and Ground Water Samples 97

3.14 Details of Soil Sampling Locations 102

3.15 Analytical Techniques for Soil Analysis 104

3.16Ato C Soil Results 105 - 107

3.17 Standard soil classification 108

3.18 Landuse/ Land Cover Breakup 114

IX

LIST OF FIGURE

3.19 Land use pattern based on Census data 2001 115

3.20 Summary of Demographic Structures in the Study Area 121

3.21 Village Wise Demographic Structure of the Study Area 122

3.22 Employment pattern 123

4.1 Stacks & Emissions details of M/s Topworth Urja and Metals Ltd 131

4.2 Resultant Concentrations of Particulate Matter (PM10) due to incremental

GLCs

135

4.3 Resultant Concentrations of Sulphur dioxide (SO2) due to incremental GLCs 137

4.4 Resultant Concentrations of Oxides of Nitrogen (NOx) due to incremental

GLCs

139

4.5 Solid waste Generation 142

6.1 Monitoring Schedule for the Environmental Parameters 150

6.2 Budgetary for Environment Management and Monitoring 154

7.1 Storage details of High Speed Diesel 156

7.2 Characteristics of HSD 156

7.3 Risk Index 158

7.4 Physiological effects of threshold thermal doses 158

7.5 Damage due to Incident Radiation Intensity 159

7.6 Heat Radiation Hazards due to Storage 160

9.1 Location of Fugitive Monitoring 188

9.2 Unit wise Solid Waste Generation 195

9.3 Plant Species for Green Belt Development 202

9.4 CREP compliance 214

Sr.

No.

Particulars Page

No.

1.1 Location of the Project Site 3

1.2 Topographical Map 4

1.3 Google Image 5

X

2.1 Plant Layout 21

2.2 Water Balance Diagram of Existing Project 27

2.3 Water Balance Diagram of Proposed Project 28

2.4 Process Flow Diagram For Ferro Alloy Plant 36

2.5 Process Flow Diagram of Rolling Mill 60

3.1 Study Area Map of the project area 67

3.2 Wind Rose Diagram 68

3.3 Temperature variations during study period 69

3.4 Relative humidity variations during study period 69

3.5 Locations of Ambient Air Quality Monitoring Stations 73

3.6 Figure Showing Locations of Noise Level Monitoring 86

3.7 Figure Showing Locations of Ground & Surface Water Sampling 94

3.8 Figure Showing Locations of Soil Sampling Sites 103

3.9 Satellite Imagery 113

3.10 Landuse/ Land cover breakup 113

3.11 Landuse Pattern in Study Area (Census Based) 117

3.12 Comparison of SC, ST & Other Population 121

3.13 Literacy % 125

3.14 Sex Ratio Comparison 125

3.15 Vocational Pattern of the Study Area 126

4.1 Resultant Concentrations of Particulate Matter (PM10) due to incremental GLCs 134

4.2 Resultant Concentrations of Sulphur Dioxide (SO2) due to incremental GLCs 136

4.3 Resultant Concentrations of Oxides of Nitrogen (NOx) due to incremental GLCs 138

7.1 Risk Contour 161

9.1 Organization of Environment Management Cell 123

XI

LIST OF ANNEXURES

Sr. No. Annexure No. Annexure Name

1 Annexure I TOR

2 Annexure II Compliance of TOR

3 Annexure III Copy of existing Environmental Clearances and its Compliance

4 Annexure IV Water Withdrawal Permission Letter

5 Annexure V Fly Ash Utilization

6 Annexure VI Minutes of Public Hearing

7 Annexure VII Flora and Fauna Report

8 Annexure VIII CSR Report

9 Annexure IX Study area of radius 10 Kms

10 Annexure X Coal linkage document

11 Annexure XI Geo-technical report

12 Annexure XII Copy of NABET accreditation

EIA study for expansion of Sponge iron plant, Induction furnaces, TMT Rolling mill & installation of

Ferro alloys unit, Alloy steel billet plant, Rolling mill and Structure mill

INTRODUCTION

~ 1 ~ PECS, Nagpur

CHAPTER 1

INTRODUCTION

1.0 INTRODUCTION

M/s. Topworth Urja and Metals Limited (TUML) has proposed to set up the expansion

unit for Sponge Iron Plant, Induction Furnaces, TMT Rolling Mill & Installation of Ferro

Alloys Unit, Alloy Steel Billet Plant , Rolling Mill and Structure Mill at village Heti,

Mouza Ukkerwahi, Post Udasa in Tehsil Umred, District Nagpur, State Maharashtra.

M/s Topworth Group is one of India's fastest growing conglomerates, with over 2,500

employees, and revenues exceeding 1.0 Billion USD.

1.1 PROFILE OF PROJECT PROPONENT

The Project is promoted by M/s Topworth Urja and Metals Limited (TUML), which is

one of the leading metallurgical company in India. M/s.Topworth Group is headed by

Chairman Mr. Abhay Lodha. The company was incorporated as "Shree Virangana Steels

Private Ltd" in November 1993 and the name was changed to "Shree Virangana Steels

Limited" in the year Nov 2001. The present name of "Topworth Urja & Metals Limited"

was given in the year 2010 in accordance with the group name and the business carried

out.

M/s. TUML proposed to enhance the production of Sponge iron from 60,000 TPA to

2,91,000 TPA by installing 2 x 350 TPD rotary kilns, M.S Billets from240 TPD to 480

TPD by installing 2 x 12 Ton Induction Furnaces & TMT Bars from 66,000 TPA To 1.5

Lac TPA , in addition to this it is also proposed to install 2 X 16.5 MVA Submerged Arc

Furnaces to produce 50000 TPA Ferro Alloys, Arc Furnace Based 4 Lac TPA Steel Melt

Shop, 3 Lac TPA Alloy Steel Bar Mill, 1.5 Lac TPA Light & Medium Section Mill for

Rolling of Steel sections and 2.5 Lac TPA Heavy Section Mill for Rolling of Structural

Steel Heavy Sections at Village Heti, Tehsil Umred, District Nagpur, Maharashtra.



INTRODUCTION

~ 2 ~ PECS, Nagpur

1.2 SITE SELECTION CRITERIA

Existing Plant in operation.

Availability of 160 acres of land.

No Rehabilitation/Resettlement required.

No National Park, Biosphere Reserve and Wildlife Sanctuary including Notified

Eco Sensitive Areas within 10 km radius.

No archaeological monument, interstate boundary and defense installation.

No notified critically polluted area.

No nallah/water body, public roads, forests within the project site.

Availability of Raw Material.

Availability of Water.

Market available for finished products.

Availability of man power.

Availability of industrial infrastructure.

1.3 DETAILS OF THE PROJECT SITE

The plant of M/s. TUML proposed to enhance the production of Sponge iron from

60,000 TPA to 2,91,000 TPA by installing 2 x 350 TPD rotary kilns, M.S billets from

240 TPD to 480 TPD by installing 2 x 12 Ton Induction Furnaces & TMT Bars From

66,000 TPA to 1.5 Lac TPA , in addition to this it is also proposed to install 2 X 16.5

MVA Submerged Arc Furnaces to produce 50000 TPA Ferro Alloys, Arc Furnace Based

4 Lac TPA Steel Melt Shop, 3 Lac TPA Alloy Steel Bar Mill, 1.5 Lac TPA Light &

Medium Section Mill for Rolling of Steel sections and 2.5 Lac TPA Heavy Section Mill

for Rolling of Structural Steel Heavy Sections at Village Heti, Tehsil Umred, District

Nagpur, Maharashtra.

The location map is shown in the Figure 1.1 and the topographical map and Google

image is shown in Figure 1.2 and Figure 1.3 respectively. Details of the project site are

presented in Table 1.1.



INTRODUCTION

~ 3 ~ PECS, Nagpur

Source: Map of India, Maharashtra, Nagpur given on Official Websites

Figure 1.1: Location of the Project Site



INTRODUCTION

~ 4 ~ PECS, Nagpur

Source: SOI Toposheet

Figure 1.2: Topographical Map

N

STREAMS

RIVER / NALA

ROAD

HABITATION

INDEX

FOREST BOUNDARY

POND

RAILWAY

7910'

2055'

200'

Canal

Can

al

Can

al

Canal

Cana

l

Amb Nadi

BHIWAPUR R.F

Dense Mixed Jungle

Dense Mixed Jungle

BHIWAPUR R.F

Open mixed jungle

Open mixed jungle

Open mixed jungle

7915' 7920'

7920'7915'7910'

2055'

200'

TOPOSHEET NO

Phukeahwar

Dudha

Makaedhokra

Dahegoon Amb NadiHeoti

DawhaSayaki

Sirpur

Kursapar

Paradgoon

Masaikkund

Bhiwapur

UtiHaladgoon

ParsodiTikhadiUmra

Sukli Khurd

Champa Chanpa

Mangli

Undri

Khapri

KHAPRI TALAV

Sonegaon

Knetapur

Sonegaon Talav

Kolarmet

Talav

Takli Kalan

Kolarmet

Kalandri

BorgaonKalandri Talav

Khairi

Nirwah

Wadegaon BarwaPipra

Ukharwahi Talav

Heti Akola

UkharwahiWirli

Aptur

Welsakhra

Udasa

Rajulwari

Thomra

Ganpaoli

Gangapur

Kanhwa

PREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES

Village-:Heti,Taluka-Umred,District-Nagpur.

10 km. STUDY AREA

55- P/1,P/5 & 55- O/4, O/8

M/s. Topworth Urja and Metals Limited.

PROJECT SITE



INTRODUCTION

~ 5 ~ PECS, Nagpur

Source: Google Earth

Figure 1.3: Google Image



INTRODUCTION

~ 6 ~ PECS, Nagpur

TABLE 1.1: DETAILS OF THE PROJECT

Sr. No. Particulars Details

1. Project Site Village-Heti, Post-Udasa, Tehsil Umred, District Nagpur, Maharashtra.

2. Nearest major road NH 7 : 24 km MSH 9 : 0.5 km

3. Coordinates Latitude: 2055'39.10"N Longitude: 7914'47.96"E

4. Nearest railway station Butibori Railway station, which is 35 Km from the plant site & Nagpur railway station 35 Km from the site.

5. Elevation above MSL 310m

6. Toposheet 55 P/1, 55P/5, 55 O/4, 55 O/8

7. Climatic conditions (Based on IMD)

Annual Max. Temperature : 47.0C

Annual Min. Temperature : 4.0C

Average Annual Rainfall : 1000 mm

Predominant annual wind direction: North-West

Relative Humidity: 35 to 81 %.

8. Nearest village Welsakhra : 2 km

9. Nearest major city Nagpur - 35 Kms

10. Nearest water body Ukkarwahi lake : 0.5 km : N Amb River : 5 km : SE

Paradgaon Lake : 3.0 Km : SW

11. Sensitive locations Archaeological structures, Historical places, Sanctuaries

and Biosphere are not present within 10 km

11. Nearest forest Bhivapur range forest 1.0 km : N

12. Water Required 3009 m3/Day

13. Water source for the project Paradgaon Dam 3 km from the site

14. Land 160Acres

15. Power 75 MW

16. Project Cost Rs. 1637.55 Crores

17. EMP Cost Rs. 26.8 Crores



INTRODUCTION

~ 7 ~ PECS, Nagpur

1.4 PURPOSE OF THE EIA

As per the Environmental Impact Assessment (EIA) Notification dated 14th September,

2006, the proposed ferroalloys manufacturing unit is categorized as Category A under

the Schedule 3(a) Metallurgical industries (ferrous & nonferrous), which mandates

obtaining prior Environmental Clearance from MoEF & CC, GOI, New Delhi.

The application to prior EC (Form-1) for the proposed project was submitted to MoEF &

CC for approval of Terms of Reference (TOR). The proposal was considered by the

Expert Appraisal Committee (EAC) during its 14th

Reconstituted Expert Appraisal

Committee (Industry) held during 19th

to 20th

December, 2013for the TOR for preparation

of EIA report. The EAC has suggested TOR for preparation of the EIA report and the

compliances of the TOR are given in Table 1.2. Subsequently, the Company had made

an application for revised capacities of the Project and revised TOR was granted in the

23rd

Meeting of the Reconstituted Expert Appraisal Committee (Industry) held on 18th

September 2014. The EIA report for Topworth Urja & Metals Limited is prepared as per

the guidelines of MoEF & CC and contains 11 chapters including Environmental

Management Plan.

In order to obtain the required Environmental Clearances, M/s Pollution and Ecology

Control Services (PECS) Nagpur have entrusted the task of undertaking Environmental

Impact Assessment (EIA) study and prepare Environmental Impact Assessment report.

This EIA report is prepared based on the data and information provided by the Proponent

and the field studies undertaken by PECS during the period of 6th

January 2014 to 6th

April

2014.

1.5 NEED FOR THE PROJECT

Global steel industry has been growing at a rapid pace during the last decade. The global

crude steel production had increased from about 900 million tonnes per annum (MTPA)

in the year 2002 1050 MTPA in the year 2004, recording a CGAR of more than 8%.

The steel production is projected to grow about 1300 MTPA by the year 2010 with a

CGAR of about 3.6%. The growth has been primarily concentrated in the developing

countries. Along with a growth in consumption, the steel industry has also witnessed a

steep increase in the prices from the year 2002-03 onwards. World Steel Dynamics



INTRODUCTION

~ 8 ~ PECS, Nagpur

(WSD) estimates that the share of the top five players in the steel industry will grow from

21% in the year 2004 to 39% by the year 2010.

India is the fourth largest producer of crude steel in the world today. Indian steel industry

is aiming for high growth during the next 5-7 years, supported by economic growth and

positive change in consumption behavior of the large and growing population. The prime

factors which will support growth of Indian steel Industry are demand driving factors,

government policies and capacity addition plan for steel.

There is a tremendous potential to create new steel capacities in India considering the

following intrinsic advantages of India in this industry,

Availability of major raw materials

Availability of technically competent personnel at relatively lower cost.

Proximity to the major consuming markets of South Asia, Middle East,

etc.

The easy availability of rich iron ore from nearby mines and water from Paradgaon

reservoir makes the said Steel manufacturing unit an optimum place to go for

establishment. There are few companies working around the proposed project, the list of

companies in 25 km radius area is as follows:-



INTRODUCTION

~ 9 ~ PECS, Nagpur

Table 1.2 List of the Industries around the project site

1.6 SCOPE OF THE STUDY

With view to assess the Environmental impacts due to the proposed expansion project

within the premises of already existing project at Heti Village, Tehsil Umred, District

Nagpur, M/s Topworth Urja & Metals Ltd. Nagpur has availed the services of Pollution

and Ecology Control Services, Nagpur (PECS), which is NABET accredited consultant

and has drafted the report as per generic structure of EIA prescribed in EIA Notification

2006. All the Water, Air, Soil and Noise monitoring were performed by M/s. Nilawar lab

Pvt. Ltd. Nagpur (MoEF & CC Accredited).

The EIA report is prepared based on the one season baseline data as per the guideline of

MoEF & CC and CPCB. The Environmental monitoring has been carried out during



INTRODUCTION

~ 10 ~ PECS, Nagpur

(6th

January to 6th

April 2014) and used to identify potential significant impact. Modelling

exercises have been carried out to predict and evaluate the impact due to proposed

activity.

The scope of present study is in line with the TOR as recommended by MoEF & CC.

The scope of study broadly includes:

Field sampling of Environmental attributes at various representative locations in

the study area to establish the baseline environmental status.

Collate and compile secondary data include socio-economic data from published

literature/ govt publications.

Estimate pollution load that would be generated by proposed project.

Predict incremental level of pollutant in the study area due to proposed project.

Prepare Environmental Management Plan (EMP) to mitigate the predicted impacts.

COMPLIANCE TO TOR CONDITIONS

The scope of the present study is in line with the TOR as recommended by MoEF & CC

vide ToR letter No. J-11011/283/2013-IA-II (I) dated 5th

November, 2014. A copy of TOR

letter Annexure-I and the Compliance to the TOR is given in Annexure-II. The copy of

existing Environmental Clearances and its compliance is attached as Annexure III.

APPROACH AND METHODOLOGY OF EIA STUDY

Approach of the EIA Study

The EIA study includes delineation of the baseline conditions of the TUML project site at its

study area of 10 km (around the project site). Based on the baseline conditions and the

project activities the potential impacts (both positive and adverse) are identified. For the

identified potential impacts, mitigation measures to negate the potential adverse impacts and

enhancement measures to enhance the positive impacts are proposed.

The proposed control measures are detailed in the Environmental Management Plan. The

entire EIA study has been carried out on the basis of the applicable environmental legislation,

regulations and guidelines of MoEF&CC .



INTRODUCTION

~ 11 ~ PECS, Nagpur

Policy and Legal Framework

The project developer, Nagpur TUML will ensure that it conforms to all National

legislations, regulations, and conventions, relating to various aspects of metallurgical

development in India. Table 1.2 shows list of various applicable Acts and Rules as set by

MoEF&CC , CPCB and CECB.

Table 1.3: Applicable Acts and Guidelines for the Proposed Project

Issues Applicable Legislation

Water 1) The Water (Prevention and Control of Pollution)

Act,1974, and amendments thereafter.

2) Water Cess Act, 1977 and amendments thereafter

Air 3) The Air (Prevention and Control of Pollution) Act,

1981and amendments thereafter.

Other Issues under the

Environment (Protection) Act,

1986,and Rules

4) The Public Liability Insurance Act, 1991 and Rules

1991.

Noise 7) The Environment (Protection) Second Amendment

Rules, 2002 (Noise Limits for New Generator Sets).

8) The Noise (Regulation & Control) Rules, 2000.

Establishment of Baseline Environmental Condition

A comprehensive database on the baseline environmental status/conditions of the study

area has been established through review, compilation and analysis of:

Existing secondary data/ literature/ information collected, and

Primary data collected through field study, survey and monitoring



INTRODUCTION

~ 12 ~ PECS, Nagpur

Collection of Secondary Data

Besides inputs from the TUML on relevant information about the project, available

relevant secondary data/ information/ records and published literature with respect to the

environment of the study area around TUML has been collected, reviewed and analyzed

to provide the overview and details of the study area.

Geology & topography of the study area including geological setting,

topography and Seismicity.

Land use and Land cover pattern was delineated by processing and analyzing

the satellite imagery (Source NRSA Hyderabad).

Meteorological data consisting of parameters like temperature, relative

humidity, rainfall, cloud cover, wind speed and wind direction, and weather

phenomena were collected and analyzed.

1Flora and fauna data from existing literature of Forests Departments,

Botanical Survey of India, Zoological Survey of India, earlier studies

conducted in the area and field survey.

Environmentally Sensitive Areas: The details about the ecologically sensitive

areas like reserve forests, national parks and wildlife sanctuaries within 10 km

of the proposed expansion project site have been given in Chapter 3.

Other Features: The distance of the project site from the nearest highways,

railway lines and airports has been established. Sites/places of archaeological,

historical and national importance, places/sites of cultural, religious and

tourist interests, defense installations etc., within a radius of 10 km of the

project site have also been explored

Field Study/Monitoring for Generation of Primary Data

The secondary data collected has been appropriately supplemented by conducting the

necessary primary data collections through field study/monitoring for one season study

period (January, February, March and April 2014). The studies which were conducted are

listed below:



INTRODUCTION

~ 13 ~ PECS, Nagpur

Ambient Air Quality Monitoring: For drawing up the baseline status of ambient air

quality in the 10 km study area around TUML, ambient air quality monitoring was

conducted in the representative locations. The parameters namely Particulate Matter 10

(PM10), Particulate Matter 2.5 (PM2.5), Sulphur dioxide (SO2) and Nitrogen dioxide

(NOx) were analyzed.

Noise Monitoring: To establish the ambient noise condition in the study area, ambient

noise level monitoring has been carried out at representative locations in the study area

using a suitable portable sound level meter over a period of twenty-four hours to obtain

day and night time Leq.

Water Quality Monitoring: To identify the water quality in and around the study area,

water samples were collected from the representative locations (both surface and ground)

and were analyzed for their physico-chemical characteristics.

Soil Monitoring: To study the soil characteristics in the study area, soil samples from

representative locations in the study area were collected and analyzed to identify the

physicochemical characteristics of the soil.

1.6.1 Environmental Impact Assessment

The environmental assessment has been conducted in accordance with the norms and

guidelines of the Govt. of India. The project data/activities has been analyzed & linked

with the existing baseline environmental conditions in order to list out the affected

environmental parameters and assess the likely impacts on such parameters. Wherever

practicable, a quantitative analysis has been performed. Compliance of the project with

national standards has been duly checked.

1.6.2 Preparation of Environmental Management Plan

Environmental Management Plan (EMP) is the key to ensure negligible impact to the

environment due to the proposed project. The desired results of the environmental

mitigation measures proposed in the project may not be obtained without a management

plan to ensure its proper implementation & function. The EMP envisages the plans for



INTRODUCTION

~ 14 ~ PECS, Nagpur

the proper implementation of mitigation measures to reduce the adverse impacts arising

out of the project activities.

1.6.3 Contents of the Report

The EIA Report is based on the primary field data generated at the project site and data

collected from secondary sources. The report comprises of 11 chapters.

Chapter 1.0 - Introduction

This chapter provides purpose of report, background information of the proposed and

expansion project, brief description of nature size and location of the project,

environmental setting of the proposed location, estimated project cost, scope,

organization of the report,

Chapter 2.0 - Project Description

This chapter provides the background information on the project set up, details of

manufacturing processes, layout of the plant and sources of pollution along with waste

generation and their treatment and disposal.

Chapter 3.0 - Description of the Environment

This chapter presents the methodology and findings of field studies undertaken to

establish the baseline conditions for the various environmental attributes.

Chapter 4.0 - Anticipated Environmental Impacts and Mitigation Measures

This chapter details the prediction of impacts using available computer models,

assessment of impact of the proposed project activities and identification of areas of

concern, It also describes the overall positive and negative impact of proposed project

activities during construction and operation phases, which need to be mitigated.

Chapter 5.0 - Analysis of Alternatives (Technology & Site)

This chapter presents the alternatives w.r.t technology to be adopted for the proposed

steel manufacturing industries.



INTRODUCTION

~ 15 ~ PECS, Nagpur

Chapter 6.0 Environmental Monitoring Programme

This chapter presents the environmental monitoring program w.r.t the general and

pollutants criteria for various environmental components as per the guidelines of CPCB

during and after the establishment of the proposed steel manufacturing plant

Chapter 7.0 - Additional Studies

This chapter presents the identification of hazards due to various units and explosive

materials etc. Based on the damage distances an onsite disaster management plan has also

been delineated. Disaster management plan, Ecological Biodiversity of the study area ,

social impact assessment (Public hearing details) and corporate social responsibility of

project proponent is also covered.

Chapter 8.0 Project Benefits

This chapter outlines the benefits resulting from the proposed steel manufacturing plant.

Chapter 9.0 Environmental Management Plan

This chapter outlines the institutional arrangements and budgetary provision for

implementation of the proposed environmental monitoring plan to check the efficacy of

the environmental mitigation measures proposed.

Chapter 10.0 - Summary and conclusion

This chapter presents the gist of the EIA report highlighting the main features in each

chapter pertaining to the environmental studies carried out and sums up the conclusion in

the end.

Chapter 11.0 - Disclosure of Consultants Engaged

This chapter outlines the brief background of the consultants engaged w.r.t their technical

expertise and nature of services undertaken.



INTRODUCTION

~ 16 ~ PECS, Nagpur

1.7 SITE PHOTOGRAPHS

Existing Plant Photographs



INTRODUCTION

~ 17 ~ PECS, Nagpur

Air Pollution Control Equipments



INTRODUCTION

~ 18 ~ PECS, Nagpur

Existing Green Belt



INTRODUCTION

~ 19 ~ PECS, Nagpur

Photographs of Fly Ash Bricks Manufacturing



PROJECT DESCRIPTION

~ 20 ~ PECS, Nagpur

CHAPTER 2

PROJECT DESCRIPTION

2.1 PLANT LAYOUT

M/s Topworth Urja and Metals Ltd. (TUML), located on Umred road, Village Heti,

Tehsil Umred, Distt. Nagpur. The proposed project site is about 35 km south east of

Nagpur city and about 12 km North East of Umred Tahsil. TUML is sourcing iron

ore/Iron Ore pellets for their existing units from Bellary / Orrisa region. The Iron ore /

Iron ore pellets are received at Butibori Railway station, which is 35 Kms away from

the plant site &32Km from Nagpur railway station. The same is brought by road also.

The proposed project coordinates is Latitude: 2055'39.10"N Longitude: 7914'47.96"E

and Ash Pond/dump coordinates is Latitude: 2055'30.24"N Longitude:

7914'46.05"E.The proposed expansion project layout is presented as Figure 2.1.

M/s. Topworth Urja and Metals Limited (TUML) have proposed to set up a Expansion

unit of Sponge iron from 60,000 TPA to 2,91,000 TPA by installing 2 x 350 TPD

rotary kiln, MS billets from 240 TPD to 480 TPD & TMT Bar From 66,000 TPA To

1,50,000 TPA. In addition to this, it is also proposed to install 2 X 16.5 MVA

Submerged Arc Furnaces and 300 TPD Sinter Plant to produce 50000 TPA Ferro

Alloys, 400000 TPA Arc Furnace based Alloy Steel Melt Shop, 300000 TPA Alloy

Steel Bar Mill, 150000 TPA Light & Medium Section Mill for Rolling of Steel section

and 250000 TPA Heavy Section Mill for Rolling of Steel Heavy Sections at Village

Heti, Tehsil Umred, District Nagpur, Maharashtra. Sponge Iron basedMini Steel Plant

also having M.S Billets plant and Rolling Mill are present in the existing premises of

TopworthUrja& Metals Limited and Captive Power Plant (30 MW) is in operation. The

terrain of the land is almost flat and low lying.



PROJECT DESCRIPTION

~ 21 ~ PECS, Nagpur

ROLLING MILL EXPANSION

PROPOSED2X350 TPD SPONGE

IRON D IVISION

86

68

67

70

69

71

66

88

95

72

82

63

62

57

6174

75

76

59

60

73\3

PLANT LAYOUT-PLAN

85

86

96

38

37

1918

17

78

20

15

1614

13

12

79

80

81

77

PROPOSEDSECTION MILL

PROPOSED

ALLOY STEEL BILLET PLANT

P ROP OSED

A LLOY S TEE L BA R MILL

PROPOSED

FERRO

ALLOY PLANT

Figure 2.1: Plant Layout



PROJECT DESCRIPTION

~ 22 ~ PECS, Nagpur

2.1.1 PROJECT COST

The total cost of the project is Rs.1637.55 Crore, which includes all proposed expansion

and new installation. The Breakup of the proposed investment is given in Table 2.1

Table 2.1 Breakup of Proposed Investment

Sr.

No.

Plant Description Estimated

Cost in (Cr.)

1. Expansion of Sponge Iron Plant by installing 2 nos of 350 TPD

Rotary Kilns.

150.00

2. Expansion of M.S. Billet Plant from 240 TPD to 480 TPD with

Ladle Refining Furnace

51.36

3. Expansion of TMT Steel Bar Rolling Mill from 66000 TPA to 1.5

Lac TPA

132.95

4. 2 X 16.5 MVA Submerged Arc Furnace Based 50000 TPA Ferro

Alloys Plant with a Sinter Plant

315.24

5. Electric Arc Furnace Based 4 Lac TPA Alloy Steel Billet Plant 248.55

6. 3 Lac TPA Alloy Steel Bar/Wire Rod/TMT Bar Rolling Mill 251.35

7. 1.5 Lac TPA Light & Medium Section Mill for Rolling of Steel

sections like Angles, Channels, round and other sections and

Beams.

162.25

8. 2.5 Lac TPA Heavy Section Mill for Rolling of Structural Steel

Heavy sections like Angles, Channels And Beams.

325.85

Total Estimated Cost in Rs. 1637.55



PROJECT DESCRIPTION

~ 23 ~ PECS, Nagpur

2.1.2. Production Scenario

The production scenario of the existing and proposed plant is given in Table 2.2.

Table 2.2 Existing and Proposed Production Capacities

Sr.

No

Name of Units Existing

Capacity

Proposed

Expansion

Total after

Expansion

1 Sponge Iron 60000TPA 231000TPA 291000TPA

2 Steel Billets 240 TPD 240 TPD 480 TPD

3 TMT Bar 66,000TPA 84,000 TPA 1,50,000 TPA

4 Captive Power plant 100MW -- 100MW

5 Ferro Alloys Plant, -- 50000 TPA 50000 TPA

6 Alloy Steel Melt shop -- 400000 TPA 400000 TPA

7 Alloy Steel Bar/Wire Rod/TMT Bar

Mill (Stainless Steel, Alloy Steel,

Carbon Steel & Wire Rods)

-- 300000 TPA 300000 TPA

8 Section Mill For Rolling of Steel

Sections

-- 150000 TPA 150000 TPA

9. Heavy Section Mill For Rolling of

Structural Steel Heavy Sections

- 250000 TPA 250000 TPA

The utility requirement for the proposed expansion project is given in Table 2.3.

Table 2.3Utility Requirement

Sr.

No.

Utility

Requirement

Existing

Requirement

Utility Requirement After

Amendment Request

For Proposed

Expansion

Total Requirement

1. Power 21.75 MW/Hr 70.75 MW/Hr 92.5 MW/Hr

2. Compressed Air 7648 m3/hr 5981 m

3/hr 13629 m

3/hr

3. Water 606 m3/day 2403 m

3/day 3009 m

3/day

4. Manpower 395 nos. 670 nos. 1065 nos.



PROJECT DESCRIPTION

~ 24 ~ PECS, Nagpur

2.1.3 Raw Material Requirement

The main raw material for the industry is Quartz and other raw materials are Iron Ore,

Electrode paste, Manganese Ore, Dolomite are procured from nearby mines in

Maharashtra and Chhattisgarh for the proposed project.

Source of Coal

By E-Auction from various WCL Coal mines. In addition to this TUML is a successful

bidder for Marki Mangli I Coal block in District Yavatmal which is at 150 km

distance. Copy of vesting order is enclosed as Annexure X.

The raw material requirement for the proposed expansion and new unit is given in

Table 2.4.

Table 2.4 Raw Materials Requirements & Sources

Sr.

No

Raw Material

Requirement

Existing

Requirement

Raw Material Requirement After Amendment

Request

For Proposed Expansion Total Requirement

1. Manganese Ore ------------- 7050 MT/M 7050 MT/M

2. Ferro Alloy 100 MT/M 600 MT/M 700 MT/M

3. Pig Iron ----------- 3500 MT/M 3500 MT/M

4. Billets 5850 MT/M 70275 MT/M 76125 MT/M

5. M. S. Scrap 1140 MT/M 6405 MT/M 7545 MT/M

6. Sponge Iron 7200 MT/M 36615 MT/M 43815 MT/M

7. Coal (DRI+ Power

plant+ Rolling mill)

69300 MT/M 28875 MT/M 98175 MT/M

8 Iron Ore/Pellets 7500 MT/M 28875 MT/M 36375 MT/M

9. Dolomite 750 MT/M 2888 MT/M 3638 MT/M

2.1.4 Water Requirement

Total water requirement for the present and expansion project is 3009 m3/day. The

source of water is met from 3 km away Paradgaon dam. The Water requirement is

primarily for industrial use (for cooling only), make-up, dust suppression system, green

belt, domestic and other miscellaneous use.



PROJECT DESCRIPTION

~ 25 ~ PECS, Nagpur

The Company has got a water allotment of 0.2 Million Cubic Metres per annum with a

provision of withdrawing additional water upto 10% extra over and above agreed quota

of 0.2 Million Cubic Metres/Annum at same rate. Water allotment letter is enclosed as

Annexure-IV. To meet this additional water requirement, the Company has also

applied for 0.5 Million Cubic Metres/Annum as additional sanction for mitigating the

future water requirements which will be as below.The water balance is given below in

Table 2.4 and water balance diagram of existing and expansion project is given as

Figure 2.2and Figure 2.3 respectively.

EIA study for expansion of Sponge iron plant, Induction furnaces, TMT Rolling mill & installation of Ferro alloys unit, Alloy steel billet plant, Rolling

mill and Structure mill

PROJECT DESCRIPTION

~ 26 ~ PECS, Nagpur

TABLE 2.5 WATER BALANCE

Make up Water Requirement For TopworthUrja& Metals Limited (For Existing & Proposed Expansion)

Sr.

No

Name of Units Existing Water

Requirement per Year

Proposed Water

Requirement per Year

Total Water Requirement

after Expansion

1. Sponge Iron Plant 6000 Cu. Mtr. 23100 Cu. Mtr. 29100 Cu.Mtr.

2. TMT Bar 23100 Cu. Mtr. 29400 Cu. Mtr. 52500 Cu.Mtr.

3. Steel Billets 14400 Cu. Mtr. 14400 Cu. Mtr. 28800 Cu.Mtr.

4. 30 MW Captive Power Plant in

operation

42768 Cu. Mtr. - 42768 Cu.Mtr.

5. 2 x 35 MW Captive Power Plant

is in construction

99792 Cu. Mtr. - 99792 Cu.Mtr.

6. Ferro Alloys Plant - 205920Cu.Mtr 205920Cu.Mtr

7. Alloy Steel melt shop - 240000 Cu. Mtr. 240000 Cu. Mtr.

8. Alloy Steel Bar Mill - 105000 Cu.Mtr. 105000 Cu.Mtr.

9. Light & Medium Section Mill For

Rolling of Steel Sections of Alloy

Steel & Carbon Steel

- 52500 Cu.Mtr. 52500 Cu.Mtr.

10. Heavy Section Mill For Rolling

of Steel Heavy Sections

- 87500 Cu.Mtr. 87500 Cu.Mtr.

11. Drinking & Sanitation 13780 Cu. Mtr. 35245 Cu.Mtr. 49025 Cu.Mtr.

12. Total in Cu. Mtr/year 199840 Cu. Mtr 793065Cu.Mtr 992905Cu.Mtr.

13. Total Cu.M/day 606 Cu.M/day 2403 Cu.M/day 3009 Cu.M/day



PROJECT DESCRIPTION

~ 27 ~ PECS, Nagpur

Figure 2.2



PROJECT DESCRIPTION

~ 28 ~ PECS, Nagpur

Figure 2.3



PROJECT DESCRIPTION

~ 29 ~ PECS, Nagpur

2.1.4.1 WATER TREATMENT PLANT

The raw water is being treated in a DM plant to maintain quality required for the high

pressure boiler. The effluent from the DM plant is being treated in a neutralization pit

before letting into the guard pond.

The blowdown water from the auxiliary cooling tower and the boiler is taken to the

Neutralization pit and from there to the Guard pond after neutralization. After cooling,

water is pumped for green belt development and ash conditioning/wetting to prevent

fugitive dust emission.

Plant have the two stream of 15m3/hr DM plant followed by single ultra filtration

system

The proposed scheme of water treatment plant is furnished below.



PROJECT DESCRIPTION

~ 30 ~ PECS, Nagpur

2.1.5 Power Requirement

The existing power requirement is 21.75 MW and after expansion it will required 70.75

MW. The existing and expansion project will require a total of 92.5 MW power. The

power requirement is/will be met from 100 MW existingPower Plant (30 MW in

operation and 2 x 35 MW under installation for which Consent to Establish and



PROJECT DESCRIPTION

~ 31 ~ PECS, Nagpur

Environmental clearance is already obtained from MPCB/MoEF, Mumbai. The Power

consumption (Electrical Energy) for existing &proposed plants is given in Table 2.6

Table 2.6:Power Consumption

Sr.

No.

Energy required for Existing Power

Consumption

Proposed Power

Consumption

Total Power

Consumption in

MW

1 Induction furnace 8.5 MW 8.5 MW 17 MW

2 Rotary kiln 1 MW 2.5 MW 3.5 MW

3 Rolling mills 2 MW 8.5 MW 10.5 MW

4 Submerged arc furnace - 23.5 MW 23.5 MW

5 Arc Furnace Steel melting

shop

- 25 MW 25 MW

6 Power Plant Home Load for

auxiliary consumption

08 MW - 08 MW

6 Pollution control equipment 1.5 MW 2 MW 3.5 MW

7 Plant lighting 0.75 MW 0.75 MW 1.5 MW

Total 21.75 MW 70.75 MW 92.5 MW

2.1.6 Land Requirement

M/s TopworthUrja and Metals Ltd (TUML), has identified 160 acres (64.7996 ha) of

land at village Heti, Tehsil Umred, District Nagpur. The proposed project site is about

35 km south east of Nagpur city. The plant layout has been developed considering the

wind direction, environmental constraints, and power evacuation corridor. The plot for

the Project isdeveloped taking into consideration various aspects like available land &

its shape, ground features & terrain, corridor for outgoing transmission lines, approach

road, prevailing wind direction and the water availability. The breakup of land use as

per the plant requirement are given in Table 2.6



PROJECT DESCRIPTION

~ 32 ~ PECS, Nagpur

Table 2.7: Break-up of Land Use (Existing and Proposed)

Sr No Description Area (Acres)

1 Plant machinery 45

2 Building construction 12

3 Green Belt (Plantation) 50

4 Open Space 53

Total 160

Out of 160 Acres of land, 50 Acres of land is for existing plant including all the units

and 110 Acres of land is for the proposed expansion project.

2.1.7 Employment potential

The existing project has employment for 395 people. The proposed expansion project

generates employment for 670 people. The total number of employment in existing and

expansion project will be 1065 people. Local people will be employed based on their

qualification and skill.

2.1.8 Transport :

SH 9 is 0.5 km; east from the project site and NH 7 at the distance of 24 kmsand a

major district road passes by along theproject site and Butibori railway station is just

35 Kms from the project site.

2.2 PROCESS DETAILS

The major facilities envisaged for this plant are as follows:

2X16.5 MVA Submerged Arc Furness based 50000 TPA Ferro Alloys Plant

with required Sinter Plant

Enhancement of capacity of existing TMT Bar Mill from 66000 TPA to 1.5 Lac

TPA.



PROJECT DESCRIPTION

~ 33 ~ PECS, Nagpur

Enhancement of capacity of existing Billet Plant from 240 TPD to 480 TPD

Steel Billet plant by installing additional 2X12 Ton Induction Furnace and also

Installation of Ladle Refining Furnace for production of better quality of steel.

Enhancement of capacity of Sponge iron from 60,000 TPA to 2,91,000 TPA by

installing 2 nos of 350 TPD rotary kilns

400,000 TPA Steel Melt Shop for production of Alloy steel Billets

300,000 TPA Alloys Steel Bar Mill.

1.5 Lac TPA Light & Medium Section Mill for Rolling of Steel sections.

2.5 Lac TPA Heavy Section Mill for Rolling of Structural Steel Heavy Sections.

2.2.1 FERRO ALLOYS PLANT FOR 50000 TPA CAPACITY

Technological considerations and selection of facilities

300 TPD Sintering machine

The main areas in the Mini Sintering Plant are:

Charge preparation

Mixing and nodulizing drum

Sinter machine

Sinter cooling system

Sinter plant automation

Environmental pollution control equipment

FERRO ALLOY SMELTING SHOP (SUBMERGED ARC FURNACE)

Based on the production capacities of various furnaces, 16.5 MVA furnace for each FeMn OR

SiMn and FeSi OR SiMn has been considered for the target production. For production of

FeMn and SiMn, both furnaces can be used to make the same and will be determined by the

market conditions. The major components of the submerged arc furnace are as follows:

Set of single phase transformers

Electrode columns



PROJECT DESCRIPTION

~ 34 ~ PECS, Nagpur

Secondary conductor systems

Furnace covers

Furnace smoke hoods

Forged pressure rings

Forged contact clamps

Furnace linings

Stoking equipment

Tapping equipment

Furnace control systems

Bag filters

Furnace charging systems

PRODUCT CASTING MACHINE

One number Pig Casting machine of 150 TPD capacity is considered for casting of Ferro

manganese and Ferro silicon produced from submerged arc furnaces.

SMELTING SHOP COMPLEX

The smelting shop complex would comprise of furnace building, day bin building, gas cleaning

plant buildings, laboratory, cooling water pump house, compressed air station etc.

The furnace building would be laid out in 4 longitudinal parallel bays. The day bin buildings

would be located close to the furnace building and parallel to it towards the raw materials

storage yard so that individual skips could be installed to deliver the charge-mix to the top of

the furnace. The gas cleaning plant buildings would also be Located close to the furnace

building and parallel to it towards the raw materials storage yard and by the side of the day bin

buildings so as to reduce the lengths of gas ducts and to avoid any possible contamination of

the finished products with the separated dusts.



PROJECT DESCRIPTION

~ 35 ~ PECS, Nagpur

REPAIR AND MAINTENANCE SHOPS

In order to meet the repair and maintenance needs of the various plant units, the following

facilities would he provided.

Repair shop

Servicing garage

Mechanical Repair Section

Repair Shop

The repair shop building would occupy on area of 40m x 12m, with road approaches to bring

in and take out the materials and equipment. It will have separate sections for mechanical

repair and electrical repair.

Servicing Garage

The servicing garage for transport equipment would be located in a separate building having a

covered area of 18m x 12m, with adequate road approaches.

Laboratory

To ensure technological control at all stages of processing and to maintain the desired quality

of end product, adequate laboratory facilities are required. The major facilities for the

laboratory would include jaw crusher, roll crusher, vibrating grinder, sieve shaker, weighing

scale, infra-red moisture tester, single pan analytical balance, hooting pads, Gas analyser,

carbon and sulphur determination apparatus, photoelectric colorimeter, conventional wet

chemical analysis, X-ray fluorescence spectrometer, induction melting furnace, briquetting

press and swing mill.

Administrative Building

Proposed Administrative/ Canteen Building shall be a modern two storey RCC framed

structure of size 36m x15m with total built up area of 900 sqm. Ground floor hall

accommodate Entry Lobby, Security In-charge Room, First-aid Room, Store-Room, Workers



PROJECT DESCRIPTION

~ 36 ~ PECS, Nagpur

Change Room and Toilets, canteen and kitchen. Office-Incharge Room, Office areas,

Conference Room, Pantry and Toilets are being located in the first floor.

RAW MATERIAL AND SERVICES

The minerals required for the proposed Ferro-alloys plant are manganese ore, quartzite and

dolomite. Other raw materials include coke, mill scale and iron/mild steel turnings and borings.

The process flow diagram of Ferro Alloys Plant in given in Figure 2.4

Figure 2.4

Process Flow Diagram For Ferro Alloy Plant

2.2.2 4 LAC TPA ELECTRIC ARC FURNACE BASED ALLOY STEEL BILLET PLANT

(Steelmaking by Electric Arc Furnace)

In Electric Arc Furnace recycled steel scrap and DRI is melted and converted into high quality

steel by using high power electric Arcs. Modern EAF is a tool to convert solid raw materials in



PROJECT DESCRIPTION

~ 37 ~ PECS, Nagpur

to liquid crude steel as fast as possible and then refine further in secondary steel making

processes.

The furnace consists of a circular bath with a moveable roof, through which three graphite

electrodes can be raised or lowered.

At the start of the process, the electrodes are withdrawn and the roof swung clear. The steel

scrap is then charges into the furnace from a large steel basket lowered from an overhead

crane.

When charging is complete, the roof is swung back into position and the electrodes and

lowered into the furnace. A powerful electric current is passed through the charge, an arc is

created and the heat generated melts the scrap. Lime and fluorspar are added as fluxes, and

usually carbon and oxygen are blown into the melt. As a result, impurities in the metal

combine to from a liquid slag.

Samples of the steel are taken and analyzed to check composition and, when the correct

composition and temperature have been achieved, the furnace is tapped rapidly into a ladle.

Final adjustments to customer specification can be made by adding alloys during tapping or

later in a secondary Steelmaking unit.

Refining the Liquid Steel Ladle Refining Furnace (LRF)

The Liquid Steel from the EAF is tapped into a pre heated ladle. The ladle is taken to Ladle

Refining Furnace for carrying out refining operations. The ladle is fitted with porous plug and

an inert gas is purged through the steel bath during entire refining operation. The steel is

deoxidized and de-sulphurised by treating under basic reducing slag which is rendered fluid by

arc heating and also by adding fluorspar to it. For making/ reducing &desulphurising slag,

burnt lime, fluorspar, ferro-silicon and powdered coke are normally added. The reducing slag

reduces the oxides in the bath and assists in the removal of sulphur as calcium sulphide. The

desulphurization is also promoted in presence of sufficient quantity of manganese in the bath,

high basicity of slag and high bath temperature. By blowing with the inert gas, the metal in the

ladle is stirred and as a result of purging its temperature and composition are equalized and



PROJECT DESCRIPTION

~ 38 ~ PECS, Nagpur

non- metallic inclusions would float up to the surface. Necessary ferro-alloys are added to the

liquid steel through a port on the ladle cover after the bath has been fully deoxidized. A

sample is, thereafter, drawn out and sent to the laboratory for final analysis. Further arc power

may be applied to increase the temperature to the desired level, if necessary. As soon as the

final analysis conforms to the desired composition and proper temperature has been attained,

the ready metal is transferred to vacuum degasser.

Vacuum Degassing

A ladle of liquid is transferred by overhead crane from the LRF unit to the vacuum degasser.

The ladle is placed in a cylindrical tank and is supported inside the tank. The tank is

constructed with the steel plate and is lined with refractory.

When the ladle has been located in the tank and inert gas supply is connected to one or more

porous plugs located in the refractory lining in the bottom of the ladle. Inert gas is blown

through the plug at control rate to stir the liquid metal in the ladle and expose the surface of the

liquid steel by pushing aside the slag layer on the surface.

The tank equipped with a flange around the upper periphery of the tank side wall is then sealed

by a cover which is located in self propelled car. The car drives over the tank and then covered

is lowered until the flange around the lower edge of the cover is connected with the tank

flange.

An O ring seal between the two flanges creates a vacuum tight seal. The volume enclosed by

the tank and the cover is then evacuated by a set of vacuum pumps connected to the tank. As

the pressure in the tank falls, the flow of inert gas through porous plug in the bottom of the

ladle can be adjusted to create the required degree of turbulence in the ladle. The dissolved

gases like hydrogen, oxygen etc are removed by effusion from the surface of steel to the low

pressure surrounding atmosphere.

In case of un-killed steels, carbon and oxygen in metal bath react under vacuum to form carbon

monoxide, which is then removed from steel in bubble form and is extracted from the tank by

vacuum system. Under vacuum conditions, the steel can boil quite violently, and for this



PROJECT DESCRIPTION

~ 39 ~ PECS, Nagpur

reason there should be sufficient freeboard of 0.9 to 1.0m in the ladle above the normal liquid

steel surface to accommodate the reaction.

The vacuum cover can be equipped with a vacuum lock with arrangement for automatic

weighing and batching of alloy additions without disturbing low pressure conditions within the

vacuum tank during treatment.

Alternately a simple pre filled vacuum bunker can be attached to the vacuum cover, which is

manually pre filled with alloys.

AOD CONVERTER

Converter process of Argon Oxygen Decarburization (AOD) was introduced in early 1970s,

and is now the preferred route for specialty electrical steel and stainless steels. Granulated flux

injection into liquid steel combined with argon stirring was also introduced in 70s. This was

soon followed by the application of cored wired feeding of alloying elements for better control

of composition and inclusion morphology. Secondary refining equipment mainly used in final

refining step for stainless production includes AOD furnace. Stainless steel contains a large

amount of chromium as a basic component. Since chromium is a strong oxides forming

element, during normal refining it is difficult to decarburize stainless steel to a sufficiently low

carbon level while preventing loss of chromium through oxidation to slag phase. Thus low

carbon levels are achieved by decreasing the partial pressure of carbon mono oxide in the

refining atmosphere to ensure preferential decarburization in the presence of chromium. In

practice this is in done in AOD furnace by dilution with argon and in VOD furnace by

reducing the pressure.

Description of AOD unit

The AOD Converter Plant shall be located near the furnace. The Steel scrap/DRI is melted

down in the Furnaces. The molten metal at temperature of 1600-1650C is transferred to the

AOD Converter Vessel via overhead crane to refine to the desired chemical composition by

addition of required Alloys/Fluxes and use of various gases. The gases media such as Oxygen,

Nitrogen, Argon& Compressed Air is injected into AOD Converter through High Blowing rate



PROJECT DESCRIPTION

~ 40 ~ PECS, Nagpur

Tuyers for good mixing effect and excellent heat efficiency. The AOD Converter complete

system comprises of following main equipments

Converter Vessel complete 2 Nos.

Top Conical Cover 2 Nos.

Trunnion Ring with Two Forged Shafts 1 No.

Main Pedestals base with Plummer Block fitted with G.M. Bushes 2 Sets

Tilting Unit consisting of drive and motor 1 set

Primary fume extraction system

Electrical Equipments like slipring Motor, Control Panel, Starter, Resistance Box,

Master Controller, Wiring, Cabling control desk.

Mechanical Equipment consisting of

Helical reduction gear Box - 01 No

Self-Aligning spherical Roller Bearing with Housing - 01 Nos

Open Gear Ring Pinion 01 set,

Arrangement with full Geared Coupling, Brake Drum, and Thruster Assembly with

brakes - 03 Nos. complete in all respects.

Item (a) & (b) mounted on steel base frame.

Rotary Pipe Joint: 02 Nos. (for Gas Supply)

Electrical Push Button Panel operated, Microprocessor Based Auto Type Gas Mixing

Station having Digital Type Flow Meter / Totaliser for Gases Complete unit.

Motorized Sampling Trolley with Drive Mechanism -1 No.

AOD Tuyer Pipe complete Assembly with end fittings & flexible piping -1 Lot

Water Cooled Hood, Bend & Pipe Line -1 Unit

Water Cooled Oxygen Top Lance Unit Complete With Drive Arrangement (Optional

Equipment)

Motorized moving Hood Trolley with Drive Mechanism.

Documentation & Manual.



PROJECT DESCRIPTION

~ 41 ~ PECS, Nagpur

UTILITIES AND THEIR CONSUMPTION

Media Purity% Max. ----- Oxygen 99.5

Pressure kg /cm2 -------------18

Flow Rate (max.)Nm3/ton ---1.25(Maximum blow rate 1.6)

throughTuyer ----------60 70 M3/ton

Consumption for stainless steel grades

Nitrogen 99.9 18 0.6 30 - 40

Argon 99.9 18 0.5 2 - 12

Compressed Air 18 0.5 30

Consumption of utilities gases depends upon:

- Steel grade to be produced

- Carbon % opening in liquid metal

- Type of Ferro- alloy used in heat making

OXYGEN PLANT (BOO BASIS)

Plant parameters

S. No Item Parameter Unit Figures

1. Capacity 200 TPD

2. Gaseous Oxygen Purity % 99.5 Pressure kg/cm2(g) 30 Production Nm

3/hr 5840

3. Gaseous Nitrogen Purity % 99.9%



PROJECT DESCRIPTION

~ 42 ~ PECS, Nagpur

PROCESS DESCRIPTION

Compression, pre-cooling & front end purification

Through the air filtering device, the process air is cleared from dust and other mechanical

Contaminations & then compressed to the required pressure (about 6.2 bar A) by multistage

centrifugal compressor. It is then cooled down first by bringing in direct contact with normal

temperature water and then by chilled water. Recycled water is chilled by bringing it with the

direct contact with waste nitrogen in nitrogen wash tower, which is generated from cold box.

Then the air enters into the absorber tower.

The air coming from the outlet of the air water tower passes through a water, CO2 and

hydrocarbons adsorbing system, which is composed of two absorbers, filled with alumina and

molecular sieves. The two absorbers are working alternatively: one is in operation while the

other is being regenerated by waste nitrogen coming from the cold box. During the heating

regeneration phase of the adsorbents: waste nitrogen gas is heated in a reactivation heater to

about 150 C and then sent to absorbers during normal reactivation.

Air separation

Air Distillation

Most of the purified process air from the purification system is entered into the primary heat

exchanger in the cold box and cooled by the returning gas. Then it enters into the bottom of the

lower column at near its dew point for its first rectification. The rising gas is sufficiently

contacted with the dropping liquid in the column. Through heat & mass transfer, the nitrogen

concentration increases in the rising gas which transforms into pure nitrogen at the top of the

column. The pure nitrogen is fed into the main condenser evaporator at the top of the lower

column for condensation. At the same time the liquid oxygen in the main condenser evaporator

is gasified.

Some of the liquid nitrogen is used as the reflux of the lower column, the other liquid nitrogen

is sub cooled through sub cooler. A stream of it can be drawn out as product. Another one is

sent into upper column after throttling.



PROJECT DESCRIPTION

~ 43 ~ PECS, Nagpur

The liquid air generated in the lower column is sub cooled by the sub cooler which then enters

into the upper column for distillation after throttling. In the upper column, all the feed is

distilled once more and product gaseous nitrogen, gaseous oxygen, waste nitrogen and product

liquid oxygen are obtained.

Generation of cold

Most of the cold needed by the plant is generated by booster turbo expander. Some of the clean

air from the air purification system is entered into the booster which is driven by the turbo

expander. It is then cooled by the after cooler of the booster, fed into primary heat exchanger in

the cold box and then into turbo expander to expand and get cold. After being cooled to a

certain temperature, the expanded air is entered into the upper column for distillation.

Product distribution

Gaseous Oxygen

The gaseous oxygen is delivered out from the cold box and pressurized by a Oxygen

compressor then to Battery limit.

Gaseous Nitrogen

The gaseous nitrogen is delivered out from the cold box and pressurized by a nitrogen

compressor, then to Battery limit.

Waste Nitrogen

The waste nitrogen is used for regeneration of the molecular sieve absorber and its pressure

from the cold box is approx. 12 KPA.

Liquid Nitrogen

The liquid nitrogen is sent out through the cold box to liquid nitrogen tank.

Dry air used for instruments & Defrosting

The dry air for the plant instruments (during normal operation) and defrosting is drawn out

from the mole sieve absorber and sent separately to instrument air pipeline or to be locally

defrosted.



PROJECT DESCRIPTION

~ 44 ~ PECS, Nagpur

Distributed control system

The control system shall be designed to meet the process requirement of the oxygen plant and

concurrently will have the features of easy operation and reliability for ensuring stable and

long term run of the plant. The process control of the complete oxygen plant is done integrally

by the distributed control system. The oxygen plant is centrally supervised and operated from

the control room. Important operations and emergency shutdown shall be carried out through

operating stations and the important parameters shall be displayed, logged and alarmed through

DCS system. Local indication instruments and local operating devices shall be provided in

accordance with the process of the plant. DCS system shall consist of the operating station,

control station, printer communication line and interfaces. Field instruments and equipments

shall be provided to match the requirements of DCS & process. A hot standby shall be

provided for DCS system

CONTINUOUS CASTING OF BILLETS

Liquid metal from VD is transferred to the continuous casting machine for casting into billets.

The main operations involved in the whole process of turning out billets are:

i) Checking the individual major components of the casting machine and their

synchronized operation;

ii) Insertion of a dummy bar to close the bottom end of the mould;

iii) Accurate centering of the tundish over the mould;

iv) Transferring the ladle to the casting aisle and placing it on the ladle stand of the

casting machine;

v) Pouring of liquid steel from the ladle through a slide gate mechanism into the lined

tundish;

vi) Pouring of liquid steel into the water cooled mould through tundish;

vii) Passage of liquid steel through water cooled mould tubes initiated by withdrawing



PROJECT DESCRIPTION

~ 45 ~ PECS, Nagpur

dummy bar;

viii) Oscillation of the mould;

ix) Maintaining a constant level of liquid steel in the mould and introducing lubricants

into the mould throughout the casting process;

x) Controlling the intensity of cooling of the emerging billets in the primary and

secondary cooling areas; and

xi) Straightening and cutting of billets.

The most important component of a casting machine is the bottomless water cooled copper

mould. The internal shape and size of the mould tube is the same as that of the cross section of

the billet / blooms to be cast. To initiate casting, a dummy bar is inserted to the bottom end of

each mould, while the other end of the dummy bar is held by withdrawal/ straightening rolls.

Molten steel at the correct temperature is poured into the mould and when it reaches the

stipulated level, the withdrawal rolls, mould reciprocation unit are operated, cooling water

circulation through the mould and in the secondary circuit is started few minutes earlier the

actual casting operation is started. The dummy bar is withdrawn, followed by hot solidified

billet. The cooling water circulating around the mould has carried away enough heat from the

liquid steel to produce a solid outer skin of sufficient strength to safely envelop the still liquid

portion at the interior that too is solidified by a secondary cooling. The rates of solidification

and withdrawal are obviously inter linked. Before beginning to withdraw the dummy bar it

must be ensured that the outer casting of the billet is strong enough for the process to continue.

An error in this regard will cause break out of the strand, which will then remain inoperative

for the rest of that heat into casting. For obtaining satisfactory surface quality of billets and for

satisfactory performance in general, the liquid steel temperature, casting speed, the rates of

primary and secondary cooling must be controlled and matched. Usually this harmonization is

developed on the basis of practice in the particular plant. If the casting speed is increased to

raise output, the quality of the central zone of the billet may suffer because of increase in

unsoundness, chemical heterogeneity and prone to internal cracking.



PROJECT DESCRIPTION

~ 46 ~ PECS, Nagpur

Lubrication

For reducing friction between the mould wall and the solidifying steel, a vegetable water free

oil such as rapeseed oil is introduced to wet the inner wall of the mould above the metal level.

The oil then seeps downward to lubricate the portion of the mould wall in contact with the

solidifying steel. The cooling system of the mould prevents the oil from being burnt off.

Mould

The mould is made of copper of high purity and high thermal conductivity. The mould is

tapered, hard plated with chromium on the inner surface. The mould tube is a copper tube

fitted into a fabricated steel water jacket. The entire mould assembly together with its cooling

jacket is oscillated by an eccentric drive.

Secondary Cooling

The cooling in the mould, called primary cooling, solidifies only the outer crust of the billet

while its interior still remains liquid or semi-liquid. Hence the billet issuing from the bottom

of the mould is immediately subjected to a secondary cooling. Water jets spray water directly

on each of its faces all down its length. The spraying should be closely controlled so that the

cooling rate may match the withdrawal speed, steel quality and product shape.

Billet Cutting

The automatic gas cutting torches are provided for cutting billets to a desired length. The

equipment comprises a water cooled structure for trolley support. Auto cutter trolley with drive

mechanism, a gas and pneumatic panels suitable for both the strands. The trolley moves on the

rails above the hot strand in the direction of discharge. During cutting, torch swings like a

pendulum across the hot strand at a predetermined cutting speed. In the forward direction

trolley moves at casting speed swing to the clamping of the hot strand whereas retracting the

trolley to the home position is carried out by motorized drive. As soon as predetermined

length to be cut is sensed, the following commands are given:

i) Positioning of the torch at the edge of the billet;



PROJECT DESCRIPTION

~ 47 ~ PECS, Nagpur

ii) Clamping of hot strand by the clamps through pneumatic cylinder;

iii) Ignition of the torch by releasing oxygen and acetylene gas.

Upon clamping, the trolley moves forward along with the hot strand at the casting speed.

Torch drive starts thereby swinging the ignited torch across the hot strand and thereby cutting

it. As soon as the torch cleans the width of the billet, the following function will take place:

i) Ignition of the torch is put off;

ii) Movement of the torch by drive is stopped and the torch retracts back to the home

position;

iii) First group of discharge roller table is made on, thereby separating the cut billet

from the hot strand;

iv) Clamps holding the hot strand are released;

v) Trolley will retract to the home position.

This completes one full cycle of cutting a billet. The complete operation is automatic;

however, it can also be carried out by means of push buttons located on the control desk

Billet Processing

The billets from a particular cast are lifted from the cooling bank and stored separately. When

cooled, they are inspected on each face for defects, surface defects are normally removed by a

swing frame grinder, etc.



PROJECT DESCRIPTION

~ 48 ~ PECS, Nagpur

2.2.3 ENHANCEMENT OF CAPACITY FROM 240 TPD TO 480 TPD BY INSTALLING 2 X

12 TON INDUCTION FURNACE BASED STEEL BILLET PLANT AND

INSTALLATION OF LADLE REFINING FURNACE.

Steel Melt Shop (SMS) Division:

1) Presently, the company is having 2 x 12 Ton capacity Induction Furnaces along with 2

Strand, 6 x 11 meters radius Caster in the Steel Melt Shop to manufacture Steel Billets.

Now, as per market scenario the company proposed for enhancement of capacity of

Steel Melt Shop from 240 TPD to 480 TPD by installing the additional 2 x 12 Ton

capacity Induction Furnace. In current design of Induction furnace the chemistry of the

steel being manufactured and its quality is maintained by dilution method. The

proportion of the various ingredients in the charge mix is manua

ANALYSIS OF ALTERNATIVES (TECHNOLOGY)

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