FEASIBILITY REPORT of 900000 TPA (0.9 MTPA)...

FEASIBILITY REPORT of 900000 TPA

(0.9 MTPA) Pellet Plant

at

Gokulpur, PO: Shyamraipur, PS: Kharagpur

District Paschim Medinipur, West Bengal

by

RASHMI METALIKS LIMITED

Premlata Building, 6th

Floor, 39-Shakespeare Sarani

Kolkata- 700 017

OCTOBER 2014

Project Report of M/s Rashmi Metaliks Limited

RML_Pellet

CONTENTS

Chapter No Particulars Page No

Chapter-1 Executive Summary 3

Chapter-2 Introduction of the Project / Background

Information

10

Chapter-3 Project Description 18

Chapter-4 Site Analysis 37

Chapter-5 Planning in Brief 40

Chapter-6 Proposed Infrastructure 46

Chapter-7 Rehabilitation & Resettlement Plan 47

Chapter-8 Project Schedule & Cost Estimate 48

Chapter-9 Analysis of Proposed & Recommendations 49


RML_Pellet

CHAPTER-1

EXECUTIVE SUMMARY 1.1 Introduction

Rashmi Group of companies is a fast growing Group in the field of manufacturing Steel, Cement, Ferro

Alloy and Power. The company has developed core competence in minerals, steel and cement with 40

years of experience. The Group’s turnover is around Rs.3000 Crores and net worth is Rs.1000 Crores.

Rashmi Group awarded ‘Ultra Mega Project’ status by Govt. of West Bengal. The Group is also engaged

in import/export of Mineral & Mineral based products. The growth of the group during last few years has

been phenomenal and fast catching the attention of bankers, professionals and industry as a whole.

Rashmi Group, through a consortium of Steel Companies, has also obtained a coal block with a reserve of

700 million tonne of high quality coal from Govt. of India.

Rashmi Group founded in 1966 got impetus from its real promoter, a true visionary, Sri Sajjan Kumar

Patwari. The group has grown from merely a re-rolling mill to a full-fledged Cement Crushing Plant having

capacity of 2 lakh tonnes per annum at Jhargram in West Bengal. In addition to this, the Group also has a

Sponge Iron Plant with a capacity of 3.0 lakh t.p.a. at Jhargram, 25 MW Captive Power Plant and a Mini

Blast Furnace Plant of 2 lakh t.p.a.at Kharagpur in West Bengal.

M/s Rashmi Metaliks Limited has been set up a 0.9 million TPA Iron Ore Pelletization Plant at village

Gokulpur, P.O Shyamraipur, and Tehsil- Kharagpur, in Paschim Midnapur district of West Bengal

after obtaining the Necessary Consent to Establishment for 1.2MTPA Pellet Plant from West Bengal

Pollution Control Board on 12.08.2010. The commercial production was started after obtaining the

necessary consent, like Consent to Consent to Operate (CFO) 02.08.2012 from West Bengal Pollution

Control Board.

The Iron ore fines are utilized in Pellet making. The power required for the plant is made available from

WBSEDCL (West Bengal State Electric Distribution Company Limited).

The existing Pellet Plant falls under category ‘A’ project and requires Environmental Clearance from

MoEF, Govt. of India as per EIA Notification 2006 as per NGT order no. Appeal No. 05 of 2014 on

28.05.2014.


RML_Pellet

Rashmi Metaliks Limited has been taken a decision to regularise the existing Pellet Plant of capacity 0.9

MTPA as per guide lines of MoEF letter F.No.L-11011/12/2014-IA.II(I) dated 8th September, 2014.

1.2 Project Site

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinipur district of

West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7 and latitude 22˚21′31″N

and longitude 87˚17′21″E.The site is well connected with NH-6 which is passing beside the project site.

Nearest Railway Station is at Gokulpur just 1.5 KM away and Kharagpur Railway station is at about 5 km

by road from the project site.

1.3 Plant Layout

The Existing Plant is established in 10 acres of land over an area of 188 acre. The layout plan for proposed

project has been prepared in such a way that space is properly and purposefully utilized, process flow is

maintained and adequate circulation space is provided for operation and maintenance. The plant layout

map, which shows the layout of Iron ore Pellet plant, Administrative building, waste disposal area, raw

material storage yard, rain water harvesting pond, RWTP and green belt etc is attached.

1.4 BRIEF PROJECT DESCRIPTION

M/s Rashmi Metaliks Limited has set up anIntegrated steel Plant along with Iron Ore Pelletization

Plant at village Gokulpur, P.O Shyamraipur, Tehsil- Kharagpur in Paschim Medinipur district of

West Bengal.

The Iron ore fines are utilized in Pellet making. The power required for the plant is made available

from WBSEDCL & Captive Power. The existing capacity of the plant is given below:


RML_Pellet

Name of the Units Units, for which

permission obtained

from Statutory

Authorities

Units under

Operation

Units under

Construction,

obtaining NOC from

WBPCB

Units, to be

implemented in

future

MBF

1X215 M3

1X 320 M3

1X215 M3

1X 320 M3

Sinter Plant

2 X 25 M2&

1X70M2

(2X25 M2)

- 1X70 M2

Pig Casting Machine 600 TPD

0.12 MTPA

- -

DRI kilns

10X100 TPD +

3X350 TPD

6 X 100 TPD 4 X 100 TPD

3X350 TPD

-

SMS 500000TPA 180000 TPA - 380000 TPA

Oxygen Plant 60 TPD - - 60 TPD

Lime Calcination Plant 1200 TPD - - 1200 TPD

Iron Ore Beneficiation 1.5 MTPA

1.5 MTPA - -

Iron Ore Pellet (EC

from MoEF)

1.2 MTPA

(2x0.6) MTPA

0.6 MTPA 0.6 MTPA (applied for

CFO)

-

Iron ore Pellet including grinding in dry process

1.2 MTPA

0.9 MTPA 0.3 MTPA

Producers Gas Plant (10x 7500 NM3/ Hr

+ 1 X 6000 NM3/ Hr)

(10x 7500 NM3/

Hr

+ 1 X 6000 NM3/

Hr)

- -

Ductile Iron Pipe Plant 0.20

MTPA

0.14 MTPA - -

Rolling Mill TMT Bar

(8-32 mm) & Wire Rod (5.5

mm -12 mm) - 0.12 MTPA

TMT Bar

(8-32 mm) & Wire

Rod (5.5 mm -12

mm) - 0.12 MTPA

- -

CPP-WHRB based DRI based WHRB–

40MW

DRI based WHRB

– 12 MW

DRI based WHRB –

18 MW CPP

DRI based WHRB – 20 MW

CPP

CPP-AFBC based AFBC based - 6 MW - AFBC based

- 6 MW

-


RML_Pellet

1.5 RAW MATERIALS

Table No. 1: Annual Requirement of Raw Materials for 1.2 MTPA Pellet Plant (Full Capacity in Tons/year):

Quantity of

Raw Materials

Reqd. in

TPA

Sizein

mm

Source of

Raw

Materials

Mode of

Transport Iron ore fines 11,00,000 0 - 10 Orissa, Jharkhand Rail

Bentonite 20,000 0.074 Bhuj, Gujarat Rail

Coke 30,000 0 - 6 Australia Ship

Dolomite 21,100 0 - 50 Orissa, Chattrishgarh Rail /Truck

1.6 WATER REQUIREMENT & SOURCE

Total make up water requirement for the 0.9 MTPA Pellet Plant is 120 m3/day which is sourced at

present from the Ground Water. Water abstraction work at Kansai River bed is in progress. The

company has obtained permission from Govt. of West Bengal to draw water. A reservoir is

constructed inside plant. Estimated make up water requirement to replenish the process and

treatment losses for the facilities

Table No.2: Total Plant Raw Water Requirement

Items Total make - up water requirement

Pelletization process 100 m3/day

Domestic use & Misc. 20 m3/day

Total 120 m3/day

1.7 SOLID WASTE GENERATION AND MANAGEMENT

Table No. 3: Solid Waste Generation and Management

Sl.

No

Process

Unit

Solid waste Quantity Ton

/ Annum

Mode of disposal

Pellet Plant Dust from

APC devices

14000 Recycled in Pellet plant.

1.8 LAND

The Pellet plant of capacity 0.9 MTPA is installed over 10 acres area. Total project area is 188

Acres. No forest land was involved in the project site. All the land involved in the project site was

Private land. The entire land is now in the name of the plant and converted to industrial use.


RML_Pellet

Table No.4: Details of Land use break up

MKD.

NO.

DESCRIPTION SIZE IN (M.X M.) AREA IN (M.Sq.) STATUS

1. GREENARY 250914.0 EXISTING

2 TAILING YARD 87623.40 EXISTING

3. WATER RESERVOIR 20.0X15.0 300.0 EXISTING

4. WEIGH BRIDGE-4 20.0X15.0 300.0 EXISTING




8. MAIN GATE 60.0X6.0 360.0 EXISTING

9. OPEN YARD 60.0X116 6960.0 EXISTING

10. OPEN YARD 32.0X127 4064 EXISTING

11. OPEN YARD 32.0X130 4160 EXISTING

12.

PELLET PLANT

(NOC from WBPCB)

222X182.0 40404 EXISTING

PELLET PLANT

(EC from MoEF)

315X182.0 57330 EXISTING

13. OPEN YARD 315X118.5 37327 EXISTING

14. WATER RESERVOIR 147X102.5 15067 EXISTING

15. SINTER PLANT-2 152X186 28272 IN PROGRESS

16. MBF-2 250X100.0 25000 IN PROGRESS

17. SECURITY OFFICE 15.0X15.0 225.0 EXISTING

18. P & A 15.0X15.0 225.0 EXISTING

19. CANTEN

140X81.0

11340

EXISTING

20. STORE EXISTING

21. ADM. BUILDING EXISTING

22. DI PIPE PLANT 365X200 73000 EXISTING

23. ROLLING MILL 275X110 30250 EXISTING

24. SMS 187X81.0 15147 EXISTING

25. SETTLING POND 141X137 19317 EXISTING

26. SWITCH YARD 113X200 22600 EXISTING

27. SINTER PLANT-1 152X186 28272 EXISTING

28. MBF-1 120X326 39120 EXISTING


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1.8 GREEN BELT DEVELOPMENT

Trees like Sonjol, Debdaru,Sishu, palash, suitable for this regionare planted in compliance of

conditions of environmental clearance. With a view toattenuate air pollutants, to resist noise

propagation from power generation units and uptake of treated effluent to some extent, the green

belt all around the periphery of project sites and in vacant areas (33% of the total acquired land) is

being developed. Tree plantation has been undertaken in a large scale on land vacated after

cessation of construction activities. Open spaces, where tree plantation is not possible are planted

with flowering herbs and grass which act as soil binders and also helpful in preventing erosion of

topsoil.

1.9 AMENITIES/FACILITIES.

1.9.1 In-Plant Facilities

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station

e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in relevant factories act. The above facilities are adequately

furnished and equipped.

1.9.2 Employment

Establishment of small and medium scale engineering ancillaries, with cascading employment

opportunities; increased revenue to the state by way of taxes and duties; improved green cover;

Better communication and transport facilities; the proposed project has enhanced the

prospects of employment. Recruitment

for the unskilled workers for the plant is from the nearby villages. The basic

amenities viz. roads, transportation, electricity, drinking water, proper sanitation,

educational institutions, medical facilities, entertainment, etc. are developed as

far as possible.


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1.9.3 Medical Facilities/ Health care camps

Medicines are provided at the first aid centre present within the plant premises, which

cater to the needs of adjoining population. Periodic health camps like: Eye camp and Health

camps for treatment of other diseases will be conducted by the company doctors.

1.10 PROJECT COST:

The project cost is Rs. 170 Cores.


RML_Pellet

CHAPTER-2 INTRODUCTION OF PROJECT /BACKGROUND INFORMATION

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

M/s Rashmi Metaliks Limited, one of the renowned Pellet manufacturing company of India,

has set up already (0.6MTPA x 2 + 0.9 MTPA) 2.1 MTPA. MoEF already issued the

Environmental Clearance for the (0.6MTPA x 2) 1.2 MTPA Iron Ore Pelletization Plant in the year

of 2012. Also Consent to Establishment NOC issued WBPCB for 1.2 MTPA Pellet Plant during

the year of 2010. A Iron Ore Pellet Plant unit of capacity 0.9MTPA is operating after obtaining the

Consent to Operate from The WBPCB on the basis of Consent to Establishment “NOC” from the

date of 02.8.2012.The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of

Paschim Midnapur district of West Bengal. The area is situated in the survey of India Topo

Sheet No. 73 N/7 and latitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected

with NH-6 which is passing beside the project site. Nearest Railway Station is at Gokulpur just

1.5 KM away and Kharagpur Railway station is at about 5km by road from the project site.

Contact Address

Address for Mr.L. B. Chourasia, V. P. – Corporate Planning

Correspondence M/s Rashmi Metaliks Limited

39, Shakespeare Sarani, Premlata Building

6th Floor, Kolkata - 700017

Works (Plant Site M/s Rashmi MetaliksLimited

Address) At Village- Gokulpur

P.O.Shyamraipur

P.S.: Kharagpur

District: PaschimMidnapur, West Bengal

2.1.1 COMPANY BACKGROUND

M/s Rashmi Metaliks Limited (RML) is the leading Pellet manufacturing company in India. RML

is incorporated under companies Act on 30th

day of January 2004 which is a flag ship company

under Rashmi Group Company.


RML_Pellet

2.1.2 ABOUT THE PROJECT

M/s Rashmi Metaliks Limited set up an integrated steel plant consist of the following unit are

given below at Gokulpur village, Tehsil- Kharagpur, in paschim Midnapur district of West Bengal.

Name of the

Units

Units, for which

permission obtained

from Statutory

Authorities

Units under

Operation

Units under

Construction,

obtaining NOC

from WBPCB

Units, to be

implemented

MBF

1X215 M3

1X 320 M3

1X215 M3

1X 320 M3

Sinter Plant

2 X 25 M2&

1X70M2

(2X25 M2)

- 1X70 M2

Pig Casting

Machine

600 TPD

0.12 MTPA

- -

DRI kilns

10X100 TPD +

3X350 TPD

6 X 100 TPD 4 X 100 TPD

3X350 TPD

-

SMS 500000TPA 180000TPA - 380000TPA

Oxygen Plant 60 TPD - - 60 TPD

Lime Calcination Plant

1200 TPD - - 1200 TPD

Iron Ore

Beneficiation

1.5 MTPA

1.5 MTPA - -

Iron Ore Pellet (EC

from MoEF)

1.2 MTPA

(2x0.6) MTPA

0.6 MTPA 0.6 MTPA

(applied for CFO)

-

Iron ore Pellet including grinding in dry process

1.2 MTPA

0.9 MTPA 0.3 MTPA

Producers Gas

Plant

(10x 7500 NM3/ Hr

+ 1 X 6000 NM3/ Hr)

(10x 7500

NM3/ Hr

+ 1 X 6000

NM3/ Hr)

- -

Ductile Iron Pipe

Plant

0.20

MTPA

0.14 MTPA - -

Rolling Mill TMT Bar

(8-32 mm) & Wire

Rod (5.5 mm -12 mm)

- 0.12 MTPA

TMT Bar

(8-32 mm) &

Wire Rod (5.5

mm -12 mm) -

0.12 MTPA

- -

CPP-WHRB based DRI based WHRB–

40MW

DRI based

WHRB – 12

MW

DRI based WHRB

– 18 MW CPP

DRI based WHRB – 20

MW CPP

CPP-AFBC based AFBC based - 6 MW - AFBC based

- 6 MW

-


RML_Pellet

M/s Rashmi Metaliks Limited has set up a 0.9 million TPA Iron Ore Pelletization Plant at village

Gokulpur, P.O Shyamraipur, and Tehsil- Kharagpur, in Paschim Midnapur district of West

Bengal after obtaining the Necessary Consent to Establishment for 1.2MTPA Pellet Plant from

West Bengal Pollution Control Board on 12.08.2010. The commercial production was started

after obtaining the necessary consent, Consent to Operate from West Bengal Pollution Control

Board on 02.08.2012.

The production from the WBPCB granted pellet plant started on 2nd

August 2012. The

production capacity of the pellet as envisaged is as under:

Table No. 2 : Production Capacity

Sl.

No.

Plant Facility Product Capacity Duration Remarks

1. Pellet Plant Iron ore Pellet 0.6 MTPA 02.02.2012 Initially started

2. Pellet Plant Iron ore Pellet 0.9 MTPA 22.08.2014 Amendment of Capacity

Major raw material of Iron ore are sourced from the iron ore belt of Joda-Barbil region. Coking

coal is imported from Australia. Bentonite is sourced from Kutch of Gujarat. Dolomite is be

sourced from Sundargarh, Odisha.

2.2 BACK GROUND OF THE PROJECT /BRIEF DESCRIPTION OF THE

PROJECT

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinipur

district of West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7 and

latitude22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is

passing beside the project site. Nearest Railway Station is at Gokulpur just 1.5 KM away and

Kharagpur Railway station is at about 5km by road from the project site.

2.3 NATURE, SIZE AND MAGNITUDE OF PROJECT:

The Pellet Plant capacity 0.9 MTPA exists within the land area 10acres in the Rashmi Metaliks

Limited premises out of total area 188 Acres.

2.4 NEED FOR THE PROJECT:


RML_Pellet

• Under existing mining scenario, a great amount of Iron Ore Reserves comprising

of fines and lumps are available, which cannot be used directly for steel making.

• In line with Mineral Conservation & Development Rules’ 1988, and increasing

global demand, the low grade iron ores are to be upgraded Pelletization for DRI /

BF usage.

• Pelletization is a step towards mineral conservation and waste reduction. More

over these plants can act as a additional source of raw material for DRI/BF.

• Pelletization of the iron ore concentrate is considered in view of high

productivity, low energy consumption and eco-friendly process.

2.5 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/

REGION:

Iron Ore Pelletization Unit:

The project objective is to upgrade the abundant iron ore fines stored at the mine

heads through Pelletization Process and make it fit for use in DRI Kiln/ Blast

Furnace, thus preventing the loss of revenue our country is losing by selling these

low grade iron as ore reject materials. Higher percentage of Iron Ore Reserves in

the country comprises of fines and lumps. These Iron ore fines/lumps cannot be

directly used for steel making. These precious material resources (fines) are

being dumped in Export market in nominal prices. In order to preserve this

precious iron ore , Beneficiation and its onward Pelletization is most sought after

agglomeration process than sintering process in view of higher productivity,

energy consumption and eco-friendly manufacturing process.

The Ministry of Environment and Forest also encourages for establishment of Iron Ore

Pelletization plant to utilize the huge stock pile of iron ore fines.

The Pelletization of iron ore fines, which remain unutilized in most of the time or

exported at nominal prices is definitely helping the State/Nation in value addition

and also increases the resources of iron ore reserves including earning of

additional revenues from mineral for the State/Nation. Required grade of Iron Ore

and better grade Iron Ore pellet will be available to DRI plants of the region which

are at the edge of shut-down due to non-availability of required grade of iron ore

as well as quantity.

Looking at the projection of demand for Steel in the present market, it can be

realized that there is a considerable demand of Pellet in the steel making

industries. To meet the demand, new industries have to be installed. Hence, the

existing Pelletization Plant by M/s Rashmi Metaliks Limited is of great significance under

present scenario.


RML_Pellet

Environmental

• Protect the surrounding environment during operation of the plant with appropriate

environmental safeguards to meet community expectations in terms

of environmental outcomes and cost.

• Ensure that ecological balance of the area shall not be adversely affected by

activities of proposed project.

• Protect native flora & fauna, quality of local surface & groundwater.

Socio-Economic

• To improve the living standard of local inhabitants.

• To address community concerns, if any.

• To improve indirect means of livelihood.

• To improve the socio-economic condition of local people.

2.6 Demand and Supply Gap (Market Scenario)

With reference to the National Steel Policy 2012 and as per Mineral Conservation

and Development Rules 1988, Government is facilitating for installation of Iron

Ore Pelletization Plant for Iron Ore fines which is stocked abundantly in all the

mines for pellet making. The reason behind it, is to extract all the mineral

contents of the Iron ore for utilization in steel making as a step towards mineral

conservation and simultaneously reduce the accumulated iron ore fines stored in

all the mines.

As per National Steel Policy 2012, India is having a total resource of 28 Billion

Tonnes of High grade Iron Ore taking cut-off grade of Iron Ore is having 50% Fe

and the fact that the figure can rise with greater efforts towards exploration. The

currently assessed reserved of Iron Ore seem inadequate for a long period if the

steel industry capacity expansion and production potential are to be fully realized.

Therefore, best utilization of the mineral resources (in this case ‘Iron Ore’) is

required. Whatever the mineral constituent present in the ore need to be

extracted from the ore for best utilization of the ore, Beneficiation and

Pelletization are two such processes by which the iron ore reject and low grade Iron ore can be

made ready for steel making purpose. For long term supply of iron ore to the steel

manufacturers with the increasing demand of Steel & simultaneously to reduce the demand

and supply gap of the iron ore in the present scenario following steps are being taken by the

Government;

Government is enhancing its support for intensive R & D efforts for developing

techno-economically viable technologies of Beneficiation and Agglomeration

suitable for the mineral extracted from different iron ore regions of the country.


RML_Pellet

The Government is taking appropriate fiscal measures, whenever deemed

necessary to encourage beneficiation and agglomeration with special emphasis

on manufacture of pellets to substitute consumption of precious lump ores by

steel producers and thereby add to efforts of conservation and environmental

degradation caused by accumulation of iron ore fines. The Government bringing different

schemes to encourage investment in beneficiation depending on the ownership of the Iron Ore,

such as those coming from captive mines and those bought out from the market.

Mineral Conservation & Development Rules1988 is a step towards MineralConservation and waste

reduction. As per Mineral Conservation & Development Rules’ 1988, and increasing global

demand, the iron ores fines are to be upgraded through Pelletization for DRI / BF usage.

The targeted demand of the steel sector can be fulfilled in this way and the Iron Ore can be utilized

rather than stored as a waste.

The prevailing demand and consumption rate of mineral resources indicates that it

will come to an end in near future. So best utilization of all mineral resources need

to be done. High grade and low grade mineral fines need to be utilized for the

purpose. The Iron Ore Processing Industries and Steel making industries have

started adopting various modern technology for utilization of low grade mineral/

mineral reject for the purpose of steel making. Demand of Beneficiation and

Pelletization process is increasing each year in Indian market and also in global

market.

The pellet market consists of a small 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 and Sweden. The market leader in the industry is CVRD (Brazil), whose

prices are generally considered as benchmark price for pellets.

Percentage use of pellets in various blast furnaces in the world varies f rom 10% to 100%.

Considering specific consumption of iron bearing raw materials in blast

furnaces as 1.55 ton per ton of hot metal and replacement of iron ore & sinter by pellets on all India

basis was 7.5% during 2004-05, 10% during 2006-07, and 20% during 2011-12.

Existing all India capacity of Pellet production is 30-36 Million Tonne /Annum and it is likely to go up

to 50 Million Tonne in another one or two years. India is targeting pellet capacity of 80 Million Tonne

by 2015-16.


RML_Pellet

As per the National Steel Policy 2012, the Department of Steel, Government of India

has projected production of 300 MT of Steel by the year 2025-26. On the basis of

30% replacement of Calibrated Lump Ore (i.e. CLO) by pellet on minimum side, the

requirement of pellet would be 51 MTPA against the present installed capacity of

about 30-36 MT. Besides, the sponge iron plants in the country which are in verge of

closure due to non-availability of requisite CLO both in quantity and quality will

consume more than 60% of the pellet in the mix. Presently more than 400 Sponge

Iron units are there in the country. During 2008-09, about 250 Sponge Iron plants

were operating in the country and the production was about 20 MT. Assuming only

400 units will be in operation up to 2020 (Government does not encourage the

establishment of more sponge iron units as these units are one of the major

contributor of pollution) then these 400 units can produce about 30 MT of Sponge

Iron and will require additional 20 MT and more of pellet.

So our iron ore pellet making is a supportive step to fulfil the iron ore demand of our country.

2.7 Imports Vs Indigenous Production

Iron Ore Pellet

In the earlier period, as the Iron ore CLO was available at a very nominal price, the

pellet manufacturers were exporting the pellets produced by them. In the present

circumstances, the cost of the Iron Ore /CLO has gone up unprecedentedly.

Therefore, all the production of pellet in the country, are being utilized by the steel

producers/ DRI Plants.

Iron Ore pellets are superior to other substitutes due to its High Cold Crushing

Strength resulting in minimal fines generation while multiple handling and resulting

in increased savings. With uniform composition of material, size and Guaranteed

Porosity, Swelling Index and negligible moisture due to dry process provides an

added advantage for Smooth Operation in Kiln / Furnace and improves productivity

2.8 Export Possibility

Generally, Iron ore rejects/sub grade ore are exported at nominal price. If it will be export after

required up gradation then more revenue can be obtained which will help to improve the

economy of our country.

In the export market, the present & future DRI / HBI producers in South-East Asia and the

Middle East / North African Region are the potential destinations for the Indian Pellets.


RML_Pellet

Supplies from Brazil and Sweden are meeting the present Middle East/ north Africa

DR pellet requirement. With transport cost being a competitive factor, Paradeep

proximity to South-East Asia and Middle East/ North Africa would definitely give

advantage to Indian pellet market over the suppliers from Brazil, North America &

Sweden.

Due to higher cost of quality raw materials, countries like China are looking to import Iron

Ore pellets, considering the techno-economic advantages using pellets for hot metal

production.

2.9 Domestic Market

India produces about 65 MT of Steel /year, yet with a population of 1.15 billion, its

per capita consumption is just 40 Kg / year compared to a global average of 150 Kg/year.

Government is evaluating every plan to encourage this consumption level higher, which is

making a very natural impact on demand of steel with the supports from growing middle class

and massive long term infrastructure investment plans. Invariably we may say that the

potential of processed iron ore or pellets are huge. India's Ministry of Steel is preparing a policy

document on the infrastructure that will be required by an industry capable of producing as

much as 300 MT of Steel per year - illustrating the long term goal. Considering the huge

Demand & Supply pattern, the future of the existing Pelletization plant is encouraging.

2.10 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Total Manpower engaged during operation of the 0.9MTPA Pellet Plant is 200. Apart from this,

500-600 persons are indirectly benefited by this project during the operation phase for logistic.

Table No. 3: Employment status

Sl. No Category No. of Employees

01. Managerial staff 06

02. Technical staff 22

03. Highly Skilled staff 24

04. Skilled staff 35

05. Semi-Skilled staff 35

06. Unskilled staff 70

07. Clerical staff 8

Total 200


RML_Pellet

CHAPTER-3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

PROJECTS

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinapur


latitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is


Kharagpur Railway station is at about 5km by road from the project site. The existing Pellet Plant

is interlinking with our 0.5 MTPA Integrated steel plant.

3.2 LOCATION AND ACCESSIBILITY

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Midnapur

district of West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7

andlatitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is


Kharagpur Railway station isat about 5km by road from the project site.

Location details of the Project Site:

Village : Gokulpur

Tehsil : Kharagpur

District : Paschim Midnapur

State : West Bengal

Latitude : 22˚21′31″N

Longitude : 87˚17′21″E

Topo sheet No. : 73 N/7

Elevation of site : Average Elevation 34m AMSL

a. Road Connectivity: The Plant site is well connected with NH-6 which is passing beside the plant.

b. Rail Connectivity: Nearest Railway Station is at Gokulpur, about 1.5km in north-eastand Khragpur junction Railway station is around 5.0kM from the plant sitein south-East direction.

c. Airport: Nearest Air Kolkata Netaji Subash Chandra Bose International Airportwhich is about 130 km from the project site in North-East direction.

d. Port: Nearest port is at Haldia about 135 km from project site in South-East direction.


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Location Map


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Plant Boundary on Mouja Map:


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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

SELECTING THE PROPOSED SITE / SITE SUITABILITY:

Suitability of a site for a plant is decided taking in account the availability land,

Source of Raw Material Source, Source of Water, Source of Fuel, well developed

transportation infrastructure/ accessibility etc. The support of the general public

towards industrialization is also a major component before choosing a site for

installation of a Project.

Shyamraipur village of Paschim Midnapur in West Bengal District was selected for the project

considering all the factors that suits for installation of a project.

Highlights of the Considerations:

A. Availability of land which involves for handling Raw material and finished products.

B. Availability of Rail Transport for handling Raw material and Finished products.

C. Availability of good road infrastructure as very heavy equipments will be required to

betransported from the nearest state highway, railway line etc.

D. Availability of Raw Material.

E. Nearest of Market for Finished product.

Considering all above factors, site selection was carried out for implementationof the proposed

Steel project. The Company got good support from Government of WestBengalfor acquisition of

identified landand there is no habitation in the site.

3.3.1 Alternative site

The site in Gokulpur village was considered for the proposed project after evaluating a

no of socio-economic factors. The alternative sites for the proposed plant were Ray Dighi

village, Burdwan District of West Bengal. Due to none fusibility for development of private

Railway siding for Raw Materials handling, far way distance to water source and R & R

problem these sites were rejected, the Plant come in Gokulpur village in Paschim Midnapur

District of West Bengal.


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3.4 SIZE OR MAGNITUDE OF OPERATION

M/s Rashmi Metaliks Limited, one of the integrated steel along with Power generation, has set

up a 0.5 million TPA Integrated steel plant consisting Iron Ore Pelletization Plant. The company

got the permission for production of Pellet of total capacity 2.4 million TPA (1.2 MTPA EC from

MoEF and 1.2 PTPA Consent to Establishment from WBPCB), 2.1 MTPA (0.6x2 + 0.9) capacity

pellet plant commissioned and balance to be implemented 0.3 MTPA.

3.5 PROCESS DESCRIPTION-IRON ORE BENEFICIATION UNIT

3.5.1 Plant Layout

The layout has been developed keeping in view the need for unidirectional and streamlined

movement of materials. A streamlined road network has beenproposed to provide easy road

access to different plant units.

The major parameters considered to develop the layout are as given below:

i) Adequate area for locating Pellet plant.

ii) Adequate area for storage and handling of different raw materials.

iii) Adequate area for various auxiliaries and ancillary facilities.

iv) Approach road, Power Sub-station and Water supply etc.

v) Dump area for storage of waste materials.

vi) Adequate road and parking space ensuring safe and smooth movement of

man and materials within the plant premises.

vii) Raw water Reservoir and Rain water harvesting viii) Area

for Green belt.

ix) Administrative building

3.6 Iron Ore Pelletization Plant

a.Raw Materials

1) Iron ore

Requirement of iron ore fines for producing 0.9 million TPA pellet is 1.1 MTPA.

2) Bentonite

Requirement of Bentonite for producing 0.9 MTPA pellet is 20000 TPA.

3) Coke

Requirement of Coke for producing 0.9 MTPA pellet is 30000 TPA.


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4) Dolomite (Binder)

Requirement of Dolomite for producing 0.9 MPTA pellet 21000 TPA.

Table No. C3-1: Quality of Raw material

Iron ore Concentrate Bentonite Dolomite

Fe2O3 92.4% SIO2 48-55% SIO2 4-6%

CaO&MgO 1-2% AL2O3 15-21% CaO 28%

SiO2 2-3% Fe2O3 8-13% MgO 30%

Al2O3 2-3% CaO 0.7-3% LOI 38-40%

LOI 1.8-3.25% MgO 0.2-3% -- ---

Moisture 5 - 8% LOI 8-12% -- --

Coke

Fixed Carbon 65-70%

Ash 9-12%

Sulphur 0.6-1% max

Bulk Density 0.8ton /cum

Volatile matter 9-11%

Moisture 8-10%

Ash melting temperature >1350 0C

Calorific value >6000 Kcal/kg

A. Palletisation process description

Plant is sub grouped for study as explained herein,

Concentrate unloading handling storage and reclaiming,

Concentrate Drying , flux grinding , flux storage , blending and mixing

Pelletizing , screening , handling

Preheating ,

Roasting ,

Cooling ,

Product handling ,

Environment control equipment ,

Electrical system


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CONCENTRATE UNLOADING HANDLING STORAGE AND RECLAIMING,

This division includes the unloading, handling storage blending and reclaiming of the iron ore

Concentrate, This consist of,

Stacking conveyor Belt Tipper type,

Covered shed,

Intermediate hoppers,

EOT crane with Grab Bucket,

Disc feeders,

Weigh feeders,

Belt conveyors

CONCENTRATE DRYING, FLUX GRINDING, FLUX STORAGE, BLENDING AND MIXING

This consist of energy efficient Concentrate Dryer, Flux storage, weighing system, storage bins ,

conveyor belts , mixer , additive grinding and handling .

PELLETIZING, SCREENING, AND HANDLING

The basics requirement of the system is to produce the right size round green pallets with sufficient

strength, One Disc is designed to produce 50 –75 TPH pellet.

PREHEATING

Preheating process in Palletisation comprises with equipment like Travelling Grate Heat Resistance fans,

Multi-cone cyclones, ESP, Induced Draft Fan. In This process heat recovered in cooling of the fired Pellet

is reused for drying, preheating, heating operations.

ROASTING

This is most important part of the pelletization process; Heat is transfer though conduction as well

radiation from refractory, rotary kiln furnace is used for this application. This rotary Kiln is suitably

refractory lined so that radiation losses are minimized.

The kiln is designed to operate at 1.8 rpm and the speed is adequate to meet the additional handling of

material though it.


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COOLING

Cooler is 60 sq. meter cooling area , look to be adequate capacity to cater the additional handling of the

fired pellets , Two set of cooling fans is sufficient to meet the cooling requirements. The entire fan are

equipped with VVFD, we envisage the continuous operation of all three fans to cater additional quantity of

fired pellet. Each fan is of capacity of 1,00,000 NM3/hour with static pressure of 6000 Pascal .

PRODUCT HANDLING

Product handling equipment are of adequate capacity and can handle the additional capacity envisaged.

The storage capacity further can be expanded in length if require at lateral stage, At this stage we do not

envisage any additional requirements.

POLLUTION CONTROL EQUIPMENT

Equipment involved are Electrostatic precipitator, Multicone – cyclones, Bag Filters at product discharge ,

Pneumatic handling system, etc. The Multi cyclone are in closed circuit which helps in reduction in dust

loads and clean hot air to the system and final outgoing flue gas through ESP has below 50 ppm per

normal meter cube. So the entire system with bag filter, multi cyclone in closed circuit with ESP is

sufficient enough to control and give clean environment.

ELECTROSTATIC PRECIPITATOR

S. No. Description Unit Designed

1 Gas flow rate at ESP exit

CUM/Hr. 500000

2 Operating Temperature at ESP exit

Deg.C 90 – 120

3 Dust Load (concentration) at ESP inlet

g/N.Cu.M 30

4 Dust Load (concentration) at ESP exit

mg/N.Cu.M 50

5 Pressure drop across ESP for design conditions

Mmwc 25

6 Gas velocity at electrode zone on total area

m/sec 0.8

7 Treatment time

Secs 16.8

8 Overall dust collection efficiency with all fields in service (guaranteed)

% 99.833


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INDUCED DRAFT FAN – MAIN

S. No. Description Unit Designed

1

Designed - Gas flow rate

M3/Hour

4,40,000

2

Static pressure

Pascal

5000

3 Operating Temperature Deg centigrade 200

4

Rated Power

KW

1120

5 Type of coupling Hydraulic

INDUCED DRAFT FAN – HR FAN

Sr no Description Unit Designed

1 Designed - Gas flow rate M3/Hour 1,20,000

2 No of fans No 1+1

3 Static pressure Pascal 5000


5 Rated Power of each fan KW 400


MUTLICONE CYCLONE – DRYING ZONE

The heat, recovered in the process of palletisation, is collected from heating zone of the travelling grate

and utilised for preheating and drying of the green pellet ,

Sr. no Description Unit Designed


2 No of cyclones No 1+1


4 Operating Temperature Deg centigrade 450-550

5 Pressure loss Pascal 800-1000

7 Size of the cyclone Width 4500

Length 7000

Height 11000

8 Efficiency % 85-95

MUTLICONE CYCLONE – PREHEATING ZONE

The heat , recovered in the process of palletisation, is collected from heating zone of the travelling grate

and utilised for preheating and drying of thegreen pellet ,


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Sr. no Description Unit Designed


2 No of cyclones No 1


4 Operating Temperature Deg centigrade 450-550

5 Pressure loss Pascal 800-1000

7 Size of the cyclone Width 4500

Length 7000

Height 11000

8 Efficiency % 85-95

INDUCED DRAFT FAN – HR FAN-PFREHEATING ZONE



2 No of fans No 1



5 Rated Power of each fan KW 400


FORCED DRAFT FAN – COOLING FANS



2 No of fans No 3


4 Operating Temperature Deg centigrade Ambient

5 Rated Power of each fan KW 200 each


PNEUMATIC CONVEYING SYSTEM – FOR RECYCLING OF THE DUST COLLECTED AT

MUTLICONE CYCLONES AND ESP


1 Designed - capacity TPH 4.5

2 No of system No ESP – 6 , Multi-cone – 3 ,

Bag Filter – 3

3 Operating cycles per hour No / hour 16

4 Operating temperature Deg 60 - 100

ELECTRICAL SYSTEM

Electrical system designed is good enough to absorb the additional drives, Transformers and breakers are

of adequate capacities. Few feeders need to be inducted to provide power to the additional drives. We do

not envisage any major changes to the system.


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Pellet Making (2 x 0.6 MTPA iron ore pellets)

The pellet making process takes place in following steps:

1. Grounding of iron ore fines and additives and storage in silos.

2. Mixing of iron ore fines and additives

3. Balling unit (for making green pellets)

4. Indurations unit (for oxidizing the green pellet)

5. Gate Kiln

6. Cooler

7. Finished pellet stockpiles, stackers and declaimer system

Composition of Pellets:

Compression strength (kg/pellet) - 250

Tumbler strength- >3%

Screening index - <95%

Abrasion index - <5%

Reduction index – 70%

Alkalinity – 0 to 0.8%

Rate of expansion – 15%

Chemical composition – Total Fe- 63%, FeO – 1%


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The pellet plant shall operate on hematite iron ore fines having 8 to 9% moisture and shall be

transported from various sources to raw material storage yard at pellet plant site. Iron ore fines

from raw material storage yard shall be conveyed to iron ore silos within the pellet plant. From

there iron ore fines are dried in the rotary kiln to reduce the moisture contents below 1% before

feeding it to the ball mill to get the requisite fineness (-325 mesh, approx 80%). The additives

likes lime stone, bentonite and coke are also ground in a roller mill on time shearing bases to the

requisite fineness of 200 mesh. Than the ground iron ore fines and additives are transported

pneumatically to the respective silos in ground material storage units. Further, mixing in peddle

mixture, green pellet formation in palletizing disc, feeding green ball in furnace using double

deck roller screen and heat hardening of green pellets in indurating machine shall be carried out.

The hearth layer separation is done using naturally: the hearth being reused as hearth layer in

the furnace.

Apart from the above units all major service facilities like material handling, water supply system,

compressed air system, coal gas, ventilation and air conditioning, plant deducting, building

structure, civil works and industrial safety, electric, instrumentation and automation have been

envisaged for the proposed pellet plant.

The plant requires a multi-storeyed structural shed with footprint of 25 m x 12 m to house coal

and related process equipments. [

Material Balance

Input Materials Quantity (TPD) Output Materials

Quantity (TPD)

Iron ore fines 3550 Pellet 3000

Bentonite powder 55 Dust 85

Dolomite fines 56 Moisture 321

Coke fines 81 Burnt loss 336

Total 3742 Total 2445

3.8.1 Source of Major Raw Material

a. Iron ore fines: Iron ore fines are purchased from the iron ore belt of Joda-

Barbil region.

b. Coke: The possible source of coking coal will be Australia. Indian steel

plants import coking coal largely from Australia, from the coalfields located

in New South Wales and Central Queensland regions.


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c. Dolomite: Dolomite the sourced from dolomite mines operating in

Sundargarh district of Odisha.

d. Bentonite: It procured from the mines in Bhuj, Gujarat.

3.8.2 Mode of transport of Raw Material

It has been assumed that major raw materials like iron ore and coal are

brought to the plant from outside sources by rail. Iron ore fines are

fed to pellet unit through conveyor system. The

incoming raw materials transported from the Iron Ore Mines to Plant by rail and unloaded at RML

private siding in the plant premises.

3.9 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT

No waste water are generated from the process. The Solid waste like ESP dust,

Broken Pellets will be reutilised in pellet making by blending with the raw material.

The plant is designed in zero discharge concept. Effluent from raw water treatment

facilities are treated in settling pond and taken to common basin. DM plant regeneration are

neutralized and taken to common basin. Soft water regeneration effluent are neutralized and

are taken to common basin for reuse. CT blow down and boiler blow down of power plant

are taken to common basin and reuse in ash handling and dust suppression. Cooling water in

Pellet plant are completely recycled in closed loop. Domestic effluent aretreated in STP and

reused for green belt.

3.10 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER

REQUIREMENT AND SOURCE

3.10.1 Source of water

Total water requirement is about 120 m3/ day, which is drawn from ground water

source through, bore well. The water abstraction work from Kansai River is work in progress.

The company already obtained the permission from the department of WRID, Govt of West

Bengal.


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3.10.2 Summary of Plant Water Requirement

Table No. C3-4: Water requirement

Items Total make - up water requirement

Pelletization process (

Grinding system, Balling

disc., cooling, etc)

100 m3/day

Domestic use , Dust

Supression& Misc.

20 m3/day

Total 120 m3/day

3.10.3 External water system

Total water requirement will be about 120 m3 /day, which is drawn from ground water source

through bore well/Kansai River.

3.10.4 Plant water system

The plant water system comprises of clarified water storage tank having 10 days

storage, filtration plant to meet the plant drinking water requirement, de-

mineralization plant, softening plant for meeting quality of plant make-up water

requirement apart from clarified water to be supplied as make-up to various re-

circulating water systems. In addition, clarified water will be supplied for plant

fire-fighting system.

In order to conserve water to the maximum possible extent, independent re-

circulating systems with cooling towers, heat exchangers, pump houses and

treatment units wherever required have been used for the project. Make-up water

of desired quality will be supplied to each individual re-circulating system. In

order to make the plant as a zero effluent discharge plant, necessary treatment

facilities have been considered to treat the waste generated within the plant and

treated water will be reused for slag cooling, dust suppression as well as for

meeting plant gardening.

3.10.5 Re-circulating water systems

The re-circulating water systems for Pelletizing plant comprises of pump house having cold well

and cooling tower for indirect cooling water circuit, direct cooling water circuit and other having

cold wells with heat exchangers, softening plant for soft water cooling circuits.


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a. Emergency water (EW) system: For vital equipment which require

emergency water during power failure, emergency water overhead tank along with

emergency power supply to specific circuit of tank filling pump have been considered for

preventing equipment damage.

b. Make-up water (MW) system: The total make-up water requirement for

the plant is to be about 600 cum per day has been supplied to cold wells of

re-circulating water systems to replenish the process loss and evaporation

loss.

c. Soft water (SW) system (make-up): A part of make-up water from

clarified make-up water pump house is supplied to softening plant through filtration plant

wherefrom soft water is supplied as make-up to soft water re-circulating systems.

d. DM water (as make-up) system: Part of clarified water from make-up

water pump house is supplied to DM plant through filtration plant wherefrom DM water will

be supplied to power plant.

e. Drinking and sanitation (DW) system: To meet the water requirement

for drinking and sanitation, a part of filtered water will be supplied to drinking water

overhead tank after necessary chlorination where from water will be supplied by gravity

distribution header to meet the different consumers of drinking and sanitation need.

f. Fire-fighting water system: In order to combat fire within the plant, a fire

water ring main with hydrants system conforming to TAC norms has been

provided. For this a twin compartmentalized sumps adjacent to fire water

pump house have been installed. The twin compartmentalized sumps is

filled up with water by taking tapping from make-up water distribution

header to meet the fire water requirement during fire exigencies. The fire

water pump house is provided with main fire water pumps both electric and

diesel driven, jockey pumps along with its accessories. Provided with

suitable corrosion protection coating /wrapping /tapes and at road-crossings

pipe sleeve is provided.


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3.11 Energy:

5 MW Power is sourced from WBSEDCL (West Bengal State Electrical Distribution Company

Limited) in 132kV system & Captive Power Plant. This electricity is coming through 132KV HT

power distribution line. The plant has a LT Power distribution room to provided power. The total

contract demand for the plant is 35MVA. However, there is a D.G set, which get automatically

started within15 seconds of power failure.

3.12 Environment Management

Air pollution control measures

Pellet plants operation is principally associated with air emission arising out of process gas

from induration plant (travelling grate kiln). Further fugitive dust will be generated from raw

material handling section, coal grinding, flux grinding and proportionating section and finished

product handling. So following air pollution control measures proposed to be adopted in the

pellet plant.

3.13 SOURCE OF EMISSION AND DIS CHARGE

Table No. C3-7: Source of Emission and Discharge

Sl.

No

Process activity Pollutants released to

the environmental

Type of pollution

1. Raw materials handling,

stock house, stock piling

and materials transfer

Coal dusts, iron ore dusts,

other fugitive emission

from transfer points

Air pollution

2. Grinding and screening of

raw materials

Coal dust, iron ore dust Air pollution

3. Dumping of composite

solid waste comprising

thickener mud and slag on

the ground

Dusts from dumps, run off

dumping area, erosion of

dumps.

Air pollution, Land

pollution and

water pollution

4. Plant sanitary waste water Waste water with

biodegradable pollutants

Water pollution


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3.14 CONTROL MEASURES

Table No. C3-8: Control Measures

Sl.

No

Location / Shop Pollution control facilities

1. Raw material handling area,

materials transfer points

Dust suppression system comprising of bag

filters, spray nozzles and piping network etc.

2. Pellet Plant a. Raw material Handling- Bag Filter in close circuit.

b. Coal grinding - Bag Filter in close circuit.

c. Flux grinding- Bag Filter in close circuit.

d. Proportionating section- Bag Filter

e. Ball Mill- Wet Scrubber

f. Travelling grate, multi cyclone in close circuit and rotary kiln- ESP

g. Hearth Layer Separation - Wet Scrubber

h. Finished product Handling - Bag filter

All stacks are suitable with pothole and working platform so that stack monitoring can be

done as per norms of statutory authority.

3.15 WATER POLLUTION:

Total make up water requirement for the project is 120 m3/day which are sourced

from the Ground Water through bore well and water abstraction from Kansai River is work in

progress. The company has due permission from WRID,Govt. of West Bengal to draw

required water.

Since the groundwater table is at safe label in and around the plant area, the ground water

availability and the ground water regime due to the existing plant will not be affected.

The domestic effluents from the canteen and the toilets within the plant premises will be

treated in STP and treated effluents will be used in green belt. The proposed plant has

achieved a zero discharge norms with reuse /recycling of treated water from different

treatment plants. Run off from various area such as ash disposal area, solid waste dumping

area and coal stock pile area will be passed through setting tanks before discharging to

outside.

In the iron ore pellet plant; there is no effluent generation from the process.

Water is used to maintain moisture in pellets. Further water is used for equipment

cooling which is completely recycled with make-up water. Scrubbing effluent will

be treated in settling tank and will be recycled in scrubbing with make-up water

in a closed circuit.


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CHAPTER 4

SITE ANALYSIS

4.1 CONNECTIVITY

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Midnapur


latitude22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is


Kharagpur Railway station is at about 5km by road from the project site.

Road: NH-6 is passing beside the existing project site in south

direction.

Rail: Nearest Railway Station is Gokulpurat about 1.5km and another junction Railway

station Kharagpur is around 5.0Km apart from the project site in South - East direction.

Air Port: Nearest Airport is NetajiSubash Chandra Bose International Airport at Kolkata,

Dumdam which is about 121 km from the project site in North – East direction.

Port: Nearest port is at Haldia about 130 km from project site in South-East direction.

Township: Nearest Town & District Head Quarter is Midnapur which is 8 km from the Site

North-East direction.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The Project set up over an area of 188 acres land. All the land involved in the project site was

private &WBIDC land. The entire land is now in the name of the plant and converted to industrial

use.

4.3 TOPOGRAPHY

The project area is mainly a plain land with an average elevation of 40 m MSL. The area is

situated in the survey of India Topo Sheet No. 73 N/7 and latitude 22˚21′31″N and longitude

87˚17′21″E. The KansaiRiver is flowing at a distance of 5.0 km from the project site in the

North direction.

There is no Reserve forest and hamlet or any habitation within the project site;


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Existing project location shown in Toposheet


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4.5 EXISTING INFRASTRUCTURE

No Infrastructure was there at the time of land acquisition. Infrastructure such as

temporary housing facility, Drinking water facility, First-aid facility, Toilet facility

are provided. Internal roads are developed inside the plant premises once all the

statutory clearances are obtained.

4.6 SOIL CLASSIFICATION

Five soil samples were collected from agriculture fields surrounding the project site. Soil samples were

collected from three different depths, 5-10 cm, 10-20 cm and 20-30 cm below the surface. The samples

were homogenized and the quantity was reduced by coning and quartering method. The samples were

packed in polyethylene bags. The soil sampling locations and analysis results are shown in Table 3.15

and Table 3.16.

4.7 CLIMATE DATA FROM SECONDARY SOURCES

The area experiences subtropical dry to wet climate. Summer starts from March and

continue up to mid-June and monsoon is from June to September. May is the hottest

month and December to January is colder months. The annual maximum

temperature varies from 28.40 C (January) to 43.60 C (May) while the annual

average minimum temperature varies from 14.40 C (December) to 29.50 C (May). On

an average 83% of rainfall is received during the monsoon season (i.e. July to

September). Wind direction and speed are most impact factors for the transportation of dusts.

Predominant wind direction is from S, SSW & NE direction.

4.8 SOCIAL INFRASTRUCTURE AVAILABLE

The project site comes under the administrative jurisdiction of Panchayat - Kalaikunda, Zilla Parishad -

Midnapur. Project area has education, drinking water facilities, transport facilities, School etc.


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CHAPTER-5

PLANNING BRIEF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES AND

TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/

DEVELOPMENT AUTHORITY CLASSIFICATION

M/s Rashmi Metaliks Limited has set up a 0.9 million TPA Iron Ore Pelletization Plant out of total

Consent to Establishment obtained 1.2 MTPA at existing Plant is located in the village Gokulpur,

P.O Shyamraipur of Paschim Medinipur district of West Bengal. The area is situated in the

survey of India Topo Sheet No. 73 N/7 and latitude22˚21′31″N and longitude 87˚17′21″E.The

site is well connected with NH-6 which is passing beside the project site. Nearest Railway

Station is at Gokulpur just 1.5 KM away and Kharagpur Railway station is at about 5km by road

from the project site. The Iron ore fines are utilized in Pellet making. The power required for the

plant is made available fromWBSEDC/Captive Power.

The site is well connected with NH-6 which is passing beside the plant. Nearest Railway Station

is Gokulpur 1.5Km apart from the existing plant site and ; at about

5km by road from the project site in South-East direction. The company has own private Railway

siding taking the take-off point from NimpyraGokulpur section for transportation of raw material.

5.2 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Total Manpower engaged during operation of the Pellet Plant is 200. Apart from this,

500-600 persons are indirectly benefited by this project during the operation phase for logistic.

Sl. No Category No. of Employees

01. Managerial staff 06

02. Technical staff 22

03. Highly Skilled staff 24

04. Skilled staff 35

05. Semi-Skilled staff 35

06. Unskilled staff 70

07. Clerical staff 8

Total 200


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5.3. LAND USE

The Project is over an area of 188 acres there is no forest land was involved in the project site. All

the land involved in the project site was private &WBIDC land. The entire land is now in the name

of the plant and converted to industrial use.

5.4 GREEN BELT DEVELOPMENT

Trees like Sonjol, Debdaru, Sishu, palash, suitable for this region are planted in compliance

of conditions of environmental clearance. With a view to attenuate air pollutants, to resist noise

propagation from power generation units and uptake of treated effluent to some extent, the

green belt all around the periphery of project sites and in vacant areas (33% of the total

acquired land) is being developed. Tree plantation has been undertaken in a large scale on

land vacated after cessation of construction activities. Open spaces, where treeplantation is not

possible are planted with flowering herbs and grass which act as soil binders and also helpful in

preventing erosion of topsoil.

5.5 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

The social infrastructure likes school and Primary Health Centre will be developed in this area.

However, the following facilities are installed within the plant site;

a. Electricity supply

b. Water supply

c. Administrative Building, Service Building

d. Construction offices and stores

e. Time and security offices

f. First Aid and fire fighting station

g. Canteen and welfare centre

h. Toilets and change rooms

i. Car parks and cycle/ scooter stands

System Design for high productivity

The productivity of the Unit and associated auxiliary objectives are achieved by adopting the

following principles;


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Use of equipment and systems of design performance and high availability which has been

fully established by a considerable record of successful operation for similar service

conditions in all plant facilities. Use of only proven design concepts and conservative designs. Strict

implementation of quality assurance norms during design, manufacture as well as installation and

commissioning stage.Strict compliance with the project company approved pre-commissioning and

commissioning roceduresas well as standard checklists forming a part of commissioning

documents for the project.

Sizing of critical equipment- margins & redundancy/standby

Adequate margins are provided while sizing all important auxiliaries and sub-systems to ensure

operation of the Unit at ultimate capacity under the worst conditions and taking into consideration

normal wear & tear.

Design for efficient operation

Centralized maintenance system is followed. All repairs of capital nature, heavy maintenance

jobs, refractory maintenance and plant civil maintenance are done by engaging specialized

external agencies.

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

standard user friendly software’s in the field of financial 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.

Operation Performance Management System (OPMS)

The operation of the plant will be optimized by implementation of OPMS. This system

will clearly define the responsibilities of all key O & M personnel including the shift-in-charge. This

will also cover the system of daily reporting to the project company Corporate Office and monthly

O&M review meetings.

Operation & Maintenance Philosophy

Most of the key positions in operation and maintenance of the proposed plant at different

categories are manned by the qualified persons having experience in the similar field. 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 carried out on site by the respective equipment supplier during equipment

erection, start up and commissioning of different plant units.


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O & M Organization

The major functions of the organization are briefly outlined below:

The Board of Directors formulates the policy and exercises overall control of the

organization through the Managing Director, who is the full time chief

executive. The Managing Director holds a dual office: as a member of the Board, he shares

the corporate responsibility of the other Directors; as chief executive, he is responsible to the Board

of Directors. In this capacity he is the link between the Board and the rest of the organization. He

interprets and implements the policies laid down by the Board. To enable the Managing Director

to exercise efficient control over the entire organization, the management functions are grouped

into two (2) major divisions namely (i) administration division and (ii) works division.

Functions of administration division:

The administration division is directly under the control of Director Administration

who is responsible for all administrative functions such as general administration

Personnel and human resource development, finance and accounts functions and

commercial functions. In carrying out these functions he is assisted by two General

Managers, namely General Managers Personnel and Administration, General

Managers Finance and Accounts. However, it suggested that some of the services,

such as canteen and catering services, horticulture and landscaping, security and

major fire fighting services, personnel transportation, general cleaning and sanitary

services are outsourced on contract basis but supervision of these functions is taken

care of departmentally.

Functions of works division:

The works division is under the overall control of a Director Works who is assisted by

one General Manager, one for production maintenance and services for environment division (i.e.

quality control and laboratory section headed by a Metallurgist and

environmental and safety) functions is directly under the control of Director Works.

General Manager (Production and maintenance) is in-charge of raw material handling,

Beneficiation Plant, Pellet Plant and power plant. General Manager (Environment and safety) is in-

charge of Environment division as well as quality control and safety.

Maintenance Management System

The maintenance of the plant is carried out as per the maintenance management system to be

developed by the project company. This system should aim at maximizing the availability

of the generating units while ensuring minimum maintenance cost and safety of plant &


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personnel. The system should cover organizational structures, preventive maintenance

schedules, detailed work specifications covering all maintenance jobs, permit-to-work

system, long term maintenance planning, safety aspects etc.

Spare Parts Management System

The primary objective of the system will be to ensure timely availability of proper spare parts

without excessive build-up of non-moving inventory. The system is covering the following aspects:

Proper codification/identification & retrieval of all spares & consumables Proper storage & protection

Spare parts indent and procurement policy Judicious fixing of inventory levels and spare part

ordering based on experience of similar Units or other benchmarks. Development of indigenous

sources/in-house capability for imported spare parts. Development of more than one source

wherever applicable.

O & M Training

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.

5.5 AMENITIES/FACILITIES

5.5.1 In-Plant Facilities

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores

c. Time and security offices

d. First Aid and fire fighting station


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e. Canteen and welfare centre

f. Toilets and change rooms

g. Car parks and cycle/ scooter stands

h. Training centre

Office space has been provided as per good practice and canteens, toilets and

restrooms according to norms laid down in relevant factories act. The above facilities shall

also be adequately furnished and equipped.

5.5.2 Employment Generation:

• Establishment of small and medium scale engineering ancillaries, with

cascading employment opportunities;

• Increased revenue to the state by way of taxes and duties;

• Improved green cover;

• Better communication and transport facilities;

The project has enhanced the prospects of employment. Recruitment for the unskilled

workers for the plant is from the nearby villages. The basic amenities viz. roads,

transportation, electricity, drinking water, proper sanitation, educational institutions, medical

facilities, entertainment, etc. are developed as far as possible.

5.5.3 Peripheral Developmental Activities:

M/s Rashmi Metaliks Limited has undertaken following activities already made around the

plant as a mark of their Corporate Social Responsibilities.

Sl. No.

Scope of Activities Already Invested Amount (Rs.)

1 Education 2025000

2 Water Supply including Drinking Water 775000

3 Health Care 3545000

4 Environment 1750000

5 Social Empowerment 1285000

6 Village Electricity / Solar Light 2530000

7 Sports and Culture 3968000

8 Infrastructure Support - construction, repair, extension etc. 3339000

9 Grant / Donation / Financial assistance / sponsorship to reputed NGOs of the society / locality doing / involve in upliftment of standard of the society and Misc.

1200000

GRAND TOTAL:- 20417000


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CHAPTER-6

PROPOSED INFRASTRUCTURE

Not applicable


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CHAPTER-7

REHABILITATION & RESETTLEMENT (R & R) PLAN

Not applicable

51


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CHAPTER-8

PROJECT SCHEDULE & COST ESTIMATES

Not applicable


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CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL ECOMMENDATIONS)

Not applicable

FEASIBILITY REPORT of 900000 TPA (0.9 MTPA)...

Documents

Transcript of FEASIBILITY REPORT of 900000 TPA (0.9 MTPA)...