PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/... · P.O. :Mihijam,...

ANJANEY FERRO ALLOYS LTD. Ferro Alloys Plant at Mouza :Bhutberia, Pre-Feasibility Report P.O. :Mihijam, District : Jamtara, Jharkhand

11

Anjaney Ferro Alloys Ltd.

PRE-FEASIBILITY REPORT for

Capacity Expansion of Anjaney Ferro Alloys Ltd. for Production of Ferro Alloys

from 16,100 to 37,800 TPA at

Village – Bhutberia, P.O. Mihijam, District – Jamtara of Jharkhand

APPLICANT M/s Anjaney Ferro Alloys Limited

FLAT-2B, 2ND FLOOR 3, MAYFAIR ROAD, KOLKATA' WB 700019


12


CONTENTS

Chapter Particulars Page no.

1. Executive Summary 13

2. Background Information 15

3. Project Description 18

4. Site Analysis 27

5. Planning Brief 29

6. Proposed Infrastructure 31

7. Rehabilitation and Resettlement (R&R) Plan 33

8. Project Schedule & Cost Estimates 34

9. Analysis of Proposal (Final Recommendations) 35


13


CHAPTER 1 EXECUTIVE SUMMARY

PREFACE

Ferro alloy refers to various alloys of iron, which are used in the production of mild steel,

carbon steel, special alloy steel and stain less steel. India’s steel production is increasing

every year, thereby the consumption of Ferro Alloys is also increasing. The Indian Ferro

Alloy industry has a capacity of 5.15 million tones. It is accounting for nearly 10%of the

world’s ferro alloy production and is among the 10 largest producers of the material in the

world. In the midst of raw material availability being a key factor for Ferro Alloy industry

growth, production is concentrated in a few pockets. India, South Africa, China and the CIS

countries represent a large source for Ferro Alloys. India’s Ferro Alloy supply constitutes of

Ferro chrome about 32%, Ferro Manganese and Silicon Manganese about 62% and rest

others. Considering the potential ferro alloys demand in India and for better utilization of

raw materials, Anjaney Ferro Alloys Ltd.decided to expand the existing production at

Mouza : Bhutberia, P.O. Mihijam, District : Jamtara, Jharkhand.

SITE DESCRIPTION

Anjaney Ferro Alloys Ltd. has been located at Mouza: Bhutberia, P.O.: Mihijam, District:

Jamtara, Jharkhand. Installed units have been be set up within the existing plant premises of

2.61 Ha.

PROJECT DESCRIPTION

M/s Anjaney Ferro Alloys Limited has installed 1x3.5 MVA SAF #1 of capacity 7 TPD for

production of Ferro Silicon in the year 1991 at the cost of Rs.300 lakhs.

The company has increased the capacity to 15 TPD during the year 1999 by installation of

1.5 MVA EAF#1 of capacity 8 TPD for production of Ferro Manganese at the cost of Rs.100

Lakhs.

During the year 2005, The Company have again increased the capacity of the plant to 46

TPD by installation of 1x8.25 MVA SAF #2 of capacity 31 TPD for production of Ferro Alloys

at the cost of Rs.800 lakhs.


14


Third expansion of the plant took place during the year 2007 when the Company has further

augmented the capacity to 108 TPD by installation of 2x8.25 MVA SAF #3 & 4 of capacity 31

TPD, each for production of Ferro Alloys at the cost of Rs. 2338.52 lakhs. The plant has

received the NOC for installation of the Units on 3.10.2007 and subsequently received

“Consent to Operate’ from Jharkhand State Pollution Control Board till 31.12.2012 vide

letter dated 31.05.12.

YEAR OF INSTALLATIO

N

COST OF PROJECT IN LAKHS

UNIT(S) INSTALLE

D

FURNACE

RATING

CAPACITY IN TONES PER

DAY

PRODUCT REMARK

1991 300 SAF #1 3.5 MVA 7 TPD Ferro Alloys: Ferro Silicon Ferro Manganese Silico Manganese Ferro Chrome

EC not required

1999 100 EAF #1 1.5 MVA 8 TPD Ferro Manganese

2005 800 SAF #2 8.25MVA

31 TPD Ferro Alloys: Ferro Silicon Ferro Manganese Silico Manganese Ferro Chrome

Total Production 46 TPD

Units installed for which Environmental Clearance is required (Presently not in operation)

2007 2338.52 SAF #3 SAF #4

8.25 MVA 8.25 MVA

31 TPD 31 TPD

Ferro Alloys: Ferro Silicon Ferro Manganese Silico Manganese Ferro Crome

EC required

Total Production 62 TPD

TOTAL PRODUCTION AFTER EXPASION 108 TPD


15


CHAPTER 2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

PROJECT

M/s Anjaney Ferro Alloys Limited is an existing plant at Bhutberia, District – Jamtara,

Jharkhand for production of Ferro Alloys. The present proposal is for capacity expansion

of the plant from 16,100 TPA to 37,800 TPA (which include production from SAF# 3 &4,

under violation and production stopped)

Details of the project are as follows:

The capacity of the plant (and Units) which is presently under operation is 46 TPD:

YEAR OF INSTALLATION

UNIT(S) INSTALLED

FURNACE RATING

CAPACITY IN TONES PER DAY

PRODUCT

1991 SAF #1 3.5 MVA 7 TPD Ferro Alloys

1999 EAF #1 1.5 MVA 8 TPD Ferro Manganese


Total Production 46 TPD (16,100 TPA)

The capacity of the plant (and Units) which is installed, for which Environmental Clearance is required, however, operation has been stopped, is 62 TPD:


UNIT(S) INSTALLED

FURNACE RATING


PRODUCT

2007 SAF #3 SAF #4

8.25 MVA

8.25 MVA

31 TPD

31 TPD

Ferro Alloys


Total capacity of the plant shall be 108 TPD after regularization of the Environmental clearance for the installed units and the installation of the proposed units (37,800 TPA):

Existing Production (In Operation)

Proposed Production (Closed due to EC

Requirement)

Total Production (After receipt of EC)

TPD TPA TPD TPA TPD TPA

46 16,100 62 21,700 108 37,800


16


PROJECT PROPONENT

M/s Anjaney Ferro Alloys Limited is a company incorporated on 23rd June 1989. Its

registered office is at Flat-2B, 2nd Floor 3, Mayfair Road, Kolkata WB 700019.

M/s Anjaney Ferro Alloys Limited is a private limited company in the business of

production of Ferro Alloys has its plant. The Company Directors Sri Amit Agarwalla has

23 Years’ experience in various businesses such as Coal Mining, Coke Manufacturing,

Refractories, Ferro Alloys and Iron & Steel.

Sri K.Shankar Raju is President (Technical) of the Company who has 28 Years’ experience

in Ferro Alloys Industry.

Sri Prabir Banerjee is Vice-President (Commercial) of the company and has 27 Years’

experience in Ferro Alloys Industry.

Turnover of the company during the year 2015-16 was 22159.

2.2 NATURE OF THE PROJECT

Project is for installation of 2x31 TPD (8.25 MVA) Submerged Arc Furnace (SAF) for

production of Ferro Alloys.

The project falls under Category ‘A’ as per the EIA Notification, 2006

2.3 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION



every year, thereby the consumption of Ferro alloys is also increasing. The Indian Ferro

Alloy industry has a capacity of 5.15 million tonnes. It is accounting for nearly 10% of the

world’s ferro alloy production and is among the 10 largest producers of the material in

the world.

In view of above Anjaney Ferro Alloys Ltd., not only wants to be a global scale producer

of Ferro Alloys but be a leading industrial base for the backward district of Jamtara and

entire Santhal Pargana region in the state of Jharkhand and thereby providing direct and

indirect job opportunities for the tribal community in this area.


17


2.4 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

Manpower for the existing operation (i.e. for the units, presently under expansion) is

150. The manpower (direct employment) for production of 108 TPD (i.e. after operation

of all units after the environmental clearance shall be 250, comprising administrative,

technical, non-technical, skilled and unskilled workforce.

In addition to this there shall be indirect requirement of manpower in transportation

sector for transportation of raw material.

---------------


18


CHAPTER 3 PROJECT DESCRIPTION

3.1 TYPE OF THE PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY

The Project involves manufacturing of Ferro Alloys Plant using Manganese Ore, Chromite

Ore, Ferro Manganese Slag, Quartz, Dolomite, Coke and Coal as raw material.

There is no interlinked project or interdependent project.

3.2 LOCATION

The location of the plant is Village – Bhutberia, P.O.- Mihijam, District – Jamtara,

Jharkhand

Figure 3.1: Google Image of Project Site

Project Site


19


Figure 3.2: Location Map

3.3 SIZE OR MAGNITUDE OF OPERATION

Present operation of the plant is for production of 16,100 TPA (46 TPD) Ferro Alloys

(Ferro Silicon, Ferro Manganese, Silico Manganese and Ferro Chrome) from 1 no. of 1.5

MVA EAF and 2 nos. of SAF (one furnace of capacity 3.5 MVA, other 8.25 MVA)


20


Proposed expansion (installed capacity, presently closed due to violation of EIA

Notification) is for production of 21,700 TPA (62 TPD) Ferro Alloys (Ferro Silicon, Ferro

Manganese, Silico Manganese and Ferro Chrome) from 2x8.25 MVA SAFs.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

Process Details

Ferro Alloys Plant: Ferro alloys are consumables required to manufacture steel. Ferro

alloys are used to manufacture various types of carbon and steel, essentially to impart

certain physical and chemical properties in a particular grade of steel viz change of

tensile strength, ductility, hardness, corrosion resistance, wear resisting or abrasion

resistance properties etc. Ferro alloys are also commonly used for de-oxidation and

refining of quality steel.

Manufacturing Process of Silico Manganese/Ferro Chrome/Ferro Manganese/ Ferro

Silicon

Physico-Chemical Conditions of the Process -The above products are smelted by a

continuous process with the electrodes submerged deep into the charge. The smelting

processes include the following stages:

1. Removal of volatiles and moisture from the charge and heating of the charge by the

heat of burning

2. Gases which leave the furnace and after-burn at the top;

3. Reduction of iron and ores with simultaneous formation of metal carbides;

4. Melting of the elements reduced with the formation of molten metal;

5. Formation and melting of slag;

6. Reduction of Manganese / Chrome and Silicon from the slag.

Hygroscopic moisture of the charge materials is removed in 10-15 minutes upon

charging, while the volatile matters are run-off in the temperature range of between

200-1000ºC. The iron contained in the manganese ore is reduced to a high extent in the

process. Ferric oxides are reduced with carbon monoxide and hydrogen at low

temperatures. Ferrous oxide is first reduced with carbon monoxide and hydrogen at

500-600°C temperature and after that with solid carbon in the deeper zones of the bath.


21


The reduction of manganese from pyrolusite occurs stepwise: MnO2->Mn3O4-> MnO-

>Mn3C with a reducing atmosphere in the furnace, the dissociation of manganese oxides

can take place at low temperatures. Carbon monoxide and hydrogen can also reduce

Mn3O4 to MnO at low temperatures. The process of smelting silico manganese

essentially consists in Manganese and Silicon being simultaneously reduced from

manganese silicates, slag, ore and quartz. The process relies on a higher temperature;

the temperature at tapping is 1500°C. Apart from the high temperature, for successful

reduction of silicon the process requires high concentration of silica in the slag. The

metal and slag are tapped from the furnace every two hours. The metal and slag are

tapped through two tap holes into a ladle or onto casting pans. The slag over flows and

collected into another ladle or in casting pans.

General: Mixed charge is delivered to the furnace from furnace bays along four movable

chutes. Three chutes serve to deliver the charge to spaces between the electrodes and

the fourth, into the space between the central electrode and furnace wall. Charging is

done periodically to allow the previous charge settled at the top, to move down. With

normal run of the furnace, yellow flames shoot up evenly all over the surface of the

furnace top. The following measures are essential to maintain the top in normal

conditions:

The charge should always have the specified composition;

• The charge should be given evenly to each phase electrode;

• Consumption of electric energy should strictly correspond to the number of unit

charges without letting the top overheat;

• Charge cones should be pierced periodically.

Disturbances in the furnace run may be caused by various factors. Most often they are

linked with an inappropriate consumption of the slag and with a deficiency or excess of

the reducer in the charge. Each type of disturbance has quite typical external features:

deep or shallow position of the electrodes, an increase or decrease in the content of

carbon or silicon, overheating or chilling of the top, evolution of white smoke at the

electrodes, ejects of coke breeze, intense slagging at the electrodes etc. The electrodes

are slipped every shift or sometimes twice a day. The metal and slag are tapped


22


simultaneously three times a shift. The ladle for tapping is mounted on a carriage under

the tap hole, the slag flows over the ladle nose into a slag pot installed on a parallel

railway. During tapping, the top hole is often poked with an iron bar so as to let out the

metal and slag completely from the furnace. The tap hole is packed with thick clay as

soon as metal appears at the ladle nose (i.e. when the ladle is filled with metal).

Manufacturing Process of Ferro Silicon

High Carbon Ferro Silicon is made by reducing quartzite with a carbonaceous reductant

in a submerged arc furnace. The techno economics of the process of ferro silicon

production improves considerably with increase in the capacity of the furnace. Silicon –

bearing substances namely quartz, rock crystal, amethyst, opal, onyx, cornelian, jasper,

sand and others are employed in the manufacture of ferro silicon, Quartz is the compact

crystalline mineral with a specific gravity of 2.59 – 2.69 hardness. Its SiO2content should

be minimum 96%, Preferably 97 – 99%, Al2O3, MgO, CaO content should be minimum

possible and P2O5content should not exceed 0.02% Volatile Matter and 4 – 6% Moisture

is a costly reductant and is used mainly for the production of high silicon alloy (90% ferro

silicon) and crystalline silicon. Quartz / Quartzite should be crushed into lumps of 35 – 70

mm in size and fines should be sieved through a 20 – 30 mm sieve for better

permeability of the charge.

Production of Ferro Silicon: The reduction of silicon from silica occurs by solid carbon at

1,500°C. Molten iron dissolves the reduced silicon and removes it from the reaction zone, thus

allowing the reaction to proceed from left to right. Since an iron-silicon alloy does not dissolve

carbon, the ferro silicon smelting furnace is usually lined with graphite.

Ferro silicon smelting is essentially a slag-less process. Still some slag formation takes place

because of the presence of impurities in raw materials, namely, aluminum oxide, calcium oxide

and magnesium oxide. Slag is generally viscous and hard to fuse.

Due to its high viscosity, some slag always remains in the furnace and causes accretions, which

decreases the yield of the furnace and increases the specific power consumption. If excess slag

accumulates in the furnace, it can be removed by addition of lime to furnace hearth. The lime

shall dilute the slag and permit its tapping. The net reaction of the silicon reduction process

may be represented as follows:


23


SiO2 + 2C = Si + 2CO

The reaction begins at 1,5000 C, and is practically complete at 1,8000 C. A further rise in

temperature causes considerable evaporation. In presence of iron, silica reduction produces

ferro silicon according to the reaction.

SiO2 + Fe + 2C = FeSi + 2CO

The following reaction may occur when an excessive amount of reductant is charged into

furnace:

SiO2 + 3C = SiC + 2CO

However, SiC is quickly destroyed by iron according to the reaction

SiC + Fe = FeSi + C

Operating Considerations:

1. Ferro silicon is generally produced in submerged arc furnaces with rotaing baths.

2. The silicon losses from evaporation are considerable. Therefore, deep and stable electrode

and uniform evolution of gases over the whole charge surface are essential to minimize the

silicon losses.

3. The electrical parameters namely electrode, secondary voltage and electrode current

considerably affect the performance of the furnace; hence these should be approximately

selected.

4. The furnace resistance is adjusted by increasing or decreasing the conductivity of the charge

mix and increasing or decreasing electrode circle.

5. Lack of reductant in the charge mix leads to the crusting of the furnace and the operation

of tap hole becomes difficult, while a excess of the electrodes, absence of slag, freezing of

the reductant in the charge mix for a prolonged period of time will lead to the formation of

caborundum.

Refining of Ferro Silicon:

The Ferro Silicon required for making steels electrical steels must have low content of

aluminum, calcium, titanium and carbon. Their presence brings down the magnetic

permeability and increases the core loss. Hence, commercial grade ferro silicon needs further

refining for the production of silicon steels. The processes for refining of ferro silicon are:

Solid /liquid oxide methods - Oxidizing treatment with gaseous /enriched air.


24


Refining with chlorine gas - Purification by carbon dioxide gas

FLOW CHART FOR FERRO ALLOYS PLANT

PROJECT HIGHLIGHTS

Project is for capacity expansion of M/s Anjaney Ferro Alloys Ltd. from 16,100 TPA to 37,800

TPA ferro alloys production by installation of 2x31 TPD SAFs as per the details given below:


UNIT(S) INSTALLED

FURNACE RATING


PRODUCT REMARK

1991 SAF #1 3.5 MVA 7 TPD Ferro Alloys EC not required 1999 EAF #1 1.5 MVA 8 TPD Ferro Manganese



Units installed for which Environmental Clearance is required (Presently not in operation)

2007 SAF #3 SAF #4

8.25 MVA 8.25 MVA

31 TPD 31 TPD

Ferro Alloys EC required


TOTAL PRODUCTION AFTER EXPASION 108 TPD (37,800 TPA)

INPUT RAW MATERIAL

HANDLING BY PAYLOADER &

DUMPERS

FEED IN BELT CONVEYOR

GRADING AND SIZING00000000

ON LINE FEED IN HOPPERS

AUTOMATIC COMPUTARIZED BATCHING AND

ON LINE FEED INTO CONVEYOR

CHARGE FOR FURNACE

CHARGE IN SAF DISCHARGE OF MOLTEN METAL

TAPPING IN CAST IRON LADLES

NATURAL COOLING

RECOVERY OF INGOTS

SIZING AND GRADING

INSPECTION DESPATCH


25


3.5 RAW MATERIAL REQUIREMENT

For manufacturing of Silico Manganese & Ferro Silicon, the key inputs required are

presented here.

Annual requirement of Raw Materials shall be as follows:

Raw Materials Raw Material Requirement for

Existing Units in Tons

Raw Material Requirement for the

Proposed Units (Units presently closed,

required EC) In Tons

Total after Expansion

In Tons

Production 16,100 TPA 21,700 TPA 37,800

Raw Materials

Manganese Ore 29,050 39,200 68,250

Fe Mn Slag (25%-32%)* 8,050 10,850 18,900

Coke 6,650 8,750 15,400

Coal 6,650 8,750 15,400

Quartz 4,900 6,650 11,500

Total 55,300 74,200 1,29,500

3.6 RESOURCE OPTIMISATION

Water Requirement

Water is pre-dominantly required in the Ferro Alloys Plant for cooling. The total

requirement of water is

50 KLD. In addition, it is used for control of dust and for drinking and sanitation, for fire

fighting and for miscellaneous purposes. The plant water system comprises a make-up

water system, drinking water and fire fighting water system as well as emergency water

supply system for the vital units of the plant. Water for the existing units is being drawn

from Borewell. Permission from the concerned authority has been obtained.

For the proposed expansion water shall be sourced from Borewell. Permission has been

obtained from the concerned authority.

Existing Additional For Installed

Units

Total

20 KLD 30 KLD 50 LD


26


3.7 SOLID WASTE GENERATION AND MANAGEMENT

Type of Waste Quantity in Tons /year Mode of Disposal

Existing Additional For Installed Units

Total

Slag 12,250 16,450 28,700 Sold at nominal value for construction and layering of highways, roads and walls due to its hardness and stony characteristics

Bag Filter Dust 350 477 827 Recycled in the process

3.8POLLUTION CONTROL MEASURES

Pollution, once generated, needs to be arrested and treated before the pollutants are

released into the ambient environment. The flue gas from the Ferro Alloys Plant is being

sent to Bag Filter before discharging to the atmosphere to comply with particulate

emission limit. All the dust collected in the Pollution Control Equipment is being recycled

in the process.

Closed circuit cooling system has been adopted in Ferro Alloys Plant. Hence there is no

scope of any waste water generation from process and cooling. Sanitary waste water is

being treated in septic tank followed by soak pit.

3.9 PLANT LAYOUT DRAWING – to attach showing existing & proposed units


27


Figure 3.3: Layout Plan


28


CHAPTER 4 SITE ANALYSIS

4.1 CONNECTIVITY

Site Location Village: Bhutberia, P.O.: Mihijam, District – Jamtara, Jharkhand

Height above MSL 187 meters

Road Connectivity Nearest National Highway is Calcutta – Delhi Highway(NH-2) – 8 km.

Rail Connectivity The nearest Railway Station is Rupnarayanpur, West Bengal – 700 meters

Nearest Airport Netaji Subhash Chandra Bose International Air Port – 233 km.

Nearest Town Nearest Town is Rupnarayanpur

Nearest River Barakar – 8 km

National Park, Wildlife Sanctuary, Reserve Forest within 10 kms.

Nil

4.2 LAND USE

The project is located within the existing plant area.

4.3 TOPOGRAPHY OF THE LAND

The land has a mild slope towards the west with control levels varying from 190 m to

186 m.

4.4 EXISTING LAND USE PATTERN

The land is Industrial Land

4.5 EXISTING INFRASTRUCTURE

Infrastructure available such as Administrative Building, Fire Water Reservoir and Fire

Water Pump house, Workshop Building, Water Storage Reservoir, Raw Water Pump

House have already been provided in the existing plant.

Facilities for Drinking Water, Rest Room, Toilets, Medical Unit, Staff Quarters already

installed. No additional facilities required.

Plant Utilities

Quality Control Laboratory: Suitable Testing Facilities re required at each step of

manufacture. A full-fledged testing laboratory is already in place for each production

unit to check the quality of the raw materials and the finished product.


29


Maintenance Workshops: a workshop complete with machine tools such as lather,

sharper, drilling machine, pedestal grinder, hacksaw machine and handling tools and

tackles is already in place

Fire Fighting Facilities: Adequate firefighting equipment shall be provided for each

production unit. Firefighting equipment consists of the following:

• Water hydrants network

• Carbon dioxide type portable fire extinguishers for electrical equipment rooms.

• Foam type extinguishers near lubrication, hydraulic and fuel oil installations.

4.6 SOIL CLASSIFICATION

The Jamtara region is composed of fine loamy soil.

4.7 CLIMATE DATA

The project site lies in Jamtara Dvision of Jamtara District.

Summer Season March to May

Rainy Season June to September

Winter Season October to February

Min Temperature 2°C in Winter

Max Temperature 45°C in Summer

Height above Sea Level 175 Mts.

Wind Direction South West to North East


30


CHAPTER 5 PLANNING BRIEF

5.1 PLANNING CONCEPT

Anjaney Ferro Alloys Ltd. has installed the following units for production of 16,100 TPA Ferro Alloys:

UNIT(S) INSTALLED FURNACE RATING CAPACITY IN TONES PER DAY

PRODUCT

SAF#1 EAF#1 SAF#2

3.5 MVA 1.5 MVA

8.25 MVA

7 TPD 8 TPD

31 TPD

Ferro Alloys Ferro Alloys Ferro Alloys


Operation of following Units shall also be start after grant of environmental clearance from MoEFCC for production of 21,700 TPA Ferro Alloys:

UNIT(S) INSTALLED FURNACE RATING CAPACITY IN TONES PER DAY

PRODUCT

SAF #3 SAF #4

8.25 MVA 8.25 MVA

31 TPD 31 TPD

Ferro Alloys Ferro Alloys

Total Production 62 TPD (21,700)

Total production after expansion shall be 37,800 TPA including production from the

closed Units.

5.2 POPULATION PROJECTION

There is no major habitation in the vicinity of the site. Manpower requirement for the

proposed expansion shall be limited to 350 which shall be sourced from local population.

Hence there will not be increase in population due to direct employment in the area for

the proposed expansion.

5.3 LAND USE PLANNING

Total area of the plant for the present installation is 6.45 Acres (2.61 Ha.).

33% of the total plant area i.e. 2.12 Acres (approx. 0.86 Ha.) shall be kept for greenbelt

development.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

The plant has well connected National Highway as mentioned in the above chapters.

Plant has also well developed connecting roads inside plants for movement of raw


31


material, storage areas for raw materials and finished products since the plant is under

operation.

There is no additional infrastructure required for the proposed expansion.

5.5 AMENITIES / FACILITIES

The following facilities are already available at the project site as it is an operational

plant:

• Administration Building

• Stores

• Time and security offices

• First aid and fire fighting station

• Canteen and welfare center

• Toilets and Rest rooms

• Car parks and cycle / scooter stands

No other additional facilities are proposed.


32


CHAPTER 6 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The industrial area (Processing Area) of M/s Anjaney Ferro Alloys Limited shall have 2

nos. of Submerged Arc Furnaces (SAFs) including facilities for Raw Material Handling

unit, Cooling Towers, Effluent Treatment Plant, Raw Materials Storage Areas, Finished

Material Storage Yard etc. Total area of the plant is 6.45 Acres (2.61Hectares).

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

There is no proposal of any residential colony as the required manpower will be sourced

from local population. Facilities like Canteen, Rest room, Toilets are already exists.

6.3 GREEN BELT

Green Belt will be developed over 33% of the plant area. Indigenous trees will be

planted in 2.12 acres (0.86 ha.) out of the total area of 6.45 Acres (2.61 Ha.). Tree

density of 1500-2000 trees per hectare (600nos. of plant per acre) with local board leaf

specification will be planted.

6.4 CONNECTIVITY

Project site is well connected by road and rail.

Road Connectivity through National Highway NH-2, which is 8 km away from the site.

Rail connectivity – Rupnarayanpur Railway Station which is 700 meters from the project

site.

6.5 DRINKING WATER MANAGEMENT

Raw water from bore wells is being treated in Water Treatment Plant and is being

supplied for drinking purpose in Offices, Canteen and Work place. Employees are being

provided potable water for drinking.

6.6 SEWAGE SYSTEM

Sufficient and suitable toilet facilities of proper standard and hygiene have been

provided. These facilities are connected with Septic Tank with Soak Pit.


33


6.7 INDUSTRIAL WASTE MANAGEMENT

There will be no waste water discharge from the plant. The water shall be used for

cooling and dust suppression. Cooling water shall be recycled after cooling in the Cooling

Towers. Blow down water from Cooling Towers shall be used for slag cooling. Zero

discharge shall be maintained after the proposed expansion.

6.8 SOLID WASTE MANAGEMENT

Fines collected from Bag Filter from Submerged Arc Furnace are recycled in the process

and / or sold to vendors. Si-Mn and M.C. Fe-Mn Slag is being utilized in road / land

development. Fe-Si Slag is reused in the Si-Mn production. A separate yard within the

premises would be earmarked to store the same temporarily.

6.9 POWER REQUIREMENT & SUPPLY / SOURCE

Power Requirement

Power requirement for the operating units (SAF# 1 & 2 and EAF #1) is 13 MVA. Total

power requirement for operation of all units after grant of Environmental Clearance

shall be 28 MVA. Substation with adequate capacity to supply necessary power for the

project already exists. Power is being supplied by Damodar Valley Corporation. The

company has also installed 1 x 63 kva & 2 x 150 kva DG set meeting emergency

requirements of the plant utilities such as circulating water for cooling critical furnace

components, in case of power shutdown.

Power Consumption for operation of the Plant shall be as follows:

Existing (Units / day)

Additional (Units /day) Installed Units

Total (Units/ day)

2,07,000 2,79,000 4,86,000

Power requirement shall be met from Damodar Valley Corporation (DVC)


34


CHAPTER 7 REHIBILITATION AND RESETTLEMENT (R&R) PLAN

The proposed expansion project has been installed within the existing plant. Hence, no

rehabilitation or resettlement plan is required.


35


CHAPTER 8 PROJECT SCHEDULE & COST ESTIMATE

8.1 PROJECT SCHEDULE

Project (2x31 TPD SAFs) has already been installed. Production stopped as Environmental Clearance of the project is required.

8.2 COST ESTIMATE

The cost for the project is Rs. 2338.52 Lakhs. Term loan availed for the project was Rs. 600 lakhs and balance 1786.69 from internal accrual. The breakup of the project cost is presented below:

S. No. Item Cost (Rs. In lakhs)

1 Raw Materials Shed 40.95

2 Furnaces of 8.25 MVA x 2 Nos. including Shell, Lining, Insulation, Secondary Bus System, Assembly Cooling System, Hydraulic System, Blowers, Panels, Cooling Tower, Gas Cleaning System, Raw Material & Finished Product Handling Systems,

1008.64

3. Supporting structures for furnaces 487.48

4 Furnace Transformer (11 nos.) 253.09

5 Switch Yard 44.76

6 Electricals 432.36

7 Pollution Control 68.45

8. Engineering Fee 2.80

Total 2338.52


36


CHAPTER 9 ANALYSIS OF PROPOSAL

Over the last few years, there has been a great change in the Indian Economic Scenario

due to Global slowdown which affected the whole world including India. The major

sector which took the toll was Steel & Power Sector.



every year; thereby the consumption of Ferro alloys is also increasing. The Indian Ferro

Alloy industry has a capacity of 5.15 million tonnes. It is accounting for nearly 10% of the

world’s ferro alloy production and is among the 10 largest producers of the material in

the world.

In view of above Anjaney Ferro Alloys Ltd., not only wants to be a global scale producer

of Ferro Alloys but be a leading industrial base for the backward district of Jamtara and

entire Santhal Pargana region in the state of Jharkhand and thereby providing direct and

indirect job opportunities for the tribal community in this area.

The Directors / Vice Presidents of Anjaney Ferro alloys Ltd. is experienced Industrialist in

the field of production of Ferro Alloys.

The technology involved in expansion project is well proven and reliable. Many plants

are operating all over the country in this pattern are successful. All equipments

purchased shall be brand new & latest in model and will be purchased from reputed

suppliers. For O&M of the plant, experienced Engineers /Technicians are available in the

region.

The region shall also be benefited from the project as there will be direct employment of

people in the Steel plant. Preference will be given to the people of the state possessing

requisite skill and qualification criteria. Also there will be lot of scope for indirect

employment of the people of the state in and around the project site like in

transportation sector.

In view of the above the Expansion Project of M/s Anjaney Ferro Alloys Limited is

technically feasible and financially viable thus, we request EAC to recommend TOR for


37


conducting the EIA Study for obtaining Environmental Clearance from Ministry of

Environment, Forest & Climate Change.

---------------------

PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/... · P.O. :Mihijam,...

Documents

Transcript of PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/... · P.O. :Mihijam,...