PRE-FEASIBILITY REPORTenvironmentclearance.nic.in/writereaddata/Online/TOR/26_May_2016... ·...

PRE-FEASIBILITY REPORT

By

Maa Mahamaya Industries Ltd. [Expansion of Steel Plant]

at

R.G.Peta & Srirampuram Village, L.Kota Mandal,

Vizianagaram District, Andhra Pradesh

Prefeasibility Report Maa Mahamaya Industries Ltd.

Table of Contents Chapter –1: EXECUTIVE SUMMARY ....................................................................................................................... 1

1.1 SALIENT FEATURES OF THE PROJECT ..................................................................................................... 1

1.2 PROJECT PROPONENT ........................................................................................................................... 2

Chapter – 2: INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION ................................................. 3

2.1 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT......................................................................... 3

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION .......................... 3

2.3 DEMAND AND SUPPLY GAP ................................................................................................................... 4

2.4 EXPORT POSSIBILITY .............................................................................................................................. 4

2.5 DOMESTIC/EXPORT MARKETS ............................................................................................................... 4

2.6 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT ...................................... 4

Chapter – 3 : PROJECT DESCRIPTION ..................................................................................................................... 5

3.1 TYPE OF THE PROJECT ........................................................................................................................... 5

3.2 LOCATION OF THE PROJECT .................................................................................................................. 5

3.3 DETAILS OF THE ALTERNATE SITES ........................................................................................................ 7

3.4 SIZE OR MAGNITUDE OF OPERATION ................................................................................................... 7

3.5 MANUFACTURING PROCESS .................................................................................................................. 8

3.5.1 Iron Ore Beneficiaition & Pelletisation Plant ................................................................................. 8

3.5.2 DRI Kiln based Sponge Iron Plant ................................................................................................ 13

3.5.3 Mini Blast Furnace ....................................................................................................................... 16

3.5.4 Steel Melting Shop ....................................................................................................................... 18

3.5.5 Rolling Mill ................................................................................................................................... 21

3.5.6 Galvanising Line ........................................................................................................................... 22

3.5.7 Lime & Dolo plant ........................................................................................................................ 22

3.5.8 Oxygen Plant ................................................................................................................................ 24

3.5.9 Power Plant ................................................................................................................................. 24

3.6 RAW MATERIAL REQUIREMENT .......................................................................................................... 25

3.7 WATER REQUIREMENT AND ITS SOURCE ............................................................................................ 28

3.8 WASTEWATER GENERATION & ITS MANAGEMENT ............................................................................ 28

3.9 POWER REQUIREMENT ....................................................................................................................... 29

Chapter – 4 : SITE ANALYSIS ................................................................................................................................ 30

4.1 INFRASTRUCTURE ................................................................................................................................ 30

4.2 CONNECTIVITY ..................................................................................................................................... 30

4.2 Land details .......................................................................................................................................... 31

Chapter – 5 : PLANNING BRIEF ............................................................................................................................ 32

5.1 Planning Concept ................................................................................................................................. 32


5.2 Population Projection .......................................................................................................................... 33

5.3 Land use Planning ................................................................................................................................ 33

5.4 Amenities / Facilities ........................................................................................................................... 34

Chapter – 6 : PROPOSED INFRASTRUCTURE ........................................................................................................ 35

6.1 INDUSTRIAL AREA (PROCESSING AREA) .............................................................................................. 35

6.2 RESIDENTIAL AREA (NON PROCESSING AREA) .................................................................................... 35

6.3 GREEN BELT ......................................................................................................................................... 35

6.4 SOCIAL INFRASTRUCTURE ................................................................................................................... 35

6.5 Connectivity ......................................................................................................................................... 36

6.6 DRINKING WATER MANAGEMENT ...................................................................................................... 36

6.7 WASTEWATER GENERATION & ITS MANAGEMENT ............................................................................ 36

Chapter – 7: REHABILITATION & RESETTLEMENT (R & R) PLAN .......................................................................... 37

Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES ....................................................................................... 38

8.1 PROJECT SCHEDULE ............................................................................................................................. 38

8.2 PROJECT COST ..................................................................................................................................... 38

Chapter – 9 : ANALYSIS OF PROPOSAL ................................................................................................................ 39

9.1 FINANCIAL AND SOCIAL BENEFITS ....................................................................................................... 39

9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES ............................................................................... 39


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Chapter –1:EXECUTIVE SUMMARY

1.1 SALIENT FEATURES OF THE PROJECT

Maa Mahamaya Industries Ltd. (MMIL), is located at R.G.Peta Village, L.Kota Mandal,

Vizianagaram District, Andhra Pradesh. The Company has received the Environmental

Clearance for the existing Sponge Iron Plant (1,12,000 TPA), Steel Melting Shop (1,18,300

TPA), Rolling Mill (1,00,000 TPA) and Power Plant (20 MW). Now, Maa Mahamaya Industries

Ltd.,proposes to go for expansion as mentioned below:

S.No Unit Existing

Production capacity (Unit)

Proposed Production

capacity (Unit)

Production Capacity After

proposed expansion

1. Iron ore beneficiation & Pelletisation

--- 6,00,000 TPA

(1 x 2000 TPD) 6,00,000 TPA

(1 x 2000 TPD)

2. DRI kiln 1,12,000 TPA (1 x 350 TPD)

1,12,000 TPA (1 x 350 TPD)

2,24,000 TPA (2 x 350 TPD)

3. Mini Blast Furance --- 1,65,000 TPA

1 x 250 M3

(1 x 550 TPD)

1,65,000 TPA (1 x 550 TPD)

4.

Steel melting shop 1,18,300 TPA 5,40,000 TPA

6,58,300 TPA

EAF --- 1 x 45 T

Ladle furnace 1 x 30 T 1 x 45 T

VD / VOD --- 1 x 45 T

Induction furnace 4 x 9 T 4 x 20 T

Billet / Bloom caster

--- 1 x 2 strand

Billet caster for IF & Rolling Mill

1 x 2 strand 1 x 2 strand

5. Rolling mill

Bar & rod mill --- 1,00,000 TPA (1 x 333 TPD)

1,00,000 TPA (1 x 333 TPD)

TMT mill 1,00,000 TPA (1 x 333 TPD)

2,00,000 TPA (1 x 666 TPD)

3,00,000 TPA (1 x 333 TPD &

1 x 666 TPD)

Section mill --- 2,50,000 TPA

(1 x 833 PD) 2,50,000 TPA

(1 x 833 PD)

6. Galvanising line -- 2,50,000 TPA 2,50,000 TPA

7. Lime & Dolo plant --- 2 x 100 TPD 2 x 100 TPD

8. Oxygen plant --- 1 x 90 TPD 1 x 90 TPD

9. Power Plant 20 MW 98 MW 118 MW


2

S.No Unit Existing


Proposed Production

capacity (Unit)


proposed expansion

Waste Heat

Recovery Boiler 8 MW (36 TPH) 8 MW (36 TPH) 16 MW

FBC Boiler 12 MW (55 TPH) 90 MW (405 TPH) 102 MW

1.2 PROJECT PROPONENT

Maa Mahamaya Industries Limited (MMIL), a Visakhapatnam based company, has become a

well known player in steel industry. MMIL is first Mini Integrated Steel Plant in Andhra

Pradesh. The company deals with the manufacture of Sponge Iron, MS Billets, TMT Bars &

Captive Power Plant. The production was so selected because of the vast knowledge of the

Directors in the field.

SUPERIOR PRODUCT QUALITY : Mangal TMT is produced through primary Steel Melting route

using the best quality Iron Ore and Imported Coal. It is subsequently processed through DRI

Plant, Induction Furnance (IF), Ladle Refining Furnace and Continuously Cast into Billets. The

resultant Steel is of Superior Quality containing no harmful ingredients and ensures the

desired and consistent properties in TMT Bars.

Directors have a vast knowledge in the field of ferrous and non-ferrous metals, including

manufacture of alloys and steel operating medium size manufacturing units.

The core competency of the Maa Mahamaya Industries Limited is to focus on making quality

of steel and making efficient deliveries to its customers. The rolling mills and the melting

shops are continuously upgraded to remain competitive with the best quality products.

Further to deliver to its customers the value added products with efficient delivery schedules

At present there is good demand for steel products like TMT Bars (Thermally Mechanically

Treated Bars), Structural Steel items like Flat, Square, Angle, Rounds, Channels & Beams of

high strength steels, which are mainly used in building constructions and Power Transmission

Lines, etc.


3

Chapter – 2: INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1 BRIEF DESCRIPTION OF THE NATURE OF THE PROJECT




TPA), Rolling Mill (1,00,000 TPA) and Power Plant (20 MW).

Proposed expansion will be carried out in partly in the existing plant and partly in the land

adjoining in to the existing plant.

2.2 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION

India’s economic growth is contingent upon the growth of the Indian steel industry.

Consumption of steel is taken to be an indicator of economic development. While steel

continues to have a stronghold in traditional sectors such as construction, housing and

ground transportation, special steels are increasingly used in engineering industries such as

power generation, petrochemicals and fertilizers. India occupies a central position on the

global steel map, with the establishment of new state-of-the-art steel mills, acquisition of

global scale capacities by players, continuous modernization and up gradation of older plants,

improving energy efficiency and backward integration into global raw material sources. Steel

production in India has increased by a compounded annual growth rate (CAGR) of 8 percent

over the period 2002-03 to 2006-07. Going forward, growth in India is projected to be higher

than the world average, as the per capita consumption of steel in India, at around 52 kg, is

well below the world average (170 kg) and that of developed countries (400 kg). Indian

demand is projected to rise to 300 million tonnes by 2025. Given the strong demand scenario,

most global steel players are in a massive capacity expansion mode, either through

brownfield or Greenfield route. Steel production capacity in India is expected to touch 170

million tonnes by 2020. While Greenfield projects are slated to add 30 million tonnes,

brownfield expansions are estimated to add 50 million tonnes to the existing capacity of 90

million tonnes. Steel is manufactured as a globally tradable product with no major trade

barriers across national boundaries to be seen currently. There is also no inherent resource

related constraints which may significantly affect production of the same or its capacity

creation to respond to demand increases in the global market. Even the government policy


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restrictions have been negligible worldwide and even if there are any the same to respond to

specific conditions in the market and have always been temporary. Therefore, the industry in

general and at a global level is unlikely to throw up substantive competition issues in any

national policy framework. Further, there are no natural monopoly characteristics in steel.

Therefore, one may not expect complex competition issues as those witnessed in industries

like telecom, electricity, natural gas, oil, etc.

2.3 DEMAND AND SUPPLY GAP

Demand for steel is high and as soon as they are processed they will be supplied to nearby

industries.

2.4 EXPORT POSSIBILITY

As the Indian steel industry has entered into a new development stage from 2007-08, riding

high on the resurgent economy and rising demand for steel. Rapid rise in production has

resulted in India becoming the 4th largest producer of crude steel and the largest producer of

sponge iron or DRI in the world. As the demand is more the export possibility of Sponge Iron

will also be more. As the demand is more the export possibility will also be more.

2.5 DOMESTIC/EXPORT MARKETS

While the demand for steel will continue to grow in traditional sectors such as infrastructure,

construction, housing automotive, steel tubes and pipes, consumer durables, packaging, and

ground transportation, specialized steel will be increasingly used in hi-tech engineering

industries such as power generation, petrochemicals, fertilizers, etc. The new airports and

railway metro projects will require a large amount of steel. Hence the domestic and export

markets for steel sector will rise.

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

The estimated manpower requirement for the proposed project is 500 numbers; the total

manpower requirement for the entire plant is 500 numbers inclusive of staff and security.

They will comprise of 20 % of skilled labors, 40 % of semi- skilled labors and 40 % of unskilled

labors.


5

Chapter – 3 : PROJECT DESCRIPTION

3.1 TYPE OF THE PROJECT




TPA), Rolling Mill (1,00,000 TPA) and Power Plant (20 MW).

Proposed expansion will be carried out in partly in the existing plant and partly in the land

adjoining in to the existing plant.

3.2 LOCATION OF THE PROJECT

Existing plant is located at R.G.Peta Village, L.Kota Mandal, Vizianagaram District, Andhra

Pradesh.

Proposed expansion will be carried out in partly in the existing plant (in R.G.Peta Village –

40.48 Ha.) and partly in the land adjoining (in R.G.Peta village 6.8 Ha and Srirampuram

Village – 17.7 Ha.) to the existing plant. Total land envisaged for the entire project will be

64.98 Ha.

The project area will span between Latitude 17°58'13.75"N- 17°58'16.88"N & Longitude

83° 9'2.71"E-83° 9'28.37"E.

The entire project area will fall in the Survey of India topo sheet no. 65 O/1.

The Index map of the project site is shown in Figure – 1.


6

Plant site


7

3.3 DETAILS OF THE ALTERNATE SITES

No alternative site has been considered, as the proposed expansion will be taken up partly in

the existing plant and partly in the land adjoining to the existing plant.

3.4 SIZE OR MAGNITUDE OF OPERATION

S.No Unit Existing


Proposed Production

capacity (Unit)


proposed expansion


--- 6,00,000 TPA

(1 x 2000 TPD) 6,00,000 TPA

(1 x 2000 TPD)

2. DRI kiln 1,12,000 TPA (1 x 350 TPD)

1,12,000 TPA (1 x 350 TPD)

2,24,000 TPA (2 x 350 TPD)

3. Mini Blast Furance --- 1,65,000 TPA

1 x 250 M3

(1 x 550 TPD)

1,65,000 TPA (1 x 550 TPD)

4.


6,58,300 TPA

EAF --- 1 x 45 T


VD / VOD --- 1 x 45 T



--- 1 x 2 strand



5. Rolling mill


1,00,000 TPA (1 x 333 TPD)


2,00,000 TPA (1 x 666 TPD)

3,00,000 TPA (1 x 33 TPD & 1 x 666 TPD)


(1 x 833 PD) 2,50,000 TPA

(1 x 833 PD)





Waste Heat




8

3.5 MANUFACTURING PROCESS

3.5.1 Iron Ore Beneficiaition & Pelletisation Plant

Iron Ore Beneficiation

Beneficiation is a process which removes the gang particle like Alumina, Silica from the Iron

Ore. Basically, it separates Fe2O3 or Fe3O4 from other impurities in the iron ore. In this process

the Fe content is improve to maximum possible extent. The highest can be 70% i.e. purest

form.

Process Decription

Iron ore fines reclaimed from the blending stockpile shall be conveyed into a surge bin within

the beneficiation plant building. Ore drawn from the surge bin by a belt weigh feeder is fed to

a spiral screw type classifier.

Washed ore from spiral classifier is screened for +4 mm and -4 mm fractions over a scalping

screen. Undersize fraction of -4 mm is pumped to sizing screens for screening off -1 mm

fraction. Oversize fractions of +4 mm from the scalping screen and +1 mm from the sizing

screens are ground in a primary ball mill in closed circuit with sizing screens to get 100% -1

mm solids suitable for gravity separation in spirals.

Washed sizing screen underflow fraction of -1 mm is pumped to dewatering cyclones.

Underflow of dewatering cyclones is beneficiated by gravity separation through two stage

spirals viz., rougher and cleaner spirals. Concentrate from spirals circuit is ground to a size

consistency of 100% passing 100 mesh and ~70% passing 325 mesh in secondary ball mills in

closed circuit with classifying cyclones. Ground concentrate from the classifying cyclones

overflow as well as the overflow from dewatering cyclones ahead of spirals are pumped to

concentrate thickener. Concentrate thickener underflow is thereafter filtered to get a product

with 8% moisture max. The filter cake is conveyed to stockpile.

Tailings from the spirals circuit is pumped to a linear screen to ensure a 100% -1 mm size

solids in the slurry being fed to high gradient magnetic separators to recover feebly magnetic

Fe units. Concentrate from high gradient magnetic separators is diverted to secondary ball

mill discharge pump box for grinding along with spiral concentrate, to desired fineness.

Tailings from high gradient magnetic separators is fed to tailings thickener.

Spiral classifier overflow is pumped to de-sliming cyclones. Overflow from these de-sliming

cyclones is fed to the tailings thickener. Underflow from de-sliming cyclones is diverted to


9

spiral tailings pump box in turn to high gradient magnetic separators to recover Fe units as

much as possible.

Tailings thickener underflow is pumped to tailings settling pond.

Clear water from concentrate thickener, tailings thickener and tailings settling pond flows by

gravity back into the process water sump for recirculation.


10

Pelletisation Unit

The iron ore pelletization unit comprises of following sections:

1. Drying & Prepn. of Iron Ore Fines

2. Grinding

3. Mixing and Blending

4. Pelletization

5. Screening

6. Travel Grate Furnace

7. Rotary Kiln

8. Cooler

9. Stacking

10. Recovery of Dust and Spillage

a. Drying & Preparation of Iron ore Fines:

Generally Iron Ore Fines, Lime Stone and Dolomite fines available, contain more than 6-7%

moisture and require drying before grinding. The drying is carried out in Rotary Drum

Dryer. The moisture content in the dry material is controlled. The low grade Iron Ore Fines

is feed in a screen for separation. Oversize/ under size moves to the primary grinding

circuit.

b. Grinding

Iron Ore Fines, Dolomite and Lime Stone are mixed in required proportion and fed into a

Ball Mill. The fineness of the product is controlled as may be necessary for particular ore

and Pellet quality.

c. Mixing and Blending

Iron Ore powder blended with Bentonite and other binding materials in desired

proportion. Small quantity of water is added during blending operation. This raw mix is

ready for Pellet making and store in feed hopper.

d. Pelletization

Controlled quantity of raw mix is fed on disc Pelletizer. Some amount of water is sprinkled

for producing Pellets. These Pellets are passed through oversize and undersize screens.

Sized Pellets are then sent to sintering section.


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e. Screening

Pellets produce in Pelletization sections are passed through oversize and undersize

screens. Rejects Pellets are sent back to raw mix silos sized Pellets are fed in to Indurations

Furnace.

f. Travel Grate Furnace

A Travel Grate Furnace is used for indurations of Pellets. This is divided into 3 sections

(Drying–Preheating–Heating). Hot Pellets at around 950ºC to 1000ºC from this Travel Grate

are dropped into the Kiln for further strengthening.

g. Rotary Kiln

Rotary Kiln receives Pellets from the Indurations Furnace where Pellets have to withstand

at high temperature approx. 1050ºC – 1200ºC. Here the Pellets gain more hardness due to

high temperature. Furnace Oil / Producer Gas is used as a fuel inside the Kiln. After the Kiln

the Pellets are passed to the Grate Cooler.

h. Cooler

Grate Cooler receives hot Pellet with temperature up to 1200ºC coming from Rotary Kiln.

Cooler has its own blowers to blast the air from bottom. The hot air from the first zone is

used as a combustion air in kiln. The hot blast of the second zone is used in the pre-heating

zone-1 of travel grate and the air from the 3rd zone is discharged to the atmosphere

through chimney as its dust concentration is well within the permissible limits of pollution

norms. Volume of cooling air in all the three zones is regulated automatically through the

temperature control loops as per the requirement. Cold Pellets at about 100ºC are

discharged on conveyors and they are quenched by the cold water for further cooling and

then conveyed to the stock pile/ loading hoppers.

i. Stacking

The screened Pellets of required size duly cooled at air cooler and subsequently natural

cooling are transported to Bunkers.


12

j. Recovery of Dust and Spillage

Spillage from drying zone and preheating zone of traveling grate, dust from the wind box of

traveling grate and dust collected through de-duster of technological process shall meet

and will be sent to dust bin via belt conveyor, after they are ground together with iron ore

concentrate at grinding mill. Spillage (dry Pellets) produced at the discharge end of

traveling grate will be fed into the kiln from the feed chute of the kiln feed end by bucket

elevation. Almost all the dust and spillage are re-circulated and recovered.

Gasifier Producer Gas

Gases


13

3.5.2 DRI Kiln based Sponge Iron Plant

Historical Background

The production of steel began in ancient times; but because of the complexity and slow speed

of the ancient process, they could not be carried out on a very large scale. Consequently, they

were replaced by the high production rate ‘indirect process,’ and the development of modern

DR Process did not begin until the middle of 19th century.

Perhaps the very first patent in U.K. for sponge iron making was in 1792 presumably using a

rotary kiln. More than 100 DR processes have been invented and operated since 1920. Most

of these have died down. But some of them have re-emerged in slightly different form.

As touched upon earlier, sponge iron is mainly produced from ore by two different routes

– (a) by reducing gases (CO and H2) in a shaft furnace, and (b) through direct treatment

with coal in a rotary kiln.

Important Features

The coal based rotary kiln process of making sponge iron is the focus of the present write up.

Although many different processes and process concepts have been emerging in this area,

there were rapid births and deaths of these processes and process concepts in the middle of

the twentieth century. But those operating successfully at present have many features in

common. Some of the common or slightly differing features are:

i. System of sealing to prevent air ingress into the reactor,

ii. System of throwing or slinging coal from discharge end of reactor,

iii. System of weigh feeding and proportioning of raw materials

iv. System of introducing controlled amount of air at regular intervals of length in such a

way that it does not oxidize the reduced product in the bed,

v. System of temperature sensing at regular intervals of length of the reactor and

recording of the same.

vi. System of indirect cooling of sponge iron-char mixture in a rotary steel cylindrical shell

using water from the outside.

vii. System of treating waste gases and maintaining desired flow profilethrough pressure

control.


14

Fig. 2.1.2.a Key steps in sponge iron making in rotary kiln

A typical process scheme for making sponge iron in a rotary kiln is presented in Fig. 2.1.2.a

While Fig. 2.1.2.a shows only the key steps, a more detailed scheme, as it would appear for a

typical operating plant.

SPONGE IRON PLANT SCHEMATIC


15

Why Should We Select A Rotary Kiln?

The rotary kiln direct reduction (RKDR) processes have been looked upon with apprehension,

mainly because there have been rapid births and deaths of processes in this group. But the

fact that it has re-emerged points to certain strengths of this process. Let us examine some of

them.

Process Strengths

Rotary kiln process has to compete mainly with the shaft process of making sponge iron and

in some cases with iron making blast furnace. As compared to them, the rotary kiln has some

advantages, as also some limitations, both with respect to the process and the product it

makes. The major process strengths of rotary kiln are:

(i) A rotary kiln can mix the solid charge as it heats and reduces it. Simultaneous

mixing helps in the dilution of CO2 concentration formed around the iron

ore/sponge iron particles – which is necessary for the reduction reaction to

proceed.

(ii) As a large freeboard volume is available above the solid charge (about 85%), the

rotary kiln can tolerate heavily dust-laden gas. When the kiln is suitably designed,

it would be best suited for utilizing the Indian high ash non-cooking coals. In shaft

reactors, generation of such dust leads to choking and channeling which leads

finally to disruption of the process.

(iii) Rotary kiln can serve the dual purpose of a coal gasifier as well as an ore reducer.

Preparation of reducing gas from coal is an expensive step, which is coming in the


16

way of commercialization of coal gasification based DR process. Therefore, rotary

kiln DR process has proved commercially viable, even with low productivity per

unit volume, because of this capability to perform two different functions

simultaneously.

(iv) In comparison to blast furnace, the temperature of reduction of iron oxide is much

lower in rotary kiln (about 1000oC as against 1500 to 2000oC in blast furnace). This

means that much less energy is required for bringing the reactants to the

temperature of reaction.

Product Strengths

Additionally, the strengths of the product made by rotary kiln are:

(i) It is easy to desulphurise iron ore while making sponge iron. Consequently, the

sponge iron of much lower sulphur content can be produced as compared to blast

furnace hot metal. For shaft process of sponge iron making, prior and meticulous

de-sulphurisation of natural gas is necessary to prevent poisoning of catalyst

used for reforming.

(ii) Sponge iron produced from rotary kiln is obtained in close granular size range. This

permits charging in electric or other steel making furnaces in a continuous

manner, obviating the need for opening and closing of roof. Continuous charging

permits partial refining during melting stage as the particle passes through the slag

layer into the mixed layer. If adequate melting energy is available, refining time,

and consequently, operation time can be considerably reduced.

3.5.3 Mini Blast Furnace

A blast furnace is a type of metallurgicalfurnace used for smelting to produce industrial

metals, generally iron, but also others such as lead or copper.

Process Description

In a blast furnace, fuel, ores, and flux (limestone) are continuously supplied through the top

of the furnace, while a hot blast of air (sometimes with oxygen enrichment) is blown into the

lower section of the furnace through a series of pipes called tuyeres, so that the chemical

reactions take place throughout the furnace as the material moves downward. The end

products are usually molten metal and slag phases tapped from the bottom, and flue

gasesexiting from the top of the furnace. The downward flow of the ore and flux in contact

https://en.wikipedia.org/wiki/Metallurgy

https://en.wikipedia.org/wiki/Metallurgy

https://en.wikipedia.org/wiki/Smelting

https://en.wikipedia.org/wiki/Iron

https://en.wikipedia.org/wiki/Lead

https://en.wikipedia.org/wiki/Copper

https://en.wikipedia.org/wiki/Ores

https://en.wikipedia.org/wiki/Flux_%28metallurgy%29

https://en.wikipedia.org/wiki/Air

https://en.wikipedia.org/wiki/Oxygen

https://en.wikipedia.org/wiki/Tuyeres

https://en.wikipedia.org/wiki/Blast_furnace#Process_engineering_and_chemistry

https://en.wikipedia.org/wiki/Blast_furnace#Process_engineering_and_chemistry

https://en.wikipedia.org/wiki/Metal

https://en.wikipedia.org/wiki/Slag

https://en.wikipedia.org/wiki/Flue_gas

https://en.wikipedia.org/wiki/Flue_gas


17

with an upflow of hot, carbon monoxide-rich combustion gases is a countercurrent exchange

process.

Mini Blast Furnaces (MBFs) are ideally suited to small scale operations. A Mini Blast Furnace

(MBF), which can be viewed as is a miniature version of conventional large blast furnace, also

has a few additional characteristic features known for their simplicity and economy.Since

MBFs are small (working volume ranges between 100 - 370 m3 corresponding to production

capacities of hot metal between 60000 - 200000 tpa) blast furnaces, the technology involved

is not only well proven, but also very sophisticated.Smaller scales of operation allows the use

of inferior grade coke and iron ore (sinter usage is difficult). Mini blast furnaces are becoming

increasingly as an economic and reliable source of iron for foundries as well as for forward

integration with steelmaking units in EAF / EOF (and sometimes even small BOF) based steel

plants

https://en.wikipedia.org/wiki/Countercurrent_exchange


18

3.5.4 Steel Melting Shop

In the proposed expansion project following will be established

EAF - 1 x 45 T

Ladle furnace - 1 x 45 T

VD / VOD - 1 x 45 T

Induction Furnace - 4 x 20 T

Billet / Bloom Caster - 1 x 2 Strand

Billet Caster for IF & Rolling Mill - 1 x 2 Strand

3.5.2.1 Electric Arc Furnaces

Major technological features of electrics arc furnace envisaged are as follows:

Eccentric bottom tapping

Water cooled side wall panels and roof

Water spray cooling of the graphite electrodes

Hot heel and foamy slag practice

Continuous feeding of directed reduced iron (DRI)

Oxygen injection facilities

Primary and secondary gas evacuation system

Process flow

Receipt of DRI

DRI will be received in the DRI/Storage bay by road through DRI plant. Facilities for

measurement of weight and temperature of DRI will be provided. DRI will also be stored in

the storage bunkers in the over head Material handling bunkers .Proper inert atmosphere

with nitrogen will be provided in the DRI storage bunkers to prevent its oxidation by

atmospheric oxygen.

Scrap handling

The scrap will be stored in pits provided scrap bay, which will have a storage capacity of about

7 days requirement of scrap. The bay will be served by magnet crane with magnet. The cranes

will be utilized for unloading of scrap from incoming vehicles by roads into the storage pits

and subsequent loading into scrap charging boxes. Scrap box will be transferred to furnace


19

bay through transfer car. Scrap charging box will be charged to electric arc furnace by EOT

crane. Weighing facility will be provided in the scrap storage bay for weight measurement of

the loaded scrap boxes.

3.5.2.2 Ladle Furnace

At ladle furnace station, heating, de-oxidation, de-sulphurisation, alloying and

homogenisation of temperature and chemical composition of steel tapped into ladle will be

carried out. The ladle furnace will help to produce various steel grades, improve productivity,

steel quality and operating indices of the melting unit.

In addition, the ladle furnace will be used as a holding furnace when casters are not ready to

receive heat or during emergency situations. Lime, de-oxidizers and ferro-alloys will be kept

on ladle furnace platform. Weighed quantity of these materials will be charged through

bunker system into ladle during LF treatment. Aluminum and petroleum coke will also be

charged manually as per the requirement.

Argon purging facilities from bottom will be provided at ladle furnace station.

3.5.2.3 Billet / Bloom Caster (1x2 Strand)

To meet the annual casting requirement, one 2-strand billet/bloom casting machine for

casting billets and blooms will be installed in the steel melting shop along with necessary

tundish and mould/segment preparations and auxiliary facilities. The continuous casting

machines will be of radial type with curved mould design.

Process Flow

The liquid steel ladle is lifted by the EOT crane and placed on the ladle turret of the

billet/bloom caster. In the mean time, a tundish lined with coldinsulating board and dried in

the tundish dryer and mounted on the tundish car is moved from the parking position to the

casting position. Ladle slide gate is opened to allow flow of liquid steel into the tundish. The

liquid steel stream from ladle to tundish is protected by ceramic shroud to ensure superior

quality of cast product.

Prior to start of casting operation, dummy bars are introduced into the moulds. The gap

between dummy bar head and mould walls are sealed with asbestos chord. Small pieces of

steel scrap are placed over the dummy bar head for chilling of initial liquid steel.


20

Water supply to moulds, secondary cooling zone and machine cooling is switched on. When

the liquid steel level in the tundish reaches a predetermined level, the submerged nozzles of

the tundish are opened for flow of metal into the moulds.

When the liquid steel level in the moulds reaches about 100-150 mm from its top, the drives

of the mould oscillating mechanisms and withdrawal and straightening units are switched on.

The withdrawal of dummy bars begins at the minimum speed and gradually increases to

normal casting speed within a few minutes. Adding requisite quantity of rapeseed oil does the

lubrication of mould walls. During casting operation, the metal level in the mould will be

maintained within predetermined limit by automatic mould level controller.

During casting operation, the metal level in moulds is also maintained within predetermined

limits by adjusting the strand withdrawal speed. The liquid steel level in the tundish is also

kept within permissible range by adjusting the opening of ladle slide gate.

The partially solidified strands after leaving the moulds passes through the strand guide

system where intensive but controlled cooling of the strands is achieved by direct water spray

through spray nozzles. The solidified strands are guided through withdrawal and straightening

unit before entering the torch cutting zone.

The dummy bars are separated from the cast strands when dummy bars reach beyond the

withdrawal and straightening unit and are stored in a dummy bar storage device till their

introduction is required for the next cast.

The cast strands are cut into predetermined length by automatic oxy-LPG gas cutting torches.

The billets from cooling bed is lifted by billet handling magnet crane and stacked in the

storage bay.

For chemical analysis of liquid steel, samples are taken from the tundish and sent to the

laboratory. The samples are also cut from cast billets and sent to the laboratory for macro-

etching, sulphur prints and determining other quality parameters.

At the end of casting, the tundish is shifted to the reserve position for drainage of remaining

slag and metal. The empty tundish is lifted by the crane and transferred to the tundish

preparation area where facilities are provided for tundish preparation.

3.5.2.4 Vacuum Degassing (VD/VOD)

After treatment of the liquid steel at ladle furnace, only special and alloy steels requiring

vacuum treatment will be brought to vacuum degassing unit. Ladle will be placed inside the


21

vacuum tank after which tank will be sealed with tank cover. Vacuum pump will be switched

on and argon gas will be simultaneously purged in the liquid steel during entire vacuum

treatment. Sample will be taken and if necessary alloying elements will be added through

vacuum lock hopper to get the desired chemical composition. Vacuum degassed steel will be

shifted to ladle turret for casting.

3.5.5 Rolling Mill

In the proposed expansion, following will be established:

Bar & Rod Mill - 1,00,000 TPA

TMT Mill - 2,00,000 TPA

Section Mill - 2,50,000 TPA

Special Features of Rolling Mill

The proposed medium section mill have the following special features to ensure minimum

energy consumption, high level of automation, higher yields, superior surface finish and close

tolerances.

Pusher type reheating furnace top and bottom fired

2-Hi reversible breakdown mill stand with electromechanical screw down of the top

roll, automatic unjamming device, overload protection and roll force measurement

system

Universal rougher and vertical edging stand

Universal finishing stand

Quick stand change / roll change facility

Level 2 automation

2 Nos. hot saws

Walking beam type cooling bed with natural cooling

Straightening facility

Piling bed

Process Description

Continuously cast billets / blooms received from the concast shop will be unloaded and

temporarily stored in the billet/ bloom storage area. Cold blooms / billets will be charged into

the reheating furnace through charging grid and roller table. During the movement inside the

furnace, the input blooms / billets will attain required rolling temperature. Reheated blooms /


22

billets will be fed to 2-Hi reversible breakdown stand. The 2-Hi reversing roughing stand will

be of conventional design with work roller tables, manipulators and tongue cut saw. The

stand will be driven by DC Motor. Sufficient number of passes will be provided in breakdown

mill stand before feeding into the roughing group of stands. Front and / back of the rolled

stock emerging out of the breakdown mill stand will be cropped by the saw installed after the

stand if required.

After the crop saw, material will be fed to the intermediate group of mill stands consisting

one universal rougher and one vertical edging stand. After being processed in these stands

the rolled stock is then fed to the finishing stand from where the final product comes out.

Two saws, one movable and one fixed are installed after the finishing stand to crop the fish

ends of the rolled products. Further these saws are also utilised in cutting the products into

commercial lengths. These cut products are then delivered to the cooling bed run in roller

table. The materials transferred to the run in roller table is being shifted to the cooling bed by

means of chain transfer arrangement, the shifted materials are naturally cooled on the

cooling bed and further shifted on to the run out roller table which will carry the products to

the straightening machine for straightening the section products. The straightened and

finished products are then transferred to the piling bed where the products are piled up and

manually bound. Bound bundles are then lifted by the two cranes provided in the bay and

stored in the yard.

3.5.6 Galvanising Line

One galvanisng line has been envisaged to galvanise the angles and channels to give value

addition to the products and cater to the increasing demand of these products in the market

especially for the transmission towers in power sector. The capacity of this line will be to

about 2,50, 000 TPA for galvanisning angles and channels.

3.5.7 Lime & Dolo plant

The lime and dolo plant will comprise of one no. vertical lime shaft kiln and one (1) No.

vertical dolo shaft kiln each of capacity 100 tpd to meet the requirement of soft lime and dolo

for steel making process.

Technological parameters

Nos. of lime kiln 1

Capacity of lime Kiln 100 tpd

No. of dolo kiln 1


23

Capacity of dolo Kiln 100 tpd

Kiln feed size, mm 25-55

Calcination temperature, °C, 950-1050(for lime) 1050-1150 (for dolo)

Specific consumption of fuel (Kcal/kg of burnt lime and dolo) 920

Working schedule of the plant: (3 shifts/day) 330 days/yr

Process description

Limestone and dolomite of size 25-55 mm will be received from mines and stored in raw

material storage yard. From there, these materials will be conveyed to raw material storage

bunker. The limestone and raw dolomite from storage bunkers will be fed to the screen by

belt conveyor and undersize limestone and dolomite of size 0-25 mm will be screened out and

stored in another bunker which is meant to store the undersize material. There will be one (1)

no. storage bunker for each kiln and one (1) no. undersize bunker for each kiln. The

undersized limestone and raw dolomite will be stored for onward disposal to other

consuming units. Screened materials of size 25-55 mm will be fed to shaft kilns by means of

skip hoist through a weigh hopper. Limestone and raw dolomite will be calcined at

temperature of 950-1050°C (for lime) and1050-1150°C (for dolo).

The lime and dolo from the kilns will be discharged to two different conveyors which are

placed below the kilns. The lime and calcined dolo will then be fed to single deck screen to

separate out undersized (0-25 mm) material. The undersized (0-25 mm) lime and dolomite

material will be stored in two separate bunkers. The sized lime and cal. dolomite of 25-55 mm

will be stored in six (6) Nos. of bunkers [three(3) Nos. of bunkers for lime and three (3) Nos. of

bunkers for calcined dolomite]. Lime and calcined dolomite of size 25-55mm will be conveyed

to SMS through belt conveyor and undersize lime (0-25 mm) will be transported through

trucks/cement tanker to other consuming units. The waste gas which is coming out from the

kiln is having 5-10 gm/Nm3 dust. This gas will be cleaned in waste gas cleaning system to vent

out the clean gas to atmosphere. The dust load at clean gas will be as per norms of country.

The dedusting system will be provided for raw material storage building, screen house

building and lime delivery bin building to keep dust free atmosphere in the lime kiln area. One

(1) No. passenger-cum-freight lift will be provided for ease of movement to different floors.


24

3.5.8 Oxygen Plant

One Air Separation Unit (ASU) of about 1 x 90 t/d capacity has been envisaged to meet the

requirement of oxygen, nitrogen and argon for the proposed steel plant. Oxygen will be

consumed in EAF of the steel melting shop in the continuous casting plant to meet the cutting

needs and also to meet the general purpose requirement of various shops of the steel plant.

Argon will be required for rinsing in ladles and also to maintain inert atmosphere in the

mould/ tundish. Nitrogen will be required for purging of gas pipelines. Oxygen, nitrogen and

argon will be produced by air separation process based on low pressure cryogenic cycle and

double column rectification system

3.5.9 Power Plant

Its is proposed to establishment 8 MW WHRB based power & 90 MW FBC based Power plant

in the proposed expansion project to meet the power requirement for various processes of

integrated plant including auxillaries of power plant.

WHRB Power Plant

Production of sponge iron in DRI kiln generates huge quantities of hot flue gases carrying

considerable sensible heat. The energy content of these gases can effectively be used to

generate electric power as well as steam for meeting various process requirements. Thus a

WHRB (Waste Heat Recovery Boiler) power plant would be an ideally suited proposition to

effectively make use of this waste gas. This WHRB Power plant would not only make the plant

independent of external source of electric power to some extent but would also result in

energy conservation and environment protection.

1 Nos. 8 MW Steam Turbo-generators (STGs) envisaged for the Power plant will be single

cylinder, multistage, extraction – cum – condensing type complete with condenser, air

evacuation system, 2 x100% condensate extraction pumps, electronic governing system,

lubricating oil system, regenerative feed heating system etc. The turbine will be fed with

steam generated from HRSG in DR kiln. The STGs will be located in the machine hall of the

power plant.

Technological / Operating Parameters

S.No. Equipment Unit Parameter

1 1x42 TPH HRSG Steam pressure at Superheater outlet

ata

66


25

Steam temperature at super heater outlet Steaming capacity Feed water inlet temperature

OC TPH

OC

490±5 42

170

2 1 x 8 MW turbo – generator, multi – stage, condensing type Inlet steam pressure Inlet steam temperature MCR capacity Generator voltage

ata OC

MW kV

62 485

8 11

FBC Power Plant

The unit will have one CFBC boiler connected to 90 MW Steam Turbine Generator. The boiler

shall be designed for continuous operation at Turbine Maximum Continuous Rating (TMCR). A

margin of 10% over TMCR shall be taken into account to arrive at Boiler rated capacity. The

boiler will be natural circulation, circulating fluidized bed combustion, two pass, non reheat,

single drum, balanced draft, semi-outdoor type. The boiler will have continuous evaporation

rating of approx. 360 tonnes/hr. (BMCR shall not be less than 110% of TMCR) with steam

parameters at super heater outlet as 98 kg/cm2 and 5400C (± 50C). The feed water

temperature at MCR at inlet to economizer is expected to be around 230 degree C. Steam

parameter are to be fine tuned at Boiler outlet based on actual plant layout and piping

arrangement. The boiler will be complete with ash /solid separator, economizer, air heater,

ducting, FD fans, ID fans and PA fans.

Air cooled condensers envisaged for Power plant to conserve water.

3.6 RAW MATERIAL REQUIREMENT

The following will be the raw material requirement for the proposed expansion project:

Raw Material Quantity (TPA)

Sources Mode of Transport

For Iron Ore beneficiation plant (Iron ore concentrate)

Iron ore fines 9,00,000 NMDC Chhattisgarh/Karnataka /

Odisha

By Rail & Road (Covered trucks)

For Pellet Plant (Pellets)

Iron ore Concentrate 6,30,000 Own Generation Covered Conveyor

Bentonite 9,000 Local area By road (through covered

trucks)

Limestone 9,000 Local area By road


26



(through covered trucks)

Coal for pellet Imported 20000 MT Vietnam/Russia/Indonesia / South Africa / Australia

By Sea, Rail & Road (Covered trucks)

Furnace Oil 8100 KL Local area By road (through covered

trucks)

Coal (Gasifier) Indian or Imported

90000 MT SCCL, Telangana / MCL Indonesia / South Africa /

Australia

By Sea, Rail & Road

(Covered trucks)

For DRI Kilns (Sponge Iron)

Pellets (for 1 x 350 TPD DRI Kilns) 170000 Own generation ----

Coal (1 x 350 TPD DRI Kilns)

Indian or Imported

160000 SCCL, Telangana / SECL / Ib Valley

Indonesia / South Africa /

Australia

By rail & road (through covered

trucks)

Through sea route, rail route & by road

Dolomite 5600 Local area By road (through covered

trucks)

For Mini Blast Furnace

Iron ore lump 50000 Chhattisgarh/Karnataka / Odisha


trucks)

Coke 99800 Own generation ----

Quartzite 4160 CG / MP region By rail & road (through covered

trucks)

Pellet 200000 Own generation By rail & road (through covered

trucks)

Mn Ore 2500 MOIL, Maharashtra/imported


trucks)

For Steel Melting Shop (MS Billets)

Hot Metal 150000 Own generation ----

Scrap 299000 Imported Through sea route & by road

Sponge Iron 112000 Own generation ----

Pig iron 15000 Own generation ----


27



Ferro alloys 6000 Local Area By road (through covered

trucks)

Aluminium 1000 Local Area By road (through covered

trucks)

Flourspar 400 Local Area By road (through covered

trucks)

For Rolling Mill (TMT bars & Structural Steel)

Steel billets 540000

40000

Own generation

Purchased from outside

----

By road (through covered

trucks)

For Galvanising line

Rolled structural products 250000 Own generation ----

For Lime & Dolo plant

Limestone 45000 Local area By road (through covered

trucks)

Dolomite 45,400 Local area By road (through covered

trucks)

Oxygen Plant

Air 90 MT -- --

For FBC Boiler [Power Generation 90 MW]

Dolochar 16800 In plant generation From Existing plant

through covered conveyors

Coal Indian 4,87,200 SCCL, Telangana / SECL By rail & road (through covered

trucks)

Imported 2,91,900 Indonesia / South Africa / Australia

Through sea route / rail route / by road


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3.7 WATER REQUIREMENT AND ITS SOURCE

Water required for the proposed expansion project will be 4000 KLD and same will be sourced

from Visakhapatnam Municipal Corportion & Ground water source. Following is the break up

of water requirement:

S.No. Water requirement Quantity in KLD

1. Iron ore Beneficiation & Pelletization 720

2. DRI kiln 350

3. Mini Blast Furnace 600

4. Steel melting shop 500

5. Rolling mill 500

6. Galvanizing line 60

7. Lime & Dolo plant 50

8. Power Plant (90 MW) 1200

9. Domestic 20

Total 4000

3.8 WASTEWATER GENERATION & ITS MANAGEMENT

There will be no effluent generation in the Iron ore Beneficiation & Pellet plant, DRI plant,

SMS, Rolling Mill as closed circuit cooling system will be adopted.

Effluent from Gas Cleaning plant of Blast Furnace will be treated in settling tank and after

treatment it will be recycled.

Effluent from power plant will be treated and after ensuring compliance with APPCB

norms, it will be utilized for dust suppression, ash conditioning and for greenbelt

development.

Sanitary waste water will be treated in septic tank followed by sub-surface dispersion

trench.


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3.9 POWER REQUIREMENT

Power requirement for the proposed expansion project will be sourced form Captive power

plant. Following will be Power requirement for proposed expansion:

S.No. Power requirement Quantity in MW

1. Iron ore Beneficiation & Pelletization 8.0

2. DRI kiln 2.0

3. Mini Blast Furnace 3.0

4. Steel melting shop 60.0

5. Rolling mill 5.0

6. Galvanizing line 0.5

7. Lime & Dolo plant 0.5

8. Power Plant (90 MW) 3.0

Total 82.0


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Chapter – 4 : SITE ANALYSIS

4.1 INFRASTRUCTURE

For establishment and successful operation of plant, it is imperative to ensure availability of

the following infrastructure:

Availability of raw coal & iron ore and its proximity to the plant to reduce cost of

transportation.

Road / Rail head connection so that the raw materials and products can be easily and

economically transported.

Availability of water.

Permanent and reliable source of power.

Adequate land for the plant, storage of raw material and products & disposal of waste

material.

4.2 CONNECTIVITY

The proposed site is well connected with Road network. The following table gives brief

regarding connectivity of the proposed site:

Component Description

Road : NH # 5 (18.0 Kms.) Aerial

Rail : Nearest station – Mallividu RS (1.3 Kms.) Aerial

Air : Vishakapatnam Air Port (29.0 Kms.)


31

Below mentioned table gives brief regarding environmental setting of the project site

S.No Particulars Distance from the site

1. Habitation : Srirampuram – 0.35 Kms.

2. National Park = No National Park is situated within the 15 km

radial distance periphery

3. Wild life sanctuaries = Nil

4. Eco Sensitive Areas = Nil

5. Forests = Advanapalem RF (7.7 Kms.),

6. Surface water bodies = Gosthani River – 6.8 Kms.

7. Costal Regulation Zone [CRZ] = Nil

4.2 Land details

Existing plant is located at R.G.Peta Village, L.Kota Mandal, Vizianagaram District, Andhra

Pradesh.



Village – 17.7 Ha.) to the existing plant. Total land envisaged for the entire project will be

64.98 Ha.


83° 9'2.71"E-83° 9'28.37"E.



32

Chapter – 5 : PLANNING BRIEF

5.1 Planning Concept




TPA), Rolling Mill (1,00,000 TPA) and Power Plant (20 MW). Now, Maa Mahamaya Industries

Ltd.,proposes to go for expansion as mentioned below:

S.No Unit Existing


Proposed Production

capacity (Unit)


proposed expansion


--- 6,00,000 TPA

(1 x 2000 TPD) 6,00,000 TPA

(1 x 2000 TPD)

2. DRI kiln 1,12,000 TPA (1 x 350 TPD)

1,12,000 TPA (1 x 350 TPD)

2,24,000 TPA (2 x 350 TPD)

3. Mini Blast Furnace ---- 1,65,000 TPA

1 x 250 M3

(550 TPD)

1,65,000 TPA (550 TPD

4.


6,58,300 TPA

EAF --- 1 x 45 T


VD / VOD --- 1 x 45 T



--- 1 x 2 strand



5. Rolling mill


1,00,000 TPA (1 x 333 TPD)


2,00,000 TPA (1 x 666 TPD)

3,00,000 TPA (1 x 333 TPD &

1 x 666 TPD)


(1 x 833 PD) 2,50,000 TPA

(1 x 833 PD)




33

S.No Unit Existing


Proposed Production

capacity (Unit)


proposed expansion



Waste Heat



5.2 Population Projection

An official Census 2011 detail of Vizianagaram, a district of Andhra Pradesh has been released

by Directorate of Census Operations in Andhra Pradesh. Enumeration of key persons was also

done by census officials in Vizianagaram District of Andhra Pradesh.

In 2011, Vizianagaram had population of 2,344,474 of which male and female were 1,161,477

and 1,182,997 respectively. In 2001 census, Vizianagaram had a population of 2,249,254 of

which males were 1,119,541 and remaining 1,129,713 were females. Vizianagaram District

population constituted 2.77 percent of total Maharashtra population. In 2001 census, this

figure for Vizianagaram District was at 2.95 percent of Maharashtra population.

There was change of 4.23 percent in the population compared to population as per 2001. In

the previous census of India 2001, Vizianagaram District recorded increase of 6.55 percent to

its population compared to 1991.The most common language in the city is Telugu.

There are no major human settlements in the close vicinity of the project site. The manpower

requirement will be sourced from the local areas to the extent possible; hence not much of

settlement of outside people in the area. However population concentration may increase

around the project site due to increase in ancillary activities.

5.3 Land use Planning

Present use of existing land is Industrial and additional land envisaged for the expansion

project will be converted for Industrial purpose.

Exsting plant is located at R.G.Peta Village, L.Kota Mandal, Vizianagaram District, Andhra

Pradesh.




34

Village – 17.7 Ha.) to the existing plant. Total land envisaged for the entire project

including existing plant will be 64.98 Ha including existing plant.


83° 9'2.71"E-83° 9'28.37"E.


5.4 Amenities / Facilities

Facilities like canteen, rest room has already been provided in the existing plant as basic

facilities to workers. No other additional facilities are proposed.


35

Chapter – 6 : PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The main plant area comprises of I/O Beneficiation & Pellet plant, DRI Kilns, Blast furnace,

Furnace sheds, Rolling mill area, raw material storage and product storage etc.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No colonization is proposed; however, facilities like canteen, rest room and indoor games

facilities will be provided in the proposed plant and one Admin building is also proposed.

6.3 GREEN BELT

More than 1/3rd of total land availability is reserved for plantation i.e. greenery.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

15 m wide greenbelt is being maintained all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast growing,

wind firm, deep rooted. A three tier plantation is proposed comprising of an outer

most belt of taller trees which will act as barrier, middle core acting as air cleaner and

the innermost core which may be termed as absorptive layer consisting of trees which

are known to be particularly tolerant to pollutants.

6.4 SOCIAL INFRASTRUCTURE

Social infrastructure will be developed as per need based in the Villages of the close vicinity of

the project.


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6.5 Connectivity

The proposed site is well connected with Road network. The following table gives brief

regarding connectivity of the proposed site:

Component Description

Road : NH # 5 (18.0 Kms.) Aerial

Rail : Nearest station – Mallividu RS (1.3 Kms.) Aerial

Air : Vishakapatnam Air Port (29.0 Kms.)

6.6 DRINKING WATER MANAGEMENT

It is estimated that 20 KLD of water will be required for domestic purpose during operation of

proposed plant. The desired amount of water will be drawn from ground water sources.

6.7 WASTEWATER GENERATION & ITS MANAGEMENT

There will be no effluent generation in the Iron ore Beneficiation & Pellet plant, DRI

plant, SMS, Rolling Mill as closed circuit cooling system will be adopted.

Effluent from Gas cleaning plant of Blast Furnace will be treated in a settling tank and

after treatment it will be recycled.

Effluent from power plant will be treated and after ensuring compliance with APPCB

norms, it will be utilized for dust suppression, ash conditioning and for greenbelt

development.

Sanitary waste water will be treated in septic tank followed by sub-surface dispersion

trench.


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Chapter – 7: REHABILITATION & RESETTLEMENT (R & R) PLAN

No rehabilitation and resettlement is required as Existing plant is located at R.G.Peta Village,

L.Kota Mandal, Vizianagaram District, Andhra Pradesh. Proposed expansion will be carried out in

partly in the existing plant (in R.G.Peta Village – 40.48 Ha.) and partly in the land adjoining (in

R.G.Peta village 6.8 Ha and Srirampuram Village – 17.7 Ha.) to the existing plant. Total land

envisaged for the entire project will be 64.98 Ha including esisting plant.


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Chapter – 8 : PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE

The plant will be implemented in 36 months from the date of receipt of Environmental

Clearance from the MoEF&CC, New Delhi & Consent from APPCB.

8.2 PROJECT COST

The estimated cost for the proposed project will be Rs. 3600 Crores.

S.No. Decription Estimated Cost

(Rs. In Crores)

1. Land & site development 12

2. Building and Civil works 500

3. Plant & Machinery including misc. fixed assets 2463

4. Engg. Supervision, project management & training charges 50

5. Preoperative & Preliminary expenses 100

6. Provision for Contingencies 125

7. Interest During Construction (ID) 250

8. Margin money for working capital 100

Total 3600


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Chapter – 9 : ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS

With the implementation of the proposed project, the socio-economic status of the local

people will improve substantially. The land rates in the area will improve in the nearby areas

due to the proposed activity. This will help in upliftment of the social status of the people in

the area. Educational institutions will also come-up and will lead to improvement of

educational status of the people in the area. Primary health centre will also be developed by

us and the medical facilities will certainly improve due to the proposed project.

9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by undertaking

following activities / responsibilities as the part of Corporate Social Responsibility.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

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