1

PROJECT REPORT

On

Modification of Value Added Products In the Existing Pig Iron Complex

At

Narayandevarakere Village, Hagaribommanahalli Taluk, Bellary District, Karnataka State.

For

M/s. SLR Metaliks Limited Bellary

Environmental Consultants

M/s. Aqua Tech Enviro Engineers,

(Environmental Engineers & Consultants)

# 3391, 6th Main, 3rd Cross, RPC Layout,

Vijayanagar II Stage, Bangalore – 560 040

Tele Phone: 080: 23141679

Fax: 080:23148166

E-mail: aquatech_enviro@yahoo.co.in

2

1. INTRODUCTION

M/s SLR Metaliks Ltd is established and operating with valid Environmental Clearance from

MOEF, New Delhi and Consent for Establishment and operation from KSPCB, Karnataka

with an iron making industry consisting of 262 m3 blast furnace with 2,00,000 TPA capacity,

33 m2 sinter plant (3,31,000 TPA) and 6 MW Blast Furnace off gas based power plant at

Narayanadevarakere Village, Hagaribommanahalli Taluk, Bellary District, Karnataka State.

Presently, the pig iron produced in the industry is sold to other industries for use in steel

making and foundries. Sinter produced is completely utilized as a captive source of blast

furnace raw material. Power generated from captive source is completely utilized in the

industry it-self.

All the existing units are fully operational. M/s SLR Metaliks Ltd is establishing expansion

projects to improve viability of the plant by value addition to the existing hot metal

production by installing additional and balancing facilities to produce more valuable

downstream products with ready market opportunity. Towards this objective, the company is

establishing 3.0 Lakh TPA Steel Plant, 3.2 Lakh TPA Rolling Mill, 1.2 Lakh TPA Coke

Oven Plant, 9.0 MW Coke Oven Off Gas Based Power Plant, 120 TPD Oxygen Plant,

10 TPH Pulverized Coal Injection and 15000NM3/hr Producer Gas Plant, for which EC from

MoEF and CFE from KSPCB is obtained. Now to improve the economics & effective

resource utilization,

Change of fuel is proposed in existing power plant from Blast furnace gas to imported

coal and

Change of fuel in Reheating furnace from FO to Blast furnace gas

Capacity reduction of producer gas plant from 15000 Nm3/hr to 5500 Nm3/hr.

1.1 Salient Features

The salient features of the proposed project are given below:

Table-1.1 Salient Features of the Proposed Project

Sl.

No. Parameter Details

1 Project

(i)Change of fuel in existing power plant from Blast furnace

gas to imported coal (ii) change of fuel in Reheating furnace

from FO to Blast furnace gas and (iii) Capacity reduction of

producer gas plant from 15000Nm3/hr to 5500 Nm3/hr

2 Project Proponents

M/s S L R METALIKS LIMITED Narayandevarakere

Village- 583 222, Lokappanahola Near Mariyammanhalli,

Hagaribommanahalli Tq. Bellary Dist., Karnataka State.

3 Location of the site

Plot / Survey No. R.S. No.:633,646, 643 & others

Village Narayandevarakere,

Lokappanahola- 583 222,

Tehsil Hagaribommanahalli

District Bellary

State Karnataka

3

4

Proposed

modifications BF Gas based captive

Power Plant. 1 x 6 MW

( existing unit)

Change of fuel from Blast

furnace gas to imported coal.

( change of 40 TPH boiler to 32

TPH AFBC boiler)

Rolling mill. 3,20,000

TPA ( expansion unit)

change of fuel in Reheating

furnace from FO to Blast

furnace gas

Producer gas plant 15,000

Nm3/hr ( expansion unit)

Change of capacity to 5,500

Nm3/hr

5

Existing capacity PRODUCTS QUANTITY

Pig Iron 2,00,000 TPA Granulated Slag 60,000 TPA

UNITS CAPACITY

Blast Furnace 1 x 262 m3

Sinter Plant 1 x 33 m2

Pig Casting Machine 2 x 500 TPD

BF Gas based captive

Power Plant 1 x 6 MW

6

Expansion units Steel plant 3,00,000 TPA

Rolling mill 3,20,000 TPA

Coke oven plant 1,20,000 TPA

Coke oven off gas based

power plant 1 x 9.0 MW

Air separation plant 120 TPD Oxygen capacity

Pulverized coal injection 10 Ton/h

7

Sl. No. in the

Schedule

Schedule-3(a) for Metallurgical industries (ferrous &

nonferrous) as per EIA Notification dated 14th September

2006 and as amended in December 2009.

8

Location Features The location of the proposed site and its immediate

surroundings is a barren land and moderately undulated with

shrubs. It is consisting of rocky & sandy soil, not suitable for

cultivation. Nearest village Lokappanahola is 1.5km, nearest

town Hospet is 10 km and nearest high way SH-25 is 4.29

km from the site.

9 Total man power Construction phase : 40 Nos

Operation phase : 80 Nos

10 Land area The above said modification is in the existing industry

premises.

11 12

13

Raw material

requirement Plant Raw material Quantity

Captive power

plant. 1 x 6 MW Indonesian coal

70,000 TPA

Producer gas

plant

5,500 nm3/hr

C grade coal 17,240 TPA

4

14

Water requirement

& Source

150 m3/d. Source: Water drawl permission from single

window clearance is 9012 m3/d. Further Permission is

available to draw 0.19 TMC of water flood period & stored

in reservoir.

15 Power requirement

& source 10-11 % of rated capacity: 660kwh

16 Project Investment INR 19 Crore (for AFBC boiler & 5,500 Nm3/hr PGP)

17 Investment for

EMP

Capital investment on EMP : Rs. 90.00 Lakh

Operating/running cost on EMP : Rs. 9.00 Lakh

18

Effluent and their

treatment &

utilization

No additional waste water generated

19

Sources of air

pollution & control

measures

1. Flue gases from 28 T/h boiler (reheating furnace). These

gases are vented through stacks of adequate height.

2. Fugitive emission at screens, conveyors, coal handing area

etc. These are sucked through vacuum suction hoods,

dedusted and vented through stacks of sufficient height.

20 Sources of solid

waste &

management

Solid waste obtained are,

1. Fly ash & bottom ash from coal fired boiler & PGP will be

used for brick manufacturing.

5

Figure - 1.1 Location of the Project

6

Figure - 1.2 Google Map of Project

3. Details of proposed modifications

3.1 Captive power plant

The process involved in iron making generate considerable quantity of gas as fuels. The energy

content of these gases can effectively be utilized to generate electrical power as well as steam for

various needs. In the existing unit power is generated from blast furnace gas. Now it is proposed to

change the fuel from BF gas to imported coal. To achieve this, it is required to install 1x32 TPH

AFBC boiler with additional coal handling system. As already provisons are made for ash handling

in the producer gas plant the same facilities will be used for ash handling. Hence no additional

waste management system is required.

3.2 Rolling mill

Steel manufactured in the steel shop will be sent to rolling mill unit for products of specified

sizes. The process includes pre-heating in the furnace and hot rolling followed by shot

blasting, mechanical surface finishing before inspection and stacking. Instead of using

7

Furnace oil for reheating furnace it is proposed to use the Blast furnace gas generated from

blast furnace unit.

Producer gas plant

Extended shaft gasifier technology will be used to produce 5,500Nm3/hr producer gas from C

grade coal.

i) Coal is lifted and delivered to the bunker by a skip-hoist or Bucket-Elevator.

ii) From the Bunker, coal is fed to the Extended shaft through double-bell feeder system

either manually or semi-automatically or fully automatically as per the exit temperature of

gas exceeding 120oC.

iii) Fed coal travels downwards and gets dried and preheated up to the distillation

temperature as per the temperature profile . Due to prolonged stay of coal in the Extended

Shaft and the gas getting better physical contact with coal interface, substantial heat transfer from

gas to coal takes place and at the same time high volatile-matters of coal get stripped off

and enter the gas-phase in turn auto-carbureting the latter.

iv)When the coal enters the generator proper, reaction between coal and air along with steam occurs

3.3 RAW MATERIALS

Sl no. Unit Raw material Quantity in TPA

1 Captive power plant 1X6

MW

Indonasian coal 70,000

2 Producer gas plant

5500 Nm3/hr

C grade coal 17,300

3.4 Water requirement

Sl. No.

Purpose Unit Quantity

Coal based power plant 1X6MW

1 DM water m3 /d 50

2 Cooling water for condenser and

auxiliaries and gas fired boiler

m3 /d 56

Producer gas plant 5,500 Nm3/hr

3 Process water m3 /d 31.2

4 Soft water m3 /d 18.0

8

3.5 SOURCE OF POLLUTION & THEIR MANAGEMENT / DISPOSAL

3.5.1 WASTE WATER MANAGEMENT

3.6 GASEOUS EMISSIONS AND APC MEASURES

3.6.1 FUGITIVE EMISSIONS

Fugitive emissions are generated in the industry mainly due to the handling of coal, solid raw

material and solid waste products and also due to vehicular movement. Dust emissions also

arise during loading and unloading of solid material. The location and source of fugitive

emission is given below

Sources of Fugitive Dust

Sl.

No. Area Monitoring Location

1 Raw Material Handling area Tippler, Screen area, transfer points, stock bin

area

2 Crusher area Coal crusher plant, vibrating screen , transfer points

3 Raw material feed area Coal feeder area, mixing area, transfer points

3.6.2. CONTROL MEASURES

Details of Dust Extraction System

Sl.

No. Location / shop Facilities

1 Coal fired boiler ESP

2 Raw material

handling area,

material transfer

points

Dust suppression system comprising of spray nozzles, piping

network, valves, solenoid valves, pumps , instrumentation

and controls , electrics, water tank etc.

3 PGP plant Cyclone/ scrubber

Sl.No Purpose Unit Quantity

Utilization

Coal based power plant 1X6MW

1 Blow down water m3 /d 18 Will be used in

slag granulation

plant Producer gas plant 5,500 Nm3/hr 2 Cooling waste water m3 /d 10 Will be used in

slag granulation

9

3.7 Control measures in coal fired boiler area:

Crusher screen in fuel handling system

Dedusting system

Bag filter

Pulsate type bag filters will be used for cleaning the dust laden gas.

Design and material specification of bag filter are

Casing and hopper: 3.15 mm steel sheet

Tube sheet : 3.15 mm steel sheet

Bag case : 4 mm dia galvanized Wire net

Fasteners : Galvanized

Gaskets : Neoprene rubber

Filter bags : Polyester needle felt, Antistatic

Filtering velocity : 25-30 mm/s

3.8 WASTES GENERATED & THEIR MANAGEMENT / DISPOSAL

3.8.1 SOLID WASTE MANAGEMENT

The solid waste generated are bottom ash (925 TPA) & fly ash (12,922 TPA) which will be

utilized for brick making. The tar generated will be sold to authorized vendor.

3.9 ASH HANDLING SYSTEM

Dense phase pneumatic conveying system will be envisaged for conveying fly ash collected

from economizer, air pre-heater and ESP hoppers. Surge hopper of adequate capacity will be

provided at the collection point of economizer and air preheater zones.

Fly ash collection equipment and disposal from Power Plant

Dust separators will be provided immediately at the outlet of the furnace and before the ID

fan. The dust will be collected in hoppers below them. They will be emptied periodically by

air suction system and the ash will be taken to a silo located at a higher level for loading into

trucks from bottom of silo. The fly ash will be sold to cement plants.

Bottom ash collection and disposal

At the bottom of the boiler, a hopper will be provided with a sealing arrangement with water

between boiler furnace and the hopper. This will give a seal against slightly negative pressure

maintenance in the furnace and also for the expansion of the furnace walls downwards on

furnace heat up. This hopper will always be filled with water, overflowing continuously at the

top seal to quench the ash and clinkers falling down from the furnace.

Ash pond

The type of construction for the ash pond is earthen bund. Earth for dyke formation will be in

layers not exceeding 200 mm thickness and compacted with sheep foot roller. The

10

compaction of earth will be done to achieve 95% maximum dry density at optimum moisture

content by number if passes. The earth will be free from roots, sods, wood, other organic

matters and any unsuitable matter for formation of dyke. The dyke will have a slope of 1 in

2.25, in both upstream and downstream side of the pond. A minimum width of 4 m will be

provided at the top of the dyke wall to facilitate man and vehicular movement. The geo-

textile lining will be provided over a sand layer followed by a sand layer along the brick on-

edge layer. The seepage water if any will be collected through the rock toe, drains and

stoneware pipe arrangements at the edge of the ash pond. A free board of 0.5 m is considered

to avoid overflow of the stored slurry and the other reason is to fill the top free board depth

with earth cover for afforestation. The bottom area will be made impervious by compacting

the earth and clay.

3.9.1 GENERAL MITIGATION MEASURES

The impacts of fugitive emissions in the industry are controlled by following measures

Haulage roads are sprinkled with water at regular intervals for which water tankers with

sprinkler arrangement are deployed.

Trucks carrying coal and other raw material are covered with tarpaulin to prevent

spreading of dust during transportation.

Green belt and greenery development around storage yards, around plants, either side of

roads and around the periphery of the industry.

The conveyors of fuel are suitably covered with hood or enclosures to control fugitive

emissions.

Dust respirators are provided for the people working dust generating locations.

All internal roads in the premise are paved /tarred.

Regular sweeping of roads is practiced with vacuum sweeping machine or water flushing

to minimize dust.

The air pollution control measures will ensure the ambient air quality to be within the

NAAQ standards for industrial areas as indicated below.

11

4.0 ENVIRONMENTAL MANAGEMENT PLAN

A comprehensive environmental management plan will be adopted consisting of

environmental protection and monitoring measures as indicated below.

Establishment of pollution control facilities.

Green belt and greenery development in and around the factory site

Paving and lining of roads and fuel storage yards so as to avoid fugitive emissions.

Fugitive emissions within the factory and storage yards are controlled by good

housekeeping, water spraying and sprinkling.

Regular Monitoring of stack emissions.

Dust extraction at dust generating machinery/equipment.

Safety & Occupational health care programmes, emergency management plan and

safety management systems will be implemented in the industry.

4.1. ENVIRONMENTAL MANAGEMENT SYSTEM

The existing industry has already established Environmental Management System to

implement and monitor environmental policy and programmes. It consists of the following.

4.1.1 Environmental Cell

Environmental cell consisting of Managing director and departmental heads. The

responsibility of the Environmental cell is to effectively manage the environmental activities

in the industry.

4.1.2 Environmental Department

Environmental department consisting of environmental engineer, laboratory chemists and

operators. The responsibility of the Environmental department is to implement and operate

pollution control and environmental protection measures.

4.2 ENVIRONMENTAL MONITORING PROGRAMME

The existing industry has already implemented self monitoring system with man power and facilities

to ascertain the compliances of environmental norms and standards. A laboratory is present in the

industry to analyze waste water, soil, stack emission, ambient air etc. The parameters will be regularly

monitored as per MoEF/KSPCB guidelines during operation of the industry.

4.3 INVESTMENT ON POLLUTION CONTROL FACILITIES

Total cost of the project (for 32 TPH AFBC boiler & 5500 Nm3/hr PGP plant) will be Rs. 1900

Lakhs. The investment to be made on EMP will be Rs. 90.00 Lakhs. Recurring cost on EMP will be

about Rs. 9.00 Lakhs per year.

12

5. Conclusion

The modification will be done in the vicinity of the existing & expansion project area.

Administrative and ancillary infrastructure facility will be made use of in expansion of the

project. Hence, the modification will be achieved with minimum resources. The solid waste

handling facilities reserved for the producer gas plant will be utilized for the proposed coal

fired boiler.

With the proposed modification, the air pollution load will reduce marginally by about 1.3%

and reduced solid waste considerably by about 84 %.

Area vel Flow

conc.

with

APC Area vel Flow

conc.

expected

with APC

m2 m/s m3/hr mg/nm3 mg/hr kg/d m2 m/s m3/hr mg/nm3 mg/hr kg/d

PM 4.91 8.30 146597.26 44.00 6450279.26 154.81 PM (Boiler chimney ) 4.91 4.60 82800.00 50.00 4140000.00 99.36

Sox 4.91 4.60 82800.00 40.00 3312000.00 79.49

Nox 4.91 4.60 82800.00 10.00 828000.00 19.87

PM (dedusting

chimeny) 1.25 9.28 41760.00 50.00 2088000.00 50.11

PM 3.80 13.80 188873.42 35.00 6610569.84 158.65 PM 3.80 5.00 68432.40 50.00 3421620.00 82.12

SOx 3.80 13.80 188873.42 10.00 1888734.24 45.33 SOx 3.80 5.00 68432.40 40.00 2737296.00 65.70

NOx3.80 13.80 188873.42 5.00 944367.12 22.66

NOx3.80 5.00 68432.40 20.00 1368648.00 32.85

PM 0.79 10.00 28278.00 50.00 1413900.00 33.93 PM 0.79 10.00 28278.00 50.00 1413900.00 33.93

SOx 0.79 10.00 28278.00 50.00 1413900.00 33.93 Sox 0.79 10.00 28278.00 10.00 282780.00 6.79

NOx 0.79 10.00 28278.00 50.00 1413900.00 33.93 Nox 0.79 10.00 28278.00 10.00 282780.00 6.79

Point source emissons Total kg/d 483.26 Point source emissons Total 477.00

-6.26

% reduction -1.29

Note: Sox, Nox were not considered in the 1st EC presentation.

Qty Unit Qty

in T/A in T/A

Fly ash 8666.00

Bottom ash 925.00

Fly Ash 16000.00 Fly Ash 4256.00

Tar 77000.00 Tar 730.00

Solid waste quantity 93000.00 TPA Solid waste quantity 14577.00 TPA

Difference between two options T/A 78423.00 TPA

% reduction 84.33

SL no Unit Fuel ParameterEmissions Emissions

Unit

Changed scenario

Fuel Parameter

Comparison of pollution load between two configurations

As per EC-1 vide J-11011/766/2008-IA II (I) dtd 30/08/10 & EC-2 vide J-11011/257/2013-IA II (I) dtd 31/03/15

1Captive Power

Plant

Blast furnace

gas Imported coal

Captive

Power Plant

Air pollution Point

sources

2

Producer Gas

Plant 15000

Nm3/hr

B grade coal

3Reheating

Furnace

Difference between two options kg/d

Blast furnace gas

NA

C grade coal

Producer Gas

Plant (5500

Nm3/hr)

C grade coal

Fuel Solid wasteSolid waste

Imported coal

Reheating

FurnaceFO

Reheating

FurnaceFO

1Captive Power

Plant

Blast furnace

gas

SL no Unit Fuel

Solid waste Point

sources

Present configuration Proposed configuration

Captive

Power Plant

Producer Gas

Plant (5500

Nm3/hr)

Reheating

Furnace

NA

NA

2

Producer Gas

Plant 15000

Nm3/hr

B grade coal

NA NA Blast furnace gas NA3