5,00,000 TPA M.S. ROLLED PRODUCT CONSISITING OF SPONGE ... · pre-feasibility report on environmental aspects of proposed 5,00,000 tpa m.s. rolled product consisiting of sponge iron

PRE-FEASIBILITY REPORT

ON

ENVIRONMENTAL ASPECTS

OF

PROPOSED

5,00,000 TPA M.S. ROLLED PRODUCT

CONSISITING OF SPONGE IRON / INDUCTION FURNACE / ROLLING MILL / WHRB / AFBC

February 2018

Survey # 91 to 95 & 97 to 103 of Amirthamangalam Village

Gummidipoondi Taluk, Thiruvallur District.

PRE-FEASIBILITY REPORT, JR Metal i

CONTENTS

1.0 EXECUTIVE SUMMARY ................................................................................ 1

2.0 INTRODUCTION / BACKGROUND INFORMATION .......................... 4

3.0 PROJECT DESCRIPTION ............................................................................... 7

4.0 SITE ANALYSIS ............................................................................................. 25

5.0 PLANNING BRIEF ........................................................................................ 32

6.0 PROPOSED INFRASTRUCTURE ................................................................ 34

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN .................... 35

8.0 PROJECT SCHEDULE & COST ESTIMATES ............................................ 35

9.0 ANALYSIS OF PROPOSAL ......................................................................... 35

Fig 1.0 Topo Map ……...………………………………………………………….8

Fig 2.0 Administrative Set-up Map………………………………………………9

Fig 3.0 Plant Layout …………………..…………………………………………10

Fig 4.0 Process Flow Diagram – Steel Division …………………………….…12

Fig 5.0 Process Flow Diagram – Captive Power Plant ……………………….19

Fig 6.0 Water Balance Diagram………………………………………………….22

Fig 7.0 Physiography Map …………..………………………………………….26

Fig 8.0 Land use Map ……….………………………….……………………….28

Fig 9.0 Drainage and Water Bodies Map…………………….………………….29

Fig 10.0 Soil Classification Map ………………………………………………….31

Pre-feasibility Report 1 J R Metal - Amirthamangalam

1.0 EXECUTIVE SUMMARY

1.1 Proposed Project

The proposed project is a Greenfield Sponge Iron Plant with Steel Rolling Mill

including billet plant, and also WHRB/AFBC based power generation.

1.2 Project Location

The proposed project will be located at Survey Nos. 91 to 95 & 97 to 103 of

Amirthamanagalam Village, Gummidipoondi Taluk, Thiruvallur District, Tamil

Nadu and is devoid of any notified Eco-Sensitive within 10 kms radius of plant site.

1.3 Project Proponent

M/s. J.R. Metal Chennai Limited a company with 2-decade long experience in Steel

Making and Marketing Business with its registered office at No.3, Manali Express

Road, TKP Nagar, Thiruvottiyur, Chennai – 600 019.

1.4 Manufacturing Process

The Iron-Ore domestically sourced, and though DRI Process is converted to Sponge

Iron. Then M.S. Scrap alongwith Sponge Iron is melted and cast into billets. The

billets are the rolled into M.S. Rolled Products. The waste heat emanating from

Sponge Iron Kilns is used to generate power in WHRB and dolochar / coal is used to

generate power from AFBC.

1.5 Production Capacity

Products Production Details (TPA)

PHASE – I PHASE - II PHASE – III

Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --

Intermediate Product – M.S. Billets Induction Furnace with Billet Caster (2 x 40 T & 1 x 30 T)

-- 4,50,000

1,50,000

Re-Rolled Steel Products (M.S. Rounds, Flats, Angles, etc.,) 1 No x 40 T Reheating Furnace

-- 5,00,000 --

Power Plant – AFBC (65 TPH) -- 16 MW --

Waste Heat Recovery Boiler (WHRB) 8 MW 8MW --


1.6 Proposed Equipments

List of Equipment Quantity

Induction Furnace 2 x 40 Tons

1 x 30 Tons

Rotary Kiln 2 x 350 Tons

Reheating Furnace 1 x 40 T

Captive Power Plant – AFBC (65 TPH) 1 x 16 MW

WHRB 2 x 8 MW

1.7 Raw Water Requirement

The raw water requirement will be 325 KLD. About 148 KLD will be recycled, and

about 177 KLD will be sourced from Borewell within the plant site.

1.8 Source of Water

Raw water will be sourced from Underground sources/Rain Water Harvesting.

1.9 Land Requirement

The total land area envisaged is 42.8 Acres, of which 27.1 Acres will be required for

Plant and utilities, and about 10.0 Acres will be earmarked for greenbelt

development.

1.10 Solid Waste Generation & Method of Disposal

The solid waste generated will be slag from melting and dolochar from sponge iron

plant.

Flyash and Bottom ash will be generated from AFBC Boiler.

The quantity of solid waste that would be generated from the Proposed Plant are as

follows


S. No. Description Quantity Generated

(T/D)

Mode of Disposal

1. Slag 130 Ground slag will be Sold to

Cement manufacturers

2. Fly ash 27.65 Sold to Cement

manufacturers

3. Bottom ash 6.91 Sold to Brick manufacturers

4. Dolochar 57 Will be used in AFBC Boiler

1.11 Man Power Requirement

About 200-employees would be needed for the operation of the proposed plant.

1.12 Air Pollution Control

The proposed plant will incorporate all air pollution control equipments including

ESP/Stack for Sponge Iron Kilns, Wet Scrubber / Stack for Electric Induction

Furnace, Wet Scrubber / Stack for Reheating Furnace & ESP/Stack for AFBC Boiler.

1.13 Estimated Project Cost

The total project cost for proposed plant is ` 350 Crores.

1.14 Pollution Control Cost

The total pollution control cost for proposed plant is ` 15 Crores.


2.0 INTRODUCTION / BACKGROUND INFORMATION

2.1 PROJECT & PROPONENT

J.R. Metal Chennai Limited (J.R. Metal) is a part of J.R. Group and is a continuously

performing company with more than two decades of experience in the field of

steel/metal trading, manufacturing and marketing. J.R. Metal Chennai Ltd is a

privately owned company.

J.R. Metal is already producing M.S. Rolled Products through its group entities to a

tune of 1,00,000 MT/Annum of Rolled Products.

J.R. Metal sells its Rolled Product both domestically and overseas. A substantial

portion of its existing production is exported.

Now, it is proposed to install a separate green field unit to produce



Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --

Intermediate Product – M.S. Billets

Induction Furnace with Billet Caster

(2 x 40 T & 1 x 30 T)

-- 4,50,000

1,50,000

Re-Rolled Steel Products (M.S. Rounds, Flats,

Angles, etc.,) 1 No x 40 T Reheating Furnace

-- 5,00,000 --



Each of the manufacturing / processing centres of JR Metal conforms to total

commitment in controlling the de-gradation of the environment by Controlling

Pollution, & maintaining greenbelt, and open space around the manufacturing/

processing complexes.


2.2 NATURE OF PROPOSED PROJECT The proposed project is a Greenfield Steel Mill consisting of Primary Sponge Iron

Plant, and Secondary Plant to produce Ingots/Rolled Products.

The proposed project will consist of Rotary Kilns to process Iron-ore to produce

Sponge Iron. The Sponge Iron, and M.S. Scrap will be melted in Electric Induction

Furnace. The molten metal is cast into billets, and the billets are then rolled into

products.

2.3 NEED FOR THE PROJECT

Government of India has approved the National Steel Policy (NSP) 2017, as it seeks

to create a globally competitive Steel Industry in India. NSP 2017 targets 300 million

tonnes (MT) Steel making capacity, and 160 kg/capita steel production by 2030.

Huge Scope for growth is offered by India’s Comparatively low per capita steel

consumption, and expected rise in consumption due to increased infrastructural

construction and thriving transport industry. Government of India focus on

infrastructure, and restarting road projects is aiding boost in demand for steel.

Further, likely acceleration in rural economy and infrastructure is expected to lead

growth in demand for steel.

India is at present third largest producer of steel, and is all set to be the second

largest producer of steel by 2021. The growth in Indian Steel Industry is largely

driven by domestic availability of raw material such as Iron-ore, and cost effective

labour.

Further, remedial measures taken by Government of India to promote domestic steel

production, such as anti dumping duties, safeguard duties, and temporary

introduction of minimum import price, notified quality control order etc.

The Policy of Government of India also stipulates adoption of energy efficient

technologies, to improve overall productivity and reduce energy intensity.


The Government of India has also announced a policy for providing preference to

domestically manufactured Iron and Steel products in Government Procurement.

This Policy seeks to accomplish PM’s Vision of “Make in India” with objective of

Nation Building and encourage domestic manufacturing and is applicable on all

Government Tenders.

India has now emerged as a net exporter of finished steel products. India has

emerged as a top exporter of steel to Vietnam, Bangladesh, Myanmar, Sri Lanka,

Nepal and other European / American Markets. The demand for Indian Steel

Products from overseas market is set to increase, owing to slowing down of Chinese

production, overall.

2.4 EMPLOYMENT GENERATION

Employment generation is one of the important objective of any development

activity. Employment is closely linked to eradication of poverty. Unemployment,

and under employment had been the chronic feature of the Indian Economy.

Steel Industry employs people with many different skills and diverse knowledge.

Steel Industry employs unskilled, semi skilled and skilled workforce of various

nature. The workers required will be right from handling of raw material, to

processing of production, and finally handling of finished products. Apart from

main activity, workers are required for maintenance and operation of utilities.

Indirect generation of employment also entails in the form of logistics, supply chain

and related commercial activities.

JR Metal will employ about 200 – direct workers and generate large scale indirect

employment in the transportation, and related commercial activities.


3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT The proposed plant is a green field steel manufacturing unit. The project upon

completion envisages production of rolled products using Sponge Iron and M.S.

Scraps as raw materials. The plant also will have a facility to produce Sponge Iron

using iron Ore.

The Proposed Plant will consist of 16 MW (2 x 8 MW) WHRB, 2 x 40 T & 1 x 30 T

Electric Induction Furnace, 1 x 40 T Reheating Furnace, 2 x 350 TPD Rotary Kiln

and16 MW AFBC based on Dolachar.

3.2 PROJECT LOCATION The proposed project of M/s. J.R. Metal is to be located at Survey Nos. 91 to 95 & 97

to 103 of Amirthamangalam Village, Gummidipoondi Taluk, Thiruvallur District,

Tamil Nadu.

The Latitude and Longitude of the project site is as follows.

The project location is as shown in Fig.1.0 – Topo Map, and Fig.2.0 Administrative

Setup Map and Fig.3.0 Plant Layout.


Fig 1.0 Topo Map


Fig 2.0 Administrative Set-up Map


Fig 3.0 Plant Layout

Pre-feasibility Report JR Metal - Amirthamanagalam

11

3.3 PRODUCTION CAPACITY The details of production capacity of the proposed project are as follows.



Sponge Iron (2 x 350 T) 1,50,000 1,50,000 --

Intermediate Product – M.S. Billets Induction Furnace with Billet Caster (2 x 40 T & 1 X 30 T)

-- 4,50,000

1,50,000

Re-Rolled Steel Products (M.S. Rounds, Flats, Angles, etc.,) 1 No x 40 T Reheating Furnace

-- 5,00,000 --



3.4 MANUFACTURING PROCESS Sponge Iron Plant The plant consists of raw material preparation unit where iron ore and non-coking

coal are crushed and screened to obtain the required sizes. These required sizes are

conveyed to stock house for storing in the respective bins. No crushing is envisaged

for dolomite/limestone, as it is received mostly in 0-4 mm size form. This limestone

is conveyed to its respective bins. The sized materials stored in bins at stock house

are charged in rotary kiln with predetermined feed rates with the help of weigh

feeders and volumetric feeders and also conveyors.

The iron ore is preheated and reduced to sponge iron in the rotary kiln at the

required and controlled temperatures and pressure. Carbon and volatile matter in

coal is utilised and converted into char. Dolomite is used for desulfurisation and in

the process becomes dolochar. Sponge iron, char and dolochar travel from kiln to

cooler and are cooled to about 80ºC by indirect cooling, using water as medium.

The material cooled and discharged from the cooler, is conveyed to product

separation system. A junction house is provided in between cooler & product


12

separation system, to take care of any eventualities occurring due to the breakdown

of the product separation system, which may happen due to breakdown of

equipment etc. The cooler discharged material is screened and separated with the

help of magnetic separators. Sponge iron lumps and sponge iron fines are taken to

their respective bins. Dolochar and char which are non magnetic are taken to a single

bin.

The schematic manufacturing process of Steel production is given in Fig.4.0.

Fig 4.0 Manufacturing process of Steel division

TMT bars, Wire rod coils, Rounds, Structural products


13

Steel melting Shop

The Steel Melting Process can be subdivided into the following stages:-

Stage 1: Production of Liquid Metal from Induction Furnace.

Stage 2: Transfer of Liquid Steel to the Ladle Furnace

Stage 3: Continuous Casting.

Induction Furnace Scrap and Direct Reduction Iron (DRI) are the main raw materials for melting in the

Induction Furnace. The scrap and DRI will be brought into the steel plant premises

by Tipper / Dumpers / Trucks and unloaded either in the open scrap yard where it

will be intermittently stored or directly into the scrap bay, whereas, Sponge Iron is

produced within the Plant at Sponge Iron Plant. The usage of scrap and DRI in the

Steel Melt Shop is in the ratio of 56:44.

Raw Materials

Qty. in % fed in charge

Recovery

Qty. fed TPA for 6,00,000

Scrap + Cast iron Pieces

56% 96%

3,36,000

DRI 44% 82% 2,64,000

The capacity in the scrap bay of scrap and DRI will be in the same ratio. The scrap

bay will store the scrap and DRI in bins. In the scrap bay the trucks will be unloaded

by EOT cranes and the tippers will tip the scrap / DRI into the bins directly.

From the bins in the Melting Bay EOT cranes will load the scrap in to a scrap bucket

which will be charged in to the Induction Furnace by EOT Crane. The first charge will

be of light scrap + cast iron pieces of about 3 T followed by DRI to be fed in 2-3

installments. The balance of heavy scrap is charged towards the end of the heat.


14

Fe metal C Si Mn P S

92.1% 0.25% 0.35% 0.5 % 0.03% 0.04%

The DRI will be mainly Coal based and will be in lumps with size range of 3 mm to 20 mm with a bulk density of about 2100 kg/ cum. The typical chemical composition of coal based DRI is:

Metallization Fe Total P S C Si

92% 94% 0.045% 0.02% 0.1% 1.8

The Induction Furnaces are Melting Units. The heat and stirring in a coreless

Induction Furnace is caused by magnetic forces which result from the interaction of

the electrical current flowing in the induction coil and in the molten bath itself melts

the metal and can increase the bath temp. to required temperature of 1600°C to

1650°C. Slag formed is taken out in the process.

The first charge of 3 t will consist of scrap and cast iron pieces only. DRI will be fed

in two or three installments. Frequent deslagging will be done to take the slag out. A

mechanical poker is provided to compact the scrap during feeding and to avoid the

formation of a bridge. The scrap mix used is shredded scrap, HMS, Cast Iron and

coal based DRI. Induction Furnace liquid steel output quality is dependent on the

quality of charge mix.

There will be 2 x 40 T Electric Induction Furnaces and 1 x 30 T Electric Induction

Furnace. The tapping temperature is maintained to approx. 1620°C.


15

The final chemistry of Liquid Metal from the induction furnace is:

C P S Temp.

0.30 max. 0.070 max 0.05 max. 1620 Deg.C

One heat in one Induction Furnace is estimated to take about 120 minutes on an

average. There will be two Induction Furnaces of 40T capacity + 1 No. of 30 T. The

Melting Bay has to therefore handle 48 heats every 24 hours.

Slag handling

The slag generated during melting will be to the extent of 10%. De-slagging will be

done by tilting the IF forward during the process while the power is reduced to a

minimum for 1-2 min. During the process of deslagging by forward tilting will be

done 5 - 6 times every heat. The slag will fall into in a slag box parked below the

Induction Furnace. The slag pot capacity will be 10 T to take care of the slag of each

heat. The slag pot will be lifted by the EOT crane and either be emptied in a dumper

or at the end of the bay. From there the slag will be taken to the slag dumping area.

Billet Casting

Liquid steel from ladle furnace is now placed in the Turret of the Continuous

Casting Machine. The Turret shall be moved and positioned over the tundish into

which the liquid steel will flow. From the tundish the liquid steel will flow into the

mould which shapes and forms the billet. The required starting ladle temperature

for the manufacture of billet for TMT rebars, wire rod, rounds, structural / grade at

the CCM is about 1650° C.

The hot billet goes through a water spray cooling chamber and comes to a

straightening cum withdrawal machine which is a set of individually driven rollers

with hydraulically pressed rollers.


16

The withdrawal machine also varies the speed of the billet to keep the level of the

mould constant as the steel flow into it varies as the metering nozzle erodes with

time. After the withdrawal machine is the oxy-fuel cutting machine which cuts the

billets into 6 m / 12 m length.

The billet by the time it reaches the cutting machine has no liquid core. The billets of

the 2 strands then come out onto a run out roller table and go into the run-in roller

table of the cooling bed. The transportation of the billets together from the run-in

roller table onto the cooling bed is done by an over head cross transfer for further

pushing of by a billet pusher on a skid Bank cooling bed.

A non-sequence casting cycle is as follows:

Placement of ladle on the Ladle turret : 2 min.

Moving the turret on position : 2.min.

Opening of the slide gate to start flow of : 1 min.

steel into the tundish

Opening the tundish metering nozzle : 1 min.

Start and end of casting including

slow start /slow finish : 25 min.

Total : 31 min.

Machine preparation : 20 min. After every sequence the CCM will have to be prepared again. The final output from

the CCM is 200 mm sq. billets in 6 m/ 12 m length.

Rolling Mill

The DRI – IF – CCM – RM route is considered for the integrated plant under

consideration, which is suitably supported by the Captive Power Plant. The main

technological facilities in different processing steps for production of rolled products


17

in DRI-SMS-RM route are as follows.

S.No Processing step Technological facility

1. Iron making Direct Reduction Plant

2. Steel making Induction Furnace

3. Casting Billet Caster

4. Rolling of Billets/ Blooms Rolling Mill

The Billets from Steel Melting Shop after Quality inspection are charged into

reheating furnace and at discharge end uniformly heated billets at a temperature of

about 1050OC – 1250OC (depending upon grade of Steel being rolled) are discharged

by an Ejector.

The heated billets are fed to different rolling mills to produce required size of

finished products.

The rolled product after last stand is transferred to Turnover Cooling Bed and cut to

specified length and after Quality inspection and requisite Color Coding, bundling

etc. is shifted to dispatch section.


18

Captive Power Plant Process Description

The process of sponge iron making by the DRI route produces a large quantity of

flue furnace gas. About 3500 N.Cu.m of flue gas with a calorific value of 900

K.Cal/N.Cu.m will be generated per ton of hot metal produced. It is estimated to

generate about 15 tons per hour of steam, which inturn generates about 8000 KW

power per kiln, and Hence total Power Generated for 2-kilns together will be 16

MW.

In addition to above, it is proposed to make use of the Dolachar generated in Kilns

alongwith some quantity of coal in the FBC boiler to generate additionally 16MW of

power, thus resulting in a total of 32MW power generation.

The Power plant will consist of a boiler house, steam turbine and generator along

with accessories such as condensers, deaerators, boiler feed pumps, controls and

instrumentation.

Process flow sheet for captive power plant is as shown in Fig 5.0.


19

Fig 5.0 Flow Diagram for Captive Power Plant

WHR / FBC BOILER

FLUE GAS

FROM ROTARY KILN & DOLACHAR/COAL

STEAM TURBINE

GENERATOR

AIR

PREHEATER

AIR

WATER

FLUE GAS

AIR

AIR COOLED CONDENSOR WATER OUT

DEAERATOR FLUE GAS TO CHIMNEY THROUGH ID FAN

32.0 MW

STEAM


3.5 RAW MATERIAL REQUIREMENT

Annual requirement of raw materials on the basis of achievable production is as follows:

FOR SPONGE IRON PLANT

Sl. No.

Raw Material Quantity (TPA) Source

1. 2. 3.

Iron-Ore Coal Dolomite/Limestone/ Quartz

5,40,000 2,70,000 14,900

Indigenous Imported/Indigenous Indigenous

FOR INDUCTION FURNACE / (BILLET)

Sl. No.

Raw Material Quantity (TPA) Source

1. 2. 3. 4.

Sponge Iron Melting Scrap Ramming Mars Refractories

2,15,000 4,32,000

1,200 620

Captive Indigenous/Imported Indigenous Indigenous

FOR RE-ROLLING MILL

The Billet produced by the Steel Melt Shop will be the Raw Material for Re-Rolling Mill

Sl. No.

Raw Material Quantity Source

1.

2.

Coal for Producer Gas Furnace Oil

23,000 TPA

4 KL/day

Imported/Indigenous Indigenous

FOR POWER PLANT

Sl. No.

Raw Material Quantity

1. Imported Coal 384 TPD


3.6 WATER / ENERGY REQUIREMENT 3.6.1 RAW WATER REQUIREMENT

The raw water requirement for the operation of the proposed plant will be as

follows, and will be sourced from ground water within plant site.

Description Qty (KLD)

Boiler Feed Make-up 20

DM. Plant Regeration 15

Induction Cooling make-up 60

Rotary Kiln Cooling make-up 160

Concast Cooling make-up 30

TMT Cooling make-up 30

Domestic Consumption 10

Total 325

The Fresh Water drawn from ground will be only 177 Cu.m/day after recycling of waste

water.

The detailed Water Balance Diagram is as shown in Fig 6.0.


Fig 6.0 Water Balance Diagram

All values are in KLD.

Raw Water 325

Induction Furnace 1 & 2 Cooling

Concast Cooling

Rolling Mill Cooling

Boiler Water Make-up (AFBC)

Boiler Water Make-up (WHRB)

Rotary Kiln Cooling

Evaporation Loss – 40



60

30

30

10

10

160

12

10

20

9

9

Green Belt

Cooling Pond I

Cooling Pond II

170

Guard Pond



110

Coal Dust Suppression /

Ash Dyke

7

D.M. Plant Regeneration

15 15

Domestic Consumption

10 9

STP 9

37

Rec

ycle

d

14

8

Har

vest

ed R

ain

Wat

er/

Bo

rew

ell

17

7

325

Neutralization Pit

RO Plant

185

RO Reject

148

30

15


3.6.2 ENERGY CONSUMPTION

The required power for the project will be met captively, and about 20 MW power

will be drawn from TNEB Grid

3.7 QUANTITY OF LIQUID & SOLID WASTES 3.7.1 LIQUID WASTE MANAGEMENT

Description of effluent generated Qty (KLD)

Boiler Blow Down 18

DM. Plant Regeration Waste 15

Induction Cooling Blowdown 20

Rotary Kiln Cooling Blowdown 110

Concast Cooling Blow Down 10

TMT Cooling Blow Down 12

Sewage 9

Total 194

The blowdowns from plant will be taken to 2- consecutive Cooling Ponds, and then

to Guard Pond after neutralization. Further the treated water from Guard Pond

taken to RO Plat for further treatment and then about 148 KLD will be recycled for

make-up water. From RO Reject about 30 KLD used for green belt and about 7 KLD

will be used for coal dust suppression and ash dyke. Hence, 177 KLD of Fresh Water

will be required for process after recycling of waste water.

The domestic sewage will be treated in Sewage Treatment Plant and about 9 KLD

discharged on land within the plant premises for green belt development.

3.7.2 SOLID WASTE MANAGEMENT

The solid waste generated will be slag from melting, and dolochar from sponge iron

plant.

Flyash and Bottom ash will be generated from Power Plant.


The quantity of solid waste that would be generated in the proposed plant are as

follows

S.

No.

Description Quantity Generated

(T/D)

Mode of Disposal

1. Slag 130 Ground slag will be given to

Cement manufacturers

2. Fly ash 27.65 Will be given to Cement

manufacturers

3. Bottom ash 6.91 Will be given to Brick

manufacturers

4. Dolochar 57 Will be used in AFBC Boiler


4.0 SITE ANALYSIS

4.1 CONNECTIVITY The proposed plant will be located at Amirthamangalam Village, Gummidipoondi

Taluk, Thiruvallur District, Tamil Nadu. The project site is located at distance of 8.00

km from Gummidipoondi Railway Station, Plant site is well connected from

Chennai Road NH-5 (Chennai – Kolkata Road), about 8 km East.

The plant site is then accessible through State Highway SH-52 from NH-5 ie the

Kaverapettai – Sathyavedu Road.

The project site is predominantly industrial area, and well connected by the Road.

4.2 LAND FORM, LAND USE & LAND OWNERSHIP The total area of the Project Site is 42.8 Acres which is Dry unclassified land. The

Land is barren unused at present. The said land is entirely owned by J R Metal

Chennai Limited.

The entire land is at present owned by J.R. Metal. 4.3 TOPOGRAPHY Topography is Plain. The Topography of the proposed project site is as shown in

Fig.7.0 Physiography Map.


Fig 7.0 Physiography Map


4.4 EXISTING LANDUSE PATTERN The Existing Land is Dry and unclassified land. The Land for the proposed project

site is barren and unused at present.

There is river/steam crossing within the 10 km radius of the site viz., Araniyar River

in South East at a distance of 6.0 km.

Also, the Plant Site is located within 10 km of Inter State Boundary (Tamil Nadu –

Andhra Pradesh).

There is the Palavakkam Reserve Forests at a distance of 2.5 km in South from the

project site. There are no national park, wild life sanctuary, or eco sensitive areas

within 10 kms of project site.

The Landuse of the proposed project site is as shown in Fig.8.0 Landuse Map and

the Drainage and Water Bodies Map is as shown in Fig.9.0.


Fig 8.0 Landuse Map


Fig 9.0 Drainage & Water Bodies Map


4.5 SOIL CLASSIFICATION The soils in general are characterized by sand/clay content, poor nitrate and

phosphorus contents. The fertility status of the lands, mostly under rain fed

agricultural use, is generally medium except in some pockets where the soils are

fertile.

The Soil Classification of the proposed project site is as shown in Fig.10.0 Soil

Classification.


Fig 10.0 Soil Classification Map

Pre-feasibility Report 32 JR Metal-Amirthamangalam

4.6 CLIMATIC DATA The climate of the project site is dry and arid coastal climate. The Max. dry & wet

bulb temperature is 42.1 / 38.7.8°C respectively and Min. dry & wet bulb

temperature 19.6 / 15.8°C respectively. The predominant wind direction in the

region W followed by SE. Average annual rain fall of this region is about 1200 mm.

The average maximum wind speed in this region is about 11 km/hr. The annual

Maximum Humidity is 100% and minimum humidity is 25%.

5.0 PLANNING BRIEF

The Plant Site is located in an area which is outside the classification regulation of

Department of Town & Country Planning.

The Revenue Classification is a dry rain fed agricultural land. The area is now dependent on the industries for their overall development and

livelihood. The area within 10 kms radius of plant site is dominated by small,

medium and large scale industries.

Some of the Large Scale Industries in the area are Michelin India Pvt. Ltd, (Automobile Tyres)

SKI Carbon Black (India) Pvt. Ltd, (Carbon Black)

SRF Limited, (Nylon 6.6)

Suryadev Alloys & Power Pvt Ltd, (1,00,000 MTPA Steel Plant & 2 x 80 MW Power Plant)

OPG Power Generation Pvt Ltd, (3 x 80 MW & 1 x 160 MW Power Plant)

Tulsyan NEC Limited, (2 x 35 MW Power Plant)

TCP Limite, (63 MW Power Plant).

Kavery Power Generation Chennai Pvt Ltd, (2 x 180 MW Power Plant)

Bhatia Coke & Energy Ltd, (Cove Oven Plant)

ARS Metals Pvt Ltd, (Steel and 1 x 60 MW & 1 x 135 MW & 1 x 350 MW Power Plant)

Tulsyan NEC Ltd (Steel Plant)


And the area also houses 2 – SIPCOT Complexes, one in Thervoy Kandigai which is

SW at 6 Kms, and the other at Gummidipoondi which is NE at 5 Kms.

The total land requirement for the proposed project is 42.8 Acres. The Land usage and Break-up are as follows.

Sl.

No.

Description Land Area

(in Acres)

1. Induction Furnace & Rolling Mill 10.0

2. AFBC Captive Power Plant 3.1

4. Rotary Kiln & WHRB 1.8

5. Switch Yard 1.6

6. Greenbelt 10.0

7. Iron Ore Stock Yard 0.4

8. Coal Storage 2.4

9. Ash dyke 2.0

10. Slag Storage 4.7

11. Scrap Yard 1.1

12. Road 1.4

13. Open Area 4.3

Total Land Area 42.8

The green belt development will be initiated even before commencement of

project activities.


6.0 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA About 42.8 Acres of land is required for implementation of the proposed project.

The Plant Site would require

A Industrial Shed to house 2 x 40 T & 1 x 30 T Induction Furnace, Concast

Machine, Reheating Furnace and Rolling Mill.

Offsite facility such as Cooling Tower, Scrubber, Water Treatment Plant and

Other Utilities.

A Storage Yard for Scrap Storage.

Facility for Installation of Coal Crusher, Rotary Kiln and Sponge Iron

Screening Facility of Sponge Iron Plant.

Facility for WHRB, Turbine & Turbine Hall, Air Cooled Condenser etc.

Facility for Boiler, Turbine, Generator of 1 x 16 MW CPP.

Air Cooled Condenser, D.M Water Plant etc for CPP.

Coal Storage Shed

The entire Plant Boundary will have 2 m width green belt.

The existing transport infrastructure will be used and there will be no new

transport infrastructure required.

6.2 RESIDENTIAL AREA J.R. Metal does not propose to have any residential accommodation within or

outside the plant area. Most of the work force requirement will be met from local

availability.

However, workers rest room, cafeteria, and canteen facility will be provided within

the plant, predominantly for the labourers.


6.3 GREEN BELT About 10 Acres of Land will be developed as Greenbelt, and will be initiated at the

project stage. More-over species selected will be in consultation with the local forest

officer, and will be predominantly consist of local species.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

The proposed plant will be located in an area of 42.8 Acres, which is Dry unclassified

land. The Land is barren unused at present. Topography is Plain. It is vacant land,

and there are no rehabilitation and resettlement or land oustees, as the land is fully

owned by M/s. J. R. Metal.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE The construction of proposed plant will take around 18 months from date of

obtaining Environmental Clearance. So, the proposed plant will be commissioned

during the September 2020.

8.2 PROJECT COST

The total project cost will be Rs.350 Crores, which is inclusive of Rs. 15 Crores for

pollution control activities.

9.0 ANALYSIS OF PROPOSAL

9.1 FINANCIAL & SOCIAL BENEFITS Social benefits results in evaluation of project from society point of view. Proposed

steel plant will involve not only construction of the plant, but also construction of


intermediaries, which are basically facilities to the workers but will also offer

economic benefit to the local population.

Pollution from plant may cause degradation of the environment, which is the cost or

price locals have to pay for economic benefits accruing because of the proposed

project.

The significance of economic development cannot be underplayed especially in a

underdeveloped area, and Government also recommends investment in projects to

contribute in well being of the Society.

The proposed project of M/s. J.R. Metal Chennai Limited would result in increased

revenues to Government of Tamilnadu, and Government of India, in terms of

cumulative tax, both indirect taxes, and direct taxes.

The proposed project of M/s. J. R. Metal Chennai Limited will also result in

augmentation of the social infrastructure, more-over investments in various

environment conservation measures will result in better living condition.

M/s. J.R. Metal Chennai Limited will invest about 0.2% of the project cost in thrust

areas for CSR activities such as income generation program, health and hygiene,

empowerment through self help groups, and water supply to near by villages.

Documents

5,00,000 TPA M.S. ROLLED PRODUCT CONSISITING OF SPONGE ... · pre-feasibility report on environmental aspects of proposed 5,00,000 tpa m.s. rolled product consisiting of sponge iron