of SHYAM METALICS & ENERGY LTDenvironmentclearance.nic.in/writereaddata/Online/...M/s Shyam Metalics & Energy Ltd steel project is located at Pandoloi, in Sambalpur district of Odisha

TECHNO ECONOMIC FEASIBILITY REPORTFor

Change in Configuration & Expansion of 1.4 MTPA Integrated Steel Plant

of

SHYAM METALICS & ENERGY LTDPandloi, PO-Rengali, Sambalpur, Odisha

Prepared by

GLOBAL TECH ENVIRO EXPERTS PVT. LTD.C-23, BJB NAGAR

BHUBANESWAR-751014PH. NO.-06742433487

Email:- [email protected]

Techno Economic Feasibility Report of M/s Shyam Metalics & Energy Ltd At: Pandloi, Dist: Sambalpur, Odisha

Global Tech Enviro Experts Pvt. Ltd.

1

CONTENTS

Contents .............................................................................................................. 1

CHAPTER-1 .......................................................................................................... 4

EXECUTIVE SUMMARY ........................................................................................... 4

CHAPTER-2 .......................................................................................................... 6

INTRODUCTION OF THE PROJECT ........................................................................... 6

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT: .......................... 6

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROPOSED PROJECT ....................... 6

2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGION ............................................................................................................ 6

2.4 DEMAND –SUPPLY GAP .............................................................................. 7

2.5 IMPORTS VS. INDIGENOUS PRODUCTION & EXPORT POSSIBILITY .................. 8

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE PROJECT ........ 9

CHAPTER-3 ........................................................................................................ 10

PROJECT DESCRIPTION ....................................................................................... 10

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS

IF ANY. ........................................................................................................... 10

3.2 LOCATION .............................................................................................. 10

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS ....................................... 15

3.8 RESOURCE OPTIMISATION/RECYCLING AND REUSE ENVISAGED IN THE

PROJECT ......................................................................................................... 24

3.9 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND

SOURCE .......................................................................................................... 24

3.9.1 WATER REQUIREMENT: ....................................................................... 24

3.9.2 POWER REQUIREMENT FOR THE PROJECT .............................................. 26

CHAPTER -4........................................................................................................ 28

PROPOSED INFRASTRUCTURE AND EMP ................................................................. 28

4.1 CONNECTIVITY ....................................................................................... 28

4.2 LAND FORM, LAND OWNERSHIP ................................................................ 28

4.3 TOPOGRAPHY ......................................................................................... 28



2

4.4 SOIL CLASSIFICATION: ........................................................................... 29

4.5 CLIMATIC DATA FROM SECONDARY SOURCE .............................................. 29

CHAPTER -5........................................................................................................ 30

PLANNING BRIEF................................................................................................. 30

5.1 PLANNING CONCEPT ............................................................................... 30

5.2 PERIPHERAL DEVELOPMENT PLAN ............................................................. 30

5.3 LAND USE PLANNING ............................................................................... 30

5.4 BENEFITS TO THE REGION AND THE COUNTRY ........................................... 31

CHAPTER -6........................................................................................................ 32

PROPOSED INFRASTRUCTURE .............................................................................. 32

6.1 INDUSTRIAL AREA DISTRIBUTION ............................................................. 32

6.2 GREENBELT DEVELOPMENT ...................................................................... 32

6.3 CONNECTIVITY ....................................................................................... 32

6.4 DRINKING WATER MANAGEMENT: ............................................................. 32

6.5 INDUSTRIAL WASTE MANAGEMENT ........................................................... 32

6.6 POWER REQUIREMENT ......................................................................... 33

6.6 INDUSTRIAL POLLUTION CONTROL ........................................................... 33

Pollution Control Equipments .......................................................................... 36

6.6.2 WATER POLLUTION CONTROL ............................................................ 37

6.7 MAN POWER REQUIREMENT ..................................................................... 37

CHAPTER -7........................................................................................................ 38

REHABILITATION & RESETTLEMENT ...................................................................... 38

REHABILITATION & RESETTLEMENT ................................................................... 38

CHAPTER -8........................................................................................................ 39

PROJECT SCHEDULE ............................................................................................ 39

8.1 IMPLEMENTATION SCHEDULE ................................................................... 39

8.2 ESTIMATED PROJECT COST ...................................................................... 39

CHAPTER-9 ........................................................................................................ 40

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ............................................. 40



3

9.1 FINANCIAL & SOCIAL BENEFITS ............................................................... 40

9.2 SOCIAL INFRASTRUCTURE ....................................................................... 40

9.3 EMPLOYMENT POTENTIAL ........................................................................ 40



4

CHAPTER-1

EXECUTIVE SUMMARY

M/s Shyam Metalics & Energy Ltd steel project is located at Pandoloi, in Sambalpur

district of Odisha. The project site is at latitude 210 40’ 50.43’’ N and longitude 840

02’ 30.63’’ E, MSL 208m. The project is located on state Highway joining Sambalpur-

Rourkela, NH-6 and 42 exist at a distance of about 25km from the site. SH-10 is passing

by the side of the project. The project is by the side of Railway line of Sambalpur-

Jharsuguda section. The nearest railway station Rengali is 8 km away from project site.

The company was initially having DRI Kilns, IFs and rolling mill and proposed expansion

and granted prior EC to setup1) 4x500 TPD DRI kilns, 2) 2x450m3 MBF, 3)3 Lakh TPA

Pellet Plant, 4)1x96m2 Sinter Plant, 5)4x8T, 4x12T IFs, 2x80/90T EAF, 6)6Lakh TPA

Rolling Mill, 7)2x6, 2x9 & 3x11 MVA Ferroalloy plant, 8)5Lakh 50 thousand Coke Oven

Plant, 9)15Lakh TPA Coal washery, 10) 60,000 TPA Lime Plant, 11)3,53,500 TPA Bloom

Caster and 12) 200 MW power Plant.

The company started production installing some of the facilities approved under EC

within its validity period and has taken validity extended vide F.No. J-11011/495/2006-

IA II (I)of MoEFCC, dated 2nd December, 2016. The company mean while intents to

setup additional 10 Lakh TPA Iron Ore Pellet Plant with existing approved 3Lakh TPA

pellet plant, and to reduce Power generation by 50 MW (from approved EC quantity of

225 MW to 175 MW), so as to keep all emissions and effluents within the approved scope

of existing EC, so as to be within the scope of 7(ii) of EIA Notification 2006.

The project is “primary ferrous” metallurgical unit belonging to schedule 3(a) category A

Water will be drawn from Hirakud Reservoir of river Mahanadi. Fresh water requirement

after the proposed change has been estimated to be 55702 KLD against 62612 KLD as

approved in EC and there will be a reduction of 6910 KLD.

Power requirement after the change has been estimated to be project is estimated to be

about 216.12 MW, whereas captive power generation will be reduced from 225 MW to

175 MW. Balance power will be purchased from state supply.

In the existing plant, the haulage roads are been installed with sprinklers and road

leading to material handling and storage have been concretized for control of fugitive

emission. Across the railway siding, 44 nos. of sprinklers are been installed which

drastically reduces the fugitive emissions due to transportation and handling.

Land

The total land required for the project is 294.84 ha out of which 127.05 ha has been

acquired and the balance acquisition is in process

Manpower

The total manpower is different categories were as follows in accorded EC and there will

not be any significant change in it with proposed change.

Executives = 155



5

Non-Executives = 2905

Total = 3060

Project cost

The estimated expansion project cost in approved EC was 3,868 crore.

Now with 50 MW reduction in power plant, there will be significant reduction in

equipment cost in the order of about 150 crores, Cost of 9 Lakh TPA Iron ore pellet plant

will almost be of the same value, so differential project cost for implementation will be

about 25 crores.

Hence the total project cost will be around Rs 3893 crores

Project completion schedule

After getting CTE from SPCB, Odisha, the construction work can be started to complete

the project in two years of time.



6

CHAPTER-2

INTRODUCTION OF THE PROJECT

M/s Shyam Metalics & Energy Ltd is spread over in an area of 295.04 ha of land in

Pandoloi village in Sambalpur district of Odisha.

The company is at present producing TMT rods in DRI-IF-Rolling mill route. The unit has

taken Environmental Clearance for its expansion for 14,44,286 TPA steel product

through DRI-MBF-EAF/IF-CCM route. Pellet Plant, Coke Oven, Coal Washery and CPP

from waste heat recovery as well as FBC.

At present the company is proposing to set up 9 Lakh TPA pellet plant which was not in

the scope of existing Environmental clearance. Along with this the company is proposing

for reduction in power generation from 225 MW to 175 MW. This power generation being

from coal based FBC (117 MW), there will be substantial reduction in pollutant emission

to atmosphere.

The emission from proposed changes being within the approved scope of EC, SPCB can

approve the change and issue consents.

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT:

The project is an integrated steel project, having scope for Coal washery, Coke oven,

Iron Ore palletization, Sinter, Hot Metal through both DRI and IF route, Rolling mill and

Ferro alloy production.

The company received EC vide letter dated 10th December, 2008 and subsequently

extended EC validity vide letter from MoEFCC, dated 2nd December,2016.

The project is primary ferrous metallurgical unit belonging to schedule 3(a) category A

Mr. B.K. Panda is project coordinator on behalf of M/s Shyam DRI Power Ltd (SDPL).

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROPOSED PROJECT

The Proposed expansion cum modification project is a brown field primary metallurgical

(ferrous) project, in which the capacity of Pellet Plant will be enhanced to 1200000 TPA

from 300000 TPA, total CPP capacity will be reduced from 225 MW to 175 MW along with

reduction in Coal Washery throughput from 1500000 TPA to 1000000 TPA. Along the

same line, considering the market potential

2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY

AND OR REGION

Steel is traditionally considered the backbone of national economic development. It is a

major input into sectors which support economic growth such as infrastructure,

machinery, power and railways, as well as being important for fast growing sectors, in

particular automobiles and consumer durables.



7

The steel industry in India is currently at an inflexion point brought about by ambitious

capacity expansion plans, entry of new players and increased competition on one hand

and consistently rising and shifting demand patterns on the other.

This rise in demand is expected to be driven by the construction, automobile and

consumer durables sectors

In the construction sector, Government spending in infrastructure is expected to surge

during the twelfth plan period, thus driving up demand for steel used in construction.

Most steel producers are planning major capacity expansions through both Greenfield

and Brownfield expansions. This, coupled with the entry of new players will result in a

significant rise in steel production over the next ten years.

TMT rods as being manufactured by the company are most suitable in construction due

to its high workability.

The other proposed product of M/s Shyam Metalics & Energy Ltd are ferroalloys like Fe-

Mn, Si-Mn, Fe-Cr and Fe-Si, which has various uses for quality steel production.

The above stated facts indicate importance steel as well as Ferro alloys products in the

development of a country. As Odisha has rich source of all the ores from Hematite to

Chromatite to Manganese ore, the project bear a lot of significance for development of

state as well as the nation.

Thus proposed integrated steel project has make in India importance to the country &

the region.

2.4 DEMAND –SUPPLY GAP

Due to pressure from the construction sector, the demand for longs will continue to

dominate the steel industry, while on the supply side, flats are expected to dominate

In the optimistic scenario, all crude steel capacity expansion targets announced by steel

companies are aggregated. Under this scenario, it was estimated that crude steel

capacity will be 259.11 MT in 2020-21. However, this will be possible only if the crude

steel capacity targets, as announced by steel producers are met. However, for 2020-21,

this scenario estimates a more reasonable capacity of 210.11 MT.

Base Case Scenario: The base case scenario gives a lower bound crude steel capacity

estimate. It accounts for delays in commissions of projects due to problems associated

with land acquisition, obtaining environmental clearances, raw material availability, etc.

The effect of these delays on the date of commissioning of projects was assessed

through interviews with experts and a review of secondary literature. According to this

scenario, crude steel capacity in the country in 2020-21 will be 178.8 MT.

Currently, demand for finished steel in India is estimated to be around 70 MT. This is

expected to more than double to 166 MT by 2020-21. This demand will mainly be driven

by the construction (real estate and infrastructure), automobile and consumer durables

sectors. It must be noted that this figure includes only domestic demand for steel.

Demand from international markets will further push this figure up.



8

2.5 IMPORTS VS. INDIGENOUS PRODUCTION & EXPORT POSSIBILITY

On liberalization of the Indian steel sector with effect from 24.5.92, iron and steel

industry was included in the list of „high priority‟ industries for automatic approval for

foreign equity investment up to 51%. This limit has since been increased to 100%.

The import regime for iron and steel has undergone major liberalization moving

gradually from a controlled import by way of import licensing, foreign exchange release,

canalization and high import tariffs to total freeing of iron and steel imports from

licensing, canalization and lowering of import duty levels. Export of iron and steel items

has also been freely allowed. Import duty on capital goods was reduced from 55% to

25%. Duties on raw materials for steel production were reduced. These measures

reduced the capital costs and production costs of steel plants.

Imports

Iron & steel are freely importable as per the extant policy.

Data on import of total finished steel (alloy + non alloy) is given below for last

five years:

Indian steel industry : Imports (in million tonnes)

Category 2010-

11

2011-

12

2012-

13

2013-

14

2014-

15

Total Finished Steel (alloy + non alloy) 6.66 6.86 7.93 5.45 9.32

Source: Joint Plant Committee

Exports

Iron & steel are freely exportable.

Data on export of total finished steel (alloy + non alloy) is given below for last

five years:

Indian steel industry : Exports (in million tonnes)

Category 2010-11 2011-12 2012-13 2013-14 2014-15

Total Finished Steel (alloy + non alloy) 3.64 4.59 5.37 5.98 5.59

Source: Joint Plant Committee

Above figures are indicative of constant increase of steel export from India and likely to

increase further in coming years.

The New Industrial policy opened up the Indian iron and steel industry for

private investment by (a) removing it from the list of industries reserved for public

sector and (b) exempting it from compulsory licensing. Imports of foreign technology as

well as foreign direct investment are now freely permitted up to certain limits under an

automatic route. Ministry of Steel plays the role of a facilitator, providing broad

directions and assistance to new and existing steel plants, in the liberalized scenario.

http://steel.nic.in/overview.htm



9

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) DUE TO THE

PROJECT

Manpower

The total manpower in different categories were as follows in accorded EC and there will

not be any significant change in it with proposed change.

Executives = 155

Non-Executives = 2905

Total = 3060



10

CHAPTER-3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND

INTERDEPENDENT PROJECTS IF ANY.

The project is a primary metallurgical (ferrous) expansion project of M/s Shyma Metalics

& Energy Ltd. Coming under category-A, schedule 3(a).

This project is independent plant without any interlink or interdependence.

3.2 LOCATION







3.3 Satellite imagery of M/s Shyam Metalics & Energy Ltd

ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE PROPOSED

SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE INTO

SHOULD BE HIGHLIGHTED.

The existing Project site is running on 295 ha of land and all the expansion jobs are

being carried out on this land and so no alternate sites have been taken in to

consideration.

3.4 SIZE OR MAGNITUDE OF OPERATION

The Project after this proposed expansion will be a 1.4 MTPA integrated steel project

manufacturing various steel products within the existing permissible EC limits.



11

Table 3.1 Project configuration and Product mix of existing and changed facilities.

A B C D E F G H

Sl. No

Facilities Configurations Prior to EC

Configurations Approved in EC

Present Operation status with CTO

Facilities Yet To be commissioned as per EC

Changes to EC Configuration Proposed

Additional Unit Configuration

Final Configuration

Final capacity In TPA

1 DRI Kilns 2x350 TPD +

2x100 TPD

4x500 TPD 2x350 TPD+

2x100 TPD +

2x500 TPD

2x500 TPD No Change Nil (2 x 350 TPD,

2 x 100 TPD,

4 x 500 TPD)

8,00,000

2 MBF Nil 2x450m3 Nil 2x450m3 No Change Nil 2x450m3 7,42,500

3 I/O

Pelletization

Nil 3 Lakh TPA 3 Lakh TPA Nil Capacity

Enhancement of 3

Lakh TPA to 6 Lakh

TPA.

6Lakh TPA 12 Lakh TPA 12,00,000

4 Sinter Nil 1x96m2 Nil 1x96m2 No Change Nil 1x96m2 8,82,000

5 S M S 4x18T IF 4x8T + 4x12T

IF

2x80/90 T EAF

with matching

LRF

4x18T + 4x8T

+ 2x12T IF

2x12T IF

2x80/90 T EAF

with matching

LRF

Change in EAF from

2 x 80/90 T to 1 x

80 T

11 x 18 T IF (15x18T +

8x8T +

4x12T) along

with 1 x 80

EAF with

matching LRF

14,44,286

6 C C M Nil 1x6 strand &

1x2 strand

1x3 & 1x2

strand

1x3 strand No Change Nil Nil 6,60,000

7 Rolling Mill 60,000 TPA 6 Lakh TPA 60,000 TPA 6 Lakh TPA No change in

production

capacity, but Wire

rods, structural,

Pipe flats & HR

Coils are to be

introduced.

TMT 100000 TPA;

Structural Mill

60000 TPA;

Pipe Mill 30000

Nil TMT 1

100000 TPA;

Structural Mill

60000 TPA;

Pipe Mill

30000 TPA;

WRM1 & 2

400000 TPA

and TMT 2

Bar 70000

TPA



12

TPA;

WRM1 & 2 400000

TPA

7 Ferro alloy

plants

Nil 2x6, 2x9 &

3x11 MVA

2x6, 2x9 &

3x11 MVA

Nil No Change Nil Nil 2,50,000

8 Coke oven Nil 5 Lakh

50 thousand

TPA

Nil 5 Lakh

50 thousand

TPA

No Change Nil Nil 5,50,000

9 Coal

washery

3 Lakh TPA 15 Lakh TPA 3 Lakh TPA 7Lakh TPA Reduced

throughput with

introduction of

Foreign Coal as

substitute

Nil 10,00,000

TPA Capacity

10,00,000

10 Lime Plant Nil 60,000 TPA Nil 60,000 TPA No Change Nil Nil 60,000

11 Bloom

caster

Nil 3,53,500 TPA Nil 3,53,000 No Change Nil Nil 3,53,500

12 C P P 15

MW(WHRB)

10 MW (FBC)

200 MW 37 MW(WHRB)

70 MW(FBC)

68 MW

(FBC)

No more additional

Power Plant &

reduction id AFBC

Power by 50 MW

Nil WHRB 58 MW

+ FBC 117

MW = 175

MW

175 MW

Source: SDPL



13

Therefore a comparison of existing vs proposed changes in the configuration is

represented in the table below. The total changes is within the EC approved quantity of

steel production for 14,44,286 TPA from this integrated Steel Plant.

Sl. No. Plant Unit

EC Status Existing / Proposed

Changes

Unit Description with configuration Capacity in TPA

1

Pellet

Existing

Pellet Plant 300000

2 PGP 5 x 2850 NM3/hr

1

Proposed

PelletPlant 1200000

2 PGP 20 x 2850 NMQ/hr

3

DRI

Existing DRI (2 x 350 TPD, 2 x 100 TPD, 4x500 TPD*)

800000

3 Proposed

DRI (2 x 350 TPD, 2 x 100 TPD, 4x500 TPD)

800000

4 Power Plant

Existing Power Plant* 225 MW

4 Proposed Power Plant 175 MW

5

SMS

Existing (EC granted for

(210000 +1200000

=1410000 TPA)

EAF ( 2x80/90 T ) 1234286

IF (4 x18T)+ (4 x8) +(4 x 12) 210000

5 Proposed EAF (1 x 80T) 673406

IF (15x18T + 8x8T + 4x12T) 770880

6 SINTER

Existing 882000 ( 1x 96 m2) 882000

6 Proposed 882000 ( 1x 96 m2) 882000

7

MBF

Existing 2x450 m3 with 2.357 factor for 350 days

742500

7 Proposed 2x450 m3 with 2.357 factor for 350 days

742500

8

Rolling Mill

Existing

TMT 60000

Structural Mill 60000

Pipe Mill* 30000

WRM I* 235000

WRM II* 235000

8 Proposed

TMT 170000

Structural Mill 60000

Pipe Mill 30000

WRM I 200000

WRM II 200000

9 SAF

Existing Ferro Alloys Plant (SAF) 250000

9 Proposed Ferro Alloys Plant (SAF) 250000

10 Coal

Washery

Existing Coal Washery 1800000

10 Proposed Coal Washery 1000000

11 Coke Oven Plant

Existing Coke Oven* 550000

11 Proposed Coke Oven 550000

Source: Sam DRI



14

Fig 2.1 LAYOUT PLAN OF THE INTEGRATED PROJECT



15

3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS

The changes proposed on accorded EC are increase of Iron Ore pellet production by

10lakh TPA and reduction of power generation by 50 MW.

Project description & Process details will remain same as described in existing EC.

Iron Ore agglomeration by Sintering and Palletization from beneficiated Iron Ore from

market, will be fed to DRI Kilns, Blast Furnaces and EAFs to produce hot metal, which

will be converted to liquid steel in LFs and cast to blooms and Billets. TMT rods etc. will

be manufactured for sale.

Ferroalloy Plants to manufacture Fe-Mn, Si-Mn, Fe-Si and Fe-Cr for internal use and sale.

Captive Power will be generated from Waste heat of flue gas from DRI Kilns, Coke Oven

gas and steam from FBCs.

There will be Coal washery to feed washed Coal to Coke Oven plant and middling to FBC.

The detailed process flow diagram for the integrated Steel Plant is represented in

Figure….



16



17

A. Pellet Plant

Pelletization process consists of number of key stages. Concentrate is fed along with a

mixture of Bentonite and other chemical additives (such as lime stone, coal and coke

breeze) and moisture, into balling devices like drum or disc to produce green pellets 9-

11 mm dia. These pellets are loaded on to a moving grate and form a packed bed.

Increasingly hot process gas is blown through it to dry and fire the pellets at 13000C.

Then ambient air cools them back to room temperature.

Grate kiln process which will be adapted by M/s Shyam Metalics& Energy Ltd,will have

three machines in series; a travelling grate, a rotary kiln and an annular cooler. Overall

the grate kiln system can be independently controlled, e.g. the speed of the grate can be

slowed to allow more drying time of the green balls. The kiln speed can be modified to

keep a constant residence time for proper induration.

Since iron ore slurry from beneficiation plant is used for pallet making, water content of

the concentrate from the thickener is about 50%. In order to reduce moisture content

ceramic vacuum disc filters are used and water content is reduced to 11% and water is

recycled.

Slurry with 11% moisture is conveyed to the feed silo. From the silo the slurry will be

transferred by belt conveyor to buffer bunker in the drying unit. Drying will be provided

with one set of Ø 3.74×22m barrel drying machine with handling capacity with 150t/hr.

water content of concentrate will be reduced to around 7% after drying and transferred

to proportioning bin. Coal and bentonite will be received by trucks and stored separately

in the yard.

Fuel coal with sizes from 0-30mm will be transferred by belt conveyor from coal store

bunker to coal preparation area, where vertical coal mill be used to grind the coal to size

of 200 mesh(fraction more than 80%). Finally grinded coal will be transferred to the

burner in the coal injection tower. The capacity of vertical mill will be 6-10t/hr and type

HRM 1100. Crushed coal of 200 mesh will be transferred to coal injection pipe at the

head of induction unit and burnt by air through blowers.

Pre-determined quantity of concentrate bentonite, limestone / dolomite, coal is sent to

intensive mixer to produce a homogeneous mixture.

B. Rolling Mill

The company now proposes manufacture of total 6,60,000 TPA rolled product

Revamp existing 60,00 TPA rolling mill to manufacture 1,00,000 TPA rolled TMT

product.

Set up 2x2,00,000 TPA wire rod mills.

Set up 1x 60,000 TPA structural mill

Set up 1x30,000 TPA Pipe mill

Set up 1x70,000 TPA TMT rod mill

I Reheating of Billets

Billets are charged from one end to a 20 TPH oil fired reheating furnace by a suitably

rated pusher and discharged at the other after being heated and soaked to desired

rolling temperature level at 1200oC. In order to avoid de-carbonization on heating, the

billet are heated slowly and uniformly up to 800oC and then rapidly to the rolling

temperature level of 1200oC.



18

II. Roughing Mill

The roughing mill contains 510 PCD 3Hi one reversing stand and one vertical edging

stand. Billet is first rolled in the first stand of roughing mill train. To and from rolling of

bottom and top pass in first stand shall be carried out till a definite section shall be

obtained in sixth pass and the Billet will be then allowed to pass through the bottom

pass of intermediate mill stand.

III. Vertical Edging Stand

The vertical edging stand will be used to produce strips with very fine plane edges. Two

nos. edging stand is incorporated in the mill. First one will be in the roughing group and

the second one will be in the intermediate group. The second stand will have 5%

concave type roll edging.

IV. Intermediate Mill

The intermediate mill contains 410 PCD 2Hi three stand and one vertical edging stand.

From the roughing mill the Billet will be then allowed to one pass through first stand of

Intermediate mill, next one pass through second stand & the next one pass through third

stand. The three intermediate stands is continuous stand. The Billet coming out from

third stand of intermediate mill will be then allowed to the first stand of Finishing mill.

V. Finishing Mill

The Continuous mill containing 310 PCD 4Hi two stands is the Finishing mill. The strip /

skelp coming out of 3rd stand shall be allowed to enter to the continuous finishing stands

driven by a proper drive. One (1) pass in each finishing stand shall be used. The finished

strip / skelp coming out of mill stand shall be collected in the coiler. These coils will be

supplied to the tube mill.

C. Coal Washery

Coal Washing is a process of separation mainly based on difference in specific gravity of

coal and associated impurities like shale, sand and stones etc so that we get relatively

pure marketable coal with add on calorific value of the coal. Coal washing separates non-

combustible material from useful combustible material. Coal washing uses gravity

separation, flotation and a technology, which uses dense media. In India dense medium

cyclones are most popular as it gives very high separation efficiency Mostly magnetite is

used as dense media. Magnetite having specific gravity in the range of 4.8 to 5.4 is used

in washery for washing process which is ground to –325 mesh and mixed with water to

maintain the desired gravity in HM Bath or HM Cyclone for separation of coal from its

impurities.

Indian coal has a very high NGM (Near Gravity Material) value and it is difficult to wash

it. Dense medium cyclone provides best solution for Indian coal. With around 221 billion

tons of non coking coal deposits, India has huge advantage in developing coal-based

sponge iron technology in India. A country having no significant resources of either

coking coal or natural gas can leverage washed and beneficiated coal causing value

addition of coal by way of reduction in ash percentage.

Beneficiated coking coals find use in manufacturing of hard coke for steel making.

Beneficiated washed Non-coking coal find use mainly for power generation.

Beneficiated Non-coking coal can be used by Cement plants, Sponge Iron plants

and other industrial plants.



19

M/s SMEL intends to beneficiate non-coking coal from IB Valley in Odisha, to upgrade its

quality for use in rotary kilns for DRI (Sponge Iron) production. The Middlings and other

products are to be further used in the proposed power plant. They are planning to set up

a plant of capacity 10,00,000 TPA that would accept (–) 20 mm coal for washing while

crushing and screening stage would accept –300 mm coal. They needed a solution for

reduction in ash of raw coal from various mines of IB valley from 38-60% to 27-36%

with surface moisture of 11-14%.

The heavy media cyclone washery consists of the following sub-systems -

Receiving and Sizing Section

Heavy Media Coal washing system

Media handling and recovery system

Process water handling and recovery system.

Receiving and Sizing Section

Raw coal is fed to a Raw Coal Hopper (Surge Bunker) for feeding to the washery. This

hopper is provided with a Grizzly of 200 mm. A Vibratory feeder draws the coal from the

hopper and feeds to a Primary Crusher preceded by a fixed screen for scalping the feed

to the primary crusher. The Primary crusher is operated in open circuit and envisaged to

reduce the size of the coal to 75 mm. This is followed by a second stage of crushing and

is set up in close circuit with a screen to ensure low generation of fines and close size

control for the products from the washery. The Vibratory screen classifies the material at

20 mm and the oversize material is sent to the crusher for crushing down to –20 mm.

The crushed fraction is re circulated back to the screen. The undersize of the screen (-

20+0 mm) is directed towards the surge bunker for feeding to the washing section.

Heavy Media Coal washing system

The -20+0 mm coal is tapped from the belt conveyor into the desliming screen for

removal of -1.0 mm material. Deslimed coal (-20+1.0 mm) is fed to the Correct Media

Tank, which also acts as the HM cyclone feed tank. Feed coal mixed with Media is

supposed to go to the HM cyclone through HM Cyclone feed pump. Admixture of coal and

media which is fed to the HM cyclone undergoes a density separation in the cyclone

where the clean coal below the cut density reports to the overflow. The middling which is

of a higher specific gravity suppose to report to the cyclone underflow. Both these

streams contain a mixture of coal and media.

Clean Coal Dewatering Screen is Double Deck Screen (5 mm & 0.5 mm). 20-5 mm

material is taken out directly and 5-0.5 mm material is passed through a centrifuge to

dewater the product

D. Induction Furnace

Steel melting scrap, direct reduced iron and pig iron/cast irons are the input raw

materials for an induction furnace. The ratio of these items and the technology of

melting these input materials varies according to the availability of raw materials and

location of the plant. Further selected raw materials is required for the production of

specific quality steel. For better and efficient operation of melting in induction furnace,

raw material charge must fulfill the following criteria.

It must be as dense as possible. Compaction of scrap is important for ensuring

uniform and rapid heating as well as for energy saving.



20

It must be clean. Rust, oil, grease, and sand etc. should preferably be nil.

It must be metallurgically clean, i.e. free from slag lumps, oxides etc., particularly

for direct reduced iron, skull and ferro alloys.

There are no or less sharp pointed edges, particularly in case of heavy and bulky

scrap.

It must be segregated from harmful ingredients like explosives, closed containers,

evaporative substances and readily available in chargeable sizes on the shop

floor.

Electricity is the only energy source for steel melting in the induction furnace. Induction

furnace is to run at maximum power since beginning. There are some misconception of

running furnace at low tap initially and then gradually increase to higher tap. Maximum

power input increases rate of melting and hence reduces cycle time of a heat. Power

factor to be maintained near to one.

Important aspects of operation

As liquid steel is excited by current opposite to current flowing in induction coil, it is

agitated to raise its surface in the center. Surface of liquid steel is risen higher as

frequency becomes lower, i.e. agitation of the liquid steel occurs stronger in low-

frequency furnace than in high-frequency furnace. This effect of agitation makes it

possible to ensure uniform temperature of the liquid steel and its uniform quality as well

as to promote entrapment of material charged and fusion of chemical composition

adjusting agents, specially carbon addition. On the other hand, excessive agitation may

cause such troubles as oxidative wearing of liquid steel and fusing out of refractories or

danger of spattering of liquid steel.

The composition of the slag varies depending on the specific process being used and the

type of steel being produced. The compositions of furnace and ladle slags are often very

complex. The slag which is formed is the result of complex reactions between silica, iron

oxide from steel scrap, other oxidation by products from melting, and reactions with

refractory linings. The slag consists of a complex liquid phase of oxides of iron,

manganese, magnesium and silicon, silicates and sulfides plus a host of other

compounds, which may include Alumina, calcium oxides and sulfides, rare earth oxides

and sulfides etc.

While producing the steel, the chemistry of end product is controlled. The chemical

analysis of all the input materials is done to have a decision on the charge mix. After

completing 50 % charging of the input materials, a bath sample is analyzed for chemical

composition. Based on the chemical analysis of the bath sample at this stage calculations

are made for further additions of the metallics. If the bath sample at this stage shows

high percentage of carbon, sulphur and phosphorus then the direct reduced iron content

of the charge is increased. Final bath sample is taken when 80 % melting is completed.

Based on the analysis of this sample, another adjustment is made in the charge. The

lower content of carbon in the sample is corrected by increasing the quantity of pig

iron/cast iron in the charge. Silicon and manganese in the metal is oxidized by the iron

oxide of the direct reduced iron. Sulphur is also diluted by the direct reduced iron.

Because of use of direct reduced iron the trace elements in the steel made in the

induction furnace remains under control.

The liquid steel is the desired output of the induction furnace. The quantity depends

upon the capacity of the furnace, and the quality depends upon the raw materials and

the steel composition. The tapping temperature depends upon the type of steel and the



21

super heat needed in the liquid steel for its end use. Tapping of steel at high

temperatures increases refractory erosion and power consumption.

Unnecessary superheating of liquid steel to high temperature costs to energy

significantly. Minimizing the overheating of molten bath saves energy. Depending on

steel specification and temperature loss during transfer of liquid steel to continuous

casting machine, superheat temperature is to be decided. In every heat, temperature of

the liquid steel bath is to be measured and monitored to get optimum energy saving.

Proper power control systems with potentiometer adjustment need to be provided for

minimizing energy losses due to overheating.

Tilting of the furnace is to effect pouring of the melt is a last operational activity before

casting. The furnace is usually tilted to achieve an angle of 90 degree or greater for

complete pouring of the liquid steel.

The various types of Induction Furnaces used for Steel making are medium frequency

and high frequency core less. Raw materials used for Steel making from IF are Sponge

Iron, Pig iron and Scrap. Alloying elements are added as per the requirement and the

induction furnaces are provided with matching billet casters

E. Power Plant

Total power production has been envisaged at 175 MW, including existing 58 MW based

on running DRI.

Sum up of 175MW: - 58 MW WHRB + 117 MW FBC power would be produced. Boilers

will have same specifications, which are as follows.

Working Pressure 66kg/cm2 abs

Super heater temperature 4850C

BFW temperature 1300C

Operating hours 365x24hrs

The boilers will be complete with evaporator steam drum, mud drum, bank of super

heaters, economizers, ID fans, ESPs and internal piping etc. Soot blowing and de super-

heating system will also be provided.

F. Electric Arc Furnace

An electric arc furnace used for steelmaking consists of a refractory-lined vessel, usually

water-cooled in larger sizes, covered with a retractable roof, and through which one or

more graphite electrodes enter the furnace. The furnace is primarily split into three

sections:

the shell, which consists of the sidewalls and lower steel "bowl";

the hearth, which consists of the refractory that lines the lower bowl;

the roof, which may be refractory-lined or water-cooled, and can be shaped as a

section of a sphere, or as a frustum(conical section).

The roof also supports the refractory delta in its center, through which one or

more graphite electrodes enter.

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

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

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

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

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



22

The hearth may be hemispherical in shape, or in an eccentric bottom tapping furnace

(see below), the hearth has the shape of a halved egg. In modern melt shops, the

furnace is often raised off the ground floor, so that ladles and slag pots can easily be

maneuvered under either end of the furnace. Separate from the furnace structure is the

electrode support and electrical system, and the tilting platform on which the furnace

rests. Two configurations are possible: the electrode supports and the roof tilt with the

furnace or are fixed to the raised platform.

A typical alternating current furnace is powered by a three-phase electrical supply and

therefore has three electrodes. Electrodes are round in section, and typically in segments

with threaded couplings, so that as the electrodes wear, new segments can be added.

The arc forms between the charged material and the electrode, the charge is heated

both by current passing through the charge and by the radiant energy evolved by the

arc. The electric arc temperature reaches around 3000 °C, thus causing the lower

sections of the electrodes to glow incandescently when in operation. The electrodes are

automatically raised and lowered by a positioning system, which may use either

electric winch hoists or hydraulic cylinders. The regulating system maintains

approximately constant current and power input during the melting of the charge, even

though scrap may move under the electrodes as it melts. The mast arms holding the

electrodes can either carry heavy busbars (which may be hollow water-

cooled copper pipes carrying current to the electrode clamps) or be "hot arms", where

the whole arm carries the current, increasing efficiency. Hot arms can be made from

copper-clad steel or aluminum. Large water-cooled cables connect the bus tubes or arms

with the transformer located adjacent to the furnace. The transformer is installed in a

vault and is water-cooled.

The furnace is built on a tilting platform so that the liquid steel can be poured into

another vessel for transport. The operation of tilting the furnace to pour molten steel is

called "tapping". Originally, all steelmaking furnaces had a tapping spout closed with

refractory that washed out when the furnace was tilted, but often modern furnaces have

an eccentric bottom tap-hole (EBT) to reduce inclusion of nitrogen and slag in the liquid

steel. These furnaces have a tap hole that passes vertically through the hearth and shell

and is set off-center in the narrow "nose" of the egg-shaped hearth. It is filled with

refractory sand, such as olivine, when it is closed off. Modern plants may have two shells

with a single set of electrodes that can be transferred between the two; one shell

preheats scrap while the other shell is utilized for meltdown. Other DC-based furnaces

have a similar arrangement but have electrodes for each shell and one set of electronics.

3.7 RAW MATERIAL REQUIRED AFTER PROPOSED CHANGES IN PELLET PLANT

AND CAPTIVE POWER GENERATION

Table 3.2 Annual Raw material requirement

Raw Materials (TPA) Total Raw

Material in

present EC

Conditions

Total Raw

Material in

Proposed

Conditions

Mode of

Transportation

Cooking Coal 774,648 774,648 By Rail

Chromite Ore 612,500 612,500 By Rail

Iron Ore Fines 803,660 1,838,660 By Rail

Iron Ore Lumps 818,923 168,923 By Rail

Coke Fines 50,772 57,500 By Rail

https://en.wikipedia.org/wiki/Ladle_(metallurgy)

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

https://en.wikipedia.org/wiki/Three-phase_electric_power

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

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

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

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

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

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

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

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

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

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



23

Indian Coal 2,238,075 1,066,825 By Rail

Imported Coal 38,175 559,052 By Rail

Total Quantity By

Rail

5,336,753 5,078,107

Iron Scrap 72,941 107,368 By Road

Lime 3,450 13,800 By Road

Dolomite 180,685 180,685 By Road

Quartz / Quartzite 141,460 141,460 By Road

Magnesite 25,000 25,000 By Road

Bentonite 2,243 8,970 By Road

Total Quantity By

Road

425,779 477,283

In addition to the above raw materials LDO/HSD, Electrode paste, Bentonite &

lubricating oil will also be required and procured from the local market on-demand.

Product marketing area

TMT rods & Ferroalloys has market all over India and Finished products are to be

transported through pollution compatible vehicles and fully covered to avoid flying with

air force or spillage on the public roads,

Raw Material Receipt & Store

Most of the raw material shall be received by rail or road. Separate store yard for the

major raw materials such as iron ore and coal exists and will be done by the

requirement.

Mode of Transport (Raw materials & products)

Transports will be done by the environmentally compliant trucks and covered trains also.

Bharat-III/ Euro-III trucks will be used in the transportation system. The raw materials &

products shall be covered fully during the transportation to avoid spillage & fugitive

emissions on the road & rail line. Major raw materials are carried in Railway racks to

their own private siding within the premises.

Raw Material Storage & Handling

Separate store yard for the major raw materials such as iron ore lumps, iron ore fines

lime stone/ dolomite, coal and Cr & Mn Ore etc are done. The material shall be unloaded

manually from the trucks in the stock yard. The yard shall have provision to store around

one months‟ stock of material.



24

3.8 RESOURCE OPTIMISATION/RECYCLING AND REUSE ENVISAGED

IN THE PROJECT

The project is an integrated steel project. The final products are TMT rods, channels,

angle, & blooms. Total power generation from the project will be 175 MW which shall be

produced from WHRB, Coke Oven & gas and AFBC boilers. Total product mix after the

expansion cum modification of the project is given in the following table.

Following optimization, recycle &reuse measures have been proposed.

1) Steps proposed for optimization of power

a) Utilization of waste heat from DRI kiln to produce steam there by generation of

own power and reduction of power draw from state grid.

b) Surplus BF gas to be burnt to generate power

c) Utilization of waste dolchar to generate power thereby reduce power drawl

d) MBF top gas pressure recovery turbine to be set up to generate about 30kwh

e) Solar lighting on internal roads to optimize power consumption

f) Variable Frequency drive ID fans and blowers will draw less power for same

output.

g) Silicon-controlled rectifier to dimmer high voltage for ESPs used for DRI kilns.

h) Use of capacitor Bank to increase power factor.

3.9 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER

REQUIREMENT AND SOURCE

3.9.1 WATER REQUIREMENT:

Water will be drawn from Hirakud Reservoir of river Mahanadi. Fresh water requirement

after the proposed change has been estimated to be 55702 KLD against 62612 KLD as

approved in EC and there will be a reduction of 6910 KLD.

Sl No. Items

Water

requirement for

Existing unit (in

KLD)

Water

requirement for

Proposed unit (in

KLD)

1 CLARIFLOCCULATOR 31306 27855

2 SOFTNER 19080 16260

3 DM PLANT 2613 2032

4 DRI-I 350 350

5 DRI-II 750 750

6 FAD 1990 1990

7 SMS-I 280 280

8 SMS-II 320 320

9 SMS-III 632 632



25

10 SMS-IV 816 816

11 MBF 2800 2800

12

ROLLING

MILL/STRUCTURAL

MILL/PIPE MILL/WRM

830 830

13 COKE OVEN 515 515

14 DRINKING

WATER/DOMESTIC WATER 300 250

15 FIRE FIGHTING MAKEUP 30 30

TOTAL 62612 55710



26

3.9.2 POWER REQUIREMENT FOR THE PROJECT

Power requirement

Power requirement as envisaged in EC was 225 MW. It is now reviewed and break -up will

be as follows.

Sl.No Facility Power requirement in MW

1 DRI Kilns 8.32

2 MBF 13.3

3 Pellet plant 5.1

4 S M S 103

5 Rolling mill 12

6 Ferro alloy Plant 50

7 Coke oven 1.9



27

8 Coal washery 3.5

9 A/C, domestic & miscellaneous 1.5

10 Power Plant internal consumption 17.5

Total 216.12

This power load has been estimated based on full load of all the units all the time.

Captive power generation 175 MW, hence about 40 MW Power has to be purchased from

state power grid to run all the facilities.

Manpower

No change in manpower as given in EC will remain unchanged with 3060. Breakup is as

follows.

Executives 155

Non-Executives 2905

Project Cost




will almost be of same value, so additional project cost for implementation will be about

25 crores.

Hence the total project cost will be around Rs 3893 crores

Project completion schedule

After getting CTE from SPCB, Odisha, the construction work can be started to complete

the project in less than one year of time.



28

CHAPTER -4

PROPOSED INFRASTRUCTURE AND EMP

4.1 CONNECTIVITY

M/s Shyam Metalics & Energy Ltd. has its existing Steel Plant at: Pandoloi in Sambalpur

district of Odisha. The project is located at latitude: 210 40‟ 50.43‟‟ N and longitude 840

02‟ 30.63‟‟ E, with 208m AMSL.

The location is well connected by road and Rail, and existing project transportation is

going on this infrastructure.

4.2 LAND FORM, LAND OWNERSHIP


acquired and the balance acquisition is in process. The detailed breakup of the land is

given in the following table:

SL

NO Facilities

Total Land in

Ha

1 Plant facilities 42.0

2

Raw Material Yard &

Finished products 8.3

3

Office & other

permanent structures 0.93

4 Internal Road 1.0

5

Rain Water harvesting

system 6.2

6 Water Reservoir 3.8

7 Green Belt 97.3

8 Vacant Space 135.31

Total 294.84 ha

4.3 TOPOGRAPHY

The district has three distinctive physiographic units such as, Hilly Terrain of Bamra and

Kuchinda in the north, plateau and ridges of Rairakhol in the south-east and valley and

plains of Sambalpur Sub-division in the south east. The topography is undulating. The

area has thin alluvial cover and the soil is mainly reddish and not very much fertile. It is

a transitional zone having hard rock as well as alluvial terrain which are flat and gently

sloping.



29

4.4 SOIL CLASSIFICATION:

The west coarse gritty soil blended with rock fragments is formed from the weathering of

pegmatites, quartz veins and conglomeratic sandstones, where as sandy soil

characteristic of granitic rocks and sandstones. This soil is of reddish colour, medium to

coarse in texture, acidic in reaction, low in nitrogen, calcium, phosphate and other plant

nutrients. Water holding capacity of this soil increases with depth as well as with the

increase of clay portions. Towards the east alluvial soil attains an enormous thickness in

the low level plains to the east. This alluvial soil is formed of alluvium brought down by

the Ajay, Damodar, Bhagirathi and numerous other rivers. These soils are sandy, well

drained and slightly acidic in nature.

The soil type of the Core zone of the study area is fine loamy typic endoaquepts in

nature. The prevailing soil types in the study area are mostly belongs to fine loamy typic

ustochrepts. The other soil types found in the study area are loamy skeletaltypic

ustochrepts, coarse loamy fluventic ustochrepts, fine loamy typic haplustalfs, fine loamy

udic ustochrepts, fine loamy udifleventivic ustochrepts

4.5 CLIMATIC DATA FROM SECONDARY SOURCE

The district experiences a warm temperate rainy climate with mild. The cold season

starts from about the middle of November and continues till the end of February. March

to May is dry summer intervened by tropical cyclones and storms. June to September is

wet summer while October and November is autumn.

Secondary information on meteorological conditions has been collected from the nearest

IMD station at Jharsuguda and IMD Book (1970-2000).

The drinking water will be met through overhead tank of existing plant



30

CHAPTER -5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The plant is an integrated steel plant having semi-mechanized operation. It is a labor

intensive project. However, depending on the production schedule, there will be

technical labor engaged for operation.

The raw materials shall be transported through covered trucks by road up to the nearest

siding for further transportation by rail. And the finished products will be transported by

both rail and road. The transportation load will not add much to the existing load on the

said road system.

Appropriate plantation program shall be undertaken along with the developmental

program to at least cover the boundary areas with thick and tall plants for containment

of the air borne pollutants within the premises, which is duly reflected in the land use

plan.

There will not be any further infrastructural development other than needed for the

commissioning of the total project component machineries. This revised expansion shall

utilize the existing infrastructural facilities for all purposes.

5.2 PERIPHERAL DEVELOPMENT PLAN

M/s Shyam Metalics & Energy Limited will make sincere efforts to improve the socio-

economic status of the local habitants. A welfare scheme will be prepared by the

company for the socio- economic development of the area. The scheme will envisage

promotion of education in the adjoining villages by giving aid to the local schools,

providing drinking water facility and organizing health check-up programs. Local people

will be given free seedlings to develop greeneries all around. The progress of the scheme

will be reviewed periodically and further action will be taken as deeming fit. This has

already been mentioned in EIA report submitted for getting prior EC for the project.

5.3 LAND USE PLANNING


acquired and the balance acquisition is in process. The detailed breakup of the land is

given in the following table:

SL

NO Facilities

Total Land in

Ha

1 Plant facilities 42.0

2

Raw Material Yard &

Finished products 8.3



31

3

Office & other

permanent structures 0.93

4 Internal Road 1.0

5

Rain Water harvesting

system 6.2

6 Water Reservoir 3.8

7 Green Belt 97.3

8 Vacant Space 135.31

Total 294.84 ha

5.4 BENEFITS TO THE REGION AND THE COUNTRY

M/s Shyam Metalics & Energy Limited shall produce TMT rods, channels and angles &

Blooms that are to be utilized in construction activities and industries. The products are

in demand and production shall contribute to the GDP growth of the country.



32

CHAPTER -6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA DISTRIBUTION


acquired and the balance acquisition is in process.

6.2 GREENBELT DEVELOPMENT

In order to combat the air pollution, noise pollution and also to improve the aesthetic,

the company proposes to develop greenbelt, landscaping and avenue plantation. 33% of

the total area i.e. about 97.3 ha of land will be demarcated for green belt purpose.

6.3 CONNECTIVITY







6.4 DRINKING WATER MANAGEMENT:

The drinking water will be met through ADDA supply. Around 15 KLD will be used for

drinking purposes.

6.5 INDUSTRIAL WASTE MANAGEMENT

Emission Management after proposed change in configuration

Two changes have been proposed in approved EC:

50 MW AFBC based power plant to be dropped; additional 6 lakh TPA I/O pellet plant to be

installed; existing 3 lakh TPA plant to be upgraded to 6 lakh TPA;additional 11 x 18 TPA IF

to be added with reduction in SMS capacity and Coal Washery.

Revised Solid waste generation & its Management

Sl.No Facility Generated

waste

Quantity in

TPA as per

EC

Revised

Quantity in

TPA

Management

1 Coal Washery Middling &

Rejects

9,98,000 6,10,000 FBC fuel

2 Coke Oven Coal Fines 28,750 28,750 8970 TPA to

Pellet Plant &

19780 TPA to

Sinter Plant



33

Bottom dust 4,379 4,379 Land fill

3 DRI Kilns FLY Ash 1,01,155 46,560 Brick

Manufacturing

Dolchar 5,06,000 5,06,000 AFBC Boiler fuel

4 Sinter Plant Dedusting dust 1,28,935 1,28,935 Recycling for

sinter making

5 Pellet Plant Dedusting dust 54,180 2,16,720 Used in Sinter

Plant

6 PGP Plant Tar & Tar oil 1,037 4,075 Reused in Pellet

Plant Kiln

7 MBF Dust & Fines 2,75,010 2,75,010 Used in Sinter

Plant

Slag 2,22,750 2,22,750 Cement Plant

8 S M S Slag 37,059 1,72,574 Road making &

land filling

Scrap 48,524 74368 Recycled in IF

8 FBC Fly ash 8,50,492 6,94,567 Reused in Brick

Industry

9 Ferro alloy plant Bag House

Dust

3,400 3,400 Land fill

6.6 POWER REQUIREMENT

Power requirement after expansion will be about 216 MW and captive generation will be

175 MW, hence about 40 MW will be purchased from DVC.

6.6 INDUSTRIAL POLLUTION CONTROL

Estimation of Pollution load change

6.5.1 Air pollution

Pollution Load Estimate due to Transportation:

Basis of Estimation:

Mode of Transportation Existing Proposed

By Rail Rack 5336753 5078107

By Road 425779 477283



34

No, of Trucks (16T) in to-

and-fro traffic

53722 59660

No. of PCU equivalents 171912 190913

Area of the Siding 28752 m2

Traffic Pollution Load Estimation:

Existing Pollutant Quantity

PM10

mg/m3

SO2

mg/m3

Nox

mg/m3

CO

mg/m3

Total No.

of

Vehicles

in PCU

Fugitive

emissions

TPA

Traffic

Pollution

1.71912 8.251776 5.501184 1.203384 171912 0.005054

Railway

Siding

64.39

Proposed Pollutant Quantity

PM10

mg/m3

SO2

mg/m3

Nox

mg/m3

CO

mg/m3

Total No. of

Vehicles in

PCU

Fugitive

emissions

TPA

Traffic

Pollution

1.90913 9.163824 6.109216 1.336391 190913 0.005613

Railway

Siding

77.09

Net Change in Traffic Pollutant Quantity w/o any EMP

PM10

mg/m3

SO2

mg/m3

Nox

mg/m3

CO

mg/m3

Fugitive

emissions

TPA

Traffic 0.19001 0.912048 0.608032 0.133007 0.000559



35

Implemented EMP Measures (As-on-date)

1. There are 44 Sprinklers installed at the Railway Siding

2. There are 64 sprinklers installed along the haulage road inside the plant premises

Net Change in Pollutant Quantity after EMP

PM10

mg/m3

SO2

mg/m3

Nox

mg/m3

CO

mg/m3

Fugitive

emissions

TPA

Traffic

Pollution

-1.33729 0.912048 0.608032 0.133007 -0.003932

Railway Siding -48.97

Ambient Air Pollution Load Estimation:

Only the units with probable emissions are considered for this evaluation

Sl.

No.

Plant Unit Existing EC

Status /

Proposed

Existing Pollutant Quantity

SPM

(TPA)

SO2

(TPA)

NOx

(TPA)

CO2

(TPA)

1

Pellet

Existing 194 382 42 1650

1 Proposed 774 563 168 6600

3

DRI

Existing 481 4800 NA 42

3 Proposed 481 3722 NA 42

4

Power Plant

Existing 1130 6288 4533 15768

4 Proposed 878 4061 3526 12264

5

SMS

Existing 101 NA NA 21

5 Proposed 75 NA NA 11

6

SINTER

Existing 7410 593 NA 78

6 Proposed 7410 593 NA 78

6 MBF Existing 33001 NA NA NA

Pollution

Railway Siding 12.70



36

6 Proposed 33001 NA NA NA

7

SAF

Existing 10.4 8.32 NA 5.30

7 Proposed 10.4 8.32 NA 5.30

8 Coke Oven

Plant

Existing 65.89 207.8 NA NA

8 Proposed 65.89 207.8 NA NA

Net Change in Ambient Air Pollution Load:

SPM

(TPA)

SO2 (TPA) NOx (TPA) CO2

(TPA)

Total pollution Load in

present EC Conditions

42393 12280 4575 17522

Total Pollution Load in

Proposed Conditions

42621 9156 3694 18947

Net Change in Pollution Load 228 -3124 -881 1425

Pollution Control Equipments

Sl.

No.

EC Status

Existing /

Proposed

Pollution Control

Systems

Implemented

1 Pellet Plant ESP & Bag House

2 DRI Bag House

3 Power Plant ESP Attached to

AFBC

4 SMS

Fume Extraction

System

Cyclone Separator

5 Sinter Plant Bag House

6 MBF GCP + Flaring

7 SAF Fume Extraction

System

8 Coal Washery ETP



37

6.6.2 WATER POLLUTION CONTROL

The waste water from canteen and office toilets will be sent to a soak pit. Canteen waste

water will be treated in a separate ETP consisting of O & G trap, settling tank, anaerobic

treatment system & gravity sand filter. Sewage from toilets will be treated in septic tank

and discharged to soak pit.

6.7 MAN POWER REQUIREMENT

The total man power requirement for plant operation on completion of the proposed

project will be around 3060 and extra 50 nos. for Security.



38

CHAPTER -7

REHABILITATION & RESETTLEMENT

REHABILITATION & RESETTLEMENT

The proposed expansion units will be implemented in the existing plant premises. The

existing lands were already derived as industrial land. As settlement will not be affected

so, no R&R facility is anticipated.



39

CHAPTER -8

PROJECT SCHEDULE

8.1 IMPLEMENTATION SCHEDULE

Time schedule for completion of various activities is given below in Table 8.1. The zero

date will commence after getting EC and consent to establish from SPCB.

Table 8.1: Tentative implementation schedule:

Sl.

No.

Activities Duration

1 Engineering

Concept Design 15 days

Basic Engineering 30 days

Detailed Engineering 90 days

2 Civil Work

Land development 15 days

Construction of plant & auxiliary facilities 150 days

3 Statutory Clearance for establishment

State clearance for establishment 20 days

State EC Clearance 90 days

4 Procurement

Place orders for long lead Equipments 90 days

Place orders for commodity items 30 days

Receipt of equipment 230 days

Installation of equipment & items 180 days

5 Erection & Commission

Inspection before commissioning 80 days

Commissioning & production trial run 40 days

Some works will proceed parallel and some in series. Critical Path Method (CPM) and

Project Evaluation & Review Technique (PERT) will be followed for completion of project

work. In short construction job will be completed within two years of time after getting

EC from MoEF&CC.

8.2 ESTIMATED PROJECT COST

Project Cost




will almost be of same value, so additional project cost for implementation will be about

25 crores.



40

CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 FINANCIAL & SOCIAL BENEFITS

The proposed expansion project is expected to bring socio-economic and environmental

benefits both at local and global level as listed below:

9.2 SOCIAL INFRASTRUCTURE

Social awareness programs will be further improved by the local authority such as

sanitation and hygiene, HIV Prevention Program.

Through this project, adult education and female education will be provided to the

illiterate adults and backward females of the villages in the project surrounding

area.

The proposed expansion project will set up training center for the male and

female youth group by considering their skills and qualification which will support

the people for self-employment.

9.3 EMPLOYMENT POTENTIAL

The project is going to create substantial employment and income. Due to this project

activity, some persons in the project area will be recruited as skilled and semi-skilled

workers by the company as per its policy. Therefore, substantial amount of employment

and income is likely to be generated for the local people. So, the project will contribute

in a positive manner towards direct employment in the project area. Some employment

potential benefits are given below:

Long term employment of up to additional 80 people in the operation phase of

the proposed expansion project.

Generating additional associated jobs due to establishment of the project.

Documents

of SHYAM METALICS & ENERGY LTDenvironmentclearance.nic.in/writereaddata/Online/...M/s Shyam Metalics & Energy Ltd steel project is located at Pandoloi, in Sambalpur district of Odisha