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Project Proponent:
M/s. Maruti Ispat and Energy Pvt. Ltd. Sy. No. 158,159, 160, 163-168 & 171, village Madhavaram and 13-19
of village Rassamarri Mandal- Mantralyam, District- Kurnool, Andhra
Pradesh.
June 2019
EXPANSION OF INTEGRATED STEEL COMPLEX at
Sy. No. 158,159, 160, 163-168 & 171, village Madhavaram and 13-19
of village Rassamarri
Mandal- Mantralyam, District- Kurnool, Andhra Pradesh.
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
1
1.1 Introduction
India is the third-largest crude steel producer in the world. In FY18, India produced
104.98 million tonnes (MT) of finished steel. Crude Steel production during 2017-18
stood at 102.34 MT Steel consumption is expected to grow 5.7 per cent year-on-year
to 92.1 MT in 2018. India’s steel production is expected to increase from 102.34 MT
in FY18 to 128.6 MT by 2021. The Government of India has allowed 100 per cent
foreign direct investment (FDI) in the steel sector under the automatic route. Nearly
301 MoUs have been signed with various states for planned capacity of about 486.7
MT.
India’s per capita consumption of steel grew at a CAGR of 4.75 per cent from 45 kgs
in FY09 to 65.25 kgs in FY17. The figure stood at 68 kgs during April-February 2017-
18. National Steel Policy 2017 seeks to increase per capita steel consumption to the
level of 160 kgs.
M/s. Maruti Ispat and Energy Pvt. Ltd. Is planning to install integrated steel plant at
Village- Madhavaram and Rassamarri , Mandal- Mantralyam, District- Kurnool,
Andhra Pradesh.
The company has obtained Environmental Clearance for the existing units vide F.No.
J-11011/1149/2007-IA II (I) dated 02.01.2009 for integrated steel complex at sy. No.
158,159, 160, 163-168 & 171, village Madhavaram and 13-19 of village Rassamarri.
Company has also taken EC extension on 16.12.2016. But till date company has
installed only 2 x 100 TPD sponge iron plant and 8 MW WHRB Plant. As the validity of
Environment for 10 years lapse, management planned to file the application for
Terms of reference as per the guildliens of EIA notification 2006.
The company already acquired 60.7 ha of land and proposed expansion will be done
within existing plant premises.
The salient features of the project are given Table 1.
Table 1-Salient Features of the Project
Project Name Maruti Ispat and Energy Pvt. Ltd
Total Area 60.7 ha
Location of Project
sy. No. 158,159, 160, 163-168 & 171, village
Madhavaram and 13-19 of village Rassamarri.
Mandal- Mantralyam, District- Kurnool, Andhra
Pradesh
Production Capacity Attached as Annexure-1
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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Raw Material Iron ore, scrab, Coal dolomite, Lime
Water demand Total Water Quantity– 1650 KLD
Sources of water Tungbhadra river
Man power 450 nos.
Electricity Consumption
56.0 MW
Source: Captive Power Plant and Andhra Pradesh
State Electricity Board
Nearest railway station Mantralyam Raod – 7.5 Km
Nearest airport Hyderabad Airport – 180 Km
Project Cost Rs. 700 crores
2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION
2.1 Identification of Project and Project Proponent
Maruti Ispat & Energy Pvt. Ltd., established in 2005, is a leading steel company
manufacturing Sponge Iron, MS Billets, Structural Steel and TMT Steel Bars. We are
ISO 9001:2008 certified company and the products what we are manufacturing are
also BIS registered.
With a progressive vision and focus on customer’s interests, the company expanded
its business operations in retail sector by adding MS Life Brand with Fe 500 & Fe 550
grades.
The Manufacturing Process using raw materials, right from Iron ore, coal and
dolomite in our DRI unit to the final product, Steel rebars are in-house manufactured
in our integrated steel plant, gives us that Extra edge required to serve all our clients
with the best quality product at extremely competitive prices. Empowered with the
most qualified and experienced personnel, Maruti Ispat & Energy Pvt. Ltd., Ltd comes
up with the best possible deal for our customers and deliver products that meet their
categorical requirements without compromising on quality. Coupled with prompt
service back up, our products and services have earned M/s. Maruti Ispat & Energy
Pvt. Ltd., a reputation of being a reliable and favored company in the construction
field arena.
2.2 Brief Information about the Project
The company is planning to install integrated steel plant at Village- Madhavaram and
Rassamarri , Mandal- Mantralyam, District- Kurnool, Andhra Pradesh.
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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2.3 Need for the Project and Its Importance to the Country or Region
The demands of steel are increasing day by day in India due to rapid Industrialization,
Booming in construction sector and other infrastructure project. Considering the said
scenario M/s. Maruti Ispat & Energy Pvt. Ltd.. is proposing to increase in existing
steel plant capacity.
2.4 Employment Generation
This plant will keep the skilled manpower hence the local village people are exposed
to the skilled jobs and get feeding to their livelihood. The estimated manpower
requirement for expansion is 1350 nos. out of which approx.. 450 will be direct
employee and 900 will be in direct employee. Employment will be provided for the
surrounding village’s people those who are educated also. The status of socio
economic will improve in these rural areas.
3.0 PROJECT DESCRIPTION
3.1 Type of Project Including Interlinked and Interdependent Projects, If Any.
No interlinked projects were associated with this project.
3.2 Location
The Location of the Project is shown in Figure – 1 and study area map is given in
Figure -2.
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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FIGURE – 1: LOCATION MAP
Project Site
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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FIGURE – 2: 10-KM TOPOGRAPHICAL MAP
3.3 Details of Alternate Sites
No alternate site was considered.
3.4 Size or Magnitude of Operation
S.no Unit Plant
Configuration
Production
Capacity
Status of
Implementation
as per old EC
1 Palletization Plant (Pellets) 1 x 3000 TPD 9,00,000 TPA Not Started
2 Sintering Plant (Sinter) 1 x 2000 TPD 6,00,000 TPA Not Started
3 Sponge Iron Kilns (Sponge
Iron)
6 x 100 TPD 1,80,000 TPA 2 x 100 TPD – is
in Operation
Remaining 4 x
100 TPD to be
Implementation
4 Mini Blast Furnace
(Hot Metal/Pig Iron)
1 x 380 m3 2,40,000 TPA Not Started
5 Induction Furnace (Billets
from CCM)
2 x 40 TPH 2,40,000 TPA Not Started
6 Billets Casting Machine/
Continuous Casting Machine
1 x 1000 TPD 3,00,000 TPA Not Started
7 Rolling Mill 1 x 1000 TPD 3,00,000 TPA Not Started
8 Power
Generation
Through
WHRB
6 x 10 TPH 20 MW 8 MW WHRB –
Civil Work
Started
Through FBC 2 x 100 TPH 2 x 18 MW Not Started
9 Ladle Furnace 1 x 40 TPH --- Not Started
10 Oxygen Plant --- 97,92,000
SM3/Annum
Not Started
3.5 Project Description with Process Details
Process Description
The proposed plant will produce steel in the form of billets and rolled products
through DRI/ MBF-IF-CCM-RM route. The iron ore is pelletized and sintered for the
preparation of iron oxide raw material for primary iron and steel making. The
iron oxide in the DRI process is reduced to sponge iron using non-coking coal in kiln.
In the mini blast furnace, the reduction is achieved by use of coke. The heat
requirement is supplied by combustion of coal/ coke. Steel making will be done using
induction furnace. The steel formed is molded into billets and rolled products by
casting mills and rolling mills.
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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Pelletization
Pellets are small crystallized balls of iron ore with a size of 9-16 mm. The Pelletization
process consists of grinding and drying or de-watering, balling and induration
followed by screening and handling. Before being fed into the Pelletization plant the
ore is upgraded by several sorting and beneficiation steps with intermediate crushing
and grinding. Af ter hot grinding the material is wetted in paddle type mixers and
combined with additives, then processed in the ball preparation plant. The balling
drum is inclined 6 to go to the horizontal plane. To obtain a well-defined green ball
size, under and oversized fractions are screened off and re-circulated.
Induration, which means thermal treatment, consists of drying, heating and cooling.
It can be carried out in two different systems; in 'straight grate' or 'grate kiln'
systems. During thermal treatment magnetite is almost completely oxidised to
hematite. This contributes to the large amounts of heat needed to operate the
process. At the end of the induration strand, the pellets are collected and screened.
Undersize or broken pellets can be recycled. Significant particulate matter emissions
may occur.
Sintering
The sinter plant essentially consists of a large traveling grate of heat resistant cast
iron. The material to be sintered is placed on top of a 30-50 mm deep layer of
recycled sinter. This bottom layer prevents the mixture from passing through the
slots of the grate and protects the grate from direct heat of the burning mixture.
At the start of the grate a canopy of gas burners ignites the coke breeze in the
mixture.
In the down-draf t process a powerful fan draws process air through the entire length
of the sinter bed into distribution chambers located underneath the grate known as
wind-boxes. The waste gas flow from a sinter plant is 17000 m3/ hr As the sinter
mixture proceeds along the grate, the combustion front is drawn downwards
through the mixture. This creates sufficient heat (1300-1480°C) to sinter the fine
particles together into porous clinker referred to as sinter.
Sponge Iron Manufacturing Process
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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Sponge iron can be manufactured either through the coal based route or the gas
based route. The proposed plant uses the coal based process in which iron ore is
reduced with non coking coal in a rotary kiln to make sponge iron. The raw materials
(iron ore, coal and dolomite), in desired quantities and sizes, are fed into the rotary
kiln from the feed end, after the rotary kiln has been fired and reaches the desired
temperature. The rotary kiln is a refractory lined cylindrical vessel on which blowers
and air pipes are mounted to provide combustion air to the kiln. The rotary kiln has -
a downward slope and is mounted on rollers to enable rotation. The angle of
inclination, rotational speed, and length of time the charge is exposed to the
atmosphere and temperature has important bearings on the quality of the
end product. The rotary kiln has three functions as: It is a heat exchanger, Vessel for
chemical reaction, Conveyor for solids.
With the rotation of the kiln, the charge moves down the slope and the surface of the
material is exposed to heat. The heat exchange takes place via the non-refractory
lining of the kiln. The reduction from oxide to metal occurs by gradual removal of
oxygen at various temperatures giving rise to various intermediate oxides.
Hot sponge iron is discharged from the kiln- discharge end and taken into the rotary
cooler. The effluent gas that contains coal volatile, fine carbon particles, iron ore and
sponge iron dust is treated separately in the waste gas handling system. The system
consists of:
(a) Dust settling chamber
(b) After burner chamber
(c) Waste heat recovery boiler
(d) Electrostatic precipitator
(e) ID fan
(f) Chimney
Direct Reduced Iron /Sponge Iron (DRI)
The process of reduction takes place inside the rotary kiln, which is mounted on 4
tyres and supported by 8 support rollers. The transverse motion of the kiln is
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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controlled with the help of hydro thruster and thrust rollers. The kiln is rotated at
the rate of 0.35 rpm with the help of a girth gear mounted on the kiln and connected
with 2 pinion drives, which in turn are coupled with gear boxes and motors.
The direct reduction of iron ore inside the kiln is held due to CO gas, which is
generated out of coal at nearly 9500C. Shell air fans are mounted on the kiln, which
inject air in controlled manner into the kiln for creating reducing atmosphere. The CO
reacts with Fe203 and reduces it to Fe. The kiln is lined with refractory for sustaining
the high temperature .
The hot DRI is then cooled by indirect cooling inside a cooler. The rotary cooler is
supported on 2 tyres and 4 support rollers. The cooler is rotated at the rate of 0.6
rpm with the help of a girth gear mounted on the cooler and connected with single
pinion drive, which is coupled with a gearbox and motor. The water is sprayed on the
cooler shell while the sponge iron travels inside the cooler and hence, the material
gets cooled at outlet to 150 0C while discharged on the product conveyor.
Product Separation
The sponge iron along with unburnt coal in the form of char comes out of the cooler.
The sponge iron being magnetic is separated out of the char by passing it through a
magnetic separator. The sponge iron and char, recovered separately, are stored in
the storage bunkers and discharged through trucks.
Off gas cleaning system
The off gases moving in counter current of material flow inside the kiln are at a
temperature of l000 OC and carry coal dust, which is pased through dust settling
chamber and after burning chamber (ABC). Air is added into the ABC for converting
CO to CO2. The hot flue gas stream is taken to the waste heat recovery boiler for
utilization of the sensible heat for making steam. The off gases are then allowed to
pass through ESP for removal of dust so that the concentration of dust is limited to
below 100 mg/ m3 before being discharged from the chimney.
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In-plant de-dusting system
Air Pollution Control Equipment like bag filter shall be installed for catching the dust
from various conveyors, material handling equipments and-product handling
equipment. The dust collected from the bag filter is sold to cement manufacturers.
Product Separation
The sponge iron along with unburnt coal in the form of char comes out of the cooler.
The sponge iron being magnetic is separated out of the char by passing it through a
magnetic separator. The sponge iron and char, recovered separately, are stored in
the storage bunkers and discharged through trucks.
Off gas cleaning system
The off gases moving in counter current of material flow inside the kiln are at a
temperature of 1000 0C and carry coal dust, which is pased through dust settling
chamber and after burning chamber (ABC). Air is added into the ABC for converting
CO to CO2. The hot flue gas stream is taken to the waste heat recovery boiler for
utilization of the sensible heat for making steam. The off gases are then allowed to
pass through ESP for removal of dust so that the concentration of dust is limited to
below 100 mg/ m3 before being discharged from the chimney.
In-plant de-dusting system
Air Pollution Control Equipment like bag filter shall be installed for catching the dust
from various conveyors, material handling equipments and-product handling
equipment. The dust collected from the bag filter is sold to cement manufacturers.
Requirement of Raw Materials for Sponge Iron manufacture
The main raw materials for sponge iron production are iron ore pellets, coal, and
dolomite.
Pig Iron manufacturing process Mini Blast Furnace Plant
The blast furnace comprise of one furnace of 380 m3 working volume and a
pig- casting machine of 800 TPD capacities. The blast furnace is envisaged to operate
with sized lump iron ore, sinter, coke, fluxes & additives. In the blast furnace, the
burden of iron ore and coke is reduced into hot metal. Coke is used both as reductant
and fuel. To maintain heat in the furnace, stove has been set up. The hot metal
produced shall be either transferred directly for primary refining or cast in pig casting
machine.
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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The liquid slag will be granulated at cast house granulation unit. The BF top gas will be
cleaned in dust catcher & gas cleaning system, and distributed to the stoves, burners
for runner drying, boilers for process and process steam supply. The surplus gas will be
exported to the AFBC power plant, where it will be utilized as supplementary fuel.
Steel Making
Steel making and continuous casting shop has been envisaged to produce about
300000 t/ yr of continuously cast billets. Two Induction Furnaces (IF) of 40 T capacities
will be installed to meet the annual requirement of liquid steel. Induction furnaces are
used to melt both ferrous and non-f errous metals. There are several types of
induction furnaces, but all create a strong magnetic field by passing an electric current
through a coil wrapped around the furnace. The magnetic field in turn creates a
voltage across and subsequently an electric current through the metal to be melted.
The electrical resistance of the metal produces heat which melts the metal. Induction
furnaces are very efficient and are made in a wide range of sizes. Induction furnaces
require cleaner scrap than electric arc furnaces; however, they do allow precise
metallurgical adjustments.
Casting & Rolling
Continuous Casting Facility
The Continuous Casting facility consists of three nos. of 2-strand continuous casting
machine for casting billets along with necessary tundish & mould/ segment
preparations and auxiliary facilities. The continuous casting machine will be of radial
type with curved mould design.
The casting ladle after treatment at the induction furnace will be picked up by the
ladle handling crane and placed on the ladle stand of the continuous casting
machine. In the mean time a tundish lined with refractory .materials, preheated to
about noooc and mounted on the tundish car will be moved from the
reserve position to the casting position. The ladle slide gate will be opened to allow
flow of liquid steel into the tundish. The liquid steel stream from the ladle to tundish
will be protected by ceramic tube to avoid oxidation and formation of inclusions in the
steel.
Prior to start of casting operation, dummy bars will be introduced into the moulds.
The gap between dummy bar head and mould walls will be sealed with asbestos
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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chord and small pieces of steel scrap will be placed over the dummy bar head for
chilling of initial liquid steel.
Water supply to moulds, secondary cooling zone and machine cooling will be switched
on. When the liquid steel level in the tundish reaches a predetermined level, the
nozzles of the tundish will be opened for flow of metal into the moulds. The liquid
steel stream from tundish to mould will be protected by shroud system to ensure
superior quality of cast products.
When the liquid steel level in the mould reaches about 100-150 mm from its top, the
drives of the mould oscillating mechanisms, withdrawal and straightening units will be
switched on. The withdrawal of dummy bar begins at the minimum speed and
gradually increases to normal casting speed within a few minutes. The lubrication of
mould walls will be done by adding requisite quantity of mould lubrication oil.
During casting operation, the metal level in mould will be maintained within
predetermined limits by adjusting the strand withdrawal speed. The liquid steel level in
the tundish will also be kept within permissible range by adjusting the opening of ladle
slide gate.
The partially solidified strand af ter leaving the mould will pass through the strand
guide rollers segments where intensive but controlled cooling of the strands will be
achieved by direct water spray with the help of nozzles. The solidified strand will be
guided through strand guides, withdrawal and straightening unit before entering in
the cutting zone.
The dummy bars will be separated from the cast strands of billet caster when dummy
bars reach beyond the withdrawal and straightening unit and will be stored in a
dummy bar storage device till their introduction is required for the next cast.
The cast strands will be cut into predetermined length by automatic Oxy-LPG cutting
torches. The cut billets will be delivered to cooling bed through run-out roller tables
Pusher will be provided for pushing billets on the cooling bed where these billets will
be marked. The marked billets will be lifted by billet handling magnet crane for storage
in the billet storage bay.
For chemical analysis of liquid steel, samples will be taken from the tundish and sent to
the laboratory. The samples will also be cut from cast products and sent to the
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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laboratory for macro etching, sulphur prints and to determine other
quality parameters.
At the end of casting, the tundish along with tundish car will be shifted to the reserve
position for drainage of remaining slag and metal. The empty tundish will be lif ted by
the crane and transferred to the tundish preparation area where facilities will be
provided for tundish preparation.
Rolling mill
Rolling mill of 300000 t/ yr capacity has been proposed in the steel complex. Blooms
shall be received in the bloom storage bay and stacked size-wise as well as grade- wise.
These shall be inspected for surface defects. Minor defects, particularly for stainless
steel, shall be rectified by grinding.
Depending on the product being rolled, blooms shall be lifted by the EOT crane and
placed on the charging gate of the reheating furnace. After this, complete operation of
the reheating rolling and cooling of bar is mechanized and automated through stand-
alone automation as well as process control from computers.
Well heated and soaked blooms are discharged from the front end of the reheating
Furnace by an extractor. The bloom then travels toward the reversing mill. On the way,
descaling takes place in a descaler by high pressure water jets. Blooms then enter the
reversing mill. Depending on the final product, a number of to and fro passes are
given at the reversing mill with the help of roller tables, manipulators and turning
device. Heavy rounds & RCS are finish rolled from the reversing mill itself and taken to
hot saw for cropping and dividing into cooling bed lengths.
Cooled bars are then lifted from the cooling bed cradle by the storage bay EOT crane
and taken for inspection or post rolling finishing operations.
Power Generation
Power generation is proposed through two techniques, viz., through WHRB technique
and through AFBC system. The two techniques are briefly discussed below:
WHRB (Waste heat recovery boiler) Technique
Sponge Iron is produced by heating Iron with Coal and other additives under
controlled conditions in Rotary Kiln. The proposed 6 x 100 TPD Kilns would generate
M/s Maruti Ispat & Energy Pvt. Ltd Pre-Feasibility Report
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approximately 240,000 Nm3/ hr of Flue Gases at 850 - 900°C. To recover the heat of
hot flue gases coming out of the Rotary Kilns, they are passed through Heat Recovery
Boiler (HRB). It consists of radiation chamber with water walls just like conventional
boiler with a drum to evaporate steam at 34-kg/ cm2 pressure. The steam is carried to
super heater system where the temperature is maintained at 430 °C. The boiler has an
economizer, which utilizes the residual heat of kiln gases to raise the temperature of
feed water from 100 to 200 °C. The output of the boilers, i.e., the high pressure steam,
will be used to generate electricity through Steam Turbo Generator Set. The flue gases
leave the convection zone and then pass through an ESP where dust is removed. The
clean gas from the ESP will be finally discharged to atmosphere through stack.
AFBC (Air Fluidized Bed combustion) Technique
In this system, char, blast furnace gases and low-grade coal (washer reject) will be
used as fuel for generation of steam. The boiler consists of a grate as fluidized air is
supplied to the bed, the bed material (particular type of sand) remains in fluidized
state. This bed material is heated through separate combustion chamber with diesel
burner. The hot air passes through first chamber raising the temperature to 450 °C
then coal is charged which burns raising the temperature further to 950 °C. In this
manner the temperature of four chambers are raised so is the rise in pressure. The
steam thus produced fed to turbine to produce electricity. Major technical parameters
of the captive power plant are as follows:
Power generation 36 MW
Fuel Char, Washery rejects and BF gases
No and type of boiler 2 No. AFBC boilers
Boiler capacity 2 x lOO TPH
Condensate recycles better than 95%
Ash handling Wet ash handling type
Flue gas cleaning Electrostatic precipitator
Particulates in flue gas 100 mg/ Nm3, Maximum
Stack height 69 meters
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3.6 Availability of Water Its Source, Energy/ Power Requirement and Source
3.6.1 Water Requirement
The details of water requirement for different purposes are presented below:
Water Requirement
Input Quantity (KLD) Output Quantity (KLD)
Makeup Water for
cooling
969 Cooling tower blow down 235
Losses 734
Boiler Feed Makeup 681 Blow down 158
Losses 523
Total 1650 1650
3.7 Quantity Of Wastes to be Generated (Liquid And Solid) And Scheme For Their
Management/ Disposal
3.7.1 Solid Waste Generation& its Disposal
Slag will be sold to construction industry and mill waste will be sold to cement
industry. The details of solid waste are given in below table:
Particular Quantity (TPD) Remark
Solid waste from Pelletization Plant 100
Filling of low laying area/road
construction
Char from Sponge Iron 150 Used in AFBC boiler
ESP & Bag filter 42 Sold to Cement Manufactures
Kiln Accretion and Mis. 4 Road Construction
Slag From MBF 481 Sold to Cement Manufactures
MBF Flue dust 48 Sold to Cement Manufactures
Slag from IF 160 Used for road construction
Solid waste from mill scales 40 Sold to Cement Manufactures
Fly ash 67 Sold to Cement Manufactures
Used Batteries 10 nos./year Sent to authorized recyclers
Waste oil 2000 l/year Sent to authorized recyclers
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3.7.2 Liquid Effluent
No liquid effluent will be generated at the plant site. The domestic wastewater
generated will be treated in STP and treated water will be reuse for green belt
development.
4.0 SITE ANALYSIS
4.1 Connectivity
4.1.1 Nearest Railway Station
Mantralyam Raod – 7.5 Km
4.1.2 Nearest Airport
Hyderabad airport is 180 km from the plant site.
4.2 Land form, Land use and Land Ownership
The Land use conversion already done.
4.3 Topography
The topography of the region is mostly plain dry industrial land and the climatic
conditions are semi-arid. The average annual rainfall is 700 mm, and the maximum
and minimum temperatures are 45 oC & 16
oC respectively.
There are no Ecological and Sensitive areas like Religious and Historic places,
Archeological Monuments, Scenic Areas, Hill Resorts, Biosphere reserves, National
Parks and Sanctuaries, Seismic Zones and Defense installations within the circular
area of 10 km radius from plant site.
5.0 PLANNING BRIEF
5.1 Planning Concept
The proposed project involves additional in Induction Furnace and rolling mill
production.
5.2 Population projection
The man power of plants includes manager, Engineer, skilled and unskilled Labours
and medical officers etc. As for the socio-economic is concerned from the plant
activity nearby villagers shall get in employment for about 900 persons. The proposed
plant activities also shall bring the positive change in the villages as the plant shall
provide direct employment to more than 450 people directly.
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5.3 Land use planning
The project is located in 60.7 ha land. There will not be change in land use as the land
already has converted in Industrial Area.
5.4 Assessment of Infrastructure Demand (Physical & Social)
On the basis of the preliminary site visit, the infrastructure demand in the villages
was assessed on the basis of need and priority. The assessment will be made in the
socio economic survey &will be submitted at the time of final presentation regarding
Environment Clearance.
5.5 Amenities/Facilities
Rest shed, first-aid centre, ambulance service, drinking water facilities, will be
provided.
6.0 PROPOSED INFRASTRUCTURE
6.1 Plant Area (Processing Area)
The main plant area comprises of Induction furnace area and rolling mill area, raw
material handling area, storage area and greenbelt area etc.
6.2 Residential Area (Non Processing Area)
As the local persons will be given employment, no residential area/ housing is
proposed within the mining lease area.
6.3 Green Belt
More than 1/3rd
(20 ha) of total land availability is reserved for plantation i.e.
greenery. Greenbelt development plan
Local DFO will be consulted in developing the green belt.
Greenbelt of 33% of the area will be developed in the plant premises as per CPCB
guidelines.
The tree species to be selected for the plantation are pollutant tolerant, fast growing,
and wind firm, deep rooted. A three tier plantation is proposed comprising of an
outer most belt of taller trees which will act as barrier, middle core acting as air
cleaner and the innermost core which may be termed as absorptive layer consisting
of trees which are known to be particularly tolerant to pollutants.
6.4 Water Management
About 1650 KLD will be required for steel project. This water will be supplied from
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ground water.
6.5 Sewerage System
The domestic wastewater generated will be sent to septic tanks followed by soak
pits.
6.6 Industrial Waste Management
No industrial waste will be generated at the plant site. The domestic wastewater
generated will Treated in STP.
6.7 Solid Waste management
Slag will be sold to construction industry and mill waste will be sold to cement
industry.
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN
There will be no displacement of houses. Hence rehabilitation and resettlement is not
envisaged.
8.0 PROJECT COST ESTIMATES
The total project will be around Rs. 700 Crores.
9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local
People Including Tribal Population, If Any, In the Area.
The proposed Expansion plant will provide employment to about 100 local people
and helping them earn livelihood. The infrastructure facilities also will be improved in
the surrounding area.
***********
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Annexure 1: Project Configuration
S.no Unit Plant
Configuration
Production
Capacity
Status of
Implementation
as per old EC
1 Palletization Plant (Pellets) 1 x 3000 TPD 9,00,000 TPA Not Started
2 Sintering Plant (Sinter) 1 x 2000 TPD 6,00,000 TPA Not Started
3 Sponge Iron Kilns (Sponge
Iron)
6 x 100 TPD 1,80,000 TPA 2 x 100 TPD – is
in Operation
Remaining 4 x
100 TPD to be
Implementation
4 Mini Blast Furnace
(Hot Metal/Pig Iron)
1 x 380 m3 2,40,000 TPA Not Started
5 Induction Furnace (Billets
from CCM)
2 x 40 TPH 2,40,000 TPA Not Started
6 Billets Casting Machine/
Continuous Casting Machine
1 x 1000 TPD 3,00,000 TPA Not Started
7 Rolling Mill 1 x 1000 TPD 3,00,000 TPA Not Started
8 Power
Generation
Through
WHRB
6 x 10 TPH 20 MW 8 MW WHRB –
Civil Work
Started
Through FBC 2 x 100 TPH 2 x 18 MW Not Started
9 Ladle Furnace 1 x 40 TPH --- Not Started
10 Oxygen Plant --- 97,92,000
SM3/Annum
Not Started