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OF
PROPOSED 1x15 MW CAPTIVE POWER PLANT,
5000 TPA FERRO TITANIUM, 3000 TPA FERRO MANGANESE,
12 TPD ALUMINIUM POWDER
AND
2.4 TPA SCANDIUM OXIDE RECOVERY PLANT
FOR
M/M/M/M/ssss SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD.SARAF AGENCIES PVT. LTD. At: Chatrapur, Dist- Ganjam, Odisha.
JULY 2016
PREPREPREPRE----FEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORTFEASIBILITY REPORT
Centre For Envotech and Management Consultancy Pvt. Ltd.
AN ISO: 9001: 2008 and BS OSHAS 18001: 2007 certified company,
Empanelled with OCCL, Govt. Of Odisha, OSPCB as Category “A” Consultant Organization,
Accredited b y NAB ET, Qual ity Counc i l o f Ind ia for EIA stud ies
As Category “A” Consultant Organization.
Regd. Off: N5/305, IRC Village, Bhubaneswar, Odisha Tele: 0674 - 2360344, E-mail: cemc_consultancy @yahoo.co.in, [email protected]
Website: www.cemc.in
CEMCCEMC
Contents
CHAPTER NO CHAPTER NAME PAGE NO
CHAPTER-1 EXECUTIVE SUMMARY 1-5
1.1 Introduction 1 1.2 Project Site 1 1.3 Plant Layout 1 1.4 Brief Project Description 1 1.5 Raw Materials 2 1.6 Water Requirement & Source 3 1.7 Solid Waste Generation & Management 3 1.8 Green Belt Development 4 1.9 Amenities/Facilities 4 1.10 Project Cost 5
CHAPTER-2 INTRODUCTION OF THE PROJECT/BACKGROUND
INFORMATION 6-9
2.1 Identification of the project & project proponent 6
2.2 Nature, size and magnitude of project 7
2.3 Need for the project 8
2.4 Project Objective and Its Importance to The Country/ Region
8
2.5 Demand supply gap 8
2.6 Employment generation (direct and indirect due to the project)
9
CHAPTER-3 PROJECT DESCRIPTION 10-23
3.1 Type of project including interlinked and interdependent projects
10
3.2 Location and Accessibility 10
3.3 Details of alternate sites and selection of the site 12
3.4 Size or magnitude of operation 12
3.5 Process Description 12
3.5.1 Plant Layout 12
3.5.2 Process Description of Ferro Titanium 14
3.5.3 Process Description of Ferro Manganese 14
3.5.4 Process Description of Scandium Oxide Recovery Plant 15
3.5.5 Process Description of Captive Power Plant (CPP) 16
3.5.6 Process Description of Aluminium Powder Plant 17
3.6 Raw material required along with estimated quantity, likely source, marketing area of final product/s, mode of transport of raw material and finished product
17
3.7 Resource optimization/recycling and reuse envisaged in the project
18
3.8 Availability of water its source, energy/power 18
requirement and source 3.9 Energy 19
3.10 Environment Management 20
CHAPTER-4 SITE ANALYSIS 24-26 4.1 Connectivity of the site 24
4.2 Land form, land use and land ownership 24
4.3 Topography 24
4.4 Existing Land use Pattern 24
4.5 Existing Infrastructure 25
4.6 Climate Data 26
CHAPTER-5 PLANNING BRIEF 27-28 5.1 Planning concept 27
5.2 Manpower Projection 27
5.3 Land use 27
5.4 Amenities/facilities 28
CHAPTER-6 PROPOSED INFRASTRUCTURE 29-30
6.1 Industrial area (processing area) 29
6.2 Residential area (Non-processing area) 29
6.3 Green belt 29
6.4 Social infrastructure 29
6.5 Connectivity 29
6.6 Drinking water management 30
6.7 Sewerage system 30 6.8 Industrial waste management 30 6.9 Solid waste management 30 6.10 Power requirement & its source 30
CHAPTER-7 REHABILITATION & RESETTLEMENT (R & R)
PLAN 31
CHAPTER- 8 PROJECT SCHEDULE & COST ESTIMATES 32-34
8.1 Project Implementation 32
8.2 Project cost 34
CHAPTER-9 ANALYSIS OF PROPOSAL
(FINAL RECOMMENDATIONS) 35
9.1 Financial and social and Socio benefits 35
9.2 Other Benefits 35
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 1
CCHHAAPPTTEERR--11
EEXXEECCUUTTIIVVEE SSUUMMMMAARRYY
1.1 INTRODUCTION
Saraf Agencies Private Limited (SAPL) is a holding company owning a group
of companies known as Saraf Group companies. The group is well diversified,
owning and operating large industrial plants. The group is establishing a Special
Economic Zone (SEZ) at Chatrapur in the district of Ganjam, Odisha and proposes
to set up the Titanium Complex to manufacture various Titanium products like
High Titanium Slag, Titanium Dioxide Pigments, Ferro-Titanium, Ferro manganese
etc.
To optimize the cost of production and attain operational ease, it is proposed to
set up a Captive Power Plant (CPP), Ferro-Titanium, Ferro Manganese, Scandium
Oxide Recovery Plant and Aluminium Powder Plant for the Titanium Complex.
The existing project is coming under category ‘A’ project and requires
Environmental Clearance from MoEF, Govt. of India as per EIA Notification 2006.
1.2 PROJECT SITE
The Proposed Plant is located in the village Mayapatna near Chatrapur of Ganjam
district of Odisha. The area is situated in the survey of India Topo Sheet No. 74
A/15 and between latitude 190 20’ 03” North and Longitude 840 57’ 32” East. The
site is well connected with NH-16 which is passing at a distance of 0.6 km from
the project site. Nearest Railway Station is at Chatrapur is at about 6.0 km from
the project site. Paradeep port is about 260 Km while the Vizag port is at a
distance of 250 Km from the project site. The nearest Airstrip is Rangelunda
(Bhanja Vihar) at a distance of about 5 Km from project site and the nearest
airport is located at Bhubaneswar, which is at about 150 Km from the project site
and Berhampur town is at a distance of 17 Km towards the West direction.
1.3 PLANT LAYOUT
The SEZ (Specially Economic Zone) will be developed on 260 Acres of land for
Titanium Complex. The layout plan for proposed project has been prepared in
such a way that space is properly and purposefully utilized, process flow is
maintained and adequate circulation space is provided for operation and
maintenance. The plant layout map, which shows the layout of Titanium Slag
Plant, Titanium Dioxide Pigment Plant, Captive Power Plant, Ferro Titanium Plant
& Ferro Manganese Plant Aluminum Powder plant, Administrative Building, waste
disposal area, raw material storage yard, rain water harvesting pond, RWTP and
green belt etc.
1.4 BRIEF PROJECT DESCRIPTION
M/s Saraf Agencies Private Limited has proposed 1x15 MW Nett (Gross 17 MW)
Coal Based Captive Power Plant, 5000 TPA Ferro-Titanium, 3000 TPA Ferro
Manganese, 2.4 TPA Scandium Oxide Recovery Plant & 12 TPD Aluminium Powder
Plant at Village - Kanamana, Chandrapada, Tikiriaberhampur, Arjyapalli,
Sriramachandrapur near Chatrapur, in Ganjam district of Odisha.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 2
1.5 RAW MATERIALS
Ferro Titanium:
Table No. C1-1: Raw Material Requirement for Ferro Titanium Plant
Sl.
No.
Item Consumption in Kg per MT
of Fe Ti
a) Ilmenite Concentrate 1500
b) Sodium Nitrate 45
c) Lime 120
d) Aluminium Powder 680
e) Mill Scale 150
f) Fluorspar 30
Ferro Manganese:
Table No. C1-2: Raw Material Requirement for Ferro Manganese Plant
Sl.
No.
Item Consumption in Kg per MT
of Fe Ti
a) Mn Ore 1250
b) Mn Ore Unroasted 250
c) Lime 130
d) Aluminium 490
e) M.S. Shots 130
f) Fluorspar 25
Scandium Oxide Recovery Plant:
Main Raw material for Scandium recovery project would be waste Titanium
Dioxide Hydrolysis acidic solution which will contain about 228 ppm of scandium
oxide. Waste acid generated from the proposed 30,000 TPY pigment plant would
be around 17548 cubic meter/year at 20% H2SO4. With 60% recovery during the
process about 2.4 TPY of Scandium Oxide of 99.99 % purity will be produced.
Aluminium Powder Plant:
Table No. C1-3: Raw Material Requirement for Aluminium Powder Plant
Sl. No. Item Sources
a) Aluminium Srap Market
b) Fuel Market
Captive Power Plant:
Imported coal from Indonesia is considered as fuel for the CPP. Coal from
Indonesia would be transported by sea route to the Paradeep Port at a distance of
260 km from the project area and then brought to the plant by rail/trucks. The
port at Gopalpur (crow fly distance of 2 km from the site) under construction may
be used after it starts its operation. Based upon the expected imported coal
characteristics the maximum daily coal requirement for the proposed CPP of 15
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 3
MW would be about 229 TPD @ MCR and annual fuel requirement is estimated at
0.71 lakh tons per annum at 85% plant load factor.
Alternately, coal from Talcher coal fields in Odisha may be considered. Coal would
be transported by road from the Talcher coal fields. Approximately, 338 TPD Coal
will be required from Talcher Coal Field in Odisha. Annual coal requirement is
estimated at 1.05 lakh Te per annum at 85% load factor.
1.6 WATER REQUIREMENT & SOURCE
Total consumptive water requirement for the proposed station size of 1x15 MW is
128 m3/hr when water cooled condenser is considered. Alternatively when air-
cooled condenser is considered it is 44 m3/hr respectively. Total water
requirement for Ferro Titanium & Ferro Manganese plant will be 10 m3/day. Water
requirement for Scandium Oxide Recovery Plant will be 100 m3/day. Water will be
sourced from Rushikulya River.
Estimated make up water requirement to replenish the process and treatment
losses for the facilities
Table No. C1-4: Total Plant Raw Water Requirement
Items Total water requirement
Captive Power Plant 128 m3/hr
Ferro Titanium & Ferro Manganese 10 m3/day
Scandium Oxide Recovery Plant 100 m3/day
Aluminum Powder plant 4 m3/day
1.7 SOLID WASTE GENERATION AND MANAGEMENT
Table No. C1-5: Solid Waste Generation and Management
Sl.
No Process unit Solid waste
Quantity
MT/Month Mode of disposal
1. Captive Power
Plant
Bottom Ash 362.1 Bottom ash would be
disposed in slurry form to
ash disposal area.
Fly Ash 3258.9 Fly ash would be disposed in
slurry form to ash disposal
area.
2. Ferro Titanium Slag 3000
Which will be mitigated with
disposal of Ash from Captive
Power Plant
3. Scandium Oxide
Recovery Plant
Minor quantity solid waste
generated will be mitigated
with waste of Titanium
Dioxide Plant
Land Use:
The SEZ will be developed over 260 Acres of land approximately out of which
around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land will
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 4
be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18
Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium Oxide
Plant. All the land involved in the project site was private & Govt. land. The entire
land is now in the name of the plant and converted to industrial use.
Table No. C1-6: Details of Land use break up for Proposed Plant
Sl. No Purpose Area requirement in acres
1. Captive Power Plant 26.0
2. Ferro Titanium & Ferro
manganese and Aluminum
powder plant.
6.18
3. Scandium Oxide Plant 1.0
Total Area 33.18
1.8 GREEN BELT DEVELOPMENT
Appropriate type of trees like Mango, Mahua, Sal suitable for this region are
planted in compliance of conditions of environmental clearance. With a view to
attenuate air pollutants, to resist noise propagation from power generation units
and uptake of treated effluent to some extent, the green belt all around the
periphery of project sites and in vacant areas (34.3 % of the total acquired land)
is being developed. Tree plantation has been undertaken in a large scale on land
vacated after cessation of construction activities. Open spaces, where tree
plantation is not possible are planted with flowering shrubs and grass which act
as soil binders and also helpful in preventing erosion of topsoil.
1.9 AMENITIES/FACILITIES.
1.9.1 In-Plant Facilities
The following facilities are provided in this plant:
a. Administrative Building, Service Building
b. Construction offices and stores
c. Time and security offices
d. First Aid and fire fighting station
e. Canteen and welfare centre
f. Toilets and change rooms
g. Car parks and cycle/ scooter stands
h. Training centre
Office space has been provided as per good practice and canteens, toilets and
restrooms according to norms laid down in relevant factories act. The above
facilities are adequately furnished and equipped.
1.9.2 Employment Generation
• Establishment of small and medium scale engineering ancillaries, with
cascading employment opportunities;
• Increased revenue to the state by way of taxes and duties;
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 5
• Improved green cover;
• Better communication and transport facilities;
The proposed project has enhanced the prospects of employment. Recruitment
for the unskilled workers for the plant is from the nearby villages. The basic
amenities viz. roads, transportation, electricity, drinking water, proper sanitation,
educational institutions, medical facilities, entertainment, etc. are developed as
far as possible.
1.9.3 Medical Facilities/ Health care camps
• Medicines are provided at the first aid centre present within the plant
premises, which cater to the needs of adjoining population.
• Periodic health camps like: Eye camp and Health camps for treatment of
other diseases will be conducted by the company doctors.
1.10 PROJECT COST:
Table No. C1-7: Project Cost Break Up
Sl.
No. Head
Estimated Cost in
Crores
1. Captive Power Plant 99.35
2. Ferro Titanium and Ferro manganese Plant
& Aluminium powder plant.
13.20
3. Scandium Oxide Recovery Plant 77.75
Net Total 190.3 Crores
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 6
CCHHAAPPTTEERR--22
IINNTTRROODDUUCCTTIIOONN OOFF PPRROOJJEECCTT //BBAACCKKGGRROOUUNNDD IINNFFOORRMMAATTIIOONN
2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT
M/s Saraf Agencies Private Limited (SAPL) is a holding company owning a
group of companies known as Saraf Group companies. The group is well
diversified, owning and operating large industrial plants. The group is establishing
a Special Economic Zone (SEZ) at Chatrapur in the district of Ganjam, Odisha and
proposes to set up the Titanium Complex to manufacture various Titanium
products like High Titanium Slag, Titanium Dioxide Pigments, Ferro-Titanium,
Titanium Sponge Metal at Village - Kanamana, Chandrapada, Tikiriaberhampur,
Arjyapalli, Sriramachandrapur near Chatrapur, in Ganjam district of Odisha. The
area comes in survey of India Topo Sheet No. 74 A/15 and between latitude 190
20’ 03” North and Longitude 840 57’ 32” East.
Table No. C2-1: Contact Address
Address for
correspondence
M/s Saraf Agencies Pvt. Ltd.
Saraf House, 4/1 Red Cross Place
Kolkata (West Bengal)
Pin - 700 001
Works (Plant Site
Address)
M/s Saraf Agencies Pvt. Ltd.
At- Chatrapur,
District- Ganjam, Odisha
2.1.1 COMPANY BACKGROUND
Saraf Agencies Private Limited is a holding company owning a group of
companies known as Saraf Group Companies. The objective of the company is to
promote new business ventures, taking over sick companies and turning them
into a viable and profitable venture.
Saraf Group is a well-diversified Group, owning and operating large Industrial
plants, as well as Real Estate development, directly employing more than 2000
workmen engaged in their various plants and construction sites.
The group is setting a Titanium Industrial complex in the state of Orissa, under
Saraf Titanium Industry, (A Unit of Saraf Agencies Pvt. Ltd.) India to manufacture
various Titanium products like, High Titanium slag, Titanium dioxide pigments,
Ferro-Titanium, Titanium sponge metal etc.
2.1.2 ABOUT THE PROJECT
M/s Saraf Agencies Pvt. Ltd. is establishing a Special Economic Zone (SEZ) at
Chatrapur, in Ganjam district of Odisha and proposes to set up the Titanium
Complex to manufacture various Titanium products. The area comes in survey of
India Topo Sheet No. 74 A/15 and between Latitude 190 20’ 03” North and
Longitude 840 57’ 32” East. The present project consists of three products namely
Ferro Titanium, Ferro Manganese & Scandium Oxide. It will have also a Captive
Power Plant of capacity 1x15 MW (Gross 17 MW).
The proposed production capacity of the company as envisaged is as under:
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 7
Table No. C2-2: Production capacity
Sl.
No.
Plant Facility Plant configuration Capacity
1. Captive Power Plant 1 x 15 MW 17 MW
2. Ferro Titanium 5000 TPA
3. Ferro Manganese 3000 TPA
4. Scandium Oxide Recovery Plant 2.4 TPA
5. Aluminium Powder 12 TPD
Land:
The plant has acquired total 260 Acres Land. All the land involved in the project
site was private & Govt. land. The entire land is now in the name of the plant and
converted to industrial use.
Water:
Total make up water requirement for the project is 7700 m3/day, out of which
128 m3/hr for Captive Power Plant, 10 m3/day for Ferro Titanium & Ferro
Manganese Plant, 100m3/day for Scandium Oxide Recovery Plant and Balance
water will be used for Existing Plant (Titanium Slag Plant & Titanium Dioxide
Pigment Plant). The water will be sourced from Rushikulya River. The company
has already submitted the application to Irrigation Department, Govt. of Odisha
to draw required water. At present this permission is under process.
Power:
Power will be generated at the CPP at 11 kV. It shall be stepped up to 33 kV for
supply to the Titanium Project. Start-up power and construction power shall be
received at 132 kV and shall be stepped down to 33 kV to feed 33 kV switchyard.
Power from the grid will be received from 132 kV Chatrapur sub-station of OPTCL
for which a LILO connection will be taken from the 132 kV transmission line
running parallel to the eastern boundary. Power requirement for Ferro Titanium
plant will be 250kwh/T. Power shall be supplied from a feeder available in the
complex. Power will be distributed in the Plant. Power requirement for the
Scandium Recovery Plant shall be nominal. Connected load will be around 400
KVA including Quality Control Laboratory. Power shall be supplied from the
complex. Power will be distributed in the Plant.
In order to operate and maintain the plant facility, including the technical and
general administrative needs, 174 personnel are engaged for proposed plant.
Priority is given to local people during employment of the un-skilled and semi
skilled workers.
The plant site is well connected through road and rail ways.
2.2 NATURE, SIZE AND MAGNITUDE OF PROJECT:
Saraf Agencies Private Limited is establish a High Titanium Slag Plant of 36000
TPA, Titanium Dioxide Pigment Plant of 30000 TPA & Pig Iron of 20000 TPA an
addition 1x15 MW Nett (Gross 17 MW) coal based Captive Power Plant, 5000 TPA
Ferro-Titanium Plant, 2.4 TPA Scandium Oxide Recovery Plant & 12 TPD
Aluminium Powder Plant in its existing plant premises at Chatrapur in Ganjam
district of Odisha.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 8
The Environment Clearance for the existing High Titanium Slag, Titanium Dioxide
Pigment & Pig Iron Plant was granted by MoEF vide File No. J-11011/658/2007-IA
II (I) dated 16.03.2016.
2.3 NEED FOR THE PROJECT:
• Security of power supply through self-generation
• Reduced costs through high fuel efficiency, particularly when in CHP
configuration
• Improved environmental performance resulting from fuel efficiency.
2.4 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/
REGION:
Ferro-Titanium & Ferro Manganese:
SAPL is proposing to expand its activity in adding values to Ilumenite, a mineral
of Titanium available in Odisha, so far not being explored due to lack of
entrepreneurship and availability of proper technology.
SAPL is contemplating of a plant having capacity of 5000 TPA Ferro Titanium.
Scandium Oxide Recovery Plant:
Our present proposal is to be set up a plant to recover Scandium Oxide from
Waste acid generated in the Titanium Dioxide Plant and finally treat it to a purity
level of 99.99 %. The Scandium Recovery Plant will have to have a modern
Laboratory having testing and analytical facilities for assessment of quality
recovered Scandium and also to conduct future R & D activities related to
Scandium.
Scandium oxide and scandium alloys are used in varieties of uses including
aerospace, sports equipment, lamps for photography etc.
Aluminium Powder Plant:
Aluminium Powder is one of the principal Raw Materials for Aluminium Thermit
Process. About 720kg of Aluminium Powder will be required per tones of Fe-Ti.
Although there are few organized sectors for manufacturing of Aluminium
Powder. There are many unorganized sectors/ small scale Industries producing
Aluminium Powder.
2.5 Demand and Supply Gap (Market Scenario)
Ferro-Titanium:
Ferro Titanium is used for the following purposes
• As clearing agent
• In deoxidizing, desulphurization & denitrification as Fe-Ti is highly reactive
with S, C, O2 & N2 forming insoluble compound and sequestering them in slag.
• Grain refiner as Fe-Ti promotes finer grain structure with steel matrix.
The plant aims at producing 30% Ti grades of Ferro-Titanium from Ilumenite.
From records, it is gathered that Indian production was in the range of 1500-
2100 Tonnes/year during 2007-2011. Import varied from 450 T to 1650
Tonnes/year during 2007-2011.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 9
There is potential for growth of Ferro Titanium from new production facility.
Scandium Oxide Recovery Plant:
Scandium is a rare metal and is expensive due to its scarcity. Due to its chemical
nature it is active and its physical characteristic (MP 1541°C BP 2536°C density
2.985) and other features make it important material for various uses.
Scandium has also gained importance for use of scandium stabilized zirconia as a
high efficiency electrolyte in solid oxide fuel cells. In aerospace industry scandium
is used as Al-Sc Alloy and also in sports equipment as bicycle frames finishing
rods golf equipment basket ball bats etc.
As the commercial uses for scandium continue to expand there is need for
improved for selectively recover scandium.
Few year back global trade of scandium (in the form of oxide) was of the order of
10 tonnes/year. Demand of scandium is on the rise for different new cutting edge
technologies.
Recovery of Scandium to the time of 2.4 Tonnes/year from hydrolysis waste acid
of 30000 TPY Titanium Dioxide plant would meet some gap in increasing global
demand of scandium for use in existing & new cutting edge technologies.
2.7 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)
Total Manpower engaged during operation of the Ferro Titanium & Ferro
Manganese plant is 75, for Scandium Oxide Plant is 54, for Captive Power Plant is
30 and for Aluminium Powder Plant is 20.
Table No. C2-3: Employment status
Sl. No Category No. of Employees
01. Ferro Titanium & Ferro Manganese 80
02. Scandium Oxide 54
03. Captive Power Plant 30
04. Aluminium Powder Plant 20
Total 179
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 10
CCHHAAPPTTEERR--33
PPRROOJJEECCTT DDEESSCCRRIIPPTTIIOONN
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT
PROJECTS
M/s Saraf Agencies Pvt. Ltd. is establish a Special Economic Zone (SEZ) at
Chatrapur, in Ganjam district of Odisha and proposes to set up the Titanium
Complex to manufacture various Titanium products like high Titanium Slag,
Titanium Dioxide Pigments, Pig Iron, Ferro-Titanium, Ferro Manganese etc. The
company is already granted Environment Clearance for Titanium Slag Plant, Pig
Iron Plant & Titanium Dioxide Pigment Plant now company proposed for another
unit i.e. Captive Power Plant, Ferro Titanium, Ferro Manganese, Scandium Dioxide
Plant & Aluminium Powder Plant. The area comes in survey of India Topo Sheet No.
74 A/15 and between Latitude 190 20’ 03” North and Longitude 840 57’ 32” East.
3.2 LOCATION AND ACCESSIBILITY
The Titanium complex is located in the village Phuljhar of Keonjhar district of
Odisha. The area is situated in the survey of India Topo Sheet No. 74 A/15 and
between Latitude 190 20’ 03” North and Longitude 840 57’ 32” East. The site is well
connected with NH-16 which is passing at a distance of 0.6 km from the project site.
Nearest Railway Station is at Chatrapur is at about 5.0 km from the project site.
Location details of the Project Site:
Village : Kanamana, Chandrapada, Tikiriaberhampur,
Arjyapalli, Sriramachandrapur
Tehsil : Chatrapur
District : Ganjam
State : Odisha
Latitude : 190 20’ 03” North
Longitude : 840 57’ 32” East
Topo sheet No. : 74 A/15
Elevation of site : Average Elevation 27.2 m AMSL
a. Road Connectivity: The Plant site is well connected with NH-16 which is passing
at a distance of 0.6 km from the project site.
b. Rail Connectivity: Nearest Railway Station is at Chatrapur, about 4.0 km from
the proposed project site.
c. Airport: Nearest Air port Biju Pattnaik International Airport is at Bhubaneswar
which is about 150 km from the project site.
d. Port: Nearest port is at Gopalpur about 12 km from project site.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 11
Fig.No.C3-1: Vicinity map of the study area
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 12
3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF
SELECTING THE PROPOSED SITE / SITE SUITABILITY:
This is a proposed expansion project within the existing plant premises of the
Titanium Slag Plant & Titanium Dioxide Pigment Plant. The project site conforms
to the environmental setting guidelines as per MoEF and has enough existing
infrastructure facilities to be selected for the expansion project. The site has
advantages of availability of raw material and other infrastructural facilities like
skilled labour, power, transportation, and water required for such type of
industries. Hence, no alternative site has been considered.
3.4 SIZE OR MAGNITUDE OF OPERATION
M/s Saraf Agencies Pvt. Ltd. has expansion of Titanium Project i.e. Captive Power
Plant, Ferro Titanium, Ferro Manganese & Scandium Oxide Recovery Plant. The
size of the project is following.
Table No. C3-1: Size of the Plant
Sl. No. Unit/Plant Capacity/Size
1 Captive Power Plant 1x15 MW
2 Ferro Titanium 5000 TPA
3 Ferro Manganese 3000 TPA
4 Scandium Oxide Recovery Plant 2.4 TPA
5 Aluminium Powder Plant 12 TPD
3.5 PROCESS DESCRIPTION
3.5.1 Plant Layout
The layout has been developed keeping in view the need for unidirectional and
streamlined movement of materials. A streamlined road network has been
proposed to provide easy road access to different plant units.
The major parameters considered to develop the layout are as given below:
i) Adequate area for locating Captive Power Plant, Ferro Titanium Plant, Ferro
manganese Plant & Scandium Oxide Plant.
ii) Adequate area for storage and handling of different raw materials.
iii) Adequate area for various auxiliaries and ancillary facilities.
iv) Approach road, Power Sub-station and Water supply etc.
v) Dump area for storage of waste materials.
vi) Adequate road and parking space ensuring safe and smooth movement of
man and materials within the plant premises.
vii) Raw water Reservoir and Rain water harvesting
viii) Area for Green belt.
ix) Administrative building
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 14
3.5.2 Process Description of Ferro Titanium:
Ferro Titanium is produced by Alumino-Thermic Process. The process involves
reduction of Ilmenite concentration in the presence of Iron Oxide/Scrap/Mill Scale
& Flux additive. The process is well suitable for small furnace for meeting of Low
Carbon Grade.
This process compared to Induction Melting Furnace process method of
production is cheaper. Hence this process is preferred for Low volume production.
Thus the composition is Titanium is lower at 30% & also it content 4 to 6%
aluminum metal. The reactions of the process are
TiO2 + /sAl = Ti + 2/3Al2O3
Fe2O3 + 2Al = 2Fe + Al2O3 (1) FeO + 2/sAl = Fe + 1/3Al2O3
These reactions result in a molten bath of FeTi with a slag layer floating on top.
Flow Diagram:
Raw Material:
Source Potential of various major raw materials is given below:
Raw Materials Source
Ilmenite IREL
M.S. Shots Market
Aluminium Powder Market
Fluorspar Market
Sodium Nitrate Market
Lime Market
3.5.3 Process Description of Ferro Manganese
The production of Low Carbon Ferro Manganese is Alumino Thermic method is
used i.e. Reduction of manganese ore by Aluminum. For this process the ore have
more than 46% Mn. The Mn/Fe ration is 9 or at least more than 6. Phosphorous &
Sulphur is as low as possible. Al2O3 should be lower but not more than 4%. For
this process if the ore is used as its is, i.e. MnO2, the reaction is violent because
the heat available is much more than the heat required. Also ore is reduced to
MnO the material becomes more inert. Therefore, it is essential that the ore is
reduced to Mn3O4 or Mn2O3. Lime is added to decrease the formation of
Crucible
Ilmenite
Cooling & Slag
Separation
LC Alloy
Separation
Packing &
Dispatch
Aluminum
Powder
Lime Fluorspar
Sodium
Nitrate
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 15
Aluminates as this loss of metal oxide. The addition of Fluorspar (CaF2) helps in
lowering the viscosity.
Lime viscosity should be around 1.2 to reduced SiO2, roasting of ore at 950°C to
convert ore to Mn3O4 will give better yield.
Flow Diagram:
Raw Material
No.
Item Consumption in Kg per
MT of Fe Ti
a) Mn Ore 1250
b) Mn Ore Unroasted 250
c) Lime 130
d) Aluminium 490
e) M.S. Shots 130
f) Fluorspar 25
Manganese ore will be sourced from Manganese Ore (I) Ltd. or other mines.
3.5.4 Process Description of Scandium Oxide Recovery Plant
During manufacturing of Titanium Dioxide Pigment, Sulphuric Acid is added to
Ilmenite/Titanium Dioxide for hydrolysis & during the process weak acidic waste
solution is generated which contains around 22.85 mg/litre of Scandium Oxide &
around to 4 tonnes considering the production 30000 TPA of Titanium Dioxide
Pigment. This is based on 80 PPM scandium in Ilmenite (or grade). Considering a
recovery of 60% about 2.4 TPA of Scandium Oxide @ 99.99 % purity can be
recovered.
The waste acid contains TiO2 (Titanium Oxysulphate, Metatitanic Acid, Ferrous
Sulphate etc.) from which Scandium Oxide is separated/Solvent Extraction.
The solvent used for extraction is Di 2 ethyl hexyl phosphoric acid and Tributyl
phosphate. Kerosene is added as catalyst or modifier to organic solvent.
In a solvent extraction column (Mixer Settler Type) the waste fed from the
bottom & solvent is fed from top. The extract phase contains scandium will be
treated in a stripping column and the extract will be recycle back to solvent &
refinating phase will be treated with oxalic acid. This will precipitate containing
scandium oxalate which will remove in a plate & frame filter press. The cake will
contain 1-5% of scandium oxide.
Crucible
MnOre
Cooling & Slag
Separation
LC Alloy
Separation
Packing &
Dispatch
Aluminum
Scrap
Lime Iron Shots
Fluorspar
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 16
The solution will be again treated & solution again treated in solvent extraction
column to enrich scandium content in the loaded organic.
The aqueous phase will be treated with Sodium Hydroxide and Scandium
Hydroxide precipitate. This will be again treated with hydrochloric acid & solvent
extracted and treating with Sodium Hydroxide containing 99.99 % Scandium
Oxide (Sc2O3) and the filter cake will be roasting for final product.
Flow Diagram:
3.5.5 Process Description of Captive Power Plant (CPP)
15 MW steam generator and turbine generator would deploy Rankine Cycle for
generating steam & power for proposed CPP. Steam Generator with Fluidized Bed
Combustion (FBC) technology has been proposed. Atmospheric Fluidized Bed
Combustion (AFBC) boiler capacity of 65 TPH will be use.
CPP may be operated both on island mode or interconnected with grid. However,
to optimize capital cost and energy charge it is proposed to operate the station by
floating on the state grid. The capacity of the boiler will be of 65 TPH.
The steam turbines would be standard multi-stage, 3000 rpm, tandem
compound, regenerative, condensing, multi-cylinder unit with three uncontrolled
extractions for regenerative feed water heating. The unit will be equipped with all
auxiliaries as per good engineering practice.
The condenser will be single-flow box-type surface condenser. It will be located
below the turbine and form an integral part. Each condenser unit would be
transverse mounted and would condense exhaust steam by circulation of cooling
WASTE ACIDIC
HYDROLYSIS SOLUTION SLOVENT EXTRACTION
BACK TO WASTE ACID TANK RAFFINATE
(AQUOUS)
STRIPING
EXTRACT
STRIPPING CHEMICAL
MAKE UP SLOVENT
SLOVENT
AQOUS SOLUTION PRECIPITATING CHEMICAL FILTRATION WASTE
CAKE
DISSOLUTION WITH HCL SLOVENT EXTRACTION
RAFFINATE (WASTE)
ORGANIC
SCRUBBING
STRIPPING
MAKE UP
SLOVENT
AQOUS SOLUTION OXALIC ACID
FILTRATION
SCANDIUM OXALATE DRYING & ROSTING HIGHLY PURITY SCANDIUM OXIDE
HCL
Zr. TI CONTANING
SOLUTION (REJECT)
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 17
water (inlet temperature 33 ºC max.) in a recirculating cooling water system
using wet type cooling tower. Clarified water would be the cooling medium in the
condenser. Stainless steel heat exchanger tubes are envisaged.
The proposed plant will be equipped with all auxiliaries plant systems like Plant
Water System, Coal Handling System and Ash Handling System.
338 TPD coal as raw material will be sourced from Talcher area which will be 1.05
lakh tons per annum at 85% load factor.
3.5.6 Process Description of Aluminium Powder Plant
The process is simple. Aluminium scrap is melted in an oil fired furnace equipped
with burners and allied items and the temperature is mentained between 720⁰ -
760⁰C. Then molten aluminium is atomized into small particles by air jet.
Atomizer system consists of atomuzer tube fitted with nozzle, headers, pipe,
fittings and collecting/cooling system. Aluminium powder will conform to IS-438.
Raw Material:
Sl. No. Item Sources
a) Aluminium Srap Market
b) Fuel Market
3.6 Raw Material Required Along With Estimated Quantity, Likely
Source, Marketing Area Of Final Product/s, Mode of Transport of
Raw Material And Finished Product.
3.6.1 Source of Major Raw Material with mode of transport
Raw Materials Source Mode of transport
CPP
Coal Indonesia/Talcher By Sea/Road
Ferro Titanium
Ilmenite IREL
M.S. Shots Market By Road
Aluminium Powder Market By Road
Fluorspar Market By Road
Sodium Nitrate Market By Road
Lime Market By Road
Ferro Manganese
Mn Ore Roasted Manganese Ore (I)
Ltd.
By Road
Mn Ore Unroasted Manganese Ore (I)
Ltd.
By Road
Lime Market By Road
Aluminium Market By Road
M.S. Shots Market By Road
Fluorspar Market By Road
Scandium Oxide Recovery Plant
Carbon powder Market By Road
Solvent (TBP or DEHPA) Market By Road
Kerosene Market By Road
DL-2-Octanol Market By Road
Ethanol Market By Road
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 18
Sulphuric Acid (98%) Market By Road
Hydrogen Peroxide Market By Road
Caustic Soda Market By Road
Oxalic Acid (99%) Market By Road
Organophosphours (P350 or
equivalent
Market By Road
Calcium Carbonate / Lime Market By Road
33% Hydrochloric Acid Market By Road
Aluminium Powder Plant
Aluminium Scrap Market By Road
Fuel Market By Road
Ilmenite is the titanium bearing mineral. It is the raw material required for
production of Titanium products. Ilmenite is recovered from Beach Sand as one of
the Constituent of Heavy Mineral Concentrate. Indian Rare Earths Ltd (IREL) is
holding mining lease rights over 32 km stretch of Coastal Belt near Gopalpur Port,
for mining of Beach Sand Minerals. IREL have set up a large mining and mineral
separation plant known as OSCOM plant at Chhatrapur for recovery of Heavy
Mineral Concentrate, including Ilmenite from Beach Sands. Currently OSCOM
Plant’s annual production of Ilmenite is about 2,20,000 tonnes ilmenite from IREL
will be used for this Project. Indian Rare Earths Ltd. (IREL) has also other mining
units at Chavara, Kerala (1,54,000 TPA ilmenite). Manvala Ruridhi, Tamilnadu
(90,000 TPA Ilmenite).
Besides, Kerala Minerals & Metals Limited is also engaged in ilmenite production
at Chavara (ilmenite 40,000 TPA).
M/s. Trimex Sands, Chennai has separation plant at Srikakulam, AP and having
2,00,000 TPA ilmenite production. Trimex Sands is contemplating expansion by
another 2,00,000 TPA ilmenite production.
Other players are VV Minerals, Beach Minerals Co., Indian Ocean Garnet Sands in
Tamilnadu producing around 4,00,000 TPA ilmenite totally.
One month’s inventory for ilmenite shall be provided. Ilmenite will be received
through trucks.
3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED
IN THE PROJECT
Waste generation in the proposed CPP is in the form of fly ash and bottom ash
which would be disposed in slurry form to ash disposal area. Slag form Ferro
titanium plant will be mitigated with disposal of Ash from Captive Power Plant.
Hence, there will be resource optimization in the proposed project.
3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER
REQUIREMENT AND SOURCE
3.8.1 Source of water
The consumptive water required for the station will be drawn from Rushikulya
River which is 10 km away from project site. Rushikulya River is 165 km long has
a catchment area of 8900 sqr. km. and perennial in nature.
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CEMC Pvt. Ltd. 19
3.8.2 Summary of Plant Water Requirement
Total 128 m3/hr water is require for the proposed 15 MW CPP when water cooled
condenser is considered. Alternatively when air-cooled condenser is considered it
is 44 m3/hr respectively. Total water requirement for Ferro Titanium & Ferro
Manganese plant will be 10 m3/day. Water requirement for Scandium Oxide
Recovery Plant will be 100 m3/day. Water will be sourced from Rushikulya River.
Estimated make up water requirement to replenish the process and treatment
losses for the facilities
Total Plant Raw Water Requirement
Items Total water requirement
Captive Power Plant 128 m3/hr
Ferro Titanium & Ferro Manganese 10 m3/day
Scandium Oxide Recovery Plant 100 m3/day
Aluminium Powder plant 4m3/hr
3.8.3 External water system
The consumptive water required for the station will be drawn from the common
intake pump house proposed to be constructed on the Rushikulya River for
Titanium Project with necessary augmentation.
3.8.4 Plant water system
As per the available data on river water quality, a cycle of concentration of 5 is
considered in the estimation. As an alternative, Air Cooled Condenser (ACC) may
be used for the water scare region. ACC may be of direct type or indirect type.
For water cooled system, evaporative cooling is deployed but in case of air cooled
system steam (for direct type) or DM water (for indirect type), primary coolant,
would be cooled by convection and/ or radiation by passing cooled air by the
fans. ACC is pitted with higher condenser pressure and thus loss of generation.
Secondly, ACC is more cost intensive and the revenue cost is marginally higher.
On overall basis, depending on ambient parameters cost of energy 4 to 5%
higher. With loss of generation, marginally higher energy cost air cooled
condenser is deployed in a ‘No Project Situation’ due to inadequate availability of
water. For ACC as option, consumptive water requirement will be around 44 m3/
hr. With the water quality available, water treatment plant would comprise
clariflocculation, sand bed filtration and demineralization plant.
3.9 ENERGY:
Power will be generated at the CPP at 11 kV. It shall be stepped up to 33 kV for
supply to the Titanium Project. Start-up power and construction power shall be
received at 132 kV and shall be stepped down to 33 kV to feed 33 kV switchyard.
Power from the grid will be received from 132 kV Chatrapur sub-station of OPTCL
for which a LILO connection will be taken from the 132 kV transmission line
running parallel to the eastern boundary.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 20
3.10 Environment Management
a. Air pollution control measures
Construction phase:
Construction phase will be for a short period and hence the impacts will also be
for a short and temporary period. During construction activities, mainly emission
of dust and gases from movement of vehicles and construction activity is
expected. However, following measures will be taken to reduce / contain such
emissions:
• Water will be sprinkled on loose top soil to prevent re-suspension of dust into
ambient air due to movement of vehicles etc.
• Separate civil construction material storage yard will be created within the site
and it will be enclosed.
• Possibility of raising green belt along with construction activity will also be
explored.
• Transport vehicles and construction equipments / machineries will be properly
maintained to reduce air emissions.
• Vehicles and equipments will be periodically checked for pollutant emissions
against stipulated norms.
• Idle running of vehicles will be minimized during material loading / unloading
operations.
• All construction workers will be provided appropriate Pollution Protection
Equipments like dust mask, ear plug, helmet, safety belt etc. and made to
wear them during working hours.
Operation phase:
Ferro Titanium & Ferro Manganese:
Proper care will be taken by installing Bag filters followed by Stack to control
source emission. Hence there will not be any major deposition of pollutants into
air, land and water.
To control fugitive dust emissions due to vehicular movement water sprinkling
and spraying system will be installed. Internal roads will be asphalted.
Captive Power Plant:
An efficient electro-static precipitator (separation efficiency of about 99.89%)
along with a properly designed boiler would keep the stack emission of particulate
matters within acceptable limits. With average quality of coal and 6 to 7 field ESP,
SPM emission shall be restricted to 1 kg per hour considering imported coal and 5
kg per hour considering indigenous coal. The final emission level will meet
statutory limit i.e. 50 mg/m3. Following measures are proposed to mitigate
negative impact of operation phase of the project on the surrounding air
environment:
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 21
• All transfer points will have bag filter attached to them to control and capture
dust emission.
• Height of all the stacks will be as per statutory requirement. All the stacks will
have stack monitoring facility (SMF) consisting of sampling port-hole, platform
and access ladder.
• Adequate spares of critical components of dust collection systems will be kept
to ensure trouble – free operations and continuous compliance to emission
norms.
• A comprehensive plan for fugitive emission control based on CPCB guidelines
is prepared and its details are given following section.
• Possibility of use of vehicles using cleaner fuel will be explored and if found
feasible will be implemented on a large scale.
• Transport vehicles will be properly maintained to reduce air emissions.
• Vehicles will be periodically checked for pollutant emissions against stipulated
norms.
• Idle running of vehicles will be minimized during material loading / unloading
operations.
b. Water pollution control measures
Construction stage:
The drainage system of construction site will be connected to the existing
drainage system at an early stage. Salient features of water quality management
comprise the following:
• All the debris resulting from the site shall be disposed off separately.
• A sediment trap shall be provided to prevent to discharge of excessive
suspended solids.
• An oil trap shall be provided in the drainage line to prevent contamination by
accidental oil spillage.
• To prevent contamination from accidental spillage of oil, the storage areas will
be bonded and will be inspected and cleaned at regular intervals.
• Proper storm water management system shall be integrated in design phase
and civil works shall be carried out accordingly at project site. Efforts will be
made to reduce the suspended solids content of storm water run offs by
routing the storm water drains through settling pits.
• Three nos. of toilets will be provided for construction workers and waste water
generated from toilets will be treated in septic tank.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 22
Operation stage:
Ferro Titanium & Ferro Manganese & Aluminum Powder plant:
Total water requirement for Ferro Titanium & Ferro Manganese plant will be 10
m3/day. For Aluminum Powder plant, water requirement will be 4m3/hr.
Scandium Oxide Plant:
Water requirement for Scandium Oxide Recovery Plant will be 100 m3/day. In
Scandium Oxide Recovery Plant after solvent extraction acidic waste hydrolysis
solution will be sent back to the TiO2 pigment plant will be mitigated along with
the effluents in pigment plant.
Captive Power Plant:
It is envisaged that the liquid wastes from CPP collected in the guard pond shall
be treated and adequate retention time permitted. The treated waste water from
the guard pond would be recycled to less priority areas for reuse. Attempt would
be made to attain zero discharge of waste water from the plant during normal
operation.
c. Solid waste Management
Ferro Titanium & Ferro Manganese:
Process unit Solid waste Quantity
MT/Month Mode of disposal
Ferro Titanium Slag 3000
Which will be mitigated with
disposal of Ash from Captive
Power Plant
Scandium
Oxide Recovery
Plant
Minor quantity solid waste
generated will be mitigated with
waste of Titanium Dioxide Plant
Scandium Oxide Plant:
Process unit Mode of disposal
Scandium Oxide Recovery
Plant
Minor quantity solid waste generated
will be mitigated with waste of
Titanium Dioxide Plant
Captive Power Plant:
Process unit Solid waste Quantity
MT/Month Mode of disposal
Captive Power
Plant Bottom Ash 362.1
Bottom ash would be disposed
in slurry form to ash disposal
area.
Fly Ash 3258.9 Fly ash would be disposed in
slurry form to ash disposal area.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 23
d. Green Belt Development
Appropriate type of trees like Mango, Mahua, Sal suitable for this region are
planted in compliance of conditions of environmental clearance. With a view to
attenuate air pollutants, to resist noise propagation from power generation units
and uptake of treated effluent to some extent, the green belt all around the
periphery of project sites and in vacant areas (34.3 % of the total acquired land)
is being developed. Tree plantation has been undertaken in a large scale on land
vacated after cessation of construction activities. Open spaces, where tree
plantation is not possible are planted with flowering shrubs and grass which act
as soil binders and also helpful in preventing erosion of topsoil.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 24
CCHHAAPPTTEERR--44
SSIITTEE AANNAALLYYSSIISS
4.1 CONNECTIVITY
Road
The site is well connected with NH-16 which is passing at a distance of 0.6 km
from the project site.
Rail Linkage
Nearest Railway Station is at Chatrapur is at about 6.0 km from the project site.
Port
Paradeep port is about 260 Km while the Vizag port is at a distance of 250 Km
from the project site. The nearest Airstrip is Rangelunda (Bhanja Vihar) at a
distance of about 5 Km from project site and the nearest airport is located at
Bhubaneswar, which is at about 150 Km from the project site and Berhampur
town is at a distance of 17 Km towards the West direction.
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP
The SEZ will be developed over 260 Acres of land approximately out of which
around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land will
be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18
Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium Oxide
Plant. All the land involved in the project site was private & Govt. land. The entire
land is now in the name of the plant and converted to industrial use.
Table No. C4-1: Details of Land use break up for Proposed Plant
Sl. No Purpose Area requirement in acres
1. Captive Power Plant 26.0
2. Ferro Titanium & Ferro
manganese & Aluminum
powder.
6.18
3. Scandium Oxide Plant 1.0
Total Area 33.18
4.3 TOPOGRAPHY
The topography of the proposed land is generally flat and well suited for
development of industrial projects.
4.4 Existing land use pattern, shortest distances from the periphery of
the project to periphery of the forests, national park, wildlife
sanctuary, eco sensitive areas, water bodies (distance from the
HFL of the river), CRZ.
The SEZ will be developed over 260 Acres of land approximately out of which
around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land
will be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 25
Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium
Oxide Plant. This area does not form part of any National Park, Wild Life
Sanctuary and Natural/Biosphere reserve.
Table No. C4-2: Environmental Setting
Sl.
No.
Areas Name/
Identity
Aerial distance
(within 10km.)
Proposed project
location boundary
1 Areas which are
important or sensitive for
ecological reasons –
Wetlands, water courses
or other water bodies,
coastal zone, biospheres,
mountains, forests
The Rushikulya rookery is
the second largest site of
Olive Ridley Turtle in the
Orissa coast. It lies along
the extreme south of the
Orissa coast, around 15 km
north of the Gopalpur port,
i.e more than 17 km from
project site
More than 17 km
3 Areas used by protected,
important or sensitive
species of flora or fauna
for breeding, nesting,
foraging, resting, over
wintering, migration
No
4 Inland, coastal, marine or
underground waters No
4.5 EXISTING INFRASTRUCTURE
Land
Total land requirement for the proposed unit is about 33.18 acres.
Utilities
Power: Power will be generated at the CPP at 11 kV. It shall be stepped up to 33
kV for supply to the Titanium Project. Start-up power and construction power
shall be received at 132 kV and shall be stepped down to 33 kV to feed 33 kV
switchyard. Power from the grid will be received from 132 kV Chatrapur sub-
station of OPTCL for which a LILO connection will be taken from the 132 kV
transmission line running parallel to the eastern boundary. Power requirement for
Ferro Titanium plant will be 250kwh/T. Power shall be supplied from a feeder
available in the complex. Power will be distributed in the Plant. Power
requirement for the Scandium Recovery Plant shall be nominal. Connected load
will be around 400 KVA including Quality Control Laboratory. Power shall be
supplied from the complex. Power will be distributed in the Plant.
Water: Total make up water requirement for the project is 7700 m3/day, out of
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 26
which 128 m3/hr for Captive Power Plant, 10 m3/day for Ferro Titanium & Ferro
Manganese Plant, 100m3/day for Scandium Oxide Recovery Plant,4m3/day for
Aluminum powder plant and Balance water will be used for Existing Plant
(Titanium Slag Plant & Titanium Dioxide Pigment Plant). The water will be
sourced from Rushikulya River. The company has already submitted the
application to Irrigation Department, Govt. of Odisha to draw required water. At
present this permission is under process.
Transport: The site is well connected with NH-16 which is passing at a distance
of 0.6 km and all modes of transports are available.
4.6 CLIMATE DATA
The cold season from December to February is followed by hot season from March
to May. The period from June to September marks the South West Monsoon and
70% of annual precipitation is received during this period. The normal rain fall of
this district is 1444 mms. May is the hottest month. With the arrival of the
monsoon by about the second week of june the day temperature decreases
slightly while the night temperature continue as it was in the summer. Towards
the end of September, after the withdrawal of south west monsoon, temperature
decreases progressively. December is the coldest month. The relative humidity
are high throughout the year specially in coastal areas. Winds are fairly strong
particularly in coastal regions in summer and mansoon months.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 27
CCHHAAPPTTEERR--55
PPLLAANNNNIINNGG BBRRIIEEFF
5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES AND
TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/
DEVELOPMENT AUTHORITY CLASSIFICATION
The Proposed Plant is located in the village Mayapatna near Chatrapur of Ganjam
district of Odisha. Plant provide many facilities is given below,
a. Administrative Building, Service Building
b. Construction offices and stores
c. Time and security offices
d. First Aid and fire fighting station
e. Canteen and welfare centre
f. Toilets and change rooms
g. Car parks and cycle/ scooter stands
h. Training centre
Office space has been provided as per good practice and canteens, toilets and
restrooms according to norms laid down in relevant factories act. The above
facilities are adequately furnished and equipped.
5.2 MANPOWER PROJECTION
• Establishment of small and medium scale engineering ancillaries, with
cascading employment opportunities;
• Increased revenue to the state by way of taxes and duties;
• Improved green cover;
• Better communication and transport facilities;
The proposed project has enhanced the prospects of employment. Recruitment
for the unskilled workers for the plant is from the nearby villages. The basic
amenities viz. roads, transportation, electricity, drinking water, proper sanitation,
educational institutions, medical facilities, entertainment, etc. are developed as
far as possible
5.3 LAND USE
The SEZ will be developed over 260 Acres of land approximately out of which
around 227 Acres land is being allotted to Existing Plant and rest 33 Acres land
will be allotted to Proposed Plant i.e. 26 Acres of land will be allotted to CPP, 6.18
Acres for Ferro Titanium & Ferro Manganese Plant and 1 Acres for Scandium
Oxide Plant. All the land involved in the project site was private & Govt. land
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 28
5.3.1 GREEN BELT DEVELOPMENT
With a view to attenuate air pollutants, to resist noise propagation from power
generation units and uptake of treated effluent to some extent, the green belt all
around the periphery of project sites and in vacant areas (34.3 % of the total
acquired land) is being developed. Tree plantation has been undertaken in a large
scale on land vacated after cessation of construction activities.
5.4 AMENITIES/FACILITIES
Plant will source water from Rushikulya River. Canteen, transportation system,
health center facilities etc. will be provided by plant for their employees.
Medicines are provided at the first aid centre present within the plant premises,
which cater to the needs of adjoining population. Periodic health camps like: Eye
camp and Health camps for treatment of other diseases will be conducted by the
company doctors.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 29
CCHHAAPPTTEERR--66
PPRROOPPOOSSEEDD IINNFFRRAASSTTRRUUCCTTUURREE
6.1 INDUSTRIAL AREA (PROCESSING AREA)
The setting up of CPP, Ferro titanium and Ferro manganese plant, Scandium Oxide
Recovery Plant, storage area, internal road, green belt area etc required 33.18
Acres land. Company uses nearest road and railway siding for goods
transportation and equipped with all other required facilities.
6.2 RESIDENTIAL AREA (NON PROCESSING AREA)
The area around the site is developed with reasonably good communication
facilities. Some area of plant is envisaged for staff canteen, toilet and bath room,
vehicle stand etc.
6.3 GREEN BELT DEVELOPMENT
With a view to attenuate air pollutants, to resist noise propagation from power
generation units and uptake of treated effluent to some extent, the green belt all
around the periphery of project sites and in vacant areas (34.3 % of the total
acquired land) is being developed.
6.4 SOCIAL INFRASTRUCTURE
SAPL will commence a lot of infrastructure developmental works in the periphery
area. Some glimpses of the developmental activities are presented below:
� Improving and building road network in the adjoining villages.
� Strengthening School buildings with playgrounds.
� Social awareness programme will further improve 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 project will set up training centre or tie up with Industrial
Technical Institutes to educate local youth as skilled labour.
6.5 CONNECTIVITY
Road
The site is well connected with NH-16 which is passing at a distance of 0.6 km
from the project site.
Rail Linkage
Nearest Railway Station is at Chatrapur is at about 6.0 km from the project site.
Port
Paradeep port is about 260 Km while the Vizag port is at a distance of 250 Km
from the project site. The nearest Airstrip is Rangelunda (Bhanja Vihar) at a
distance of about 5 Km from project site and the nearest airport is located at
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 30
Bhubaneswar, which is at about 150 Km from the project site and Berhampur
town is at a distance of 17 Km towards the West direction.
6.6 DRINKING WATER MANAGEMENT
Drinking water facilities will be provided for employees. A water treatment plant
is envisaged for providing potable water to the employees. After ensuring the
drinking water standards prescribed by CPCB water will be supplied for drinking
purpose.
6.7 SEWERAGE SYSTEM
A garland drain around the plant is envisaged to collect surface run-off during
rainy season.
6.8 INDUSTRIAL WASTE MANAGEMENT
The liquid wastes from CPP collected in the guard pond shall be treated and
adequate retention time permitted. The treated waste water from the guard pond
would be recycled to less priority areas for reuse. Attempt would be made to
attain zero discharge of waste water from the plant during normal operation.
Total water requirement for Ferro Titanium & Ferro Manganese plant will be 10
m3/day. Water requirement for Scandium Oxide Recovery Plant will be 100
m3/day. In Scandium Oxide Recovery Plant after solvent extraction acidic waste
hydrolysis solution will be sent back to the TiO2 pigment plant will be mitigated
along with the effluents in pigment plant.
6.9 SOLID WASTE MANAGEMENT
362.1 MT/Month bottom ash and 3258.9 MT/Month fly ash will be generate for
proposed CPP. 3000 MT/month slag will generate form Ferro Titanium plant.
Bottom ash and fly ash would be disposed in slurry form to ash disposal area.
Slag will be mitigated with disposal of Ash from Captive Power Plant. Minor
quantity of solid waste from Scandium Oxide Recovery Plant will be mitigated
with waste of Titanium Dioxide Plant.
6.10 POWER REQUIREMENT & SUPPLY/SOURCE
Power will be generated at the CPP at 11 kV. It shall be stepped up to 33 kV for
supply to the Titanium Project. Power requirement for Ferro Titanium plant will be
250kwh/T.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 31
CCHHAAPPTTEERR--77
RREEHHAABBIILLIITTAATTIIOONN && RREESSEETTTTLLEEMMEENNTT ((RR && RR)) PPLLAANN
The project is going to come up on 33.18 acres area. There is no existence of
displaced habitants in the identified area as additional plant install within the
existing land. Land is also devoid of any vegetation. Local people will be engaged
for construction and operation activities.
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 32
CCHHAAPPTTEERR--88
PPRROOJJEECCTT SSCCHHEEDDUULLEE && CCOOSSTT EESSTTIIMMAATTEESS
8.1 PROJECT IMPLEMENTATION
Planning Of Activities
Careful planning of all the activities is one of the pre-requisite for timely
completion of the project. Following activities will be given special attention.
Pre Project Activities
• Management Approvals.
• Selection of location
• Land acquisitions
• Statutory Clearances
• Financial Approvals and Tie ups.
• Selection of Consultants
• Conceptual Design
• Preparation of main machinery tender
• Evaluation of tenders
Project Activities (Implementation Stage)
• Firm up basic design
• Main Machinery Order placement
• Detailed engineering of the project
• Statutory approvals of Building Plans.
• Preparation of Tender, Evaluation of tenders received and Order placement for
balance machinery
• Completion of procurement activities on time
• Release of civil drawing for civil construction
• Civil construction
• Supply of mechanical & electrical equipment
• Inspection of major machinery at supplier’s works
• Erection of all plant & machinery
• Commissioning of the plant
Statutory Clearances
The proposed project will require various statutory approvals and clearances from
various authorities of the Government. Clearances required for the proposed
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 33
project shall be identified in due course and necessary action will be taken to obtain
the same.
Project Schedule
The total project implementation schedule for CPP is 24 months and 9 months for
Ferro titanium and Ferro manganese project and 15 months for Scandium Oxide
Recovery Plant from start of basic project engineering. The external agencies such
as consultants, machinery suppliers, contractors of civil construction and
equipment will be selected carefully well in advance. An effective project team has
been formulated with an experienced Project Manager as its leader.
The project schedule has been contemplated as below:
Table C8-1: Project Schedule
Sl. No. Task Time Taken
CPP
1. Pre-project Activities & coming into
force of contract (-) 6 to 0 months
2. Technology supply & completion of
Basic Engineering 0 to 2 months
3. Detailed Engineering 2 to 3months
4. Tendering, Procurement Action &
supply of Plant & Equipment &
Electricals
3 to 5 months
5. Civil & Structural Work 4 to 18 months
6. Erection of Equipment 18 to 20 months
7. Trial run & Commissioning 20 to 21 months
Ferro Titanium and Ferro manganese Plant & Aluminum powder
Plant.
1 Process know-how & Basic
Engineering
0-1 month
2 Approval of Basic Engineering by
SARA
1-2 months
3 Detailed Engineering 2-3 months
4 Tendering, Procurement action,
Supply of Plant & Equipment
3-4 months
5 Civil & Structural Work 4-6 months
6 Erection of Equipment 6-8 months
7 Trial Run & Commissioning 8-9 months
Scandium Oxide Recovery Plant
1 Process know-how & Basic
Engineering
0-2 month
2 Approval of Basic Engineering by
SARA
2-3 months
3 Detailed Engineering 2-8 months
4 Tendering, Procurement action, 3-10 months
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 34
Supply of Plant & Equipment
5 Civil & Structural Work 4-10 months
6 Erection of Equipment 9-13 months
7 Trial Run & Commissioning 13-15 months
8.2 PROJECT COST
An indicative estimated capital cost of the proposed Plant is Rs. 190.3 Croers
including the pre-operative expenses, contingency and interest during
construction.
A broad break-up of the indicative estimate of the Project capital cost is provided
below:
Table No. C8-2: Project Cost
Sl.
No.
Head Estimated Cost in
Crores
1. Captive Power Plant 99.35
2. Ferro Titanium, Ferro manganese &
Aluminium Powder Plant
13.20
3. Scandium Oxide Recovery Plant 77.75
Net Total 190.3 Crores
Pre-feasibility Report of M/s Saraf Agencies Pvt. Ltd.
CEMC Pvt. Ltd. 35
CCHHAAPPTTEERR--99
AANNAALLYYSSIISS OOFF PPRROOPPOOSSAALL ((FFIINNAALL EECCOOMMMMEENNDDAATTIIOONNSS))
9.1 Financial and social benefits
9.1.1 Improvements in the Physical Infrastructure
SAPL has envisaged a lot of infrastructure developmental works in the periphery
area.
� Improving and building road network in the adjoining villages.
� Strengthening School buildings with playgrounds.
� Providing the Drinking Water Facilities.
9.1.2 Improvements in the Social Infrastructure
� Social awareness programme will further improve 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. Sponsor the education to Poor Students of the Proposed
Area.
� Provide & conduct the Free Eye & Health Check up Programmes.
9.1.3 Employment
It is estimated that the additional requirement of manpower for the project will be
179.
Table No. C9-1: Category-wise Manpower
Sl. No. Category Man Power
1 Captive power plant 30
2 Ferro titanium & Ferro Manganese 80
3 Scandium Oxide Recovery Plant 54
4 Aluminium Powder Plant 20
Total 179
9.2 OTHER BENEFITS
• Development of the local area in terms of an enlarged market.
• Besides above, indirect benefits have also occurred to the region by way of
increase in industrial production.