PROPOSED MODIFICATION OF PRODUCT MIXenvironmentclearance.nic.in/writereaddata/Online/TOR/09_Dec_2017... · PRE-FEASIBILITY REPORT Centre For Envotech and Management Consultancy Pvt

OF

PROPOSED MODIFICATION OF PRODUCT MIX

To Produce Ferro-Chrome in addition to Existing Product

Mix of Ferro-Manganese, Silico-Manganese

IN

Barjora Plasto Steel Park Village: Namabandh-Sitarampur, P.O.: Ghutgoria, Block: Barjora

Dist.: Bankura, West Bengal

FOR

M/s Sonic Thermal Private Limited 4th Floor, 37, Shakespeare Sarani

Kolkata, West Bengal; PIN - 700017

AUGUST 2017

PRE-FEASIBILITY 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 by NABET, Quality Council of India 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

mailto:@yahoo.co.in,

mailto:[email protected]

http://www.cemc.in

CONTENTS

Chapters Subject Page No. 1 Executive Summary 1-4

2 Introduction to the Project and Background Information 5-10

2.1 Identification of Project & Project Proponents 5

2.1.1 Identification of Project 5

2.1.2 Identification of Project Proponent 5

2.2 Project Highlights 7

2.3 Need Of The Project & Its Importance To The Country & The Region 7

2.3.1 Need of Ferroalloy Project 7

2.2.2 Estimated Steel Demand and required Crude Steel Capacity, 2011-12 to 2025-26

8

2.2.3 Production of Ferro Alloys During 2006-07 to 2010-11 (Quantity in Metric Tonnes)

9

2.2.4 Domestic Consumption 9

2.2.5 Installed Capacity and Export/Import Scenario 9

2.3 Employment Generation 10

3 Project Description 11-46

3.1 Type of Project 11

3.2 Location (Map Showing General Location, Specific Location And Project Boundary & Project Site Layout) With Coordinates

11

3.3 Details of alternate sites considered & the basis of selecting the proposed site, particularly, the environmental consideration gone into should be highlighted

17

3.4 Size or magnitude of operation 17

3.5 Project description with process details (a schematic diagram /flow chart showing the project layout, components of the project etc. should be given)

17

3.5.1 Project Description 17

3.5.2 Ferro Alloys Plant-Process Description 18

3.5.2.1 Submerged Electric Arc Furnace 18

3.5.2.2 Technology and Process Description-General 20

3.5.2.3 Physico Chemical Considerations for Different Products 28

3.6 Raw Materials Required along with estimated quantity, source, marketing area of final product/s, Mode of Transportation of raw materials and Finished Product/s

41

3.6.1 Raw Materials Required, Likely source, Mode of Transportation 41

3.6.2 Quantification of Product after Expansion, Marketing Area & Mode of Transportation

42

3.6.3 Resource optimization/recycling and reuse envisaged in the project, if any, should be briefly outlined

42

3.6.4 Availability of water & its source; energy /power requirement & source 43

3.6.4.1 Water requirement and its source 43

3.6.4.2 Power Requirement and its source 44

3.6.5 Quantity of waste to be generated (liquid & solid) and scheme for their management/ disposal

44

3.6.5.1 Quantity of liquid waste to be generated and scheme for their management/ disposal

44

3.6.5.2 Quantity of solid waste to be generated and management/ Disposal Scheme

45

3.5.6.3 Source of Air Pollution and Control Measures 45

4 Site Analysis 47-57

4.1 Connectivity 47

4.2 Land form land use and land ownership 47

4.3 Topography (Along With Map) 48

4.4 Existing Land use pattern (agriculture, non-agriculture, forest, water bodies, (including area under CRZ), shortest distance from the periphery of the project to periphery of the forests National Parks, wild life sanctuary, eco sensitive areas, water bodies(distance from HFL of the river), CRZ. In case of Notified Industrial Area a copy of the notification should be enclosed

51

4.5 Existing Infrastructure 54

4.6 Soil Classification 54

4.7 Climate data from secondary sources 56

4.8 Social Infrastructure Available 57

4.8.1 Educational Facilities 57

4.8.2 Health Facilities 57

5 Planning Brief 58-59

5.1 Planning concept (type of industries, facilities, transportation, etc) town & country planning /development authority classification

58

6 Proposed Infrastructure 58-61

6.1 Industrial Area (processing area) 60

6.2 Residential Area (non processing area) 60

6.3 Green Belt 60

6.4 Social Infrastructure 60

6.5 Connectivity (Traffic & Transportation Road /Rail /Water Ways, Etc) 61

6.6 Drinking Water Management (Source & Supply Of Water) 61

6.7 Sewerage System 61

6.8 Industrial Waste Management 61

6.9 Solid Waste Management 61

6.10 Power Requirement & Supply/Source 61

7 Rehabilitation and Resettlement (R & R) Plan 62

7.1 Policy to be adopted (central/state) in respect of the project affected person including home oustees, land oustees and landless laborers (a brief outline to be given)

62

8 Project Schedule & Cost Estimates 63

8.1 Likely date of start of construction and likely date of completion (time schedule for the project to be given)

63

8.2 Estimated project cost along with analysis in terms of economic viability of the project

63

9 Analysis of Proposal Final Recommendations 64

9.1 Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area

64

LISTS OF TABLES

Chapters Name of the Table Page No.

C1 - 1 Existing and Proposed Expansion Facilities 1 C1 - 2 Existing Production Range & Capacity per Month 2 C1 – 3 Proposed Production Range & Capacity per Month 2 C1 – 4 Existing and Proposed Product Mix 3 C1 – 5 Supporting Facilities 3 C2- 1 Company Background 6 C2 - 2 Project Highlights 7 C2 - 3 Estimated Steel Demand & Required Crude Steel Capacity (million tonnes) 8 C2 – 4 Production of Ferro Alloys during 2006-07 To 2010-11 9 C2 - 5 Domestic Consumption of Ferroalloys (in Kilo Tonnes) 9 C2 - 6 Ferroalloy Capacity in India (2012 estimates) 10 C2 - 7 Ferro Alloy Export ( ‘000 MT) 10 C2 - 8 Growth of Imports of Ferroalloys in India ( ‘000 MT) 10 C3 - 1 Project Configuration 17 C3 - 2 Technical Characteristics of Furnace 26 C3 - 3 Raw materials for Fe-Mn and their chemical composition 30 C3 - 4 General Charge Composition 31 C3 - 5 Composition of different grades of Silico Manganese 32 C3 – 6 Raw materials for Si -Mn and their chemical composition 33 C3 – 7 General Charge Composition 33 C3 – 8 Probable reactions and equilibrium temperatures during carbothermic

reduction of chromite in Fe-Cr manufacture 35

C3 – 9 Raw materials for Fe-Cr and their chemical composition 37 C3 – 10 General Charge Composition in Ton per ton of finished product 38 C3 – 11 Raw Materials Required, Likely source, Mode of Transportation 41 C3 – 12 Quantification of Product after Expansion, Marketing Area & Mode of

Transportation 42

C3 – 13 Water Requirement and its source 43 C3 – 14 Power Requirement and its source 44 C3 – 15 Waste Water Generation/Recycle and Reuse 44 C3 – 16 Quantity of solid waste to be generated and management/ Disposal Scheme 45 C3 – 17 Source of Air Pollution and Control Measures 45 C4 – 1 Location of Water bodies, Reserve Forests & Hill from Project Site 48 C4 – 2 Land Use Classification 54 C4 – 3 Monthly Weather Averages Summary (Years on Record 102) 56 C4 – 4 Educational Facilities in Bankura District 57 C4 – 5 Health Facilities 57 C5 – 1 Existing Area of M/s Sonic Thermal Pvt. Ltd. 58 C6 – 1 Existing & Proposed Plantation 60 C6 – 2 CSR Activities Taken Up During Last Four Years 60

LISTS OF FIGURES

Figures Name of the Figure Page No. C3 - 1 Index Map 12

C3 - 2 Location Map 13

C3 - 3 Vicinity Map 14

C3 - 4 Google Earth Map 15

C3 - 5 Plot Plan 16

C3 – 6 Electric submerged are furnace, schematic view 19

C3 – 7 General Process Flow Diagram of Ferroalloy Production 21

C3 – 8 Process Flow Diagram of Briquette Plant 23

C3 - 9 Schematic Flow Diagram of Bag Filter System 29

C3 - 10 Process Flow Diagram of Ferro-Manganese 31

C3 - 11 Process Flow Diagram of Silico-Manganese 34

C3 - 12 Process Flow Diagram of Ferro-chrome Alloy 38

C3 - 13 Process Flow Diagram of Metal Recovery Plant 40

C3 - 14 Water Balance Diagram 43

C3 - 15 Schematic Diagram of EIA & EMP Process of the Project 46

C4 - 1 Contour Map, Bankura District WB 50

C4 - 2 Physiographic Map of Bankura District 51

C4 – 3 Map showing National Parks, Wild Life Sanctuary 52

C4 – 4 Land Use /Land Cover Map 53

Prefeasibility Report of

M/s Sonic Thermal Pvt. Ltd.

CEMC Pvt. Ltd. Page 1

CHAPTER - 1

EXECUTIVE SUMMARY

M/s Sonic Thermal Pvt. Ltd. is having a ferroalloy plant in the Plasto Steel Park; situated at

village Namabandh-Sitarampur, PO: Ghutgoria, Dist.: Bankura in West Bengal. For

establishment of the plant necessary Consent to Establish was obtained by the company

from West Bengal Pollution Control Board (WBPCB) vide reference No. NO 23801, dt.

10.05.2005. Consent to Operate for the plant was first availed vide reference No. CO

16764, dt 17.03.11. The consent to operate granted for manufacturing of ferro-manganese

and Silico-manganese in 4 X 7.5 MVA furnace and 1 X 5 MVA furnaces was valid up to

31.12.2018. The Consent to Establish being obtained by the company prior to EIA

Notification 14th September, 2006, no application was made by the company for obtaining

Environmental Clearance (EC) from MoEF & CC, Govt. of India. The company obtained

Consent to Establish order for installation of a briquetting plant of for briquetting

Manganese ore fines and a zigging plant for metal recovery from slag vide Reference Letter

No. 110453, dt. 12.02.2013

At present the company is having the manufacturing facilities as per the configuration in

the Table No. C1-1. Due to fluctuating trends in the demand for Fe-Mn and Si-Mn, the

manufacture these products have become uneconomical at the scale and level of

production. The promoters, therefore, propose to use the manufacturing facilities inter alia

for manufacture of Fe-Cr. The market scenario for various ferroalloy products are given in

section 2.2 of this report.

Table No. C1-1: Existing and Proposed Expansion Facilities

Sl.

No.

Facilities Total Existing

capacities

Proposed Capacity Ultimate

capacity

1 Ferro Alloys (Ferro

Chrome /Ferro

Manganese) /Silico

Manganese in Submerge

Electric Arc Furnace

4 X 7.5 MVA and

1 X 5 MVA

The facility is used

for manufacture of

Fe-Mn and Si-Mn

The existing

furnaces will be used

for making Fe-Cr

4 X 7.5

MVA 1 X 5

MVA

2

Manganese Ore

Briquetting Plant

20 TPH The existing

briquette plant will

be utilized for

briquetting of

chrome ore fines

20 TPH

3 Zigging Plant 100 TPH The existing Zigging

Plant will be used

100 TPH




Table No. C1-2: Existing Production Range & Capacity per Month

Name of

Existing

Products

SEAF Monthly Capacity/ Identification Total Existing

Production Capacity

(Monthly)

SEAF-1

(7.5 MVA)

SEAF-2

(7.5 MVA)

SEAF-3

(7.5 MVA)

SEAF-4

(7.5 MVA)

SEAF-5

(5 MVA)

Ferro

Manganese 1540 MT 1540 MT 1540 MT 1540MT 990 MT 7150 MT

Silico

Manganese 1100 MT 1100 MT 1100 MT 1100 MT 660 MT 5060 MT

Table No C1-3: Proposed Production Range / Capacity per Month

Name of

Products

SEAF Monthly Capacity/ Identification Total

Production

Capacity

(Monthly)

SEAF-1

(7.5 MVA)

SEAF-2

(7.5 MVA)

SEAF-3

(7.5 MVA)

SEAF-4

(7.5 MVA)

SEAF-5

(5 MVA)

Ferro


Silico


Ferro

Chrome 1600 MT 7465 MT 1600 MT 1600 MT 1065 MT 7465 MT

The furnaces will be producing either of the above products.

The existing plant is continuing operation since 2012. After obtaining consent to establish

in respect of the Manganese ore briquetting plant and zigging the same were installed and

have been commissioned. The manufacturing facility is located in the Barjora Plasto Steel

Park which is an Industrial Estate developed by WBIDC. Total land acquired for this project

by M/s Sonic Thermal Pvt. Ltd. is 15 Acres. The site is well accessible by rail and road.

i) Nearest Railway Station is Durgapur at a distance of 14km North East of project site.

ii) Nearest Township is Durgapur at a distance of 14km from the project site.

iii) The district head quarter Bankura is at a distance of 30km from project site

iv) Nearest National Highway is NH-19 (Old Numbering NH – 2 i.e. Grand Trunk Road,

connecting Kolkata to Delhi) is at a distance of 18km from project site; SH-9

connecting Durgapur to Bankura is at a distance of 2.5km from the project site.

v) Nearest Airport is at Andal; 15km North West of project site. Netaji Subhash Chandra

Bose International Air Port at Dumdum is 150km East of the project site.

vi) Nearest Sea Port is at Haldia at a distance of 274km in South East direction.

vii) The project site is also having good connectivity with other sea ports like Kolkata,

Paradeep and Dhamara.

The site is having advantages of proximity to 2 Coalfields i.e. Ranigunj Coal field of ECL

and Dhanbad coalfields of BCCL. It is also very near to Durgapur a prominent industrial

hub of India. Chrome Ore can be procured in rake loads from Sukinda, dist: Jajpur, Odisha

and unloaded in nearby railway siding of Eastern Railways at Durgapur. DVC HT

transmission line (132 KV) passes through the plant premises, which is an added advantage.




The cost of the existing project is about Rs 80.00Crores. It has the potential to engage

about 15 persons in the permanent set up and 100 contractual persons. No further

construction shall be necessary as the same installation would be used for making Fe-Cr.

The major raw material required for the proposed Ferro alloy plant are Manganese Ore,

Non-coking Coal, Coking Coal, Limestone /Dolomite, Quartz, Chromites ore etc. Most of the

minerals including chromites, limestone/dolomite etc will be sourced from neighboring

state Odisha whereas coal both coking will be sourced from neighboring coal fields of ECL

and BCCL.

Technology which have been adopted for various sections are up-to-date technology

aiming at lower energy consumption, less water consumption and zero effluent discharge,

recycle and reuse of solid wastes, etc.

The existing Ferro Alloys plant includes 4 X 7.5 MVA SEAFs, 1 X 5 SEAF, a briquetting unit

and a zigging unit. The plant presently produces Ferro-Manganese, Silico-Manganese and

Fe-Mn slag. The approved production capacity of the products as per the WBPCB is as

follows. M/s Sonic Thermal Pvt. Ltd. proposes to manufacture Fe-Cr in the existing

furnaces. The proposed production of Fe-Cr is mentioned below:

4 X 7.5 MVA furnaces: 6,400 MT/month or 76,800 MT/year

1 X 5 MVA furnace : 1,065 MT/month or 12,780 MT/year

Total Production of proposed Fe-Cr = 76,800 MT/year + 12,780 MT/year = 89,580 MT/year

With inclusion of Fe-Cr in the product Mix the final proposal for EC shall be as follows:

Table No. C1-4: Existing and Proposed Product Mix

Sl.

No.

Description of

Products

Existing Capacity of

4 X 7.5 MVA

furnace in Tons

Existing Capacity of

1 X 5 MVA furnace

in Tons

Total Capacity in

Metric Tons/

Annum (MTPA)

1. Ferro Manganese

(Fe-Mn) *

73,920 11,880 85,800

2. Silico Manganese

(Si-Mn) *

52,800 7,920 60,720

3. Manganese Slag

(by-product)

39,600 7,920 47520

4. Ferro Chrome

(Fe-Cr) *

-- -- 89,580

* Ferrochrome is the proposed product to be manufactured in the existing furnaces

Table No. C1-5: Supporting Facilities

Product/ Process throughput Briquetting Plant Zigging Plant

Mn Ore Briquette 15,000 TPA --

Cr Ore briquette 15000 TPA --

Zigging throughput -- 100 T/day




The slag generated in Ferro-manganese plant will be used for manufacture of silico-

manganese. Silico-Manganese slag may be used for manufacture of Slag Cement or as road

base material. The slag generated in Ferrochrome plants after TCLP test will be utilized as

road base material. The fresh water requirement will be optimized by taking recycling and

cascading measures. The dust from Air Pollution Control devices of Ferroalloy Plant will be

used in briquette making.

Point source emissions from various manufacturing facilities as well as fugitive emissions are

/will be maintained within statutory limits by installation of bag filters and other pollution

control equipments. Secondary fugitive emission during tapping will be controlled by

provision of suction hood and ID Fan arrangement and the fumes will be passed through

existing GCP system. Fugitive dust are /will be controlled by providing water sprinklers as

well as by providing suction hoods at all transfer points followed by suitable ducts and pulse

jet bag filters. The fugitive emission from tap holes will be arrested by suction hood, suitable

ducting and passed through bag filters before being vented to atmosphere through stack

The existing infrastructure facilities will be utilized for successful manufacturing of the

proposed product. The manufacture of the proposed product will improve the viability of the

existing Ferroalloy plant as well as will contribute to better performance of group companies

by way of supplying needed input material.

Water requirement for the project will be about 506 KL/d which will be sourced from supply

means of Barjora Plasto Park Industrial Area. Presently, however, the water requirement is

met by direct purchase of water through tankers. Adequate recycling and cascading

measures will be taken to reduce fresh water consumption. Cooling /bleeding water will be

treated and used for dust suppression.

Green belt development is in progress. Suitable plant species will be planted all along the

internal roads, plant boundary, raw material storage & handling, dust prone areas. It is

planned to plant saplings considering the parameters as type, height, leaf area, crown area,

growing nature, water requirement etc. Green belt will be progressively developed on land.

The various aspects of the Pre-Feasibility Report as per MoEF Guidelines vide O.M. J- 11013

/41/2006-IA.II (I) dt. 30-12-2010 is given in the subsequent sections.




CHAPTER - 2

INTRODUCTION TO THE PROJECT & BACK GROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

2.1.1 Identification of Project

M/s Sonic Thermal Pvt. Ltd., village- Namabandh-Sitarampur, PO- Ghutgoria, PS- Bajoria,

Dist.- Bankura, West Bengal is presently operating a Ferroalloy plant having configuration

as detailed in Table No.C1-1. The plant is being operated with due permission from West

Bengal Pollution Control Board. As mentioned in the consent to establish was obtained by

the promoter from the WBPCB as early as 10.05.2005.The consent being granted by the

WBSPC prior to EIA Notification in September 2006, no EC was obtained from MoEF. The

company now proposes to modify the product mix of the existing Ferroalloy plant. There

will not be any capacity enhancement. Since no EC has been availed by the company, it

seeks Environmental Clearance (EC) for the Factory with all the product mix

The Sub-merged Electric Arch furnaces of 4 X 7.5 MVA and 1 X 5.0 MVA have already been

installed for production of Ferro-Manganese and Silico-Manganese. Due to market

fluctuation for the demand of Fe-Mn and Si-Mn, the plant sometimes remains under

shutdown. The promoters therefore propose to add Fe-Cr to the product Mix so as to make

the plant more viable. No additional furnace or enhancement of capacity is envisaged. The

existing facility is having adequate pollution control measures in place which is being

narrated in Chapter-3. It is also having Manganese ore briquetting plant which can be

utilized for briquetting Chrome ore fines.

The project is set up over an area of 15 acres in the Plasto Park Industrial area which is an

Industrial Estate developed by West Bengal Industrial Development Corporation. The water

demand of the facility which is about 506 KL/day will be met from the water mains of

Barjora Plasto Park Industrial Estate of WIDCL. The power demand of 41 MW shall be

sourced from DVC grid.

M/s. Sonic Thermal Pvt. Ltd has excelled in both physical and financial performances within

a short span of time of their inception. The directors along with key persons of the group

are confident for the successful operation of proposed Ferro Alloys Plant

2.1.2 Identification of Project Proponent

M/s Sonic Thermal Pvt. Ltd. is a company which is part of the well known industrial house

of India namely the Eurasia group and is promoted by them. The Eurasia group is

renowned manufacturer of Sponge Iron (DRI), Ferro Alloys, Steel Billets, Engineering Steel

Castings, Captive Power, TMT Rebars and Organic Darjeeling Tea since last three decades

in India. The group has following manufacturing facilities located at eastern states of India.

The group turnover is more than 20,000 million (INR) and employing more than 3000

people. Mr. Vikash Bansal and Mr. Satpal Bansal are currently in the Board of Directors of

the company.




Table No. C2-1 : Company Background

NAME OF COMPANY PRODUCTS FACTORY LOCATION

Brand Alloys Ltd

(An ISO & BIS

Certified, RDSO

Approved “CLASS A”

Foundry & NABL

Accredited)

-Indian Railways Casnub Bogie

& Its Components. -Indian Railways Cms

Crossing, Coupler Components. -TMT Rebars.

-Steel, Alloy & Stainless Steel Casting Upto 20 M.T Single

Piece,Machining & Assembling As Per Customer Drawing,

Design & Specification.

-Steel, Alloy & Stainless Steel

Centrifugal Casting Upto 600 Dia & 3000 Mm Length.

-Steel Billets. -Sponge Iron (DRI).

Factory: Unit – I

NH-2 Delhi Road Post : Sreerampur, Hooghly Pin-712223

West Bengal, India

Factory : Unit – II Vill.: Murusuan, Post :Palaspanga

Dist.: Keonjhar, Odrisha, India

Haldia Steels Ltd

(An ISO & BIS

Certified Company)

-Ferro Alloys (Si-Mn & Fe-Mn)

-Steel Billets

-Sponge Iron (DRI)

-Captive Power Plant

Factory : Unit – I Raturia Industrial Area Angadpur, Durgapur

West Bengal, India Factory : Unit – II

Raturia Industrial Area Angadpur, Durgapur

West Bengal, India

ISPAT DAMODAR LTD

(An ISO & BIS

Certified Company))

-Ferro Alloys (SiMn & FeMn)

-Steel Billets

-Sponge Iron (DRI)

-Captive Power

Factory Nabagram P.O-Digha, P.S-

Neturia, Purulia, West Bengal, India

Sonic Thermal Pvt.

Ltd.

(An ISO Certified)

-Ferro Alloys (Si-Mn & Fe-Mn)

Factory

Ghutghoria, Barjora, Dist-

Bankura, West Bengal, India

Brand Steel and

Power(P) Ltd Songr Iron Factory

Vill: Murusuan,

Po:Palaspanga, Block: Keonjhar Sadar, Dist:

Keonjhar, Odisha, India

The Arya Tea Company

Ltd Since 1885

(An IMO Organic, DNV

& Fair Trade Certified)

Organic Darjeeling Tea

Garden Address

Arya Tea Estate

Darjeeling Railway Station

Darjelling (N.F.Railway) ,

West Bengal, India




2.2 PROJECT HIGHLIGHTS

The principal features or highlights of the proposed project of M/s Sonic Thermal Pvt. Ltd.,

under study are as follows:

Table No. C2-2: Project Highlights

Location Plot No. 19 and 100, Barjora Plasto Steel Park, Village: Namobandh-

Sitarampur, PO: Ghutgoria, P.S. Barjora, Dist.: Bankura in West Bengal.

Its geographical co-ordinates are Latitude 230 25’ 51” N and Longitude

870 15’ 32” E with altitude above mean sea level (MSL) of 85m.

Land

requirement

The units are located on a piece of own vacant land measuring 7.96

Hectares (15.00 Acres), allotted by the West Bengal Industrial

Development Corporation Ltd. (WBIDCL).

Raw water

requirement

& source

As per an initial estimate, water to the tune of 506 KL/day will be

required for the project. The makeup water will be sourced from Water

Mains of Barjora Plasto Park Industrial Area of WBIDCL. Presently the

makeup water is brought in tankers.

Effluent

generation &

disposal

The plant has been designed as a zero discharge plant.

The water is being re-circulated after cooling and treatment. The entire

wastewater will be recycled for various purposes inside the plant.

Domestic wastewater will be treated in Septic tank & Soak pit system.

Air pollution

control

Adequate control measures like bag filters, dust extraction /suppression

system and stacks of adequate height at relevant points already exist.

Solid Waste

Management

Ferro Manganese Slag is being used for making Silico-Manganese. Ferro

Chrome Slag will be subjected to TCLP test. Subject to passing TCLP test

it will be used as base material for construction of roads. Silico

manganese slag will be used for preparation of Slag Cement or as road

base material. The dust collected from the bag filters will be reused in

the briquette plant

2.3 NEED OF THE PROJECT & ITS IMPORTANCE TO THE COUNTRY & THE REGION

The project as identified above aims at production of Ferro-manganese, Silico-manganese,

and Ferrochrome which will be used in i) production of alloy steels which are vital inputs

for steel manufacture, ii) production of coke which is a basic input for reduction of iron ore

in BF, iii) production of con cast steel, iv) production of structural steel and rebar.

Following paragraphs justify the need of the project.

2.3.1 Need of Ferroalloy Project

Ferro Alloys are used in steelmaking which consists of less than one Percent of the total

raw material required for steel production. Despite of being a very low constituent, Ferro

Alloys are vital additives for steel making. The principal function of ferroalloy addition is

that it increases the resistance of steel to corrosion & oxidation, improves its hardenibility,

tensile strength at high temperatures, wear and abrasion resistance and increases its other

properties like creep strength etc. Ferro Alloys are generally used to impart engineering

properties to steel. Ferro Alloys are vital input for producing all type of steel and are used

as raw material in the production of special steels, alloy steels and stainless steel.




Demand Drivers of Ferro Alloys are:

Crude Steel Production

Alloy and special steel Production

Stainless Steel Production

The National steel policy 2005 envisaged a target production of 110 million tones by 2019-

2020. It enunciated important milestones/physical targets and an overarching broad policy

framework to achieve the stated end on an assumed 6.9% growth in steel consumption,

7.3% growth in steel production and a 23% share of exports in total production by the

year 2019‐20.

Since then, however, the Indian economy experienced a paradigm shift with the actual

performance of the economy as well as that of Indian steel industry surpassing the

projected levels of performance. Steel consumption grew by 10% per annum from 2005‐06

to 2011‐12 and production at an annual rate of 7.8% during the same period thereby

surpassing the NSP 2005 projections by a significant margin. The NSP 2012 therefore

envisages capacity build up of 300 Million Tonnes, a finished steel production of 275 Million

Tonnes. Taking growth scenario of 7% and 8% of GDP the policy statement envisages a

growth at CAGR of 7.8% and 8.9% respectively.

The increased in production of steel required increase in Ferro Alloy production. Thus,

Ferro-alloy plant of 4X7.5 MVA and 1X5MVA SEAFs were set up for production of bulk

ferroalloys of Fe-Mn Si-Mn and Fe-Cr to meet the need of the country. The factory was set

up in village: Namobandh-Sitarampur, PO: Ghutgoria, PS: Bajoria in Bankura district in the

Plasto Park area which is an Industrial state developed by WBIDC. However, over the years

the demand of products Fe-Mn and Si-Mn showed a decline trend where as the demand of

Fe-Cr has increased. As can be seen from the Tables below, the indigenous consumption of

Fe-Cr has jumped from 311 kilo tones 2008-09 to 403 kilo tones 2011-12. Due to this the

import of Fe-Cr has increased from 2 kilotonnes in 2009 to 34 kilotonnes in 2011-12. The

Fe-Cr manufacturing facilities were also less in comparison to Manganese alloy units as can

be seen from Table No. C2-4. The promoters therefore wish to include Fe-Cr in the product

mix so as to make the plant viable. Apart from meeting internal needs of the company, the

products will also have good market as many steel plants are located in adjacent Durgapur

area of Bardhman district of WB.

2.2.2 Estimated Steel Demand and required Crude Steel Capacity, 2011‐12 to 2025‐26

Table No. C2-3: Estimated Steel Demand & Required Crude Steel Capacity (Million Tonnes)

Growth Scenario Projected Demand for Finished Steel

2011‐12 (Actual)

2025‐26 CAGR (%)

Implicit GDP

Elasticity

GDP Growth at 7% pa (Base Case)* 70.92 202 7.8% 1.11

GDP Growth at 8%* 70.92 233 8.9% 1.11

Crude Steel capacity required to sustain

projected demand in the base case

88.40 244

Note: * The assumed growth rates are average for the years between 2011‐12 and

2025‐26, notwithstanding possibilities of yearly fluctuations /swings within the period.

Source: National Steel Policy 2012




India has enough scope of Ferro alloy industry as raw materials are available for its

production, there are indigenous demand as well as demand in the export market. The

production and demand figures are given below.

2.2.3 Production of Ferro Alloys During 2006-07 to 2010-11 (Quantity in Metric Tonnes)

Table No. C2-4: Production of Ferro Alloys during 2006-07 To 2010-11

2010-11 2009-10 2008-09 2007-08 2006-07

Bulk Ferro Alloys:

HC Ferro Manganese 390,000 341,883 372,286 364,908 281,013

MC Ferro Manganese 8,000 8,222 8,386 7,704 9,190

LC Ferro Manganese 6,000 6,018 5,775 3,905 6,523

Silico Manganese 1,250,000 1,066,485 889,434 886,325 738,314

MC Silico Manganese 24,000 24,108 24,087 27,106 29,581

LC Silico Manganese 25,000 25,454 22,368 33,576 15,067

Ferro Silicon 117,000 97,682 110,742 96,972 92,632

HC Ferro Chrome

/Charge Chrome

1,030,000 890,916 790,072 964,806 801,138

LC Ferro Chrome 2,000 2,007 1,352 235 230

Total Bulk Ferroalloys 2,852,000 2,462,775 2,224,502 2,385,537 1,973,688

Noble Ferro alloys 33,360 30,858 27,235 29,185 27,763

Total 2,885,360 2,493,633 2,251,737 2,414,722 2,001,451

Growth percentage 15.70% 10.74% (-) 6.75% 20.65% 21.64%

Source: IFAPA

2.2.4 Domestic Consumption

Table No. C2-5: Domestic Consumption of Ferroalloys (in Kilo Tonnes)

Ferro Alloy 2005-06 2008-09 2011-12

Si-Mn 443 589 700

Fe-Cr 375 311 403

Fe-Mn 233 277 292

Fe-Si 174 156 229

Others 83 91 115

Source: IFAPA

2.2.5 Installed Capacity and Export/Import Scenario:

Capacity increase of the Ferro Alloy Industry in general followed the course to meet the

planned target levels of the Steel Industry in the country and to continue to remain

potential exporters of Ferro Alloys in the international market for earning substantial foreign

exchange for the country. After initiation of the liberalization programme, there has been a

spurt in the export of Bulk Ferro Alloys, like all other products. The present scenario indicates

that the ferroalloy production in the country is driven not only indigenous demand but also

exports. The installed capacity as well as the export figures is given in the tables below.




Table No. C2-6: Ferroalloy Capacity in India (2012 estimates)

Ferroalloy Capacity In Million Tonnes

Mn Alloys 3.16

Chrome Alloys 1.69

Ferro Silicon 0.25

Noble Alloys 0.05

Total 5.15

Table No. C2-7: Ferro Alloy Export ( ‘000 MT)

Category 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

Export 517 640 961 960 863 1555 1533

Domestic 1308 1520 1558 1420 1819 1460 1740

Total 1825 2160 2519 2380 2682 3015 3273

Export % 28 30 38 40 32 52 47

Source:IFAPA

Ferroalloy Imports:

Although India is a large exporter of Ferroalloys, due to uncertain economic conditions in

the developed world, many ferroalloy companies (mainly from the CIS, Russia and

Kazakhstan) which restricted themselves to supplying to customers in the developed world

(US, EU, Japan) and to China have started making inroads into India. This has led to stiff

rise in imports of ferroalloys (25% CAGR) for the years as reflected in the table below.

Table C-8 Growth of Imports of Ferroalloys in India ( ‘000 MT)

Ferroalloy 2005-06 2008-09 2011-12

Fe-Si 74 83 149

Refined Alloys 44 42 66

Fe-Cr 1 2 34

Fe-Mn 5 6 10

Total 124 133 259

2.3 Employment Generation:

As there is no expansion, only modification to product mix is being proposed, there is no

possibility of employment generation.




CHAPTER - 3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

It is an existing Ferroalloy plant which is operating at Barojia Plasto Steel Park Industrial

area of WBIDCL. The proponents want to modify the product mix with inclusion of Ferro-

chrome in addition to existing Fe-Mn and Si-Mn. The modification will be carried at

present site at village: Namobandh-Sitarampur, PO-Ghutgoria, PS: Barjora, Dist.

Bankura, WB. The modification will render the plant economically viable. No additional

facility will be set up. The existing Ferroalloy plant with pollution control measures and

briquetting plant shall be utilized for manufacture of Ferro-chrome. The raw materials for

the existing plant are Mn ore, Quartz and Chrcoal. For proposed modification chrome ore,

coke, quartz and lime stone will be used as raw material. The power requirement of the

plant will be sourced from DVC grid and Water requirement will be met from the water

mains of Barjora Plasto Steel Park Industrial Area of WBIDCL.

As per EIA Notification 2006 the proposed Ferro Alloy Plant falls under Schedule in serial

No. 3 (a) - Metallurgical Industry (ferrous & non- ferrous). Based on general conditions

mentioned in the schedule of EIA Notification, the project is categorized as Category A.

3.2. LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION AND

PROJECT BOUNDARY & PROJECT SITE LAYOUT) WITH COORDINATES:

The project is located in the Barjora Plast Steel Park Industrial Area developed by the

West Bengal Industrial Development Corporation Limited for providing industrial

infrastructure to prospective enterpreanures. The Co-ordinates of Project site are as

mentioned earlier in Chapter 2.

The inclusion of Ferrochrome production will be achieved in the existing industrial

complex the consisting of Ferroalloys Plants of M/s Sonic Thermal Ltd. The site is already

developed and connected to road and rail network. Adequate transportation facilities are

available for transportation of product to important destinations.

By incorporation of Fe-Cr production in the existing factory premises, M/s Sonic Thermal

Ltd. is planning to increase the economy of existing plant and to earn greater revenue by

selling ferroalloys, which will be used for manufacturing steel and alloy steel products,

structural steel etc. Hence the proposed modification project will be beneficial and

techno-economically feasible. Hence, no alternative site is analyzed. Financial and social

benefits with special emphasis on environmental consideration and benefit to the local

people will be kept as top priority for the proposed project.

The site selection has been made in view of the fact that the company has existing facility

in the location, the location is well connected by road and rail network; proximity to raw

materials and water. Environmental pollution control measures will be undertaken to

restrict the pollution below the limits stipulated by CPCB/ WBPCB/ MoEF & CC.




Fig. No. C3-1: Index Map




Fig. No. C3- 2: Location Map




Fig. No.C3- 3: Vicinity Map




Fig. No.C3- 4: Google Earth Map




Fig. No. C3-5: Plot Plan




3.3 Details of alternate sites considered & the basis of selecting the proposed site,

particularly, the environmental consideration gone into should be highlighted.

The existing project is located at Barjora Plasto Steel Park an industrial area at village:

Namobandh-Sitarampur, PO: Ghutgoria, PS: Barjora, in the District of Bankura, West

Bengal over Plot No19 and 100. In view of the fact that the proponents are operating

ferroalloy plant the same location since 2012 the infrastructure is already developed. The

modification of product mix shall be carried out in the same location. Therefore, no other

location has been considered for the above proposal.

3.4 Size or magnitude of operation:

The configuration of the project has been given Table below;

Table No. C3-1: Project Configuration

Facilities Existing

Capacities

Proposed

Modification

Ultimate Capacity

Ferro Alloys(Ferro Chrome

/Ferro Manganese /Silico

Manganese /Ferro silicon)

SEAF

4 X 7.5 MVA &

1 X 5 MVA (For

manufacture of

Fe-Mn & Si-Mn)

4 X 7.5 MVA &

1 X 5 MVA (For

manufacture of

Fe-Cr)

4 X 7.5 MVA 1 X 5

MVA (For Manufacture

of Fe-Mn, Si-Mn and

Fe-Cr)

3.5 Project description with process details (a schematic diagram /flow chart

showing the project layout, components of the project etc. should be given)

3.5.1 Project Description

The proposal is for availing EC for the existing plant which operates a ferroalloys plant of

4 X 7.5 MVA and 1 X 5 MVA for production of Fe-Mn and Si-Mn and proposes to utilize

the furnaces for production of Fe-Cr also.

The raw materials will be sourced from neighboring state Odisha as well as local market.

The raw materials as well as finished products will be transported through the existing

rail and road network.

Total land acquired for the proposed project is 15 acres. Total water requirement for the

proposed project will be about 506 KLD. Water requirement for the project is being

sourced from Water Mains of West Bengal Industrial Development Corporation. Presently,

however, water is sourced through tankers as the water from WBIDC system is not

available as yet. The same source will be adequate for manufacture of Fe-Cr also.

Electricity requirement will be about 32 MW which will be available from in DVC Grid. The

details of various units of the proposed project with production capacity are given below;

1. Ferro Alloys Plant with capacity of Fe-Mn 78,000 TPA or Si-Mn 68,500 TPA or Fe-Cr

89,580 TPA.

The manufacturing process technologies are indigenous and well established. The details

are given below:




3.5.2. Ferro Alloys Plant-Process Description:

Most of the Ferro-alloys e.g. Ferro-silicon, Ferro-manganese, Silico-manganese,

Ferrochrome, etc. are produced by smelting process. Smelting of the charged materials is

carried out in submerged electric furnaces equipped with transformer of proper ratings.

The process developed in India during 90s is based on basic process parameters as

offered by ELKEM, Norway, in the past. Various Indian furnace manufacturers

successfully developed furnace design up to 12.5 MVA electrical ratings for manufacture

of different grades of ferro-alloys based on ELKEM Technology. The process for the

manufacture of Ferro Alloys viz. Silico Manganese, Ferro manganese, Ferro-Chrome and

Ferro-Silicon by submersible Arc furnace technology is well established in India. All the

companies manufacturing Ferro Alloys are using the above technology.

3.5.2.1 Submerged Electric Arc Furnace

A schematic view of typical submerged electric arc furnace design is depicted in Figure

No C3-6. The lower part of the submerged electric arc furnace is composed of a

cylindrical steel shell with a flat bottom or hearth. The interior of the shell is lined with 2

or more layers of carbon blocks. The furnace shell may be water-cooled to protect it from

the heat of the process. A water-cooled cover and fume collection hood are mounted over

the furnace shell. Normally, 3 carbon electrodes arranged in a triangular formation

extend through the cover and into the furnace shell opening. Prebaked or self baking

(Soderberg) electrodes ranging from 76 to over 100 cm (30 to over 40 inches) in

diameter are typically used. Raw materials are sometimes charged to the furnace

through feed chutes from above the furnace. The surface of the furnace charge, which

contains both molten material and unconverted charge during operation, is typically

maintained near the top of the furnace shell. The lower ends of the electrodes are

maintained at about 0.9 to 1.5 meters (3 to 5 feet) below the charge surface. Three

phase electric current arcs from electrode to electrode, passing through the charge

material. The charge material melts and reacts to form the desired product as the electric

energy is converted into heat. The carbonaceous material in the furnace charge reacts

with oxygen in the metal oxides of the charge and reduces them to base metals. The

reactions produce large quantities of carbon monoxide (CO) that passes upward through

the furnace charge. The molten metal and slag are removed (tapped) through 1 or more

tap holes extending through the furnace shell at the hearth level. Feed materials may be

charged continuously or intermittently. Power is applied continuously. Tapping can be

intermittent or continuous based on production rate of the furnace.

Submerged electric arc furnaces are of 2 basic types, open and covered. Most of the

submerged electric arc furnaces in India are open furnaces. Open furnaces have a fume

collection hood at least 1 meter (3.3 feet) above the top of the furnace shell. Moveable

panels or screens are sometimes used to reduce the open area between the furnace and

hood, and to improve emissions capture efficiency. Carbon monoxide rising through the

furnace charge burns in the area between the charge surface and the capture hood. This

substantially increases the volume of gas the containment system must handle.

Additionally, the vigorous open combustion process entrains finer material in the charge.

Fabric filters are typically used to control emissions from open furnaces.




Covered furnaces may have a water-cooled steel cover that fits closely to the furnace

shell. The objective of covered furnaces is to reduce air infiltration into the furnace gases,

which reduces combustion of that gas. This reduces the volume of gas requiring

collection and treatment. The cover has holes for the charge and electrodes to pass

through. Covered furnaces that partially close these hood openings with charge material

are referred to as "mix-sealed" or "semi-enclosed furnaces".

Although these covered furnaces significantly reduce air infiltration, some combustion

still occurs under the furnace cover. Covered furnaces that have mechanical seals around

the electrodes and sealing compounds around the outer edges are referred to as "sealed"

or "totally closed". These furnaces have little, if any, air infiltration and undercover

combustion. Water leaks from the cover into the furnace must be minimized as this leads

to excessive gas production and unstable furnace operation. Products prone to highly

variable releases of process gases are typically not made in covered furnaces for safety

reasons. As the degree of enclosure increases, less gas is produced for capture by the

hood system and the concentration of carbon monox2+ide in the furnace gas increases.

Wet scrubbers are used to control emissions from covered furnaces. The scrubbed, high

carbon monoxide content gas may be used within the plant or flared.

The molten alloy & slag that accumulate on the furnace hearth are removed at 1 to 5

hour intervals through the tap hole. Tapping typically lasts 10 to 15 minutes. Tap holes

are opened with pellet shot from a gun, by drilling or by oxygen lancing. The molten

metal and slag flow from the tap hole into a carbon-lined trough, then into a carbon-lined

runner that directs the metal and slag into a reaction ladle, ingot molds, or chills (Chills

are low, flat iron or steel pans that provide rapid cooling of the molten metal). After tapping

is completed, the furnace is resealed by inserting a carbon paste plug into the tap hole.

Fig. No. C3-6:




Chemistry adjustments may be necessary after furnace smelting to achieve a specified

product. Ladle treatment reactions are batch processes and may include metal and alloy

additions. During tapping, and/or in the reaction ladle, slag is skimmed from the surface of

the molten metal. It can be disposed of in landfills, sold as road ballast, or used as a raw

material in a furnace or reaction ladle to produce a chemically related ferroalloy product.

After cooling and solidifying, the large ferroalloy castings may be broken with drop

weights or hammers. The broken ferroalloy pieces are then crushed, screened (sized),

and stored in bins until shipment. In some instances, the alloys are stored in lump form

in inventories prior to sizing for shipping.

Smelting in an electric arc furnace is accomplished by conversion of electrical energy to

heat. An alternating current applied to the electrodes causes current to flow through the

charge between the electrode tips. This provides a reaction zone at temperatures up to

2000°C. The tip of each electrode changes polarity continuously as the alternating

current flows between the tips.

3.5.2.2 TECHNOLOGY AND PROCESS DESCRIPTION-GENERAL

The process technology area relates to only ferro alloy production. This plant has been

designed for production of Ferro-Manganese and Silico-Manganese. However, flexibility in

furnace design and operation, electrode operation and transformer design exists for

manufacture of Ferrochrome also.

Four nos. submerged electric arc furnaces each having 7.5 MVA rating and one furnace of

5 MVA rating have been be installed in this ferroalloys plant. The submerged arc process

is a carbothermic reduction smelting operation. The reactants consist of metallic ores

(ferrous oxides, silicon oxides, manganese oxides, chrome oxides, etc.) and a carbon-

source as reducing agent usually in the form of coke, low-volatility coal or wood chips.

Limestone may also be added as a flux material. Raw materials are crushed, sized, and in

some cases, dried, and then conveyed to a mix house for weighing and blending.

Conveyors, buckets, skip hoists or cars transport the processed material to hoppers

above the furnace. The mix is then gravity-fed through a feed chute either continuously

or intermittently, as needed. At high temperatures in the reaction zone, the carbon source

reacts with metal oxides to form carbon monoxide and to reduce the ores to base metal.

The process flow diagram is common for all the products which is presented in Fig. No.

C3-7. The process of manufacture consists of the following sections:

Raw Material Receipt and Storage

Sizing, Screening and Feeding of of Raw Materials

Briquetting of Fines

Raw Material Batching

Melting in Ferroalloy Furnace

Handling of Hot Metal and Slag

Metal Recovery

.




ID FAN

Flue gas

i) Raw Material Receipt and Storage

Incoming raw material i.e. Coal, Quartz, Charcoal, etc. will be received by trucks and

stacked separately in the stockyard. The material will be procured in required size range

and quality. Appropriate storage methods shall be adopted.

ii) Sizing, Screening and feeding of Raw Material

Raw material will be fed to a ground hopper by dumpers. The material will be drawn from

ground hopper to screening station where fines will be removed. The screened material

will be conveyed to the Bunker. The bunkers will be fed with reversible conveyors.

Fig. No. C3-7: General Process Flow Diagram of Ferroalloy Production

INPUT OF SIZED

AND GRADED

RAW MATERIALS

HANDLING BY

PAYLOADERS

AND DUMPERS

FEED IN DAY BINS

THROUGH BELT

CONVEYORS

BATCH

PREPARATION BY

COMPUTERIZED

WEIGHMENT

BRIQUETTE

PLANT

Manganese Ore fines

/ Chrome Ore fines

TAPPING IN

CAST IRON

LADELS

DISCHARGE OF

MOLTEN

METAL

REACTION IN THE

FURNACE

CHARGING IN TO

FURNACE

HEAT

EXCHANGER

BAG FILTER

Natural Cooling

of Metals

Sizing , Grading

and Packing

DISCHARGE OF

SLAG

METAL

REECOVERY

PLANT

FLUE DUST STACK

RECOVERED METAL

INSPECTION DESPATCH

SLAG FOR REUSE

AND/OR ROAD

BASE MATRIAL




Each bunker will be provided with vibratory feeder. Each set of 4 bunkers will have one set

of weigh hopper. Material from each bunker will be withdrawn and weighed separately in

the weigh hoppers and dumped to a common surge hopper provided with a vibratory

feeder through a conveyor.

The weight of raw materials in required quantity from the surge hopper will be fed to the

feed hopper provided at the top platform. The material from feed hopper shall be conveyed

to charging bins and correction bin, which will be located around the circumference of the

furnace. These charging bins shall feed the raw material mix through chutes and slide

gates into the furnace.

iii) Briquetting: Process Description of the Briquette Plant

Converting fines or concentrate into briquettes is necessary due to the following reasons;

Direct use fines in the furnace are hazardous.

It decreases porosity and causes eruptions

MnO/Cr2O3 loss through slag is extremely high.

Reduces effective volume of the furnace.

Yield & productivity comes down considerably.

Creates unstable condition for operation.

Process employed for making briquettes;

Feeding of dry fines / concentrate & binders.

Batching in desired proportions.

Thorough mixing in pan mixer.

Pressing in briquette press using roller segments.

Storage and curing.

Binders used;

Hydrated lime

Molasses

Specification of hydrated lime;

Ca (OH)2 : 65 % min

SiO2 : 8 % max

Al2O3 : 7 % max

MgO : 3 % max

Size : 200 mesh

Specification of molasses;

Specific Gravity: 1.38 min

Brix : 800 min

Major Raw Material Handling Equipments for Briquette Plant;

1dryer of capacity 20 TPH.

One Pan Mixture of capacity 20TPH.

2 Press of capacity 20 TPH each.

One air compressor.

Two vibrating screens.

Molasses lifting pump.

Lime hoist.

No. of conveyors shall be put to match the flow circuit.




Fig. No. C3-8 : Process Flow Diagram of Briquette Plant




Pollution control measures at Briquetting Plant

Only fugitive emission will be generated in briquetting plant while drying Manganese

Ore/chrome fines at dryer & at different transfer points of fines. M/ Sonic Thermal Pvt.

Ltd. will provide bag filter at dryer and transfer points of briquetting plant to control

fugitive dust emission. M/s Sonic Thermal Pvt. Ltd. assures to maintain fugitive emission

level as per government statutory norms as fixed by MoEF&CC and State Pollution

Control Board, WB.

iv) Batching of Raw Materials

Batching is the most important part of the process. The total process control and quality

control is largely dependent on accurate batching. This is nothing but accurate weighing

of different raw materials in the required proportion and taking simultaneously as a

quantum. This is done with the help of a raw material batching system consisting of

vibrating feeders, load cells, weigh hoppers and conveyors. The total operation is

controlled by a PLC. The required proportion of the raw material mix is determined by

means of material balance made by a metallurgist based on the combination of

theoretical calculations and practical assumptions from past experience.

v) Smelting in Ferroalloy Furnace

Fe-Mn/Si-Mn/Fe-Cr is produced in submerged electric arc furnace. Details of furnace have

been already discussed earlier in this chapter. The outer & bottom wall of the furnace is

made up of steel sheet, which is water-cooled. The outer shell as well as the bottom is

lined with refractory materials like carbon block, refractory bricks, silicon carbide bricks,

tamping paste, castables and mortars etc. depending on the lining design. Silicon carbide

bricks will be used for tap hole lining The furnace shell along with the refractory lining

forms the crucible for holding the molten metal & slag and provides the space for

reactions at very high temperature.

The electrodes are the carriers of electricity in to the furnace. Self-baking continuous

Soderberg electrodes are used in these furnaces. In fact these are the heart of the

furnaces. Electric arcing takes place inside the charge to produce high temperature and

provides the necessary heat energy for endothermic reactions.

The furnace will be provided with water-cooling system for:

- Cooling of current conducting pipes and contact clamp.

- Cooling of electrode holder ring

- Cooling of electrode shell

- Cooling of supporting framework exposed to heat from furnace top.

For furnace tapping, tap hole arcing device (moving around the furnace) shall be provided.

Electrical connection to the arcing device shall be made manually after positioning.

Various raw materials are analyzed. Depending on the composition and specification of

metal to be produced a material balance is prepared. This shows the proportion in which

various raw materials are to be mixed before feeding in to the furnace. Once the

materials are fed in to the furnace in desired proportion it is called the burden. The

burden under goes various physical and chemical changes simultaneously. Various

metallic & nonmetallic oxides like MnO,Cr2O3, FeO and SiO2 get reduced to their

elementary form by the reaction of fixed carbon in reductants with the respective oxides.




For example in case of ferrochrome production, the following reactions will take place in

the furnace.

Cr2O3 + 3C 2Cr + 3CO

FeO + C Fe + CO

SiO2 + 2C Si + 2CO

Al2O3, MgO, CaO and SiO2 are the main oxides, which form the gangue in the ore and

reductants. They combine together along with certain amount of unreduced Cr2O3 and

FeO to form slag. Metal & slag gets accumulated at the bottom of the furnace as a result

of smelting and is tapped out from time to time.

Metal & slag are tapped out simultaneously through the tap hole and collected in different

receptacles like ladle; CI pans etc. metal & slag are separated from each other due to

difference in their specific gravity by the method of decantation or simply by casting in

pans. Pure metal is cast in moulds or beds.

Slag Chemistry:

Formation of a suitable slag is of paramount importance in ferroalloy production, as it not

only determines the stability of operation but the total economy of the process. The slag

composition is determined taking in to account the specification of product, gangue

materials present in the ore and available fluxes. Temperature and fluidity of slag

assumes primary consideration. The temperature of slag is maintained 50 – 1000 C above

the metal temperature. The total temperature profile inside the furnace is maintained by

the slag temperature and hence by slag composition. The slag composition in typical case

of ferrochrome manufacture is maintained in the range as mentioned below;

Slag Composition

Cr2O3 : 8 - 10 %

FeO : 2 – 3 %

SiO2 : 28 - 30 %

Al2O3 : 22 - 26 %

MgO : 20 - 24 %

CaO : 8 – 10 %

Guiding principle to maintain slag composition

MgO / Al2O3 : 0.9 – 1.1

Basicity : 1.1 – 1.2

Tapping and Casting:

Metal and slag formed inside furnace as a result of smelting is tapped out at regular

interval from the furnace through tap hole provided in the side lining of the furnace. The

interval is determined based on the power in put and previous tapping condition. Tap

hole is cut by oxygen lancing at the stipulated place to make a way for molten metal &

slag to flow out. The molten metal is collected in a combination of ladle, CI pan and sand

bed arranged in cascading manner. Metal is collected in the ladle and CI pan along with

some slag. But the sand bed accommodates only slag. After tapping the tap hole is




closed with the help of plug clay made out of clay and carbonaceous particles derived

from electrode paste. Metal & slag from the ladle are separated by decantation in the

molten state and the pure metal is cast in moulds. After cooling the metal moulds are

shifted to metal handling yards for further handling. The slag is sifted to slag yard for

further processing in metal recovery plant.

Tapping & Casting materials used

Oxygen lancing pipe

Oxygen gas

MS rods

Sodium silicate

Sand

CI ladles

Refractory ladles

CI pans

Rectangular moulds

vi) Technical Characteristics of Furnace:

There are four nos. of Submerged Electric Arc Furnaces each of 7.5 MVA capacity and

one no of 5 MVA capacity for Production of Ferroalloy products like Fe-Mn, Si-Mn or Fe-

Cr. The technical specification of the furnaces is presented below;

Table No. C3-2 : Technical Characteristics of Furnace

Parameter SEAF of 7.5 MVA

Capacity

SEAF of 5.0 MVA

Capacity

Installed Capacity 19,200 T/yr 12,780 T/yr

Electric Furnace power 7.5 MVA 5.0 MVA

Range of Transformer

secondary voltage, V

70-140V 70-140V

Electrode current, kA 32 21

Type of electrode Shoderberg self baking

electrode

Shoderberg self baking

electrode

Diameter of electrode (mm) 900 750

Number of electrode 3 3

Pitch circle diameter (mm) 2200 1800

Electrode travel, Hydraulic Hydraulic

Method of Charging

Continuous charging

through skip, teller hoist

and charging chutes

Continuous charging

through skip, teller hoist

and charging chutes

Method of tap changing Automatic Automatic

Inner dia of shell,( mm) 6800 5550

Shell height,( mm) 4400 3590




vii) Metal Handling

The hot metal tapped from the spout will be collected in a ladle on rails. The liquid metal

from the ladle will be poured into sand moulds with the help of a crane. Manual breaking

and packing shall be carried out for dispatch. Metal cakes are handled with the aim of

removing slag contamination and meeting the size specification. The moulds are broken

manually to serve both the purpose. Manual sorting is done to separate out slag. In

certain cases chipping is necessary to separate out sand and slag contamination from the

metal surface. As a result of the metal handling process the following out puts are

generated.

Sized pure metal (sifted to sales yard for dispatch after confirmatory analysis)

Slag & metal contaminated mixture (sifted to MRP for further processing)

Undersized metal particles containing small quantity of slag particles (sifted to

MRP for further processing)

viii) Air Pollution Control System for Ferro Alloy Furnace

During operation of submerged are furnace some fugitive emission is observed at times

which depends mainly on the quality of raw materials used.

There are 4X 7.5 MVA and 1X5MVA ferroalloy furnaces. Fixed hoods are provided over

the respective ferro alloy furnace to capture fumes. The furnace hood is connected to air

to gas cooler and then to a modular Off – Line Pulse Jet Bag Filter and finally to an ID fan

through inter connecting ducting.

Fugitive fumes/dusts will be captured along with the surrounding air stream due to

strong suction/draught created by a suitable Induced Draught Fan. Captured fumes at a

temperature of around 280 ºC will be transported to a gas cooler. Hot fumes will pass

through the tubes and the ambient air will be blown over the tube so that the fume

temperature is dropped to about 110 ºC.

It is then passed through a modular Off-Line Pulse Jet Bag Filter having Polyester needle

felt non woven filter bags where the dusts /fumes will be separated and only clean

filtered air will pass through the filter bags. Clean air having PM level below 150 mg/ NM3

will then be vented out through a chimney. Ladder platform and sampling port has been

provided at the appropriate position as per WBPCB norms.

Collected dusts in the dry form will be taken out of the Bag Filter by a rotary airlock valve

having geared motor drive arrangement. Dry dusts is being disposed off in gunny bags.

the stack monitoring of various stacks in the plant is being regularly done by the SPCB,

West Bengal and the same are found to be within the limit of 150 mg/Nm3.




3.5.2.3 Physico Chemical Considerations for Different Products:

A. FERRO- MANGANESE

Metallurgical Reactions involved during production of Ferro-manganese & Silico-manganese:

• 2MnO2 + C → Mn2O3 + CO

• 3 Mn2O3 + C → 2Mn3O2 + CO

• Mn3O2 + C → 3MnO + CO

• MnO + C → Mn + CO

• Fe2O3 + 3C → 2Fe + 3CO

• SiO2 + 2C → Si + 2CO

• P2O5 + 5C → 2P + 5CO

High-carbon ferro-manganese is made in three phase open or closed top furnace of a

power of 7,500-18,000 KVA at a linear voltage of 120-130 V with a current of 33-38 kA,

operating at a voltage of 120-130 V. The charge for making high-carbon ferro-

manganese is composed of manganese ore and coke/coal.

Physico-Chemical Conditions of the Process: High carbon ferro manganese is

smelted by a continuous process with the electrodes submerged deep into the charge.

The following processes take place when making high carbon ferro manganese:

Pre-heating of the materials;

Drying and removal of volatiles & moisture from the charge; heating of the charge

by the heat of burning gases which leave the furnace & after-burn at the top;

Reduction of oxides;

Melting of the elements reduced with the formation of molten ferro-manganese;

Formation and melting of slag;

The iron contained in the manganese ore is reduced to a high extent in the process.

Oxides are reduced with carbon monoxide and hydrogen at low temperatures. Ferrous

oxide is first reduced with carbon monoxide and hydrogen at 500-600°C temperature and

after that with solid carbon in the deeper zones of the bath.

The reduction of manganese from pyrolusite occurs stepwise:

MnO2 > Mn3O4 > MnO > Mn3C

With a reducing atmosphere in the furnace, the dissociation of manganese oxides can

place at low temperatures. Carbon monoxide and hydrogen can also reduce Mn3O4 to

MnO at low temperatures.




Fig. No. C3-9 : Schematic Flow Diagram of Bag Filter System




The manufacturing process of ferro-manganese consists of smelting of manganese ore,

quartz and charcoal at 1400-1600 degree Celsius, in submerged electric arc furnace.

Manganese ore is the basic raw material having major constituent of ferro-manganese

alloys, i.e. manganese ore and Charcoal is used as reductant. The body of the furnace is

cylindrical in shape, lined with fire bricks, silicon carbide bricks and carbon tamping paste.

Three tap holes are provided at 1200 apart for draining out both the molten alloy and slag.

The raw materials are charged into the furnace manually in specified proportion. The

charged material is smelted in the furnace by electric power delivered through three

electrodes. The electrodes are partially submerged in the charge and are supported on

hydraulic cylinders for upward and downward movement to maintain the desired electrical

conditions in the furnace.

As the charge enters the smelting zone, the alloy is formed by reaction of the oxides and the

reductant. The alloy so formed is heavy and gradually settles at the bottom of the furnace.

The furnace is tapped at regular intervals. The tap hole is opened by oxygen lancing pipes

and once tapping is completed the tap-hole is closed with clay plugs.

High Carbon ferro-manganese can be smelted with addition of fluxes or by fluxless process.

In the latter case, a valuable by-product of the process is high manganese low phosphorus

slag which is used in smelting silico manganese and manganese metal. Manufacturing of

high carbon ferro-manganese may be done through two alternative process:

i) Flux Process

ii) Flux less Process

In the flux process, the charge includes fluxes like limestone to take care of the gangue

material in the charge as is conventional in the smelting process of other ferroalloys. Ferro

manganese is tapped after draining out the slag from the furnace.

In the second process, no flux is added to the charge mix. As a result the manganese

recovery is low and the slag is rich in residual manganese. This manganese rich slag can be

used in recycling through the smelting furnace as a constituent of the charge mix, replacing

part of the manganese ore.

Table No. C3-3: Raw materials for Fe-Mn and their chemical composition

Sl. No. Constituents Mn Ore Dolomite Coke

1 MnO 46-48% -- --

2 CaO + MgO -- 55% --

3 Al2O3 5% -- --

4 Fe2O3 5-15% -- --

5 Ash -- -- 20%

6 Fixed Carbon -- -- 60%

7 Volatile Matter -- -- Balance




Charge Composition:

Table No. C3-4: General Charge Composition

Input Material Amount in Tons per Ton of Product

Mn Ore 2.3

Dolomite 0.35

Low Ash Met Coke 0.6

BRIQETTE PLANT

MANGANE

SE ORE

FINES

ZIGGING

PLANT

RECOVERED

METAL

Fig. No. C3-10: Process Flow Diagram of Ferro-Manganese




B. SILICO-MANGANESE

High-carbon Silico-Manganese is made in three phase open or closed top furnace of a

power of 5,000-12,000 KVA, operating at a voltage of 90-100 Volt. The composition of

different grades of silico-manganese is given below:

Table No. C3-5: Composition of different grades of Silico Manganese

Mn % in different

grades of Si-Mn

Contents (%)

Silicon Carbon Sulphur Phosphorous

60-65 14-18 2.30 0.04 0.30

65-70 15-18 2.00 0.04 0.25

Size: 10-50mm (90% minimum)

Silico-manganese is produced by carbothermic reduction of oxidic raw materials in

electric submerged arc furnaces. The same type of furnaces is used for Fe-Mn and Si-Mn

alloys. Operation of the Si-Mn process is often more difficult than the Fe-Mn process

because higher process temperature is needed.

Standard silico-manganese with 18-20% Si and about 70% Mn is produced from a blend

of HCFeMn slag with about 35 to 45% MnO, manganese ores, quartzite, (Fe) Si-remelts

or off grade qualities, and coke. Sometimes minor amounts of MgO-containing minerals

are added, e.g. dolomite [CaCO3.MgCO3] or olivine [(MgO)2.SiO2].

The discard slag from the SiMn process normally contains 5 to 10% MnO. Low carbon

silico-manganese with around 30% Si is produced by upgrading standard alloy by

addition of silicon wastes from the ferrosilicon industry. Manganese ores normally contain

unwanted elements that cannot be removed in the mining and processing stages. Of

special importance is phosphorus due to the strict demands in respect of this element

both in the Fe-Mn and Si-Mn alloys. Iron, phosphorus and arsenic are reduced more

easily than manganese and will consequently go first into the metal. Their content in the

final alloy must therefore be controlled by selection of ores. The HCFeMn slag is a very

pure source of manganese because the easily reduced impurities in the ores have been

taken up by the HCFeMn metal in the preceding process step. The content of impurities,

like phosphorus, in Si-Mn alloys is therefore controlled, not only by the selection of

manganese ores, but also by the relative amounts of manganese ores and HCFeMn slag

in the raw material mix.

A process temperature of 1600 to 1650°C is necessary to obtain metal with sufficiently

high content of Si and discard slag with low MnO. Fe-Mn slag has a relatively low melting

temperature (about 1250°C) compared with Mn-ores. Accordingly, a high share of Fe-Mn

slag will tend to give lower process temperatures. When the Mn-ore starts melting at

around 1350°C, it will contain a mixture of a solid and a liquid phase, where the solid

phase is MnO. Further heating and reduction to 1550°C or more is necessary before the

melting ore will mix with the slag and flow freely. With a high share of Mn-ore in the mix,

the surface temperature and process temperature in the cokebed zone will be higher.




The specific power consumption for production of standard Si-Mn from a mixture of Mn

ore, HCFeMn slag and Si-rich metallic remelts, can typically be 3500-4500 kWh/tonne

metal, dependent first of all on the amount of metallics added to the feed. The power

consumption will increase with the Si-content of the metal produced, and also with the

amount of slag per tonne of SiMn. Each additional 100 kg slag produced will consume

additionally about 50 kWh electric energy. About 100 kWh per tonne of metal and some

coke will be saved if the ore fraction in the charge is reduced to MnO by CO gas

ascending from the smelt reduction zone

The charge for making high-carbon Silico-Manganese is therefore composed of

manganese ore, Quartz HC Fe-Mn slag and coke.

Physico-Chemical Conditions of the Process

The following processes take place when making high-carbon Silico-Manganese:

(a) Removal of volatiles and moisture from the charge and heating of the charge by

the heat of burning gases which leave the furnace and after-burn at the top;

(b) Reduction of iron and ores with simultaneous formation of metal carbides;

(c) Melting of the elements reduced with the formation of molten metal;

(d) Formation and melting of slag;

(e) Reduction of Manganese and silica from the slag.

Table No. C3-6: Raw materials for Si -Mn and their chemical composition

Sl. No. Constituents Mn Ore Quartz Coke

1 MnO 38-40% -- --

2 SiO2 3% 97% --

3 Al2O3 5% 1% --

4 Fe2O3 17% 0.5% 0.5%

5 Ash -- -- 20%

6 Fixed Carbon -- -- 60%

7 Volatile Matter -- -- Balance

Charge Composition:

Table No. C3 – 7: General Charge Composition

Silico manganese is more stable compounds than manganese carbides. Therefore the

higher the Si content in the Silico manganese less is its carbon content. 20% Silico

manganese is used for smelting of medium carbon Ferro manganese and 30% used for

production of metallic manganese.

Input Material Amount in Ton /ton of finished product

Mn Ore 1.80 T

Fe-Mn Slag 0.60 T

Dolomite 0.35 T

Low Ash Met Coke 0.60 T

Casing Sheet 0.01 T




Silico Manganese is an alloy of silicon, manganese, iron and some other elements in

small percentage. Silicon and manganese are the principal de-oxidants in steel making.

Silico Manganese is used on a large scale as an alloying element in the manufacture of

spring /Alloy steel/ stainless Steel/ tool steel. Silicon has positive effect on mechanical,

physical and chemical properties of steel and is widely used in manufacture of structural,

tool grade and special steel.

The production process of transformer grade steel also requires silicon. Manganese has

the additional property of controlling the effect of sulphur by forming Manganese

Sulphide, which floats out of liquid steel. The quality of silico manganese produced is

given in following table.

Fig. No. C3-11: Process Flow Diagram of Silico-Manganese

MANGANESE ORE

FINES

BRIQUETTE PLANT

ZIGGING PLANT

SLAG

BAY

RAW MATERIAL YARD STORE

MANGANESE

ORE

LAM COKE DOLOMITE FERRO-

MANGANESE

SLAG

ELECTRODE

PASTE

OXYGEN

MIXING BAY

SUBMERGED ELECTRIC

ARCH FURNACE

SILICOMANGANES

E SLAG

LIQUID SILICO

MANGANESE

POURING BAY

CASHING

SHEETS

SILICO MANGANESE

MOULD KNOCKOUT

FINISHED

PRODUCT STORE BRAKING TO

PROPER SIZE




C. FERRO-CHROME

More than 80% of the world production of ferrochromium is used in stainless steel

making. There are four grades of ferrochrome produced commercially, characterized

broadly in terms of their carbon and chromium contents;

High carbon ferrochrome (Cr : >60%, C : 6-9%)

Charge chrome (Cr : 50-60%, C : 6-9%)

Medium carbon ferrochrome (Cr : 56-70%, C : 1-4%) and

Low carbon ferrochrome (Cr : 56-70%, C : 0.015-1.0%)

The demand for low-carbon ferrochrome, produced by reacting Fe-Cr-Si alloy with a

Cr2O3CaO based slag, has decreased dramatically during the last two decades mainly due

to the commercial development of AOD and VOD processes which allow removal of

carbon from stainless steels with acceptable loss (oxidation) of chromium. These low and

ultra-low carbon ferrochrome grades are used mainly for final adjustments of

composition and for super alloys which are melted in coreless induction furnaces. The

ultra-low ferrochrome, produced by aluminothermic reduction of chromite, is relatively

pure but very expensive and consequently, not widely employed in the steel industry.

As a result the high-carbon ferrochrome has become the most widely produced and

consumed grade of chromium-containing ferroalloys. The production of high carbon

ferrochrome is based on reduction smelting of chromite ore with coke in the presence of

silica in a submerged arc furnace.

Physico- Chemical Conditions of the Process:

The conventional smelting process for producing ferrochrome is carried out in electric

reduction furnaces having Soderberg electrodes submerged in the burden material. To

achieve steady process of the reduction reactions, the gas flow and partition through the

burden should be uniform enough to avoid channeling of carbon monoxide gas produced

by the reactions. This requires the charges to be primarily comprised of lumpy ore with a

minimum of ore fines; also, the ore should not be friable so that excessive degradation of

the ore does not occur in the furnace. However, due to increasing mechanization of the

ore mining operations and the necessity of using ferrugneous friable ores, there is

considerable generation of ore fines, with grain size smaller than 1 mm, which calls for

some form of agglomeration (such as pelletizing, briquetting or sintering) of the feed

materials. Another important cost factor of the conventional technology is the high power

consumption which is in the range of 4000-4200 KWh/t-FeCr alloy.

Table No. C3-8: Probable reactions and equilibrium temperatures during

carbothermic reduction of chromite in Fe-Cr manufacture

Reaction T in 0K for P,co = 1 atm

Fe3O4 + C = 3FeO + CO 942

FeO + C = Fe + CO 1001

Cr2O3 + 3C = 2Cr + 3CO 1698

Fe3O4 + 5C = Fe3C + 4CO 983

3FeO + 4C = Fe3C + 3CO 1001

7Cr2O3 + 27C = 2Cr7C3 + 21 CO 1571




SiO2 + 3C = SiC + 2C0 1805

3SiO2 + 2SiC = Si + 4SiO + 2CO 2082

Cr 203 + 3Cr7C3 = Cr23C6 + 3CO 1800

Chromite ores contain iron oxides and gangue which have significant effects on the

reduction reactions in submerged are smelting. Studies on solid-state reduction of

chromite have shown that the iron oxides get reduced more readily than the chromite

oxides. Thus, an ore rich in iron oxide will have high reducibility at relatively low

temperatures. Accordingly, the reduction of chromic oxide in such ores will also occur at

relatively lower temperatures with the likely formation of a carbon-rich chromite carbide

(Cr3C2, or Cr7C3) known to be stable at lower temperatures.

The gangue present in a chromium ore has a significant effect on the temperature of the

smelting zone thereby influencing the carbon content of the ferroalloy. An ore having a

relatively high MgO content will require a higher smelting temperature. Further, if silica

flux addition is reduced or lime is added, the liquidus temperature of the slag will

increase thus promoting high smelting temperatures. In practice, it has been found that

a MgO : AI2O3 ratio close to 1.0 forms high smelting slag which promotes low carbon

levels in ferro alloys.

It has been argued that, because of their high surface to volume ratio, fine ores react

readily at low temperatures forming a product high in carbon. The use of chromite-

carbon agglomerates is reported to have produced high carbon ferrochromium since they

start reacting at lower temperatures. On the other hand, coarse-sized ores will not be as

reactive and thus can survive to a lower depth in the burden and react with high carbon

alloy, thereby, promoting a lowcarbon ferrochromium.

Silicon Content of High Carbon Ferrochrome

The silicon content of the ferrochromium should be low as it is an undesirable element in

stainless steels. A low silicon content is favored by a low operating temperature, a high

carbon content in the ferroalloy and a basic slag. Other impurities are not. Known to

affect the silicon content significantly. In general, the specifications for ferrochromium

call for a silicon level below 3%. This can be achieved by forming a layer of chromic oxide

ore in the lower portion of the slag which oxidizes some silicon in addition to carbon.

Phosphorous Content of High Carbon Ferrochrome

Phosphorous is detrimental to both the mechanical properties and corrosion resistance of

stainless steels. In the submerged arc smelting of chromite ore, a portion of the

phosphorus contained in the charge is vaporized and removed with the off-gas; however,

up to 60 percent can be retained in the alloy.

For low phosphorous levels (<0.02%) in ferrochromium, the phosphorus content of the

raw materials should be as low as possible. Also a relatively low operating temperature

will promote removal of phosphorus into the slag phase, especially under oxidizing

conditions. However, due to the highly reducing and hot conditions in the submerged arc

furnace, there are no easy ways to produce a low phosphorus ferrochromium from high

phosphorus ore/coke.




The charge for making high-carbon Ferro-Chrome is therefore composed of Chromite ore,

coke & quartz. The following processes take place when making high-carbon ferro-chrome:

(a) Removal of volatiles and moisture from the charge and heating of the charge by

the heat of burning gases which leave the furnace and after-burn at the top;

(b) Reduction of chromite ores with simultaneous formation of metal carbides;

(c) Melting of the elements reduced with the formation of molten metal;

(d) Formation and melting of slag;

(e) Chrome ores are mostly friable in nature and necessitate some form of

agglomeration before being charged into the furnace along with other raw

materials. Most of the chrome alloy producers in India have adopted the

briquetting process towards agglomeration of fines. M/s Sonic Thermal would adopt

briquetting technology for the friable chrome ores.

(f) Slag: The slag coming out of the smelting process, though it contains a relatively

low Cr in form of Cr203 contains inevitably metallic FeCr. The metallic FeCr in form

of ''trapped" droplets is incorporated inside of the solidified slag. The slag of the

process is sent to the slag treatment line where it is crushed and screened and the

fractions rich of FeCr having magnetic properties are separated from the remaining

slag by two magnetic separators. The magnetic fractions are returned back to the

smelting furnaces while the poor slag is dumped to the slag deposit. Magnetic

separation is not the most efficient way to recover the mechanical FeCr losses

within the slag. However, the treated slag deposited in the dump area is kept to be

probably retreated by a more sophisticated and efficient method in future

Table No. C3-9: Raw materials for Fe-Cr and their chemical composition

Sl.

No.

Constitue

nts

Chromite

Ore Hard

Lump (%)

Chromite

Ore Fines

(%)

Quartz

(%)

Dolomi

te (%)

Magnesi

te (%)

Coal

(%)

Coke

(%)

1 Cr2O3 40-44 min 50-52 max -- -- -- -- --

2 FeO (total) 11 max 13 max 0.6 2.0-2.5 -- -- --

3 Al2O3 10 max 10 max 1 0.8-1.5 -- -- --

4 SiO2 12 max 5 max 98 4.5-5.8 -- -- --

5 CaO 4-6 4-6 0.3 28-30 45 -- --

6 MgO 15-18 10-12 0.2 18-20 -- -- --

7 Sulphur

(as SO3)

0.005 0.005 -- -- -- -- --

8 Phosphoro

us

0.01 max 0.01 max -- -- -- 0.01

max

0.01

max

9 Cr:Fe 1.8:1-2:1 -- -- -- -- --

10 Ash -- -- -- -- -- 12 max 14 max

11 Fixed

Carbon

-- -- -- -- -- 50

min

84

min

12 Volatile

matter

-- -- -- -- -- 38

max

2 max

13 Moisture -- -- -- -- -- 10 max 8 max




Charge Composition and Utility Consumption:

Table No. C3–10: General Charge Composition in Ton per ton of finished product

Raw Material and Utilities Consumption /Ton of Charge Chrome

(Salable Product)

Chrome Ore Hard Lump (+50 mm size) 0.381 T

Chromite Ore briquette 1.9 T

Chromite Ore Friable Lumps 0.127

Quartzite 0.279

Magnesite 0.05 T

Coal 0.293T

Coke 0.501 T

Electricity Around 3800 to 4000 KWH (With briquette

charge without preheating)

For an average of 40 - 42% Cr2O3 content in the blended ore of the charge and a Cr/Fe

ratio of 3.0 - 3.2, the specific ore consumption per ton FeCr min. 65% is 2.7 - 2.9 tons.

STORE

OXYGEN

CHROME ORE

FINES

BRIQUETTE PLANT

ZIGGING PLANT

SLAG

BAY

RAW MATERIAL YARD

CHROME

ORE HARD

LUMP

CHROME ORE

FRRIABLE

LUMPS

QUAR

TZITE

COAL

ELECTRODE

PASTE

MIXING BAY

SUBMERGED ELECTRIC

ARCH FURNACE

FERROCHROME

SLAG

LIQUID

FERROCHROME

POURING BAY

FERROCHROME

MOULD KNOCKOUT

FINISHED

PRODUCT STORE BRAKING TO

PROPER SIZE

MAGN

ESITE

COKE

Fig. No. C3-12: Process Flow Diagram of Ferro-Chrome Alloy




Adaptability of Existing Furnaces for Production of Ferrochrome:

In order that the same furnaces can be used for different products the furnaces must be

flexible so that they can be suitable for manufacture of different products.

o For manufacture of different products different charge composition will be made

which have different electrical resistance.

o For the reduction reaction to be ensured for different feed compositions, different

current densities will be required.

o The electrodes used should be suitable for different current densities which in turn

should be suitable for increase/decrease in surface temperature of the electrodes

as reaction temperature will vary for different products.

o The tapping voltage will be different for different products. In modern furnaces on

line voltage changing device have been incorporated to adjust the tapping voltage

as per need.

o The transformer capacity needs to be adequate foe different electrical load.

In modern furnaces all the above have been inbuilt so as to make it flexible for

manufacture of different products.

Metal Recovery from Slag and Mixture:

Some quantity of mixtures gets generated at various point of handling of molten metal &

slag. Manual separation of metal and slag from the mixture is not economical beyond

certain level. So such mixtures are processed in the Metal recovery plant for metal

recovery. In the Metal recovery plant the mixture is crushed to smaller size with the help of

a jaw crusher followed by cone crusher in order to ensure better liberation of metal. The

mixture is subjected to gravity separation in water medium in the jigs. The liberated metal

is separated which contains still some amount of slag mix and nonmetallic portion. They are

separated out by screening and manual picking.

The same process is repeated for processing of pure slag. Pure slag is not actually pure. It

contains metal content to the extent of 4 – 4.2 % mainly in the form of nodules and

entrapments. Undersize metal particles are processed in the jigs only to remove the small

quantity of nonmetallic content present in them.

After making the fines and chips sized output from metal recovery plant free from non-

metallic contents or reducing it to the desired level they are handed over to sales yard for

dispatch after confirmatory analysis.




Fig. No. C3-13: Process Flow Diagram of Metal Recovery Plant




The slag generated from the furnaces contains 4-4.2% of saleable metal (Ferro Alloys). The

entrapped metal is recovered from the slag in the metal recovery plant (MRP). The metal

recovery plant consists of:

Feed Hoppers

Drizzly Feeder

Jaw Crusher

Cone Crusher

Vibrating Screen

Storage Hopper

Jig Feed Hopper

Hydraulic Jig

Other accessories such as Motors, conveyors etc.

Process flow diagram of metal recovery plant is given above.

3.6 Raw Materials Required along with estimated quantity, source, marketing area of

final product/s, Mode of Transportation of raw materials and Finished Product/s

3.6.1 Table No. C3– 11: Raw Materials Required, Likely source, Mode of Transportation

Sl.

No.

Raw Material Consumption

in tonnes per

ton of product

Amount

in tonnes

Likely Source Mode of

Transport

Ferroalloy Plant-Ferro chrome (89,580 TPA)

1. Chromites Ore Hard

Lump

0.32 28,640 Sukinda, Jajpur

dist., Odisha

By rail /road in

covered trucks

2. Chromite Ore

Briquettes /Hard lump

1.9 170050 Own plant --

3. Chromite Ore Friable

Lump

0.13 11635 Sukinda, Jajpur

dist., Odisha

By rail /road in

covered trucks

4. Quartzite 0.28 25060 Mines in Bankura,

W. Bengal and

Chhatisgarh

By rail /road in

covered trucks

5. Coke 0.5 44750 Local Market By Road in

Covered

Trucks

6. Coal 0.3 26850 Nearby Coal Mines

of ECL & BCCL

By rail /road in

covered trucks

7. Electrode Paste 0.025 2237 Maharastra Carbon

Ltd., Graphite

India, Durgapur

By rail /road in

covered trucks

Ferroalloy Plant-Ferro Manganese (85,800 TPA)

1. Manganese Ore 2.3 197340 OMC Manganese

mines in Odisha

By Rail /Road in

covered trucks

2. Dolomite 0.35 30030 Biramitrapur,

Sundargarh

dist., Odisha

By Rail /Road

in covered

trucks




3. Low Ash Met Coke 0.6 51,480 Durgapur Steel

Plant /Coking

Plant of

Durgapur

Projects Ltd.

By Rail /Road

in covered

trucks

4. Electrode Paste 0.015 1,287 Maharastra

Carbon Ltd.,

Graphite India

Ltd., Durgapur

By Rail /Road

in covered

trucks

Ferroalloy Plant-Silico Manganese (60,720TPA)

1. Manganese

Ore/Pellets

1.79 108689 Manganese

Mines in Odisha

/Chhatisgarh

By Rail /Road

in covered

trucks

2. Dolomite 0.35 21253 Mines in Odisha,

Chhatisgarh

By Rail /Road in

covered trucks

3. Fe-Mn Slag 0.6 36432 Own Production --

4. Low Ash Met coke 0.6 36432 Imported coal From Australia

by Ship & then

by Rail /Road

5. Electrode Paste 0.025 1518 Maharastra

Carbon Ltd.,

Graphite India

Ltd., Durgapur

By Rail /Road

in covered

trucks

6. Cashing Sheet 0.01 607 Steel Plants Of

SAIL/TISCO

By Road

3.6.2 Table No. C3 - 12: Quantification of Product after Expansion, Marketing Area &

Mode of Transportation

Sl.

No.

Product Amount, TPA Market Mode of

Transport

1. Ferroalloys 85,800 (Fe-Mn),

60,720(Si-Mn) or

89,580(Fe-Cr)

Will be sold to steel

manufacturers in West

Bengal

By Road in

covered trucks

3.6.3 Resource optimization/recycling and reuse envisaged in the project, if any,

should be briefly outlined

The process selected envisages recycling all the materials collected in the pollution

control equipments thereby ensuring no generation of solid waste.

Ferro manganese slag generated in the manufacture of Fe-Mn will be used for the

manufacture of Silico-Manganese.

Cooling Water used in the process will be recycled.

Washing water from jiggning plant will be treated in settling tank and completely

recycled in a closed loop with make –up water.




3.6.4 Availability of water & its source; energy /power requirement & source

3.6.4.1 Water requirement and its source:

Table No. C3-13: Water Requirement and its source

Sl.

No.

Facility Water Required

m3/day

Source

1. Make up water for Ferroalloys

Cooling Make up

Soft water plant

regenerator

350

30

From the Water Header of

Barjora Industrial Estate or by

tankers from river Damodar

2. Briquetting 20 - do -

3. Jigging 100 - do -

4. Domestic 06 - do -

Total 506

N.B: There is no Water treatment plant at present. The process water being purchased

by tankers. In future when the supply through the Industrial Estate water header would

be started, a water treatment plant may be considered depending on water quality.

.

5 m3/day

Fig. No. C3-14: Water Balance Diagram

506 m3/day

350 m3/day

30 m3/day Settling tank Used for dust

suppression

100 m3/day

Settling Tank

20 m3/day

6m3/day STP

Green Belt

Development

Jigging plant

(make-up)

Soft water

Regeneration

Cooling Water

(make-up)

Briquetting plant

Domestic Use




3.6.4.2 Power Requirement and its source:

Table No. C3-14: Power Requirement and its source

Sl.

No.

Plant Facility Power Requirement

per Tonne of Product

(Kwh)

Annual

Production

(Tonnes)

Total Power

Requirement

(MW)

1 Ferroalloy Plant 4000 89,580 40.9

Total 40.9 say 41 MW

The Ferroalloys plant is energy intensive process. We have taken ferrochrome production

as basis as the power demand for Fe-Cr is high in comparison to Fe-Mn. As such the total

estimated demand of power for the entire project shall be 40 MW. Power will be drawn

from the DVC grid as it s being drawn at present.

3.6.5 Quantity of waste to be generated (liquid & solid) and scheme for their

management/ disposal

3.6.5.1 Quantity of liquid waste to be generated and scheme for their management/

disposal

The plant will be designed for a zero effluent discharge. Effluent generated in various

units will be treated so that it can be used for secondary purposed like toilet flushes, floor

washing, green belt development dust suppression etc. In the table below tentative

disposal amount and their treatment and reuse scheme is furnished.

Table No. C3 - 15: Waste Water Generation/Recycle and Reuse

Sl. No.

Facility Waste water generation/Recycle/Reuse

1 Ferroalloy

Plant

There will be no process effluent. Cooling water will be

completely recycled in closed loop with makeup water. 35 KLD

waste water generated from soft water plant will be taken to

guard pond after treatment in settling pond and reused in dust

suppression/ green belt development

2 Soft Water

Regeneration

30 KLD will be reused for dust suppression

2 Jigging Plant 90 KLD will be recirculated through settling pond

3 Domestic

effluent

5 KLD will be treated in STP and reused for green belt

development.




3.6.5.2 Table No. C3 - 16: Quantity of solid waste to be generated and management/

Disposal Scheme:

* The ferroalloy furnaces can be inter alia used for manufacture of Fe-Mn, Si-Mn,

Fe-Si, or Fe-Cr. In that case the maximum of the slag produced has been shown.

* All the solid wastes will be subjected to TCLP test to ascertain that they are non-

hazardous before their disposal.

3.5.6.3 Source of Air Pollution and Control Measures

Table No. C3-17: Source of Air Pollution and Control Measures

Sl.

No.

Source of Pollution Pollutants Measures adopted for control

1. Submerged Electric Arc Furnace

I Smelting Particulate

Matter

Dust extracting system with

hooding connected to Ambient

Air Cooler, Cyclone Separator,

Bag Filter and stack

Water sprinkling system

II Taping

III Product Handling

IV Unloading of Raw

Materials

V Tapping of gases Dust Fume extraction systems such

as canopy hooding/other

tapping hoods duly ducting the

emissions from various sources

connected to Bag filter

Water sprinkling system

a. Exposed Metal

b. Slag Surfaces

c. Cast Handling

d. Refining

e. Product Crushing

and Cleaning

Sl.

No.

Description of

Solid Waste

Quantity in TPD Disposal Practice

Existing

Plant

After Proposed

Modification of

Product Mix

I. Ferroalloy Plant

1 * Slag from ferroalloy plant

Fe-Mn slag 120 120 Used as raw material for Si-Mn

Si-Mn slag 212 212 Used as road construction material

Fe-Cr Slag -- 272 TCLP test will be conducted and

then the slag will be used in road

making.

2 Dust from APC devices 0.7 0.7 Recycled back to Briquetting Plant

II. Hazardous Wastes

1. Used Oil /Used

Lubricants /used

cotton wastes

0.2 TPA 0.2 TPA Will be sold to authorized Re-

processors





Village: Namabandh-Sitarampur, PO: Ghutgoria, PS: Barjora, Dist.: Bankura, WB

FACILITIES:

Ferroalloys Plant

WATER REQUIRED:

Amount: 506 Kl/day

Source: River

Damodar-through

Durgapur Municipal

Corporation Pipes

Land: 15 acres

of allotted plot in

Plasto Steel Park

Industrial Area,

Bankura, WB

RAW MATERIALS:

- Non coking Coal

- Met Coal

- Dolomite

- Chromites Ore

- Manganese Ore

- Quartzite

ENVIRONMENTAL IMPACT ASSESSMENT-ATTRIBUTES

Air:

Process

emission,

Fugitive

emissions,

Vehicular

emossions.

PM2.5,

PM10,

SO2, NOx

Water: CT

blow down,

Soft water

regenerati

on, pH,

TDS, TSS

Noise:

Noise

generating

Machines,

Vehicles

Soil:

Excavation,

Seepage/

drainage

from

material

storage

area and

ash pond

Bio-

diversity:

Impact due

to noise, air

pollution,

water

pollution

and loss of

habitat

R&R:

Evacuati

on due

to land

acquisiti

on

Solid Waste:

Ferroalloy slag,

Bag filter dust,

HAZ WASTE:

Used Oil, Used

Resin

AIR:

ESP

Bag

Filter

WATER:

ETP, STP,

Recycle

and

Reuse

NOISE:

Green Belt,

Pads,

Insulation,

Silencers,

Enclosures,

PPE

SOIL:

Plantation,

Water

Sprinkling

BIO-

DIVERSITY:

Conservation

of Flora and

fauna. No Wild

life sanctuary

within study

area

R&R:

Land

already

procured.

No R&R

action plan

SOLID WASTE:

Disposal in solid

waste dump

yard, reused/

recycled.

Hazardous waste

disposed in

secured land fill,

used oil sent to

authorized re-

processers

ENVIRONMENTAL MANAGEMENT PLAN

Fig. No. C3-15: Schematic Diagram of EIA & EMP Process of the Project




CHAPTER - 4

SITE ANALYSIS

4.1 CONNECTIVITY

a. This product mix modification project is already existing at village Namabandh-

Sitarampur, PO:Ghutgoria, PS:Barjora, Dist. Bankura, WB in the Plasto Steel Park-an

industrial Estate Developed by the West Bengal Industrial Development Corporation.

The site is having advantages of proximity to 2 Coalfields – i. e. Ranigung Coal field of

ECL and Dhanbad coalfields of BCCL.

b. Nearest Railway station is at Durgapur on Eastern Railway which is about 14 Km N-E

of the project site.

c. H.T. power line corridor of DVC is running over the subject plot of land.

d. Nearest sea port is at Haldia at a crow-fly distance of 274 KM in S-E direction of the

project site.

e. Other sea ports like Kolkata, Paradeep and Vishakhapatanam are also well connected

by road and rail.

f. Nearest Air Port is at Andal at a distqance of 15 Km N-W and Netaji Subhas Chandra

Bose Airport at Kolkota is at an aerial distance of 150 KM East of project site.

g. Nearest National Highway NH 2 is at a distance of 18 KM and NH 60 (State Highway)

is at 2Km.

Location Advantages

The location of the project at Namabandh-Sitarampur, District-Bankura has the following

advantages:

a. Proximity to Coal mines of ECL & BCCL which will ensure easy supply of coal at

reduced cost of carriage.

b. Mn Ore and Chrome ore can be procured in rake loads from mines in Odisha (SE

railway) and unloaded in nearby railway siding of E Railway near Durgapur.

c. The sub-station to supply power to the plant is near the gate. This sub-station draws

power from overhear DVC grid.

d. Location of the site near Durgapur, Bankura and Asansol will provide for adequate

social infrastructures.

e. Location of the site close to National Highway No. 60 and NH 2 gives easy access and

convenience for transportation.

f. Bankura district is categorized under Group ‘C‘ of Incentive Scheme of Govt. of West

Bengal which provides for additional incentives.

4.2 LAND FORM LAND USE AND LAND OWNERSHIP

The study area comprises of different land forms like river bodies, reserve forests, hills,

water reservoir etc. The distance of such land forms from project site are mentioned

below;




Table No C4- 1: Location of Water bodies, Reserve Forests & Hill from Project Site

Location Distance Direction

From Project Site

Rivers

Damodar River 5.6km NE

Barjor Nala 3.8km N

Tartari Nala 1.6km NW

Kanjor River 6.7km SE

Subhankari Nala 4.2km S

Water Reservoir

Kanjor Reservoir 7.5km SE

Barrage on Damodar River 6km NE

Reserve/Protected Forests

Beliator P.F. 900m W

Gangajalghati P.F. 9km WSW

Gobindapur P.F. 8.6km S

4.3 TOPOGRAPHY (ALONG WITH MAP)

Bankura district has been described as the “Connecting Link between the Plains of Bengal

on the east and Chota Nagpur Plateau on the west.” The areas to the east and north-east

are low lying alluvial plains, similar to predominating rice lands of Bengal. The surface

gradually rises to the west giving way to undulating country, interspersed with rocky

hillocks. Much of the country is covered with jungles. Bankura district is bounded on the

north and a part of north-east by the district of Burdwan from which it is separated by

the natural barrier of the Damodar River. The south-east of the district is bounded, over

a small distance, by the district of Hooghly, while along the entire southern and western

boundaries of Bankura lies respectively the districts of Medinipur and Purulia (Source –

www.Bankura.org – Natural Resource).

Bankura consists of two different tracts. The western portion marks the gradual descent

from the table land of Chota Nagpur to the delta of lower Bengal, consisting largely of

spurs projecting from the western table land and of low swelling ridges. However, there

is no marked ridge of hills. In the central portion of the district there are rolling downs

eventually merging with the alluvial plains. Biharinath which is located near Saltora is the

highest hill of the district having height of 1480 ft (451 meters.). Susunia is the second

highest hill of Bankura having height of 1450 ft (442 meters.). These hills are found in

the high hilly region/hard rock area in the western part of the district. Contour map of

Bankura District with indicating of the Project Site has been presented in Fig. No. C4-1.

The general elevation of the area ranges from 16 to 150 m above the mean sea level

(MSL) with a gentle gradient from west to east. Most of the rivers originate from western

upland and flow almost parallel to each other carrying seasonal flow of water. Major river

Damodar forms the northern boundary of the district and flows from northwest to

http://www.Bankura.org




southeast. The river Dwarakeswar drains the central part of the district, while river

Kanqsabati flows in southeasterly direction draining the south-western part of the district.

The western part of the district has poor, ferruginous soil and hard beds of laterite with

scrub jungles and Sal (Shorea robusta) woods. Long broken ridges with irregular patches

of more recent alluvium have marks of seasonal cultivation. During the long dry season

large extents of red soil with hardly any trees lend the country a scorched and dreary

appearance. In the eastern part the eye constantly rests on wide expanses of rice fields,

green in the rains but parched and dry in summer.

Bankura district can be geologically divided in three categories according to the height of

a total land area of 3,84,496 hectors

1. High hilly region / Hard rock area: The region consists of the areas like Saltora, Mejia,

Khatra, Ranibandh, Gangajalghati etc. covering 176915 Hec. Most of this area does

not have irrigation facility.

2. Uneven lands / Hard rock ring area: This consists of the areas like Bankura, Barjora,

Chatna, Onda, Simlapal, Taldangra, Raipur, Sarenga etc. It covers 150611 Hec.

3. Even alluvial lands / alluvial area: This type of land includes the areas like Bishnupur,

Sonamukhi, Patrasayer, Indus, Joypur, Kotulpur etc. covering 56970 hec.

The study area consists of a rolling country covered by laterite and alluvium. While

metamorphic or gneissose rocks are found to the extreme west, to the east there is a

wide plain of recent alluvium. Strong massive runs of hornblendic varieties stretch across

the region in tolerably continuous lines, the general strike being nearly east and west.

The most characteristic geological feature of the area is the area of laterite and

associated rocks of sand and gravel. At some places one finds hard beds of laterite. At

other places it is decomposed and reorganised. Locally, the ferruginous rock is called

kankar. The calcareous concretions, commonly used as the sources of lime, are known as

ghutin. The Gondwana system is represented in the northern portion of the area. The

beds are covered with alluvium contains seams of coal belonging to the Raniganj system.

Physiographic Map of the District - Bankura representing the Project Site has been

presented by Figure C4-2.




Fig. No. C4-1: Contour Map, Bankura District WB.




4.4 Existing Land use pattern (agriculture, non-agriculture, forest, water bodies,

(including area under CRZ), shortest distance from the periphery of the project

to periphery of the forests National Parks, wild life sanctuary, eco sensitive

areas, water bodies(distance from HFL of the river), CRZ. In case of Notified

Industrial Area a copy of the notification should be enclosed

No forest land is involved in the Plant area. The wildlife map showing the distance of the

project site from the National Park / Sanctuaries and Elephant /Tiger Reserve and their

corridors is given in Fig. No. C4- 3.

C4-2




Sanctuaries & National Parks

1. Ballavpur

2. Bethuadahari

3. Bibhutibhusan

4. Buxa

5. Chapramani

6. Chintamani Kar

7. Haliday

8. Jaldapara

9. Jorepokhri Salamander

10. Lothian Island

11. Mahananda

12. Raiganj

13. Ramnabagan

14. Sajnakhali

15. Senchali

16. Buxa

17. Gorumara

18. Neora Valley

19. Singalila

20. Sunderban

Tiger Reserve

1. Buxa

2. Sunderban

List of Sanctuaries/National Parks/

Tiger Reserves in West Bengal

Fig. No. C4-3 : Map showing National Parks, Wild Life Sanctuary




Fig. No. C4-4 : Land Use /Land Cover Map




The land use map of 10km radius of the project area is given above, which shows the

land use pattern in the surrounding of the plant area. The land use / land cover of the

region can be divided into 7 categories. The categories of land use/ land cover for the

proposed study area are shown in the following table;

Table No. C4-2: Land Use Classification

Sl. No. Land Use Category Area in Sq. Km Area in %

1. Agricultural Land 201.665 64.17

2. Plantation 5.125 1.63

3. Forest Cover 48.28 15.36

4. Human Settlements 15.877 5.05

5. Urban area 14.561 4.63

6. Sandy bed 10.985 3.50

7. River/ Water body 17.793 5.66

Total 314.286 100

4.5 EXISTING INFRASTRUCTURE

The Ferroalloy plant is already operating. The industrial area is well developed with well

connected road and rail network. The social infrastructure is also well developed

4.6 SOIL CLASSIFICATION

National Bureau of Soil Survey & Land Use Planning (Indian Council of Agricultural

Research) carried out soil survey of Bankura district in West Bengal. Barjora police

Station area is a part of Bankura district and it forms the part of study area of this PFR.

The following are the soil survey data of the area which are relevant from the point of

view of soil classification.

The land under Barjora police station limits has the following land series associations

which are briefly stated here along with their significant character. The data have been

collected from the web.

1. The Dulaidi series

The Dulaidi series belong to the coarse-loamy, mixed, hyperthermic family of Typic

Ustifluvents. The soils, formed in coarse textured flood plain alluvium, are medium to

coarse textured, very deep, well drained and moderately acidic in nature. The available

moisture capacity is low to medium. These soils are cultivated to mustard, til, maize and

pulses. They are grouped under land capability class Ills and land irrigability subclass 3s.

The productivity potential is medium.

2. The Dayalpur Series

The Dayalpur soils belong to the fine-silty, mixed, hyperthermic family of Typic

Haplaquepts. The soils, formed in alluvium, are moderately fine textured, very deep,

imperfectly drained, and medium to slightly acidic in nature. The available moisture

capacity is medium. These soils are mostly cultivated to rice. The soils are grouped under

land capability class IIw and land irrigability class 2d. The productivity potential is

medium to High.




3. The Kantaban

The Kantaban soils belong to the fine, mixed, hyperthermic family of Typic Haplaquepts.

The soils are developed in alluvium and are moderately fine in texture, very deep,

imperfectly drained and very strongly acidic in nature. Available moisture capacity is

medium. The soils are cultivated to rice. They are grouped under land capability class

IIw, and Irrigability class 2d. The productivity potential is high.

4. Ramsagar Series

The Ramsagar soils belong to the fine, mixed, hyperthermic family of vertic Haplaquepts.

The soils, formed in alluvium, are fine textured, very deep, moderately well drained and

neutral to mildly alkaline in nature. The available moisture capacity is moderate. The

soils are grouped under land capability class IIw and land irrigability class 2d. The

productivity potential is high.

5. Mringindih Sries

The Mringindih soils belong tto the fine-loamy, mixed, hyperthermic family of Ultic

Palusatalfs. The soils formed in old alluvium are medium textured, very deep, well

drained and very strongly acidic in nature. The available moisture capacity is medium.

These soils are partly under forest and partly cultivated to vegetables, wheat and

potatoes. The soils are grouped under land capability class lIs and land irrigability class

2s. The productivity potential is medium.

6. Taldangra Series

The Taldangra soils belong to the loamy-skeletal, mixed, hyperthermic family of

Plinthustalfs. The soils, formed in old alluvium, are moderately fine textured, moderately

deep to deep, well drained and very strongly acidic in nature. The available moisture

capacity is medium. These soils are used for horticultural and plantation crops viz.

mange, citrus sp., guava and cashew. They are grouped under land capability class IIIe

and land irrigability class 3s. The productivity potential is low.

7. Ranga Series

The Ranga soils belong to the clayey-skeletal, mixed, hyperthermic family of Lithic

Ustochrepts. The soils, formed on upper undulating plain, are, coarse textured,

moderately deep, well drained and very strongly acidic in nature. The available moisture

capacity is low . These are under forest vegetation cromprising Sal and Mahua. These

soils are grouped under land capability class VIe and land irrigability class 6. The

productivity potential is low.

8. Bhulanpur Series

The Bhulanpur soils belong to the fine-ioamy, mixed, hyper thermip -family of ultic

Haplustalfs. The soils, formed in moderately coarse textured alluvium, are deep, sandy

clay loam in texture, well drained and strongly acidic in nature, the AWC is low. The soils

are under forest (Sal, Mahua). They are grouped under land capability class VIe. Their

productivity potential is low.

9. Hatikheda Series

The Hatikheda soils belong to the fine, mixed, hyperthermic family of Udic Ustochrepts.

The soils, formed in alluvial and colluvial deposits, are fine textured, very deep,




imperfectly drained and medium acidic in nature. The available moisture capacity is

medium. These soils are cultivated to paddy. These are grouped under land capability

class IIw and land irrigability subclass 2t. The productivity potential is medium.

10. Hariharpur Series

The Hariharpur seriess belong to the fine-loamy, mixed, hyperthermic family of Ultic

Haplustalfs. The series is formed on alluvial deposits, are moderately coarse textured,

very deep, moderately well drained and moderately acidic in nature. The available

moisture capacity is medium. They are cultivated to pulses - black gram and green gram;

mustard, vegetables, etc. These soils are grouped under land capability class lIs and land

irritability class 2s. Their productivity potential is medium.

11. Asugaria Series

The Asugaria soils belong to the loamy-skeletal, mixed, hyperthermic family of Typic

Ustorthents. The soils, formed in colluvial deposits, are moderately coarse textured,

shallow, well drained and very strongly acidic in nature. The available moisture capacity

(AWC) is low. The soils are mostly cultivated under rainfed agriculture for crops such as

maize, black 9ram (urad, Kalai), green gram(mung), mustard (sarso). They are classified

under land capability class VIe, land irrigability class 6. In general the productivity

potential of these soils is low.

4.7 CLIMATE DATA FROM SECONDARY SOURCES

The climate of the district is of tropical dry subhumid, with normal annual rainfall ranging

from 1100 mm in the western part to 1400 mm in the eastern part. The mean daily

minimum temperature ranges from 120C (in winter) to the maximum of 460C (in

summer). The variations in the number of rainy days and soil moisture limitations are

common. Severe drought periods lasting for weeks adversely affect the crop growth and

yields during main cropping Kharif season.

The weather data as recorded at IMD Jamshedpur which is the nearest IMD station is

provided below. Data produced may have slight variations for Bankura as Jamshedpur is

about 100 Km away from Bankura.

Average Temperature

ANNUAL JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC

F 78.9 66 70.7 80.3 87.4 90.2 87.5 83.1 82.6 82.5 79.4 71.7 65.4

Average High Temperature

F 89.2 78.7 83.4 93.8 100.5 101.9 96.1 89.3 88.3 89.1 87.8 83.1 78.1

Average Low Temperature

F 68.7 53.4 58 66.8 74.4 78.5 78.9 76.9 77 76.1 71.1 60.3 52.8

Average Precipitation

In mm 55.6 0.5 1.2 1.3 1.6 2.9 8.9 11.8 13.9 9 3.8 0.4 0.1

Average Number of Days with Precipitation

Days 71.3 1 1.9 2.1 3.1 5.1 10.9 14.6 15.4 11.2 4.6 1 0.5

Average Length of Day

Hours 12.5 11.3 11.8 12.4 13.1 13.7 14 13.8 13.3 12.6 12 11.4 11.1

Table No. C4-3: Monthly Weather Averages Summary (Years on Record 102)




4.8 Social Infrastructure Available:

4.8.1 Educational Facilities Table No. C4-4: Educational Facilities in Bankura District

Sl. No. Type of Educational Facility Number

1. Sishu Siksha Kendra 448

2. Primary School 3551

3. Junior High School 348

4. Secondary / Madhyamik High School 189

5. Higher Secondary School 248

6. High Madrasa 3

7. Degree College 15

8. Technical College (Bishnupur, Chhatna, Sabrakone) 3

9. Engineering College 2

10. Medical College 1

11. Day Students’ Home 1

12 District Library 1

4.8.2 Health Facilities

Table No. C4-5: Health Facilities

Sl.

No.

Type of Health

Facility

No. of

Facility

No. of

Beds

Sl.

No.

Type of Health

Facility

No. of

Facility

No. of

Beds

Facilities under H & FW, Govt. of W.B. Facilities under Pvt. /NGO

1 Medical College &

Hospital 1 1217 1

Nursing Homes under Pvt./ NGO

48 829

2 Sub Divisional

Hospital 2 350 2 X-Ray Diagnostic Centre 25 NA

3 Rural Hospital 5 220 3 Pathology Diagnostic

Centre 46 NA

4 Block Primary

Health Centre 17 495 4 USG Diagnostic Centre 51 NA

5 Primary Health

Centre 70 496 5 CT Diagnostic Centre 4 NA

6 Sub Centre 564 NA 6 Polyclinic Diagnostic

Centre 9 NA

7 PP Unit including

Urban Family

Welfare Centre

3 NA 7 Diagnostic Centre (Lab.)

Run by PPP in RH 4 NA

8 Gouripur Leprosy

Hospital 1 550 8

Diagnostic Centre (Lab.) Run by PPP in BPHC

3 NA

Total : 663 3328 Total : 190 829

Facilities under other than H & FW (No. of Facility: 4, No. of Beds: 68)

1 District Correctional

Home Hospital 1 8 3 Bankura Police Hospital 1 10

2 RLT & RI, Gouripur 1 50 4 S.E. Railway Hospital 1 NA




CHAPTER - 5

PLANNING BRIEF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, TRANSPORTATION, ETC)

TOWN & COUNTRY PLANNING /DEVELOPMENT AUTHORITY CLASSIFICATION

The proposed project is located at Village: Namabandh-Sitarampur, PO: Ghutgoria, PS:

Barjora, Dist.: Bankura, West Bengal in the Plasto Steel Park area. Already an alloy steel

Plant is with 4 X 7.5 MVA SEAFs and 1 X 5 MVA SEAF are operating for manufacture of

Fe-Mn and Si-Mn with consent to operate from WBPCB. The proponents plan to utilize the

facility for production of Fe-Cr. As such no additional facility will come up and the facility

will be utilized with variations in operational conditioned for manufacture of Fe-Cr. Main

raw material like manganese ore, chrome ore, Lime stone etc will be brought in rake

loads from the neighboring state Odisha. Non coking coal will be brought from ECL or

BCCL coal fields which are very nearby. Coking coal will be brought from Raniganj and

Jharia Coal fields. Infrastructure facilities in the area are well developed and the sight has

well connectivity by road and rail. The nearest town Durgapur, Asansol and Bankura are

14, 40 and 30km away respectively and easily accessible by road. All facilities such as

schools, collages, hospitals and markets are available. Durgapur and Asansol are bigger

industrial towns which offer good market for the products.

(ii) Population Projection

The Submerged Electric Arc Furnaces are being operated by skilled operators and

experienced engineers. Same set of personnel shall operate the plant when the plant

switches from present product range to manufacture of Fe-Cr. There will not be any

increase in population due to change in the product mix. The development of new

residential facility is not contemplated.

(iii) Land use planning (breakup along with green belt etc.)

The proposed project will be constructed with well developed green belt all around the

boundary of the plots as well as all around the various units. The land use breakup of the

proposed project is given below.

Table No. C5 – 1: Existing Area of M/s Sonic Thermal Pvt. Ltd.

Sl.

No.

Item Existing Area

in acres

1 Plant Built Up area 2.5

2 Raw Material and Finished Product-Storage Yard 2.0

3 Solid Waste Storage 2.5

4 Other Ancillary Area 1.0

5 Water Reservoir & Rain water harvesting 1.0

6 Internal Roads and Administrative Building 1.0

7 Green Belt 5.0

Total Land 15




Total land of the proposed project is 15 acres and about 5 acres land will be converted to

Green Belt. It is proposed to plant 600 saplings every year. Suitable plant species will be

planted all along the internal road, raw material storage & handling, ash/dust prone

areas. It is planned to plant saplings considering the parameters as type, height, leaf

area, crown area, growing nature, water requirement etc. Green belt will be

progressively developed on land earmarked for the purpose.

(iv) Assessment of Infrastructure Demand (Physical & Social)

The road and rail infrastructure are already well developed in the area which are required

for the transport of the raw material from and finished goods to the various part of the

country. The manpower will be mostly sourced from the locality and their social

infrastructure is also developed. The inflow of money in terms of taxes to Gram

Panchayats and salaries to the manpower will further improve the physical and social

infrastructure.

(v) Amenities/Facilities

The following facilities shall be provided in the project site:

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

i. Communication facility.

j. Emergency vehicle for shifting the workers during accident etc.

Office space has been provided as per good practice and canteens, toilets and restrooms

according to norms laid down in Factories Act 1948 and amendments thereof. The above

facilities shall also be adequately furnished and equipped.




CHAPTER - 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

The infrastructural facilities are already developed in the premises of the unit as per the

requirement and no additional facilities are required as the proposal is only for

modification of product mix.

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

The local peoples will be employed for the proposed project. The development of

residential area is not needed.

6.3 GREEN BELT

Green belt development work will be undertaken on area of 5 acres. About 600 saplings

will be planted per acre. The details of existing Green Belt and Development of Green

Belt Plan for the proposed project are given below. The existing plantation has been done

alongside the boundary wall and in the vacant land earmarked for the purpose. The

plants in the existing green belt include Devil Tree (Alstonia scholaris), Mahaneem (Melia

azadiracta), Gulmohar (Delonix regia), Acasia (Acacia auriculiformis), Mango (Mangifera

indica), Silk Tree (Albizia procera) with survival chance of 65%. The future development

will also include above local species.

Table No. C6 – 1: Existing & Proposed Plantation

Sl.

No.

Year of Plantation Area (in

acres)

No of

Saplings

Cumulative

Area

% of Total

Area

1 Existing Plantation 2 1200 2 13.3

2 1st after availing EC 1 600 3 20.0

3 2nd year 1 600 4 26.6

4 3rd year 1 600 5 33.33

Total 5 3000

6.4 SOCIAL INFRASTRUCTURE

The social infrastructure in the region is well developed due to the proximity of the

location to Durgapurand Assansol. Further development will be undertaken through CSR

activities. Details of CSR activities already done and proposed to be carried out are

detailed below.

Table No. C6 - 2: CSR Activities Taken Up During Last Four Years

Sl. No. CSR Activity Taken up Year Expenditure

1 Pond Renovation in Namobandh,

Ghutgoria, Kadasol & Jaysinhapur villages

2014-15 Rs.1,5 lakhs

2 Modernisation of Library in Namobandh

village & renovation of School boundary

wall

2015-16 Rs.1.5 lakhs




3 Supply of drinking water in summer

months to the villages under Barjora GP,

Ghutgoria GP and Pakhannaa GP

2013-14, 2014-

15, 2015-16

and 2016-17

Rs. 1.5 lakhs

4 Conducting eye camps for eye check up

and distributing free medicines

2016-17 1.25 lakhs

5 Tube well facility in nearby villages of

Ghutgoria, Kadasol, Tikargram and

2016-17 1.45 lakhs

The company will continue to do CSR activities in future. It is proposed to install tube

wells in the water scarcity areas in future. CSR activities will be finalized after

consultation with the villagers as per demand in public hearing. The annual budgetary

provision will be made as per MoEF norms.

6.5 CONNECTIVITY (TRAFFIC & TRANSPORTATION ROAD /RAIL /WATER WAYS, ETC)

The connectivity in terms of traffic, transportation road is already developed and good.

There are well connected roads in the area. Nearest National Highway is NH2 (connecting

Kolkata to Delhi) is at a distance of 18 Km from project site, NH60 is at a distance of

2Km from the project site. The nearest railway station and railway siding is at Durgapur

at a distance of 14 km from project site.

6.6 DRINKING WATER MANAGEMENT (SOURCE & SUPPLY OF WATER)

The water for the factory will be sourced from the water header of Barjora Industrial Area

of WBIDCL. Part of the same water will be use for sanitation and drinking purpose after

proper treatment. For the adjoining areas in the buffer zone of 10 km radius, tube wells

will be dug in water scarcity areas. In summer the drinking water is being supplied in

tankers to the villagers whenever required. The same practice will be continued to meet

temporary scarcity conditions

6.7 SEWERAGE SYSTEM

Sewage treatment plant will be provided for the treatment of domestic effluent and

treated effluent will be utilized for green belt development.

6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial effluent generated from proposed project will be treated in Settling Pond and

ETP. The treated effluent will be utilized for Green Belt development.

6.9 SOLID WASTE MANAGEMENT

Dusts collected in pulse jet bag filters will be reused in pellet manufacture in sister

briquette plant Majority of solid wastes will be utilized for pellet manufacture. The solid

waste generated in Ferromanganese plant will be used for silico-manganese. Slag

generated in Ferrochrome manufacture will be under go TCLP test. Subject to passing the

test the same will be utilized for the construction of the roads and balance quantity will be

disposed of by landfill. If the slag will be found to be hazardous, then it will be given to

hazardous waste reprocessors.

6.10 POWER REQUIREMENT & SUPPLY/SOURCE

The power requirement of about 41 MWH will met from DVC Grid.




CHAPTER - 7

REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT

AFFECTED PERSON INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS

LABORERS (A BRIEF OUTLINE TO BE GIVEN)

The rehabilitation and resettlement (R&R) is not required for the proposed project as it

will be constructed on the land acquired by the company after giving due compensation.




CHAPTER - 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

(TIME SCHEDULE FOR THE PROJECT TO BE GIVEN)

This is a modification proposal for product mix which envisages production of

Ferrochrome in the existing facility. Therefore no construction job will be carried out.

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT

The gross capital investment of the project is about Rs 80.0 Crores. There will not be any

extra facility addition to the existing plant. The economic viability is good due to

availability of raw materials, market and infrastructural facilities.




CHAPTER - 9

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 modification of product mix will have good financial and social benefits to

the local people.

Documents

PROPOSED MODIFICATION OF PRODUCT MIXenvironmentclearance.nic.in/writereaddata/Online/TOR/09_Dec_2017... · PRE-FEASIBILITY REPORT Centre For Envotech and Management Consultancy Pvt