36
Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal Global Tech Enviro Experts Pvt. Ltd. 1

Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

  • Upload
    others

  • View
    0

  • Download
    0

Embed Size (px)

Citation preview

Page 1: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

1

Page 2: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

2

TABLE of CONTENTS

CHAPTER-1 .......................................................................................................... 5

EXECUTIVE SUMMARY ........................................................................................... 5

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

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

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

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

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND REGION...................... 6

2.3.1 DOMESTIC SCENARIO ............................................................................. 7

2.3.2 GLOBAL STEEL SCENARIO ................................................................... 9

2.4 EMPLOYMENT GENERATION DUE TO PROJECT ............................................ 10

2.5 METHODOLOGY OF THE STUDY................................................................. 10

2.6 ENVIRONMENTAL MANAGEMENT PLAN: ..................................................... 12

2.8 AUTHORIZATION .................................................................................... 13

2.9 ACKNOWLEDGEMENT: ............................................................................. 13

CHAPTER-3 ........................................................................................................ 14

PROCESS DESCRIPTION ....................................................................................... 14

3.1 TYPE OF THE PROJECT: ........................................................................... 14

3.2 LOCATION OF THE PROJECT ..................................................................... 14

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING

THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GONE

INTO SHOULD BE HIGHLIGHTED. ....................................................................... 15

3.4 SIZE OR MAGNITUDE OF OPERATION ........................................................ 16

3.5 PROCESS DESCRIPTION .......................................................................... 16

Table 3.1: PROJECT CONFIGURATION & PRODUCT MIX ................................. 16

Fig 3.1 Flowsheet of the process ................................................................... 17

FIG 3.2 LAYOUT MAP OF THE PROJECT SITE................................................... 20

3.5 MAJOR RAW MATERIAL INVENTORY .......................................................... 21

Table 3.2: Raw Material Inventory .............................................................. 21

3.6 WATER REQUIREMENT ............................................................................. 21

3.7 POWER REQUIREMENT ............................................................................ 22

3.8 SOLID WASTE: ....................................................................................... 22

Table 3.3: Solid Waste Generation & Management ........................................ 22

3.9 MANPOWER ............................................................................................ 22

CHAPTER -4........................................................................................................ 23

SITE ANALYSIS ................................................................................................... 23

4.1 CONNECTIVITY ....................................................................................... 23

Page 3: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

3

4.2 LAND FORM, LAND OWNERSHIP ............................................................... 23

Table 4.1: Land Use Pattern for the proposed plant ....................................... 23

4.3 TOPOGRAPHY ......................................................................................... 23

4.4 LAND USE PATTERN ................................................................................ 24

Table 4.2 Land use pattern of buffer zone .................................................... 24

Fig- 4.1: Land Use Map of the area ............................................................... 25

4.5 EXISTING INFRASTRUCTURE .................................................................... 25

4.6 SOIL CLASSIFICATION: ........................................................................... 25

4.7 CLIMATIC DATA FROM SECONDARY SOURCE .............................................. 26

Table 4.3: Summarized Meteorological Data Collected from Durgapur IMD: ..... 26

CHAPTER -5........................................................................................................ 27

PLANNING BRIEF................................................................................................. 27

5.1 PLANNING CONCEPT ............................................................................... 27

5.2 PERIPHERAL DEVELOPMENT PLAN ............................................................. 27

Fig 5.1: MANAGEMENT HEIRARCHY ............................................................... 28

5.3 LAND USE PLANNING .............................................................................. 28

Table 5.1: Land Use Pattern for the proposed project .................................... 28

5.4 ASSESSMENT of INFRASTRUCTURE DEMAND .............................................. 29

CHAPTER -6........................................................................................................ 30

PROPOSED INFRASTRUCTURE .............................................................................. 30

6.1 INDUSTRIAL AREA DISTRIBUTION ............................................................. 30

6.2 GREENBELT DEVELOPMENT ...................................................................... 30

6.3 CONNECTIVITY ....................................................................................... 30

6.4 DRINKING WATER MANAGEMENT: ............................................................. 30

6.5 INDUSTRIAL WASTE MANAGEMENT ........................................................... 30

6.5.1 WASTE MANAGEMENT ....................................................................... 30

6.5.2 SOLID WASTE GENERATION & MANAGEMENT ....................................... 30

6.5.3 POWER REQUIREMENT ...................................................................... 31

6.6 INDUSTRIAL POLLUTION CONTROL ........................................................... 31

6.6.1 AIR POLLUTION CONTROL.................................................................. 31

Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES ......................... 31

6.6.2 WATER POLLUTION CONTROL ............................................................ 31

6.7 MAN POWER REQUIREMENT ..................................................................... 32

CHAPTER -7........................................................................................................ 33

REHABILITATION & RESETTLEMENT ...................................................................... 33

REHABILITATION & RESETTLEMENT ................................................................... 33

CHAPTER -8........................................................................................................ 34

Page 4: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

4

PROJECT SCHEDULE ............................................................................................ 34

8.1 IMPLEMENTATION SCHEDULE ................................................................... 34

Table 8.1: Tentative implementation schedule: ............................................. 34

8.2 ESTIMATED PROJECT COST ...................................................................... 35

CHAPTER-9 ........................................................................................................ 36

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION) ............................................. 36

9.1 FINANCIAL & SOCIAL BENEFITS ............................................................... 36

9.2 SOCIAL INFRASTRUCTURE ....................................................................... 36

9.3 EMPLOYMENT POTENTIAL ........................................................................ 36

9.4 BENEFITS TO THE REGION AND THE COUNTRY ........................................... 36

Page 5: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

5

CHAPTER-1

EXECUTIVE SUMMARY

M/s Supershakti Power & Infrastructures Ltd., is a proposed green field Integrated Steel

project will be under M/s Sai group which formed in the year 1995 and is well known in

the Eastern India for their quality products viz. Supershakti TMT Bars, Billets, Ingots,

Sponge Iron.The group aims to be the most efficient and reliable steel producer and

carry out its business operations with utmost regard for safety of the people and

environment. It is committed to protect and improve the environment and abide by the

laws and regulations concerning the same.

M/s Supershakti Power & Infrastructures Ltd. Proposes to setup 0.35 MTPA Integrated

Steel Plant at Mandalpur inside Jamuria Industrial Estate formed by ADDA.PO- Ikra, Dist:

-Paschim Burdwan, West Bengal. The project is located from latitude230 41‟ 23.81‟‟ N to

230 41‟42.99” N and longitude 870 05‟ 21.69‟‟ E to 870 5‟ 39.66” E with 115m AMSL.

The proposed project is a green field integrated steel project of category-A, proposing to

setup 2x500 TPD DRI Kilns, 4x25T IF & 1x20T IF with LF & CCM,2x10 MW CPP (WHRB),

30 MW CPP (AFBC/CFBC) & 2x600TPD Rolling Mill to produce 0.35 MTPA consisting of

Channels, angles, TMT rods & coils as per market demand.

The proposed project will be setup on 50 acres of land on western side of existing

running plant; M/s Super Smelter Ltd. of the group.

Total fresh water requirement for the project is estimated to be about 75 m3/hr (1800

m3/day) which will be sourced from Ajay river through water supply line of its sister unit

M/s Super Smelter Ltd. Air-cooled condenser will be used for captive power plant

exhaust steam condensation, there by water requirement will be low.

The waste water generated from the various processes will be sent to the waste water

treatment. After treatment the treated water will be recycled for the processes again. No

contaminated water will be discharged outside project boundary. Waste water from

administrative building, canteen and office toilets will be sent to a STP for treatment and

reuse.

Power requirement for the project on full load running will be about 50 MW and captive

generation will be 50 MW, hence no power will be purchased from outside.

The project will plan to give more employment opportunities to skilled & unskilled

workers by Direct & Indirect Employment. There will be direct employment of about 400

technical & non-technical personnel. Indirect employment will be another 600, so total

man power requirement for plant operation on completion has been estimated to be

1000.Besides this some contractual workers are to be employed to manage canteen,

security and housekeeping during construction as well as operation phase.

The estimated project cost is about 540 crores. Cost of the project includes cost

towards land and site development, buildings, plant and machinery, engineering

expenses on drawings and documents, ESC & miscellaneous fixed assets, preliminary

and pre-operative expenses, provision for contingencies and margin money for working

capital.

Project is planned to be completed within 2 years after obtaining EC.

Page 6: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

6

CHAPTER-2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

M/s Supershakti Power & Infrastructures Ltd., belongs to Sai Group, unit well known in

the Eastern India for its quality products viz. TMT Bars, Billets, Ingots, Sponge Iron etc.

M/s Sai group has existing integrated steel plant; namely M/s Super Smelter Ltd,

running at: Mandalpur in Jamuria Industrial Estate developed by Asansol Durgapur

Development Authority (ADDA).M/s Supershakti Power & Infrastructures Ltd is proposing

a green field integrated steel project adjacent to M/s Super Smelter Ltd on its western

side.

The company has acquired about 50 Acres of barren, water logging low land and is

proposing to set up a 0.35 MTPA green field Integrated Steel Plant on it in Jamuria

Industrial Estate. Jamuria Industrial Estate in state of WB, is endowed with easy access

to rich and abundant resources of coal and well connected to the markets with road and

rail and is a major industrial centre.

Shri Sitaram Agarwal is promoter of the “Sai” Group. He has three decades of experience

in steel Industry and is a well-known for pioneering steel industry in Primary as well as

secondary sector.

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The proposed project is a green field Integrated Steel project of category-A, proposing

2x500 TPD DRI Kilns, 4x25T& 1x20T IF with LF & CCM 20 MW CPP (WHRB), 30 MW CPP

(AFBC/CFBC)& 2x600T Rolling Mill. All the units of the proposed project will be set up on

50Ac (20.23 ha) ha of barren low land already acquired at Mandalpur in Jamuria

Industrial Estate.

2.3 IMPORTANCE OF THE PROJECT TO THE COUNTRY AND

REGION

TMT rod, and coil products are normally used in constructional/structural work due to its

workability & has high market demand. Steel is a basic commodity for all industrial

activity and its consumption marks industrial prosperity. The steel industry has

tremendous forward and backward linkages in terms of material flow, income and

employment generation.

Steel is a core industry and thus its demand is strongly linked to the overall economic

activity of the nation. Given the inherent long-term potential of the Indian economy and

its cyclical nature, the long-term prospects of the steel industry are fairly comfortable.

The demand and production has been growing at a healthy rate for the last few years

and the forecast for the next decade and half is also very promising.

It has been estimated by certain major investment houses such as Credit Suisse that

India‟s steel consumption will continue to grow at 16 % rate annually fuelled by demand

for construction projects worth US $1 trillion. The scope for raising the total consumption

for steel is huge, Per capita consumption of steel at current levels is about 65 kg. As a

Page 7: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

7

comparison per capita steel consumption in China is 430 kg and the world steel

consumption per capita average is 180 kg.

By 2020-21 the demand at 7 % and 8 % GDP growth is estimated to be 123 million tons

and 137.5 million tons respectively. Taking a mean figure of 130 million ton, there is a

need of 65 million ton in 10 years‟ time. This translates into an average growth

requirement of about 10 million tons per year.

2.3.1 DOMESTIC SCENARIO

The Indian steel industry has entered into a new development stage from 2007-

08, riding high on the resurgent economy and rising demand for steel.

Rapid rise in production has resulted in India becoming the 3rd largest producer of

crude steel in 2015 and the country continues to be the largest producer of

sponge iron or DRI in the world.

As per the report of the Working Group on Steel for the 12th Five Year Plan, there

exist many factors which carry the potential of raising the percapita steel

consumption in the country. These include among others, an estimated

infrastructure investment of nearly a trillion dollars, a projected growth of

manufacturing from current 8% to 11-12%, increase in urban population to 600

million by 2030 from the current level of 400 million, emergence of the rural

market for steel currently consuming around 10 kg per annum buoyed by projects

like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas

Yojana among others.

India produced 88.97 million tons (mt) , 89.79 mt and 96 mt of crude steel during 2014,

2015 and 2016 respectively. India‟s steel exports grew 150.0 per cent year-on-year to

0.75 MT in February 2017, while steel imports declined 46 per cent year-on-year to 0.49

MT. Total consumption of finished steel grew by 3.4 per cent year-on-year to 76.22 MT

during April 2016-February 2017.

This was on account of higher output by the major Indian steel companies. The

imposition of Minimum Import Price (MIP) encouraged the producers to increase their

output. Care Ratings said that the consumption of steel, on the other hand, grew by just

3.2% to 73.75 MT during April-December 2016.

The National Steel Policy 2017, released by the government, aims to increase steel

production. Thus, both production and consumption of steel is expected to remain

buoyant in 2017-18, the report said.

The major factors driving the growth of steel demand in India are

Manufacturing sector is expected to grow @ 12–15% as compared to 10% at

present

Construction sector is slated to grow @ 10% from 8% at present

Significant growth in Auto sector – Production of Passenger cars @ 9% and 2-

wheelers @ 16% during 2005-15.

Major infrastructure initiatives with impact on steel demand :

Electrification of all villages, Expansion and Modernization of Distribution Systems

of National Grids, Mass Transport Systemsin major cities, National Distribution

Network for Natural Gas,

Page 8: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

8

Dedicated Railway Track for Freight Movement between metrocities, Expansion of

National Highways Network, Modernisation/New Sea and Air ports.

Affordable investment requirement for such mini steel plants, and

Increasing demand for construction steel, which can be profitably produced from

such mini steel plants

Out of new capacity for steel production, 60% is expected to come through Blast Furnace

route, 33% through Sponge iron – Electric Arc Furnace route and balance through other

routes. This has to be met by expanding capacity of the existing plants as well as by

installing green field steel plants. Large and medium capacity steel plants have adopted

the BF route.

Government Initiatives

Some of the other recent government initiatives in this sector are as follows:

The Government of India has approved a joint venture (JV) between MSTC Ltd

and Mahindra Intertrade Ltd, for setting up India's first green field auto shredding

and recycling facility, which will aide in saving of foreign currency, as a result of

import substitution of scrap.

Union Minister of Steel, Mines, Labor and Employment, has launched the National

Mineral Exploration Policy (NMEP), which will help to adopt comprehensive

exploration of non-fuel and non-coal mineral resources that would give a major

boost to the economy.

Metal Scrap Trade Corporation (MSTC) Limited and the Ministry of Steel have

jointly launched an e-platform called 'MSTC Metal Mandi' under the 'Digital India'

initiative, which will facilitate sale of finished and semi-finished steel products.

The Parliament of India has cleared amendments to the Mines and Minerals

Development and Regulation (MMDR) Act, which will enable companies to transfer

captive mines leases similar to mines won through an auction, and which is

expected to lead to increased Mergers and Acquisitions (M&A) of steel and cement

companies.

The Ministry of Steel has announced to invest in modernization and expansion of

steel plants of Steel Authority of India Limited (SAIL) and Rashtriya Ispat

NigamLimited (RINL) in various states to enhance the crude steel production

capacity in the current phase from 12.8 MTPA to 21.4 MTPA and from 3.0 MTPA to

6.3 MTPA respectively.

The Minister of Steel & Mines has reiterated commitment of Central Government

to support the steel industry to reach a production target of 300 Million Tonne Per

Annum (MTPA) in 2025.

The Ministry of Steel is facilitating setting up of an industry driven Steel Research

and Technology Mission of India (SRTMI) in association with the public and

private sector steel companies to spearhead research and development activities

in the iron and steel industry at an initial corpus of Rs 200 crore (US$ 30 million).

The Central Board of Excise and Customs (CBEC) has issued a notification

announcing zero export duty on iron ore pellets, which will help the domestic

industry to become more competitive in the international market.

Page 9: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

9

Government has planned Special Purpose Vehicles (SPVs) with four iron ore rich

states i.e., Karnataka, Jharkhand, Orissa, and Chhattisgarh to set up plants

having capacity between 3 to 6 MTPA.

SAIL plans to invest US$ 23.8 billion for increasing its production to 50 MTPA by

2025. SAIL is currently expanding its capacity from 13 MTPA to 23 MTPA, at an

investment of US$ 9.6 billion.

Some of the major investments in the Indian steel industry are as follows:

Tata Steel has signed an agreement to purchase a majority 51 per cent stake in

Creative Port Development (CPDPL), which has a concession agreement with the

Odisha government to develop a 10 million-tonnes-per-annum (MTPA)

Subarnarekha port at Chamukh village in Balasore district of Odisha.

Tidfore Heavy Equipment Group, the China-based infrastructure giant, is looking

to enter the Indian market by signing an investment agreement worth US$ 150

million with Uttam Galva Metallics, to expand its Wardha unit along with South

Korean steel major Posco.

ArcelorMittal SA is looking to set up a joint venture (JV) factory in India with

state-owned Steel Authority of India Ltd (SAIL), to manufacture high-end steel

products which could be used in defence and satellite industries.

JSW Group plans to invest around Rs 10,000 crore (US$ 1.5 billion) at Salboni in

West Bengal to set up 1,320 Megawatt (MW) coal-based power plant, 4.8 million

tonne cement plant and paints factory over a period of next five to seven years.

National Mineral Development Corporation (NMDC) has planned to invest Rs

40,000 crore (US$ 6 billion) in the next eight years to achieve mining capacity of

75 Million Tonnes Per Annum (MTPA) by FY2018-19 and 100 MTPA by FY2021-22,

compared to 48 MTPA current capacity.

Posco Korea, the multinational Korean steel company, has signed an agreement

with Shree Uttam Steel and Power (part of Uttam Galva Group) to set up a steel

plant at Satarda in Maharashtra.

ArcelorMittal, world‟s leading steel maker, has agreed a joint venture with Steel

Authority of India Ltd (SAIL) to set up an automotive steel manufacturing facility

in India.

Iran has evinced interest in strengthening ties with India in the steel and mines

sector, said ambassador of the Islamic Republic of Iran, Mr Gholamreza Ansari in

his conversation with Minister of Steel and Mines, Mr Narendra Singh Tomar.

Public sector mining giant NMDC Ltd will set up a greenfield 3-million tonne per

annum steel mill in Karnataka jointly with the state government at an estimated

investment of Rs 18,000 crore (US$ 2.7 billion).

JSW Steel has announced to add capacity to make its plant in Karnataka the

largest at 20 MT by 2022.

2.3.2 GLOBAL STEEL SCENARIO

Steel production in the world is dominated by China followed by Japan. In 2016, the

world crude steel production reached 1628 million tonnes (mt) and showed a growth of

0.8% over 2015.

China remained world‟s largest crude steel producer in 2016 (808 mt) followed by

Japan (105 mt), India (96 mt) and the USA (79 mt).

Page 10: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

10

World Steel Association has projected Indian steel demand to grow by 5.4% in

2016 and by 5.7% in 2017 while globally, steel demand has been projected to

grow by 0.2% in 2016 and by 0.5% in 2017. Chinese steel use is projected to

decline in both these years - by 1% in 2016 and by 2% in 2017.

Per capita finished steel consumption in 2015 is placed at 208 kg for world and

489 kg for China by World Steel Association

Steel is a key driver of the world's economy. The industry directly employs more than

two million people worldwide, with a further two million contractors and four million

people in supporting industries. According to the World Steel Dynamics (WSD)

organization, global steel production (as also demand for it or consumption) will grow at

an annual average compounded rate of growth of 1.28 per cent during 2015-2025 to

reach only 1873 million tonnes by 2025. Other well-known forecasts, this figure was to

be achieved by 2020.

[Source: Ministry of Steel]

2.4 EMPLOYMENT GENERATION DUE TO PROJECT

The project will plan to give more employment opportunities to skilled & unskilled

workers by Direct & Indirect Employment. The total man power requirement for plant

operation on completion of the proposed project will be around 1,000 including 400

direct employment. Contractual workers are to be employed to manage canteen,

security and housekeeping during construction as well as operation phase.

2.5 METHODOLOGY OF THE STUDY

Environmental issues must be addressed during project planning before the actual

project is executed. In the same way as economic, financial, institutional, or technical

analysis, Environmental Impact Assessment (EIA) is an integral part of the project. EIA

is the process in which environmental factors are integrated into project planning and

decision-making so as to achieve ecologically sustainable development. Best-practice EIA

identifies environmental risks, lessens conflicts by promoting community participation,

minimizes adverse environmental effects, informs decision makers, and helps lay the

base for environmentally-sound projects. Benefits of integrating EIA have been observed

in all stages of a project, from exploration and planning, through construction,

operations, decommissioning, and beyond site closure.

The process of EIA usually consists of the following stages:

Screening

Scoping

Baseline Study

Environmental Impact Identification, Prediction and Assessment.

Environmental Management Plan

Decision making relative to the proposed action.

Study Documentation

Page 11: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

11

Screening: Assessment the need for an EIA. Whether there is any possibility of

significant stress or shock on the supportive and assimilative capacity of the surrounding

environment.

Scoping: Identification of issues and impacts to be considered in the EIA study

Baseline Study: Conducting necessary field studies for generation baseline

data to define the pre-project environment. The baseline study to be done in

non-monsoon period as per the approved TOR conditions given by MoEFCC.

For Impact Prediction and Assessment, the details of most of the baseline

data will be collected during the study period of 03 months to be undertaken

during non-monsoon period. There will be elaborate data collection with

respect to geology, geomorphology, hydrogeology, drainage pattern; land

use pattern etc. and the subsequent satellite map will be prepared with a 10

km radius buffer zone.

Details of the micro-meteorological data will be collected with respect to

hourly wind speed & wind direction, humidity, temperature, cloud cover,

rainfall data etc. The corresponding frequency distribution of wind behaviour

with wind rose diagram has been prepared. This will form the meteorological

data input to Air Quality Prediction Model.

The existing ground level concentration of Particulate Matter (PM10 and

PM2.5), Sulphur Dioxide (SO2), Nitrogen Oxide (NOx) and Carbon Monoxide

(CO) are analysed during the study period in the core zone as well as buffer

zone including at least one in the down wind direction. The air sampling

location and others will be chosen studying the wind rose and using standard

procedures.

Surface water & ground water analysis is done in core zone and buffer zone

as per the parameters in relevant standard.

The soil testing is done in core and buffer zone.

The average noise quality both in day and night.

All the procedure of collection of sample, frequency of collection, analysis

procedures etc are done as per CPCB norms.

Details of the ecological survey are taken up with respect to flora and fauna

including avifauna and aquatic fauna with an emphasis on endangered

species in the core zone as well as in the buffer zone.

Socio-economic data of the region is collected with respect to literacy,

economic status, occupation, living standard, health etc. of the local

population. There are detailed data collections about infrastructure facilities

like transportation, communication, education health etc.

Detailed survey of the 15 Km. region around the project is conducted to find

out any location of sensitive areas like wild life sanctuaries, historical

&archaeological sites, defence installations etc.

Environmental Impact Identification, Prediction and Assessment

Different environmental impact areas are identified and expressed in matrix

form.

Page 12: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

12

Qualitative prediction of impact is done with respect to land use, ecology and

noise and socio-economic.

Details of water and waste water inventory are to be prepared to find out

their impact on the environment.

Solid wastes Inventory (both hazardous and non-hazardous in nature) will be

done to predict and assess their impact on environment.

Detailed information about stacks with respect to height, diameter, flue gas,

temperature, velocity and flow and the inter stack distances will be

calculated.

Emission inventory with respect to PM, SO2, NOx will be calculated.

Micro-meteorological data along with stack and emission inventory data is

input to the air quality prediction modelling software.

Quantitative prediction of air pollutants in the form of incremental ground

level concentration (GLC) is done by Air Quality Prediction Modelling Software

(ISC-AEROMOD-ISCST-3) developed by USEPA.

Maximum resultant GLC will be calculated at locations taking into

consideration of background GLC and precipitation due to plant operation

depending on predominant wind direction.

Subjective impact assessment using matrix method is carried out to calculate

the total impact score without mitigation measures.

This has been done as per the approved TOR conditions given by MoEFCC.

2.6 ENVIRONMENTAL MANAGEMENT PLAN:

Following environmental management plan is proposed to reduce the predicted adverse

impacts and to make provision to compensate for any residual adverse impact

Air Pollution control Equipments (APCE) to be setup.

Disposal management of the solid waste and effluents generated from

these APC equipments will be chalked out.

Fugitive dust emission from the different storage & transfer point and haul

road emissions and their detailed control aspects shall be covered.

Considering water as important and valuable utility, company will formulate

a water management plan for minimum use of the fresh water.

Waste water management dealing with treatment methodologies and

recycling/reuse of treated waste will be prepared.

Storage of storm water in the monsoon in water harvesting ponds and the

use of the same water in lean season will be planned.

Zero discharge norms with a comprehensive water and waste water

management plan will be evaluated.

A detail of the solid waste inventory, its characterization and their usage

potentiality will be discussed. Solid waste plant process and reuse of the

solid waste for different purposes will be examined.

Page 13: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

13

Noise control devices with different equipments at design stage, protective

measures at work zone sites and supply of protective gears to affected

personnel will given in detail.

Realizing the need for the greenbelt cover as a very good sink for pollutants

and the aesthetical aspects the company will go for a comprehensive

plantation program as per MoEFCC Norms.

Detailed plan for greenbelt development with respect to allocation of area,

fund allocation, selection of the species and maintenance plan will be

covered. Peripheral development plan that includes development in

infrastructure, health education and socio-cultural aspects will be

emphasized.

Details of the EMP cell with respect to monitoring laboratory, technical man

power and fund allocation is discussed. Details of monitoring program with

respect to pollutant parameters. Monitoring scheduled and reporting as per

statutory requirement will be planned.

Safety and disaster management plan with onsite emergency plan to deal

with the unforeseen accidents will be covered.

Beneficial aspects of project with respect to direct and indirect employment,

business opportunities and peripheral development will be discussed.

Trickledown effect of all the project benefits to affected local population will

be analysed.

Taking in to consideration of the environmental degradations due to the

project implementation and the consequent environmental management

plan followed by the post project benefits, the subjective assessment with a

Total Impact Score will be analysed to draw a summary conclusion.

2.7 LITIGATION/COURT CASE AGAINST THE COMPANY

No, litigation or court cases are pending against the project or the land already acquired,

and/or no direction/order has been passed by any court of law against the project.

2.8 AUTHORIZATION

M/s. Supershakti Power & Infrastructures Ltd has entrusted M/S Global Tech Enviro

Experts Pvt. Ltd., Bhubaneswar for the preparation of TEFR for their green field

integrated steel project. In accordance to the scope of work, M/s. GTEEPL team visited

the project site to take general view and will again visit the project site and collect base

line data like Air, Water, Soil & Noise from the project site and availability of

infrastructure facilities like raw materials, water, power and transportation facilities in

detail. The team will also make socio-economic study of 10km buffer zone of the project

site to know existing status of the locality and flora & fauna.

2.9 ACKNOWLEDGEMENT:

M/s GLOBAL TECH ENVIRO EXPERTS PVT LTD, Bhubaneswar expresses its deep

gratitude to M/s. Supershakti Power & Infrastructures Ltd for the assignment entrusted

to them.

Page 14: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

14

CHAPTER-3 PROCESS DESCRIPTION

3.1 TYPE OF THE PROJECT:

0.35 MTPA Integrated Steel Plant, green field project of M/s Supershakti Power &

Infrastructures Ltd. will be a primary metallurgical Plant manufacturing 0.35 MTPA TMT

rods & Coils, angles and channels., This project is independent plant without any

interlink or interdependence.

3.2 LOCATION OF THE PROJECT

M/sSupershakti Power & Infrastructure Limited proposes0.35 MTPA Integrated Steel

Plant at Mandalpur, PO- Ikra, Dist:-Paschim Burdwan, West Bengal. The project is

located at latitude 230 41’ 42.99’’ N and longitude 870 05’ 34.90’’ E with 115m AMSL.

Page 15: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

15

The corner co-ordinates of project site are as follows.

Pt 1: 23041‟ 42.99” N and 870 05‟ 34.90” E

Pt 2: 230 41‟ 39.32” N and 870 05‟ 25.67” E

Pt 3: 230 41‟ 32.92” N and 87005‟ 19.35” E

Pt 4: 230 41‟ 23.81” N and 870 05‟ 37.95” E

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS

OF SELECTING THE PROPOSED SITE, PARTICULARLY THE

ENVIRONMENTAL CONSIDERATIONS GONE INTO SHOULD BE

HIGHLIGHTED.

Any other site has not taken into consideration. A single patch of 50 acres of barren land

adjacent to existing Infrastructural facilities of sister plant M/s Super Smelter Ltd was

not available. The plant will be located which is endowed with easy access to rich and

abundant resources of coal and various other minerals in the locality. Rail connectivity,

nearness to the market and well-established communication network are other criteria in

selecting the plant site. Availability of water, electric power and labor is also important.

Favorable climatic conditions and good rainfall is conducive to high labor. So no

alternate site has been taken into consideration.

Page 16: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

16

3.4 SIZE OR MAGNITUDE OF OPERATION

The proposed project will be setup on 50 acres of land which has already been acquired

with total project cost of about 450 crores. The project after execution will produce 0.35

MTPA TMT rods & Coils,

3.5 PROCESS DESCRIPTION

M/s Supershakti Power & Infrastructures Ltd now proposes an Integrated Steel Plant

with following configuration

Table 3.1: PROJECT CONFIGURATION & PRODUCT MIX

Sl.

No.

Plant Facilities Configuration Production

Capacity (in TPA)

End Use

1 DRI Kilns 2 x 500 TPD 3,20,000 Sponge Ironto IF

2 Induction

Furnace with LF

& CCM

4x25 T, 10 H

1X20T, 10 H

3,84,000 Billet to Rolling mill

9 Rolling mill 2 x 600 TPD 3,50,000 TMT Rods & Coils for

sale

12 Power Plant 1x20MW(WHRB)

1x30MW(AFBC)

50 MW power Internal Consumption

Page 17: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

17

Fig 3.1 Flowsheet of the process

Page 18: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

18

A. DRI kilns

Sponge iron is the metallic form of iron produced from reduction of iron oxide below the

fusion temperature of iron ore (1535 ◦C) by utilizing hydrocarbon gases or carbonaceous

fuels as coal. The reduced product having high degree of metallization exhibits a

„honeycomb structure‟, due to which it is named as sponge iron. As the iron ore is in

direct contact with the reducing agent throughout the reduction process, it is often

termed as direct reduced iron(DRI).

Sponge iron, also known as "Direct Reduced Iron" (DRI) and its variant Hot Briquetted

Iron (HBI) have emerged as prime feed stock which replace steel scrap in EAF/IF as well

as in other steel-making processes. It is the resulting product of solid state reduction of

iron ores or agglomerates (generally of high grade), the principal constituents of which

are metallic iron, residual iron oxides, carbon and impurities such as phosphorus,

sulphur and gangue (principally silica and alumina). The final product can be in the form

of fines, lumps, briquettes or pellets. Direct reduction processes available can be broadly

grouped under two categories based on the type of reductant used. These are:

1)Solid based processes

2)Gas based processes

Indigenous solid (coal) based Process

In India, the coal based DRI production process employs a rotary kiln as the main

reactor wherein the process of reduction of the iron oxide is carried out with coal as

reductant. Refractory lining of about 150-200 mm thickness is given inside the kiln to

protect the shell. The kiln has a general slope of 2.5 - 3% down towards the discharge

end. There are air blowers mounted on the kiln shell having dampers to provide required

air for combustion at different heating zones.

M/s Supershakti Power & Infrastructure Limited proposed to set up 2x500 TPD coal

based DRI kilns based on indigenous Lurgi Technology.

B. IF

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

and high frequency. Raw materials used for Steel making from IF are Sponge Iron, Pig

iron and Scrap. Alloying elements are added as per the requirement and the induction

furnaces are provided with matching billet casters

M/s SSPIL is proposing to set up 4x25T& 1x20T medium frequency coreless IFs

Proposed design Parameters of Induction Furnace

Sl.

No.

Parameter Unit Value/Feature

1. Liquid Steel Production T/yr 3,84,000

2. No. of Furnaces 5 20T& 25T with 10 crucibles

3. Type of furnace - A.C medium frequency coreless,

twin shell each with common

power pack per furnace.

4. Nominal Transformer Rating KW 4900

5. Heats/Day/Furnace - 10

Page 19: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

19

6 No. of working days Annum - 320

C. Power Plant:

Dolchar coming out of DRI kilns still have calorific value in the tune of 1800kcal/kg, a

potential source of heat to generate steam for power generation.

This dolchar with additional support of fresh boiler grade coal will be subjected to grate

firing in AFBC boilers. The combustion will sustain with 50% support of fresh coal to

dolchar and it is estimated that about 30 MW power can be generated from the steam

produced on combustion. Steam from DRI Kilns will generate 20 MW Power. Total Power

will be 50 MW

D. TMT

Coal based DRI kilns will produce sponge iron utilizing lumpy hematite iron ore, DRI grade

coal and dolomite. Sponge iron will be melted in Induction Furnace along with purchased

Pig iron from local market. Iron scraps will also be purchased from market and in plant

generation. This melt will be cast in CCM to produce hot billets. Finally, hot billets will pass

through series of rolling mills and iron rods, coils and angles will be produced.MS rods and

coils in short period water quenching will be converted to TMT rods, highly suitable for

construction purpose.

.

Page 20: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

20

FIG 3.2 LAYOUT MAP OF THE PROJECT SITE

Page 21: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

21

3.5 MAJOR RAW MATERIAL INVENTORY

Table 3.2: Raw Material Inventory

Sl.No Material Quantity in

TPA

Source Mode of

transport

1 Hematite Iron Ore

Lumps

4,65,000 Odisha Rail/Road

2 Boiler grade Coal 3,46,000 Raniganja Coal

field

Road

3 DRI grade Coal 3,84,000 Raniganja Coal

field

Road

4 Lime 45,000 Sundargarh

Odisha

Rail/Road

5 Pig iron 46,000 Local Road

6 Sponge Iron 65,000 Local Road

In addition to the major raw materials shown in the above table, H2SO4 for DM plant and

LDO for start-up of DRI & Boilers in small quantity will also be required.

Raw Material Receipt & Store

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

major raw materials such as iron ore and coal will be done.

Mode of Transport (Raw materials & products)

Transports will be done by the environmentally compliant Bharat-III/ Euro-III trucks.

Coal will be purchased from Raniganja coal field/ local or e-auction. The raw materials &

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

emissions on the road.

Raw Material Storage & Handling

Separate store yard for the major raw materials such as iron ore lumps, lime stone/

dolomite, DRI & Boiler grade coal etc will be built on impervious floor and under shed.

The material shall be unloaded manually from the trucks in the stock yard. The yard

shall have provision to store around 15 day‟s stock of material& just on time schedule for

receiving of Raw material to be maintained.

3.6 WATER REQUIREMENT

Total fresh water requirement for the project is 75 m3/hr (1800 m3/day) which will be

sourced from Ajay river, through existing pipeline for M/s Super Smelter Ltd, its sister

concern.

Waste Water Management

Page 22: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

22

The waste water generation from the various processes will be sent to the waste water

treatment. After treatment the treated water will be recycled for the processes again.

The waste water from administrative building, canteen and office toilets will be

discharged to a soak pit.

3.7 POWER REQUIREMENT

Power requirement will be about 50 MW and captive generation will be 50 MW, hence

about no power will be purchased from outside excepting during construction work,

which will be about 1 MW.

3.8 SOLID WASTE:

Table 3.3: Solid Waste Generation & Management

Rolling mill scraps, mill scale are to be recycled to IF for remelting with fresh charge. The

Solid wastes will be treated as by products and these will be fully utilized.

3.9 MANPOWER

The project will plan to give more employment opportunities to skilled & unskilled

workers by Direct & Indirect Employment. The total man power requirement for plant

operation on completion will be about 1000 including 400 direct employees. Besides this

some contractual workers are to be employed to manage canteen, security and

housekeeping during construction as well as operation phase

Solid waste Quantity in TPA Utilization Measures

Char 80,000 To be burn in AFBC to produce steam for

power Plant

Fly Ash-DRI 1,28,000 To be sold to brick/cement

manufacturers

Fly Ash-Power Plant 87,400 To be sold to brick/cement

manufacturers

Bottom Ash 52,500 Cement Plant

IF Slag 62,000 To be used as river sand substitute for

construction jobs and low land filling

after iron recovery

Page 23: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

23

CHAPTER -4

SITE ANALYSIS

4.1 CONNECTIVITY

M/s Supershakti Power & Infrastructures Ltd. Proposes 0.35 MTPA Integrated Steel Plant

at Mandalpur PO- Ikra, Dist:-Paschim Burdwan, West Bengal. The project is located at

latitude230 41’ 31.61’’ N and longitude 870 05’ 39.82’’ E with 115m AMSL.

The location is well connected by road and Rail. The site is only 3.7 km away from the

NH 2. Ikrah railway station is 0.5 km away. Block Development Office is only 0.4 km

away from the site. Kazi Nazrul Islam Airport is about 13 km away from the site.

4.2 LAND FORM, LAND OWNERSHIP

The total land available for the proposed project is about 50 Ac (20.23 hectares).

Table 4.1: Land Use Pattern for the proposed plant

SL

NO

Items Total Land in

Ac

1 Plant Facilities 16.6

2

Raw Material Yard &

Finished products 4.0

3

Office & other permanent

structures 1.2

4 Internal Road 1.5

5

Rain Water harvesting

system 2.5

6 Water Reservoir 3.5

7 Green Belt 16.5

8 Solid waste storage yard 4.2

Total 50.00

4.3 TOPOGRAPHY

The topography is undulating. The area has thin alluvial cover and the soil is mainly

reddish and not very much fertile. It is a transitional zone having hard rock as well as

alluvial terrain which are flat and gently sloping.

Page 24: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

24

Jamuria is characterized by undulating topography with rugged hilly terrains in the

western parts. The western half of the area resembles a promontory jutting out from the

hill ranges of Chotonagpur plateau and consists of barren, rocky and rolling country with

a Laterite soil rising into rocky hillocks, the highest being 227 m. Ajay-Barakar divide is a

convex plateau, the average altitude being 150 m from the mean sea level. The gradient

is westerly to the west and to the east it is northerly towards Ajay and southerly towards

Damodar below the latitude. The average elevation of Burdwan plain is about 104 m

above the Mean Sea Level (MSL). This area is a low lying alluvial plains with riverine

aggregates.

4.4 LAND USE PATTERN

The proposed green field project area is present at Mandalpur in Jamuria Industrial

Estate, Paschim-Burdwan district of West Bengal. It is also noted that the core zone i.e.

the project boundary or the battery limit does not belong to part of any National Park,

wild life sanctuary or Natural/ Biosphere reserve. It also does not contain any features of

archaeological/ historical and cultural/aesthetic importance.

Table 4.2 Land use pattern of buffer zone

LANDUSE CATEGORY AREA IN SQ.KM.

RURAL SETTLEMENT 14.1

URBAN SETTLEMENT 12.4

Page 25: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

25

RIVER SAND 12.3

INDUSTRIAL SITE 2.4

COLLERIES 33.2

DISUSED COLLIERIES 15.1

CROP LAND 175.5

FALLOW LAND 17.2

DEVELOPING AREAS 16.2

RIVER / WATER BODY 10.4

WATER LOGGED AREA 5.2

Total 314.0

Fig- 4.1: Land Use Map of the area

4.5 EXISTING INFRASTRUCTURE

The location is well connected by road and Rail. The site is only 3.7 km away from the

NH 2. Ikrah railway station is 0.5 km away. Block Development Office is only 0.4 km

away from the site. Kazi Nazrul Islam Airport is about 13 km away from the site.

4.6 SOIL CLASSIFICATION:

Different types of soil are encountered in different topographical biological and

hydrological as well as geological condition within the Burdwan district. In the west

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

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

Page 26: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

26

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

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

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

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

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

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

drained and slightly acidic in nature.

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

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

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

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

udic ustochrepts, fine loamy udifleventivic ustochrepts

4.7 CLIMATIC DATA FROM SECONDARY SOURCE

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

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

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

wet summer while October and November is autumn.

It is proposed to collect base line data during Summer as winter is coming to its end.

Secondary information on meteorological conditions has been collected from the nearest

IMD station at Durgapur and IMD Book (1970-2000). Predominant wind direction is SW.

Table 4.3: Summarized Meteorological Data Collected from Durgapur IMD:

Study

Period(Summ

er Season)

Wind Speed

(Km/Hr)

Temperature

(oC)

Relative

Humidity

(%)

Rainfall (mm)

Cloud

Cover

(Oktas)

Mean Max Min Max Min Max Min 24 hr Max Total

March 6.2 0.1 21.9 19.8 66 62 Nil Nil

0

April 6.9 0.3 21.1 18.4 64 60 Nil Nil

0

May 7.1 0.5 17.1 27.1 57 30 Nil Nil

0

Page 27: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

27

CHAPTER -5

PLANNING BRIEF

5.1 PLANNING CONCEPT

The Proposed plant is an Integrated Steel Plant having semi-mechanized operation. It is

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

additional technical labour engaged for operation.

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

material handling Plant site. And the finished products will be transported by both rail

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

system.

Appropriate plantation program shall be undertaken along with the developmental

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

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

plan.

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

commissioning of the total project component machineries.

5.2 PERIPHERAL DEVELOPMENT PLAN

M/s Supershakti Power and Infrastructure Limited will make sincere efforts to improve

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

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

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

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

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

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

Page 28: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

28

Fig 5.1: MANAGEMENT HEIRARCHY

5.3 LAND USE PLANNING

The total land of 50 Ac is available for this green field project. The detailed breakup of

the land is given in the following table:

Table 5.1: Land Use Pattern for the proposed project

SL

NO

Items Total Land in

Ac

1 Plant Facilities 16.6

2

Raw Material Yard &

Finished products 4.0

3

Office & other permanent

structures 1.2

4 Internal Road 1.5

5

Rain Water harvesting

system 2.5

6 Water Reservoir 3.5

7 Green Belt 16.5

8 Solid waste storage yard 4.2

Total 50.00

Page 29: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

29

5.4 ASSESSMENT of INFRASTRUCTURE DEMAND

The proposed project will put negligible amount of load on existing infrastructure in

terms of physical and social. So, demand for additional infrastructure is not anticipated.

Page 30: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

30

CHAPTER -6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA DISTRIBUTION

50 Ac of industrial barren low land in Jamuria Industrial Estate has already been

acquired where the proposed Integrated Plant will be set up.

6.2 GREENBELT DEVELOPMENT

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

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

the total area i.e. about 16.5Ac of land will be demarcated for green belt purpose.

6.3 CONNECTIVITY

The location is well connected by road and Rail. The site is only 3.7 km away from the

NH 2. Ikrah railway station is 0.5 km away. Block Development Office is only 0.4 km

away from the site. Kazi Nazrul Islam Airport is about 13 km away from the site.

6.4 DRINKING WATER MANAGEMENT:

The drinking water will be met from Ajay river water after filtration and treatment.

6.5 INDUSTRIAL WASTE MANAGEMENT

6.5.1 WASTE MANAGEMENT

The wastes which will be generated from the process are some used oil,Fly Ash & bottom

Ash from DRI Kilns and Power plant and slag from Induction Furnace. The induction

furnace slag being equivalent to river sand can be used for land filling& construction

work. The hazardous waste like used oil, batteries and resins from DM water plant will be

sold to recyclers and dealers. The waste water from canteen and office toilets will be

sent to a soak pit. Industrial waste water will be treated in a ETP consisting of O & G

trap, settling tank, anaerobic treatment system & gravity sand filter. Sewage from toilets

will be discharged to soak pit.

6.5.2 SOLID WASTE GENERATION & MANAGEMENT

Solid waste Quantity in TPA Utilization Measures

Char 80,000 To be burn in AFBC to produce steam for

power Plant

Fly Ash-DRI 1,28,000 To be sold to brick/cement

manufacturers

Fly Ash-Power Plant 87,400 To be sold to brick/cement

manufacturers

Bottom Ash 52,500 Cement Plant

IF Slag 62,000 To be used as river sand substitute for

construction jobs and low land filling

after iron recovery

Page 31: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

31

6.5.3 POWER REQUIREMENT

Power requirement for the proposed project will be about 50 MW on full load and captive

power generation from WHRB & AFBC will be 50 MW, hence about no power be

purchased from outside.

6.6 INDUSTRIAL POLLUTION CONTROL

6.6.1 AIR POLLUTION CONTROL

It is envisaged to install state of the art air pollution control measures in the proposed

project, as given below.

Table 6.1: PROPOSED AIR POLLUTION CONTROL FACILITIES

Sl No Plant/ Area Proposed Pollution Control Measures

1

Raw Material Handling

Raw Material Handling,

Transfer Points, Junction

Houses

Water sprinkling will be provided at the

transfer points of material at RMHP

One Bag filter, ID fan & 30m stack

2 Induction Furnace 5 nos of Bag Filters,5 nos ID fans & 3 stacks

3 DRI 2 nos of 3 phase ESPs

4 Power Plant One no. of 3 Phase ESP

6.6.2 WATER POLLUTION CONTROL

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

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

treatment system & gravity sand filter. Sewage from toilets will be discharged to soak

pit.

Page 32: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

32

6.7 MAN POWER REQUIREMENT

The total man power requirement i.e. direct employment for plant operation on

completion of the proposed project will be around 400 and Total direct & indirect

employment will be 1000:

Direct man power break up will be as follows.

Grade NOs

Managerial 60

Supervisory 40

Skilled 100

Unskilled 200

Total 400

Page 33: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

33

CHAPTER -7

REHABILITATION & RESETTLEMENT

REHABILITATION & RESETTLEMENT

The proposed unit will be a green field project. The land is barren and water logged low

land in side Jamuria Industrial Estate. There is no settlement in side this 50Ac of land. As

settlement will not be affected so, no R&R facility is anticipated.

Page 34: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

34

CHAPTER -8

PROJECT SCHEDULE

8.1 IMPLEMENTATION SCHEDULE

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

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

Table 8.1: Tentative implementation schedule:

Sl.

No.

Activities Duration

1 Engineering

Concept Design 15 days

Basic Engineering 30 days

Detailed Engineering 90 days

2 Civil Work

Land development 15 days

Construction of plant & auxiliary facilities 150 days

3 Statutory Clearance for establishment

State clearance for establishment 20 days

State EC Clearance 90 days

4 Procurement

Place orders for long lead Equipments 90 days

Place orders for commodity items 30 days

Receipt of equipment 230 days

Installation of equipment & items 180 days

5 Erection & Commission

Inspection before commissioning 80 days

Commissioning & production trial run 40 days

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

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

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

EC from MoEF&CC.

Page 35: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

35

8.2 ESTIMATED PROJECT COST

Project Cost

The estimated project cost is 540crore. Cost of the project includes cost towards land

and site development, buildings, plant and machinery, engineering expenses on

drawings and documents, miscellaneous fixed assets, preliminary and pre-operative

expenses, provision for contingencies and margin money for working capital.

This will be as follows.

Sl. No. Cost Head Estimated Cost, in Crore

1 Cost of Land& its

development earth work &

civil structure

90.00

2 Plant Machinery& Pollution

control devices

410.00

3 Consultant Expenses 0.80

4 Contingency 3.20

5 Margin for WC 10.00

6 Misc. Fixed Assets 7.00

7 Prel. Expenses 5.00

8 ESC Activities 14.00

Total 540.00

The project cost to be met from own and loan from Banks.

Page 36: Techno Economic Feasibility Report of M/s Supershakti Power ...€¦ · Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd At: Jamuria Industrial Estate,

Techno Economic Feasibility Report of M/s Supershakti Power & Infrastructures Ltd

At: Jamuria Industrial Estate, Mandalpur, P.O-Ikra, Dist-Paschim-Burdwan, West Bengal

Global Tech Enviro Experts

Pvt. Ltd.

36

CHAPTER-9

ANALYSIS OF PROPOSAL (FINAL RECOMMENDATION)

9.1 FINANCIAL & SOCIAL BENEFITS

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

both at local and global level as listed below:

9.2 SOCIAL INFRASTRUCTURE

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

sanitation and hygiene, HIV Prevention Program.

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

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

area.

The proposed project will set up training centre for the male and female youth

group by considering their skills and qualification which will support the people for

self employment.

9.3 EMPLOYMENT POTENTIAL

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

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

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

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

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

potential benefits are given below:

Long term employment of up to 1000 people in the operation phase of the

proposed project.

Generating additional associated jobs due to establishment of the project.

9.4 BENEFITS TO THE REGION AND THE COUNTRY

M/s Supershakti Power & Infrastructures Ltd,shall produce TMT rods,coils, angles and

channels., The products are in demand and production shall contribute to the GDP

growth of the country.