1.0 EXECUTIVE SUMMARY : SKS ISPAT & POWEER LTD. : Mr ...environmentclearance.nic.in/writereaddata/Online/... · 124485.413 113660.245 92762.146 153408.089 183253.225 159145.11 186874

Pre-Feasibility Report (PFR)

Anacon Laboratories Pvt. Ltd. Nagpur, Maharashtra. 1

1.0 EXECUTIVE SUMMARY

1.1 Name of the Project Proponent: : SKS ISPAT & POWEER LTD.

1.2 Location : 18th Mile Stone, Bilaspur Road, Village: Siltara, Tehsil: Dharsiva Raipur (C.G.) - 493 111

1.3 Office (Regd.) : 501-B, Elegant Business Plaza J.B. Nagar, Andheri-Kurla Road Andheri (E), MUMBAI – 400 059

1.4 Name of Promoters : Mr. Pankaj K Jha (Whole Time Director)

1.5 Existing, Proposed and Total Capacity of SMS Division

Existing Production capacity & configuration

Proposed Change/ configuration

Total production capacity & configuration

Remarks

SMS – 3,31,500 TPA 3 x 12T Induction Furnace & 3 x 15T Induction Furnace

SMS – 3,31,500 TPA (No change in approved capacity) 4 x 15T Induction Furnace

SMS – 3,31,500 TPA (Initially approved capacity) 3 x 12T Induction Furnace 7 x 15T Induction Furnace

Four more Induction Furnace of (15T each) to be installed to achieve approved rated production

1.6 Total Project Area : Total project 225 Acres (91.05 Ha.) including proposed

land 02 acres (0.809 ha) within existing premises

1.7 Number of Shift : Round the Clock (4 Shift)

1.8 No. of Working Days : 320 Days

1.9 Cost of Project : Existing: Rs. 1000.00Cr; Proposed: Rs. 25.00Cr.

Total Cost: 1025 Cr(Rs.)

1.10 Man Power Utilization : Employment (SMS Division)

Existing = 122, Proposed = 70, Total = 192

1.11 Water Requirement Existing water requirement is 4,764 m3/d, No additional water required (Source: Kharun River)

Drawl of water 4800m3/day, permission already obtained from WRD, CG.

1.12 Power Requirement : Existing 85 MW (No additional power requirement) Source: Captive generation (CPP)

1.12 Greenbelt : 33% green belt already developed within existing plant premises (52,000 Nos.)

1.12 Project Implementation Period : 06 Months

1.13 Environment Consulting Organization

: Anacon Laboratories Pvt. Ltd. Head Office: 60, Bajiprabhu Nagar,Nagpur-440 033, Lab. : FP-34, 35, Food Park, MIDC, Butibori, Nagpur – 441122 MS Ph. : (0712) 2242077, 9373287475 Fax: (0712) 2242077 Email: [email protected], [email protected] website: www.anaconlaboratories.com



2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of project and project proponent:

SKS Ispat and Power Limited, is an ISO 9001-2008, ISO 14001-2004 certified Steel conglomerate,

having 6 Lakh tons per annum Integrated Steel Plant in Raipur, Chhattisgarh. The company has Rich

experience of 40 years in the Steel Industry enables to understand and serve valuable customers in a

highly professional and cost effective manner.

SKS Ispat & Power Limited, presently have various facilities in their existing integrated steel plant in

Siltara, Raipur. Some of them are sponge Iron Plant having capacity of 2,70,000 TPA (2x100 TPD

and 2x350 TPD), 85 MW power plant (25 MW Waste Heat Recovery Boilers (WHRB) and 2x30 MW

CFBC & AFBC boilers) and other interrelated units with investment of Rs. 1000 crores. SKSIPL are

committed to be part of Chhattisgarh State for industrialization progress undertaken by the

Government of Chhattisgarh for optimum utilization of natural and human resources available in the

state. The SKS group is establishing a 1200 MW IPP in District Raigarh of Chhattisgarh State with an

investment of Rs. 7000 crores (of which around 3500 cores spent) as well as an integrated Cement

Plant of 3.0 MTPA at District- Bilaspur with an estimated investment of Rs.700 crores.

At the existing integrated steel plant company has proposed to add the following

modification/enhancement with existing SMS project only details are presented in Table 1.

TABEL 1: PRODUCTION/ GENERATION CAPACITY EXPANSION AND CHANGE IN

CONFIGURATION



Total production capacity& configuration

Remarks




Four more Induction Furnaces of (15T each) to be installed to achieve approved rated production

Sponge Iron - 2,70,000 TPA 2 x 100 TPD & 350 x 2 TPD Kiln

- Sponge Iron - 2,70,000 TPA 2 x 100 TPD & 350 x 2 TPD Kiln

No change at present

Rolling Mill (4 Nos.) - 3,84,000 TPA

- Rolling Mill (4 Nos.) - 3,84,000 TPA


Ferro Alloy – 29,400 TPA

- Ferro Alloy – 29,400 TPA No change at present

Power Plant – Total 85 MW 25 MW WHRB and 2 X 30 MW CFBC & AFBC CPP.

- Power Plant – Total 85 MW 25 MW WHRB and 2 X 30 MW CFBC & AFBC CPP.


Gasifire (5 Nos.) 5 x 8000 Nm3/Hr.

- Gasifire (5 Nos.) 5 x 8000 Nm3/Hr


Oxygen/Nitrogen Plant – 170 NM3/Hr.

- Oxygen/Nitrogen Plant – 170 NM3/Hr.




2.2 Brief Description of Nature of the Project:

The project already has existing integrated steel plant having the sponge iron plant 2,70,000 TPA (2x100 TPD and 2x350 TPD), 85 MW Captive power plant (25 MW Waste Heat Recovery Boilers (WHRB) and 2x30 MW CFBC & AFBC boilers), Ferro Alloy plant 29,400 TPA, Rolling Mill (4 Nos.) - 3,84,000 TPA, Gasifire (5 Nos.) 5 x 8000 Nm3/Hr, Oxygen/Nitrogen Plant – 170 NM3/Hr and Steel Melting Shop (SMS) having capacity of SMS – 3,31,500 TPA(3 x 12T IF & 3 x 15T IF with investment of Rs. 1500 crores at Siltara, Tehsil Dharsiwa, Raipur, Chhattisgarh.

Now, said proposal is only modification/ enhancement in the existing configuration of furnaces at

existing steel division with additional 4nos x 15T capacity induction furnace with 6/11 CCM without

change in the existing capacity of the issued environmental clearance.

Justification for Modification/Enhancement of SMS Division:

• M/s. SKSIPL going to increase the unachieved capacity of Steel melting shop by adding the 4

Nos. of induction furnace hence all initially approved estimated parameters will be the same.

PRODUCTION IN (MT)

2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

124485.413 113660.245 92762.146 153408.089 183253.225 159145.11 186874 172607

PERCENTAGE CAPACITY UTILIZATION (3,31,500 TPA)

37.5% 34.2% 27.9% 46.2% 55.2% 48.0% 56.37% 52.06%

• There will be no use of fossil fuels (Coal and Diesel).

• Presently sponge production and ferro alloys are not fully utilized hence company have to sale in

open market. After proposed adding of 4 nos. of IF’s,its internal consumption of sponge will be

increased which results in reduction in outgoing number of vehicles.

• After this arrangement, companies internal consumption will be increased which results in

reduction in outgoing number of vehicles which further result in reduction of fugitive emission on

road

• It is further clarified that the technology of low frequency induction furnaces has improved a lot

and it runs under high efficiency. The electricity consumption is less as compared to old

technology.

Existing Project Details:

The details of existing production profile is mentioned in Table 2

TABEL 2: EXISTING PRODUCT PROFILE

Product Total Quantity Remarks

Sponge Iron - 2,70,000 TPA

EC granted by MoEF dated. August 25,2006 (F.No. J-11011/99/2006 – IA II(I)

Steel Billets production Unit (SMS) -

3,31,500 TPA

Palletization Plant – 3,00,000 TPA

Structural/re-rolled products

3,84,000 TPA

Captive Power Plant (Total 85 MW)

WHRB – 25 MW&2 X 30 MW CFBC & AFBC CPP.



Product Total Quantity Remarks

Gasifire (5 Nos.) 5 x 8000 Nm3/Hr Consent to establish was obtained vide order no.1689/TS/CECB/2013 dated 01/07/2013. Renewal of Consent was obtained vide order No.307/TS/CECB/2015dtd. 21.04.2015 valid till 31/01/2018

Oxygen/Nitrogen Plant 170 NM3/Hr.

Proposed Project Details:

The company now proposes only modification/enhancement in the existing configuration of furnaces

at existing steel division with additional 4nos x 15T capacity induction furnace with 6/11 CCM without

change in the existing capacity of the issued environmental clearance. The proposed details of

capacity are mentioned in Table 3.

TABEL 3: DETAILS OF MODIFICATION/ENHANCEMENT OF SMS PROJECT



Total production capacity & configuration

Remarks




Four more Induction Furnace of (15T each) to be installed to achieve approved rated production

2.3 Need for the project and its importance to the country and/or region:

Steel is one of the most important products of the modern world and is of strategic importance for

any industrial nation. Historically, all nations during their industrialization phase have been

supported by a strong steel industry of their own. From construction, industrial machinery to

consumer products, steel finds a wide variety of applications. It is also an industry with diverse

technologies based on the nature and extent of use of raw materials.

India is the 4th largest producer of steel in the world accounting for production of 81.54 million tons

of crude steel in 2013-14. It also holds the third position in consumption of steel. Thus there is

great potential of steel industry in India.


i.e. 3,31,500 TPA also in order to meet the in-house demand of raw material for MS rounds and

CTD bars and to meet the market requirement in timely manner, the proposed project is

undertaken.

Advantages of the project

- Improved productivity of the existing process. - Reduced operation cost due to sharing of infrastructures and manpower with existing unit

reducing overhead by almost 30% - Since the materials handling will be similar to existing operation, synergy of activities will bring

economies to the unit. - Dedicated and experienced workforce is available. - Ready market for the supply of finished products. Easy accessibility to the thriving markets of

Chhattisgarh, Madhya Pradesh, Bihar, UP and Odisha form another major locational advantage factor.

- Technology has already been successfully tried in existing plant.



2.4 Demand-Supply Gap

Steel production of India accounted for 14.33 million tons in 1990-91, which gradually increased to

36.12 million tons in 2003-04. Rapid rise in production has resulted in India becoming the 3 rd 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 per capita 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. At the time of its release, the National Steel Policy

2005 had envisaged steel production to reach 110 million tonnes (mt) by 2019-20. However, based

on the assessment of the current ongoing projects, both in greenfield and brownfield, the Working

Group on Steel for the 12th Five Year Plan has projected that domestic crude steel capacity in the

country is likely to be 140 MT by 2016-17 and has the potential to reach 149 MT if all requirements

are adequately met. The National Steel Policy 2005 is currently being reviewed keeping in mind the

rapid developments in the domestic steel industry (both on the supply and demand sides) as well as

the stable growth of the Indian economy since the release of the Policy in 2005.India is expected to

become the world's second largest producer of crude steel in the next 10 years, moving up from the

third position, as its capacity is projected to increase to about 300 MT by 2025. Huge scope for

growth is offered by India’s comparatively low per capita steel consumption and the expected rise in

consumption due to increased infrastructure construction and the thriving automobile and railways

sectors.

The National Steel Policy 2005 is currently being reviewed keeping in mind the rapid developments in

the domestic steel industry (both on the supply and demand sides) as well as the stable growth of the

Indian economy since the release of the Policy in 2005.

2.5 Imports vs. Indigenous production

The Indian infrastructure sector is likely see a massive growth due to increasing economic status thus

in order to keep the supply ready to match the demand of construction steel in India and to achieve

the rated production by modification/enhancement of SMS becomes important for M/s. SKS Ispat and

Power Ltd.

2.6 Export possibility

Export of Steel is always possible, the Government of India is also encouraging export of steel,

however proposed quantity will be domestically consumed. The world steel market is for about 1500

Million Tonnes, out of which about 50% is being produced by China, the global demand even if

increased by 2% per annum then it requires addition of 30 Million Tonnes additional production

capacity. Since China has already reach to saturation level of increasing the production therefore

India has better chance to share the world market by increasing its production in an energy efficient

manner. The unit being located in the eastern sector can export the steel to Bangladesh; Bhutan; and

Burma and Nepal also.

2.7 Domestic/ Export Markets

Domestic market with real estate, infrastructure projects, industrial projects are available for purchase

of steel which is estimated to be around 80 million tonnes per annum. The estimated growth in

infrastructure is likely to increase the demand of steel to more than 150 million tonnes by the year

2025. In view of this, it is required to make advance planning for creating the facility and infrastructure



to meet this demand. The domestic market as well as export market both will require good quality

steel, produced with minimum energy consumption and minimum cost of production.

The project has potential to cater to the domestic demand as well as export demand of steel to

domestic as well as export oriented steel plants.

2.8 Employment Generation (Direct and Indirect) due to the project:

The total employment generated by the existing integrated steel plant is about 1000 employees.

However, the existing and likely proposed employment generation in SMS division due to project is

given in Table 4.

TABLE 4: EMPLOYMENT GENERATION

Particulars Existing Proposed

Admin Staff : 08 05

Production staff : 114 65

Sub-Total : 122 70

Total : 192 Nos.

3.0 PROJECT DESCRIPTIONS

3.1 Type of project

SKS Ispat & Power Limited, was granted Environment Clearance vide letter no. J-11011/99/2006-IA.II(I) dated 25.08.2006 and presently operating various facilities in their existing integrated steel plant with an investment of around Rs.1000 Crores in Siltara, Raipur. The company now proposes only modification/enhancement in the existing configuration of furnaces at existing steel division with additional 4nos x 15T capacity induction furnace with 6/11 CCM without change in the existing capacity (3,31,000 TPA) of the issued environmental clearance. As the existing induction furnaces are not running efficiently (as per the present designed capacity). Thus, to achieve the rated production M/s. SKSIPL have to make addition of IF’s without change in total capacity of existing steel division. The proposed addition of IF’s will be established in the existing plant premises only no additional land required outside the plant side. Project falls under Category A (secondary metallurgical processing) Item 3(a) of the schedule of EIA notification of Sept 14, 2006 issued by MOEF & CC. 3.2 Location

Details about the Project area are presented in Table 5.

TABLE 5: DETAILS ABOUT THE PROJECT AREA

State Chhattisgarh

District/ Tehsil Tehsil- Dharsiwa, District- Raipur

Village Siltara

Khasara No. Private Industrial Land: Khasra No. 102/1-9

Area 225 Acres

Toposheet No. 64G/11

Geo-coordinates Latitude : 21023’29”N

Longitude : 81°38’46”E

The index map and location is presented in Annexure-I, Location map showing 10 km radius of study

area shown in Annexure-II



Annexure – I

INDEX MAP



Annexure – II

STUDY ARA MAP

(10 KM RADIAL DISTANCE FROM THE PROJECT SITE)

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

particularly the environmental considerations gone into should be highlighted.

Proposed modification/enhancement of SMS will be within the existing plant premises; hence,

alternative sites are not examined.



3.4 Size or Magnitude of Project

The existing and proposed production capacity with details regarding configuration are presented in

Table 6

TABLE 6: PROPOSED MODIFICATION/ENHANCEMENT OF SMS PROJECT



Total production capacity & configuration after expansion

Remarks





3.5 Project description with process details:

Induction Furnaces (proposed 4 x 15 Ton Induction Furnaces)

M/s. SKS Ispat and Power Limited is having following in the steel melting shop:

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

frequency. Mild steel, Stainless Steel and low and high alloy Steel can be made from these furnaces.

Raw materials used are Steel melting Scrap and Direct Reduced Iron. Alloying elements added as

per requirement

Manufacturing Process

The induction furnace continuous casting route is adopted for steel melting. The induction furnace -

continuous casting route is proposed to be adopted for additional steel melting.

DRI from the DR plant will be conveyed to the overhead storage bins, which shall be located in the

melt shop. DRI will be discharged onto traveling vibratory feeders for charging into the furnaces.

Plant return scraps from various generating points and purchased scrap is transported to the scrap

bay of steel melting shop. One crane is provided in the scrap bay for unloading and loading of scrap

and pig iron in scrap buckets. These are transported to the furnace bay by electrically driven scrap

bucket transfer car. The scrap buckets are weighed in the scrap bay. Scrap is stored on furnace

working platform near the furnace for charging.

The scrap is charged into the crucibles for generating the hot heel for DRI charging. Necessary

carbon in the form of pig iron/ petroleum coke is added into the crucibles to ensure the availability of

necessary carbon in the bath. Once the molten bath has been formed and minimum temperature of

the bath has been achieved, sponge iron is charged in small batches and the slag formed is removed

periodically. After the completion of charging of sponge iron, a sample is drawn to determine the

composition of the bath. After achieving the desired melt analysis, the temperature is raised to the



tapping temperature taking into account additions of predetermined amount of ferroalloys to achieve

the required tapping composition of the melt.

Continuous Casting

The continuous casting technology has gained worldwide acceptance because of high yield,

economics of operation and better product quality. Hence this technology is chosen for our steel

plant casting the liquid steel into billets. The existing continuous caster will be utilized for producing

steel billets, which is equipped with moulds, mould oscillating mechanism, secondary cooling

segments, withdrawals and straightening unit, gas cutting unit, dummy bar insertion system, run out

roller tables, cross transfer mechanism and cooling bed. The caster is controlled from the pendant

control panels and also from main control room located on the casting platform and the auxiliary

control room near the gas-cutting unit. The tap-to-tap time of the induction furnaces is matched with

the casting cycle time so as to have maximum number of sequential cast.

Ladle

The ladle is picked up by ladle handling crane and placed on the ladle stand. A refractory lined

Tundish, fully dried and fitted with preheated nozzles mounted on Tundish car is moved from the

reserve position to the casting posit

Pictorial View of Billets formation Pictorial View of Ladle

Prior to the start of the casting operation, the dummy bars will be introduced into the mould. The gap between the dummy bar and mould walls is sealed with asbestos cords and small pieces of steel scraps are placed over the dummy bar head for chilling of initial metal. Water supply to mould, secondary cooling zone and machine cooling is switched on at this stage. When the liquid steel level in the Tundish reaches a predetermined level, the tundish nozzles are opened. When the metal level in the mould reaches about 100-150 mm from its top the drive of the mould oscillating mechanism as well as withdrawal and straitening unit is switched on. The withdrawal of dummy bar begins at the minimum speed and gradually increased to normal speed within few minutes. The mould is lubricated with liquid lubricant. During casting operation the metal level in the mould is maintained within predetermined limits by adjusting flow of metal into the mould or by adjusting the withdrawal speed.

The liquid metal level in Tundish is also kept within permissible range by adjusting theopening of ladle slide gate. The partially solidified billets after leaving the mould pass through strand guide roller segment where intensive but controlled cooling of billets is affected by water spray nozzles. The



solidified billets are guided through withdrawal and straightening units before entering the gas cutting zone. The dummy bar is separated from the billet for the gas cutting unit and is stored till its introduction is required for the next hit. The cast billet is cut to predetermine length by gas cutting torches. The size billets are delivered to the cooling bed through run out roller table and cross transfer mechanism. The billets are marked on cooling bed by the marking unit for identification/tracking.

ASSUMPTIONS

Some of the important assumptions relating to the production of billet is as under: No. of Working days 320 Days Furnace Capacity

No. of Furnace -4 Nos.

Capacity per Charges -15 MT

Total heats per day -10 nos.

Total capacity -600 tons per day

(140 minutes per heat)

Capacity Utilization

1st year of operation - 80 %

From 2nd year and ahead - 90 to 100 %

For uninterrupted operation of the plant the raw material to be kept in the raw material yard is as

given under, these holdings period is suggested taking into account the availability, transit period and

any unforeseen interruptions in the supply channel.

Sponge iron - 2 Months

Pig Iron - 2 Months

Scrap - 2 Months

Ferro Alloys - 2 Months

Work in Progress - 15 Days

Finished Outputs - 22 Days

Stores and Spares - 3 Months

The above holding periods have been specified taking into account the activity in stand alone basis.

RAW MATERIAL SPECIFICATIONS

Sponge Iron - + 3 to – 20 mm\

Pig Iron - + 100 to - 150 mm

Scrap - + 20 mm to – 150 mm

Ferro Alloys - +20 to – 70 mm



CONTINUOUS CASTING M/C

Continuous casting is the process to solidify molten steel into a semi finished billet, bloom, or slab for

subsequent rolling. Prior to the introduction of the continuous casting in 1950s, steel was poured into

stationary molds to form ingots. But continuous casting has substantially added to improved yield,

quality, productivity and cost efficiency.

Steel from the electric arc furnace is tapped into a ladle and taken to the continuous casting machine.

The ladle is raised onto a turret that rotates the ladle into the casting position above the tundish.

Liquid steel flows out of the ladle into the tundish and then into water-cooled copper mold.

Solidification begins in the mold, and continues through the first zone and strand guide. In this

configuration, the strand is straightened, torch-cut and then discharged for intermediate storage or

hot charged for finished rolling. The melting /casting/ rolling processes are linked while casting a

shape that substantially conforms to the finished product. The complete chain from liquid metal to

finished rolling can be achieved within two hours.

The Product end-use dictates the quality, grade and shape of the cast product (billet, bloom, slab,

beam blank, and/or round).

To start a cast, the mold bottom is sealed with a dummy bar head attached to dummy bar. The

dummy bar is held in place hydraulically by Straightener Withdrawal units. This head prevents

liquid steel from flowing out of the mold. The steel poured into the mold is partially solidified,

producing a steel strand with a solid outer shell and a liquid core. In this primary cooling area, once

the steel shell has sufficient thickness, about 10–20 mm, the staightener withdrawal units are started.

The moving dummy bar starts to withdraw the partially solidified strand out of the mold along with the

dummy bar.

Liquid steel continues to pour into mold to replenish the withdrawn steel at an equal rate. The

withdrawal rate depends upon the cross-section, grade and quality of steel being produced, and may

vary widely depending upon section, quality and machine design parameters

Casting times are typically matched with the EAF tap-to-tap time. Upon exiting the mold, the strand

enters a roller containment section and secondary cooling chamber in which the solidifying strand is

sprayed with water to promote solidification. This area preserves cast shape integrity and product

quality. Larger cross-sections require extended roller containment. Once the strand is fully solidified

and passed through the staightener withdrawal units, the dummy bar is disconnected, removed and

stored. Following the Straightener, the strand is cut into individual pieces of required length and

discharged for further processing by rolling.



Main Features:

Production capacity - 300,000 tons/year

Remains same (Existing Capacity)

Days of liquid steel supply/year - 320

Grades of steel to cost - Low, Medium, and high carbon steels

Heat size - 15 t

Source of liquid metal - 15 t Induction Furnace

Type of ladle - Bottom pouring with slide gate system and

porous plug

Billet size - 140x140,150x150 and 125 x 125 mm.

Billet quality -- Internationally acceptable for size surface

Quality, mechanical and metallurgical

Properties

MACHINE PARAMETERS

Type of machine - 2/3 strand, curved mould, bow type

Machine Radius - 6 / 11 m billet.

Method of ladle placement - Rotating turret with independent lifting and

lowering if the arms along with facilities for

Weighment

Strand cooling - air / mist

EMS - to be provided

Tundish - of adequate size capacity to facilitate

Sequence casting & inclusion removal

Mould level control - to be provided with the mould

Billet cutting - to be provided along with auto operation

Method of discharge - on horizontal discharge roller table

Dummy bar - flexible / rigid with replaceable heads for

different sizes

Casting speed - variable for various grades

Mould oscillation - short lever arm, variable frequency and

variable stroke of oscillation. The frequency of

oscillation to be coupled with the casting



speed to maintain a constant negative strip

time

Tundish car - With lift lower and centering device

Withdrawal system - hydraulically pressurized withdrawal machine

with Individual driven rolls for maintaining

straightness of the cast strand while casting

Drive - DC or VVVF Drives for withdrawal

straightener, Mould oscillation with perfect

synchronization between withdrawal

straightener & oscillation

Figure 1 Process Flow Chart



Source of water:

Raw water requirement is been met from the Kharun river for which WRD department Govt. of CG

has allotted 1.8 MCM (4800 KLD) of water. The Kharun river is at a distance of about 4 km from the

existing plant location. Anicut has been constructed on the river and an intake well along with the

pump house is constructed by SKSIPL at downstream of the Anicut and about 4 km long cross-

country piping system for transportation of river water. The river water is stored at 2 nos. of common

reservoir within the station boundary.

3.6 Raw materials required along with estimated quantity, likely source, marketing area of

final product/s, Mode of transport of raw Materials and Finished Products.

Estimated raw materials quantity likely to be sourced from outside, mode of transportation is given in

Table 7.

TABLE 7: ESTIMATED RAW MATERIAL CONSUMPTION

Sl. Description Quantity (MTPA) Source

1 Sponge Iron 323213 From Captive generation/Open market.

2 Pig Iron 51343 Open Market

3 Scrap 18218 Open Market

4 Ferro Alloys 3643 Captive Generation

Total= 3,96,417

Note: 1. Existing requirement of Raw materials as we are not increasing the existing approved Capacity. 2. All Types of Raw materials are being transported through Road by covered truck and final product will be charged directly to the Existing Rolling Mills

TABLE 8: MATERIAL BALANCE

STEEL MELTING SHOP (Capacity- 3, 31,500 TPA)

MATERIAL BALANCE (T/T OF PRODUCT) – BILLET PRODUCTION

(A) INPUT (B) OUTPUT

Sponge Iron 0.975 Total liquid metal 1.043

Pig Iron 0.155 Slag 0.131

Scrap 0.055 Total 1.174

Ferro Alloys 0.011 (C) LOSSES

Total 1.196 Burning losses (A-B) 1.196-1.174=0.022

(D) MATERIAL BALANCE D=A-(B+C) = 1.196- (1.174+0.022)=0

3.7 Resource optimization/ recycling and reuse envisaged in the project, if any, should be

briefly outlined.

During the process, marginal water will be used and will be recovered and recycled for process use; hence no waste water generation are envisaged.

The effluent generated from the operation is utilized for water sprinkling on roads & yards.



The source of domestic wastewater is only from the office toilets of the plant are being completely disposed off into the soak pit via septic tank. Soak pit overflows used in horticulture

activities.

3.8 Availability of water, its source, Energy/ Power requirement and source:

Availability of water and its source:

Raw water requirement is met from the Kharun River for which WRD, Govt. of CG has allotted 1.8

MCM of water. The Kharun river is at a distance of about 4 km from the existing plant location. Anicut

has been constructed on the river and an intake well along with the pump house is constructed by

SKSIPL at downstream of the Anicut and about 4 km long cross- country piping system for

transportation of River water. The river water is stored at 2 nos. of common reservoir within the

station boundary. No water will be abstracted from groundwater and no further water is required for

the project

Energy/ Power requirement and source:

The electric power requirement for the project will be fulfilled from captive power plant. The detail of

captive Power plants are as follows (Table 9):

TABLE 9: ENERGY/POWER REQUIREMENT AND SOURCE

Sr. No. Existing capacity of CPP

1. AFBC– 30 MW

2. CFBC – 30

3. WHRB -25

Total = 85 MW

3.9 Quantity of wastes to be generated (liquid and solid) and scheme for their

Management/disposal:

Slag generated is being crushed for metal recovery and dust generated is used for area

development as filling material. As there is no additional capacity increase than already approved

capacity, the waste disposals would be within norms.

100% of wastewater will be recycled and Zero discharge condition will be maintained.

100% Mill scale is used for captive consumption in SMS Plant as raw material.

Miss-Roll and End Cuts 100% are used in captive consumption in Steel Melting Shop as raw

materials.

The fly ash generated shall be utilized in our own Fly Ash Bricks Plant and remaining if any, shall

be supplied to other Bricks manufacturing Units and Cement Plant.

The liquid steel produced will be used in a manner to produce hot billet suitable for Re Rolling,

thus online hot Re Rolling practice will be adopted.

Mill scale generated in the Rolling mill will be100% used in SMS plant.



TABLE 10: QUANTITY OF WASTES TO BE GENERATED

Description Quantity of Waste generated Method of Collection Method of Disposal

Billet Scale (Existing) (5.17 TPD) 0.5 % OF PRODUCTION

Manual Used In Furnaces

Billet Scale (Proposed) (4.14 TPD) 0.4 % OF PRODUCTION


Slag (Existing)

186 TPD (18 % OF TOTAL CHARGE MIX) At full capacity

Manual Slag Crush/Metal Recycle

Slag (Proposed) Manual Slag Crush/Metal Recycle

3.10 Schematic representations of the feasibility drawing which give information of EIA

purpose.

S. No. Particulars Impacts Remediation Proposed

1. Change in

land use.

Permanent change in land use

related to:

Installation of machineries

Plantation in and around the plant

Recharge potential development

The project is already an Industrial

area and the proposed expansion

will be within plant premises, devoid

of vegetative tree cover and having

only the grass cover. Part of the

land will be covered by tree

plantation to the extent of 33% of

area being brought under industrial

activity. The greenery will be taken

up within the plant boundary and

additionally outside the plant

boundary.

Water will be sourced from River

Kharun, no groundwater will be

abstracted for the project activities

hence, natural recharge of

groundwater level will not be

affected through proposed project

activities.

2. Transportation

of material

The existing network of

transport gets reduced (+ve

impact)

• Presently sponge production and ferro alloys are not fully utilized hence company have to sale in open market. After proposed adding of 4 nos. of IFs its internal consumption of sponge will be increased which results in reduction in outgoing number of vehicles.

• After this arrangement companies internal consumption will be increased which results in reduction in outgoing number of vehicles which further result in reduction of fugitive emission on road



S. No. Particulars Impacts Remediation Proposed

3. Gaseous and

Particulate

Emission to

The atmosphere

Air quality All necessary steps will be followed to

minimize the emission from point

sources as well as line sources. Thus

the standards of Stack Emission and

Ambient Air quality will be maintained

as per prescribed limits.

4. Discharge of

effluent

Impact of water quality. Zero discharge is already being

implemented at existing ISP and in will

be continued further.

5. Withdrawal of

ground /

surface water

Availability of ground/surface

water is affected.

Water will be sourced from River

Kharun, no groundwater will be

abstracted for the project activities

hence, natural recharge of ground

water level is not affected through

project activities. Permission

regarding drawl of river water is

granted from water resource

department.

6. Operation of

equipment

and vehicles

likely to

generate

noise.

Impact on human health due

to excess noise level beyond

permissible level.

All the process equipment will be

installed on anti-vibration pad with

sufficient provisions to minimize

generation of noise. The high noise

generating equipment like turbine and

generator will be enclosed with noise

suppressing enclosures.

The buildings as well as boundary wall

and green belt will ensure the

attenuation of noise outside the

boundary within the prescribed limits.

7. Fire Hazard

due to storage

of fuel etc.

Risk to the surrounding

habitation.

Necessary precautions to prevent fire

and all the provisions to control fire

shall be provided.

8. Employment

to outsiders

Socio-economic disparity with

local community

Priority of employment will be given to

local people, as already sufficient

qualified and trained local youth are

available.

9. Cultural impact Local population feels isolated The promoters proposed to employ

local masses in the project, hence no

such impact on cultural diversity is

likely to take place.

10. Disposal of solid

and hazardous

wastes

Create odorous problem,

nuisance condition related to

the disposal of solid wastes.

Deterioration of soil,

productivity pollution in ground

water/surface water due to

leaching and surface runoff.

Domestic wastes will be segregated

for organics and Inorganics. Organic

wastes will be used for composting

and inorganics for approved vendors.

Disposal of hazardous wastes will be

done as per hazardous wastes

handling and disposal rule.



4.0 SITE ANALYSIS

4.1 Connectivity.

The proposed project is situated at Siltara village, Tehsil Dharsiva, Raipur district of Chhattisgarh

state. The site is well connected with Road/Rail. The existing road network will be used for

transportation activities. The details are as follows:

Nearest Road: Raipur-Bilaspur-Kolkata Highway (NH-200)about 1.89 km, E

Nearest railway station- Mandhar, 08 km (Railway Station) (SE) & Raipur, 12 km (E)

Nearest airport- Raipur 24.28 Km, SE

4.2 Land Form, Land use and Land ownership.

The proposed activities will be within the existing integrated steel complex. SKSIPL is already having

existing 225 Acres (91.05 Ha.) of land at village Siltara at Raipur District. The proposed land identified

for the modification/enhancement of SMS will be 02 acres (0.809 ha) within existing plant premises. It

is Private Land already developed for industrial activities.

4.3 Topography (along with map)

The project area located at Siltara village in Raipur District of Chhattisgarh state. General topography

of the region was observed to be flat with low undulating plain and the plant site having gentle slope

toward West. Dominant features of the land are being the lateritic, sandy loamy plain and broad

alluvial plain of River Kharun. The project located at 21023’29”North Latitude and 81°38’46”East

longitude on the Topo sheet No. 64, G/11. The site specific Topography map is given in Figure 2.

FIGURE 2: SNAPSHOT OF GOOGLE SATELLITE IMAGERY SHOWING FLAT TOPOGRAPHY

Geology

The project area falls in Raipur District. It mainly covers the rocks of Chandi Formation, Raipur Group

of Chhattisgarh Super Group.

Raipur Formation: It is represented by Chandi Formation of Raipur group which is part of

Chhattisgarh Super group of Meso to Neoproterozoic age. Lithological it comprises of limestone and



dolomite: reddish brown, fine to medium grained, hard and compact. Clay pockets are also observed

in area which are Green to olive green, soft to moderately hard, occurs as pockets and lenses and

patches of chert of green, buff, red, massive and compact rock are observed in area.

HYDROGEOLOGY

The study area comes under Mahandi River Basin. The principal Aquifer system within study area is

Sedimentary rocks. The Pre- monsoon ground water level observed within the study area is 3-5m

while the post monsoon water level observed in the area is 2-3m. Water table contour observed in the

study area is from 250m amsl. As per CGWB, 2013 data the study area falls in safe category of

groundwater development with observed groundwater development of 64%. However, No Ground

water will be utilized for project related activity. The yield of aquifer observed within the area is 1-8

lps. Dendritic type of drainage pattern is observed in study area which follows the regional slope.

4.4 Existing land use pattern (agriculture, non-agriculture, forest, water bodies

(distance from HFL to the river), CRZ. In case of notified industrial area, a copy of Gazette

Notification should be given:-

Existing land use is a private industrial land. The land is being used for Industrial Purpose.

5.0 PLANNING BRIEF

5.1 Planning concept (type of industries, facilities transportation Town and Country

Planning Development authority Classification.

Project concept:

Steel Melting Shop (SMS): Sponge iron, ferro alloys, pig iron and imported stainless steel scrap are

being charged from the top of Induction Furnace. Arcing melt the contents. Oxygen blowing is done.

Steel is tapped and chemistry correction is done in ladel refining furnace. Liquid steel is casted into

billets in continuous casting machine. Slag is taken out from slag tap hole.

Town and Country Planning Development authority Classification:

The project falls within Siltara village near to Siltara Industrial Area surrounded by a various

Industries. Town and country planning department has already classified land as industrial. Adequate

road facilities are already developed and available for transportation of raw materials as well as

finished products.

5.2 Population Projection.

The existing industry is providing employment to about 1000 people including 192 people for SMS division. During construction phase, about 60 workmen i.e labors and workers will be hired from nearby villages. After modification/enhancement in SMS division (operation phase) total workforce will be around 70. Since the plant is located in the Raipur district in which trained manpower are already available therefore the employment will be mostly given to local people therefore there will not be any substantial increase in the population of local villages. However, due to increase economic growth, the local youth will be benefited and employment. 5.3 Land use planning (breakup along with green belt etc.).

The proposed activities will be within the existing integrated steel complex. SKSIPL is already having

existing 225 Acres (91.05 Ha.) of land at village Siltara at Raipur District. The land for the



modification/enhancement of SMS will be 02 acres (0.809 ha) within existing plant premises. It is a

private land already developed for industrial activities. The plantation details within the plant premises

in given in Table 11.The breakup of the land for the various activities is presented in Table 12.The

layout map showing proposed project site is depicted in Figure. 3.

TABLE 11-PLANTATION DETAILS

1 Total area of Plant 91.05 Hec (225 Acres)

2 Area reserved for plantation 33% of the total plant area

3 Total no of plants planted 80,000

4 Total alive plant 52,000

5 Survival rate 65%

6 Places at plantation done Inside the plant premises, labour colony,Bacholers Hostel,Bana Village,nearby villages,approch road from Bilaspur-Raipur road to SKS plant etc.

7 Types of Plant Neam, Chatim, Gulmohar, Peltophorum, Karanj, Teak

etc.Including ornamental plants at gardens/lawns.

TABLE 12: LAND BREAKUP

Sl. No. Details Area (In Acres.) Area (In Ha.)

1 Sponge Iron Plant 5.56 2.25

2 WHRB CPP 3.5 1.41

3 Billet Production unit 3.2 1.29

4 Rolling Mill 6.2 2.50

5 Coal based Power Plant 5.5 2.22

6 Ferro Alloys 3.2 1.29

7 Oxygen Plant 2.6 1.05

Central QC Lab 3.2 1.29

Fly Ash Bricks Plant 1.0 0.404

8 Automobile 3.2 1.29

8 Roads 12.56 5.08

9 Other Buildings (Canteen,ADM etc.) 8.42 3.40

10 Reserved for Green Belt 74.25 30.04

11 Water Reservoir 18.5 7.48

12 Raw Material Storage Yards 10.3 4.16

13 Dispatch Yard 8.5 3.43

14 Slag Crusher 2.5 1.01

15 Residential Area 9.5 3.84

16 Reservoir for Rain water Harvesting 9.5 3.84

17 Temples 3.3 1.33

Truck & Other Parking 8.5 3.43

18 Hazardous Waste storage area 1.5 0.60

18 Vacant Land 20.52 8.30

Total 225 91.05



FIGURE 3: LAYOUT OF EXISTING INTIGRATED STEEL PLANT OF M/s. SKSIPL SHOWING

PROPOSED SITE WITHIN EXISTING PREMISES

Proposed site for installation of 4 nos. of

IF’s having capacity of 15T each



5.4 Assessment of Infrastructure Demand:

No substantial additional infrastructure is required for the proposed activities. The available road

network and natural sources of water supply and drainage system are adequate. However in order to

have smooth transport of men and materials the existing approach road of existing steel complex will

be extended to proposed project within plant premises. Water will be sourced from river Kharun.

There is no other major infrastructural requirement for the project.

9.1 Amenities/Facilities:

The project modification/enhancement of SMS division does not require additional large amenities or

facilities. As it already has necessary arrangement for the project for meeting water supply for

drinking purposes, toilet facilities for workers as well as inward/outward transport operators, parking

facilities, as well as canteen for workers and guests. The septic tank has been built for disposal of

domestic effluent generated. A canteen with rest room is also available for the supply of tea; snacks;

food to the workers, drivers and visitors etc. Sufficient parking space is already created for the

parking of trucks, cars, etc.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial Area (Processing Area)

About 0.809 Ha land will be used for the construction of induction furnaces for SMS division out of the

total 91.05 Ha. The proposed site is well connected with concrete road; remaining area will be used

for open space and green belt development, parking bay, etc. as given in land use statement.

6.2 Residential Area (Non Processing Area)

There is no residential area proposed in the plant area; as the existing villages have adequate

facilities to accommodate the additional manpower residential requirements. Most of the local people

will only be employed so the need of the additional residential colony in the plant is not required.

6.3 Green Belt

Greenbelt in an around 30.04 Ha. (33%) is already developed, having local species with broad leaves

and higher canopy. The ever green as well as native plants species will be selected for the purposed

of green belt. The existing plantation is around 52, 000 within plant premises of M/s. SKSIPL.

6.4 Social Infrastructure:

The project area lies within the district of Raipur. There is no requirement to build any social

infrastructure within the plant area, however, a small temple already exists and the infrastructure for

amenities to the workers such as kitchen, canteen, rest room etc. is already provided which will be

further augmented with the expansion of the project.

6.5 Connectivity (Traffic and Transportation Road, Rail/Metro/Waterways etc.).

The proposed project is situated at Siltara village, Tehsil Dharsiva, Raipur district of Chhattisgarh

state. The site is well connected with Road/Rail. The existing road network will be used for

transportation activities. The details are as follows:

Nearest Road: Raipur-Bilaspur-Kolkata Highway (NH-200)about 1.89 km, E

Nearest railway station- Mandhar, 08 km (Railway Station) (SE) & Raipur, 12 km (E)

Nearest airport- Raipur 24.28 Km, SE



6.6 Drinking Water Management (Source & Supply of water)

There will be no additional water requirement for proposed modification/enhancement of SMS

division. The water requirement will be fulfilled through existing available water. SKSIPL has already

obtained consent for drawl of water through Kharun river (1.08 MCM) from water Resources

Department, Govt. of Chhattisgarh, vide letter No. 5425/315/JS/TS/AJP/03-D-4 dated 06/11/2004. No

groundwater will be abstracted.

6.7 Sewerage system

Infra-structural services including water supply, sewage, drainage facilities and electrification will be

made. The existing toilet facilities will be available to the workers to allow proper standards of

hygiene. These facilities are connected to a septic tank and soak pits. Waste water drainage system

of the plant is well connected to the sewerage channel facilities to ensure minimum impact on the

environment.

6.8 Industrial Waste/ Solid Waste Management.

100% of Industrial Solid waste will be used in the following manner:

6.9 Solid Waste Management

Slag as generated is crushed for metal recovery and dust generated is used for area development as filling material .As there is no addition capacity, the waste disposals would be within norms.

Thick green belt will be developed all around the periphery of the plant and vacant places within

the premises so as to reduce the pollution load and improve the aesthetics of the area.

TABLE 13: DISPOSAL OF SOLID WASTE

Description Quantity of Waste generated Method of Collection Method of Disposal

Billet Scale (Existing) (5.17 TPD) 0.5 % OF PRODUCTION


Billet Scale (Proposed) (4.14 TPD) 0.4 % OF PRODUCTION


Slag (Existing)

186 TPD (18 % OF TOTAL CHARGE MIX) At full capacity

Manual Slag Crush/Metal Recycle

Slag (Proposed) Manual Slag Crush/Metal Recycle

6.10 Power Requirement & Supply/source.

The electric power requirement for the project will be fulfilled from 85MW Captive Power plant.

7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN

7.1 Policy to be adopted (Central/ State) in respect of the project affected persons

including home oustees, land oustees and landless laborers (a brief outline to be

given):

The proposed project does not have any directly displaced persons, due to acquisition of land. There

are also no land oustees or project affected persons or home oustees, thus R&R plan is not

applicable here. However, the priority for employment will be given to local persons living in the

adjoining villages. In addition to this, promoter will also contribute for the welfare of the people of local

surrounding.



7.1.1 Details of Corporate Social Responsibility by M/s. SKS Ispat and Power Ltd.

The company is actively involved in CSR activities for the welfare of the surrounding areas and

budgetary provision is made every year. In 2013-14, company has spent Rs. 19,04,058 for different

activities as a part of CSR activities. For the year 2014-15 company had spent Rs. 24,01,584 for

different CSR activities and for the year 2015-16 company has made the provision of Rs. 8,36,052

has been made available by the company Table 14-16.

TABLE 14: CSR ACTIVITIES DURING THE YEAR 2013-14

Sr. No. Particulars Cost (In Rs.)

1 Beatification and cleaning of village pond, disposal of solid waste generated from plant, construction/repairing of pond bank and chabutraghat, etc. at Gram Parastari.

5,00,000

2 Expenditure for religions programme at village murathi,Charoda, Dharsiwa and Siltatara

33,401

3 Expenses under Chief Minister KanyadanYojana 1,00,000

4 Cooperation fund towards the Times of India Corporate Cricket 25,000

5 Expenses towards environment conservation 8,21,965

6 Expenses towards distribution of Medicine and providing medical facilities, organizing Health check-up camps in nearby villages surrounding the plant area.

4,23,692

Total 19,04,058



1 Organizing free Health check-up camps at village Parastari 500,00

2 Organizing Eye check-up camps at village Murraithi 40,000

3 Expenses under Chief Minister Kanyadan Yojana 1,00,000

4 Plantation/Greenbelt and beautification along SKS approach road, approach road of industrial area and nearby villages.

1,00,000

5 Expenditure towards religious programme at village murathi,Charoda, Dharsiwa and Siltatara

1,00,000

6 Expenses towards environment conservation 6,55,556

7. Expenses towards distribution of Medicine and providing medical facilities, organizing Health check-up camps in surrounding industrial area and nearby villages.

13,56,028

Total 24,01,584



1 Provision made towards organizing various activities 1,00,000

2 Plantation/Greenbelt and beautification along approach road of SKS and industrial area and nearby villages.

1,00,000

3 Expenditure towards religious programme at village 1,00,000




muraithi,Charoda, Dharsiwa and Siltatara

4 Provision towards environment conservation 4,36,052

5 Provision towards distribution of Medicine and providing medical facilities, organizing Health check-up camps in surrounding industrial area and nearby villages.

1,00,000

Total 8,36,052

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Likely date of start of construction and likely date of completion:

SCHEDULE FOR APPROVAL AND IMPLEMENTATION

Proposed Project

Activities at the site will be carried out after grant of Environmental clearance from Ministry of

Environment & Forests and Consent to establish from Chhattisgarh Environment Conservation Board

(CECB). The schedule for implementing the proposed project is given in Table 17.

TABLE 17: PROJECT IMPLEMENTATION SCHEDULE

Particulars Implementation Date/Time Period

Start of Construction After Receipt of Environmental Clearance &

Permission of Establishment.

Construction Period

Installation of additional of Induction Furnaces at

SMS,

03 Months

Commercial Production Period

Commercial Production will be started After 03 Months

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

The estimated project cost will be Rs. 25.00 crores for installation and operation. The project is

economically viable

TABLE 18: PROJECT COST

Existing Project Cost (Rs. In Crores)

Proposed expansion cost (Rs. In Crores)

Total Cost (Rs. In Crores)

1000 25 1025

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

9.1 Financial and social befits with special emphasis on the benefit to the local People

Including Tribal Population, If Any, in The Area.

• M/s. SKSIPL going to increase the unachieved capacity of Steel melting shop by adding 4 Nos. of

induction furnaces hence all initially approved estimated parameters will be the same.

• There will be no use of fossil fuels (Coal and Diesel).

• Presently sponge production and ferro alloys are not fully utilized hence company have to sale in

open market. After proposed adding of 4 nos. of IF’s its internal consumption of sponge will be

increased which results in reduction in outgoing number of vehicles.



• After this arrangement companies internal consumption will be increased which will result in

reduction in outgoing number of vehicles and further reduction in fugitive emission on road

• It is further clarified that the technology of low frequency induction furnaces has improved a lot

and it runs under high efficiency. The electricity consumption is less as compared to old

technology.

• Further, M/s. SKSIPL has already decided to give topmost priority for employment to local people

within the plant, and outside the plant in direct and indirect employment. Out of over 70

people to be employed from the proposed project activities, the company would be employing

more than 40 people from local area, which would naturally involve tribal people also who are

more than 60% in population and also are now well qualified as well as competent to take the

employment in the proposed industry. The local population is likely to be benefited by payment of

salary and wages to the local community employed.

On overall assessment of the project with technical and financial aspects, it is concluded that the

proposed modification/enhancement of SMS division of integrated steel plant is technically highly

feasible and financially profitable.



Appendix I

APPROVAL LETTER FROM WATER RESOURCES DEPARTMENT







Appendix II

EXISTING ENVIRONMENTAL CLEARANCE LETTER, MoEF, NEW DELHI











Appendix III

EXISTING CONSENT LETTER













Documents

1.0 EXECUTIVE SUMMARY : SKS ISPAT & POWEER LTD. : Mr ...environmentclearance.nic.in/writereaddata/Online/... · 124485.413 113660.245 92762.146 153408.089 183253.225 159145.11 186874