For FERRO ALLOYS MANUFACTURING – 6000 TPA PRODUCT MIX LOW CARBON …environmentclearance.nic.in/writereaddata/EC/14092018... · 2018. 9. 14. · obtaining Environment Clearance

M/s JAMSHEDPUR CHLOROCHEM PVT.LTD. At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

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For FERRO ALLOYS MANUFACTURING – 6000 TPA

PRODUCT MIX

LOW CARBON FERRO CHROME / LOW CARBON FERRO MANGANESE - 3600 TPA

and FERRO MOLYBDENUM – 1200 TPA and

FERRO VANADIUM – 1200 TPA

BY JAMSHEDPUR CHLOROCHEM PVT. LTD.

AT

Plot No. NS-88, 6TH Phase ,Adityapur Indusrtial Area, Gamharia, District-Seraikela Kharsawan

Environment Consultant Vardan Environet

(QCI and NABET/EIA/1619/RA 0037) D-142, Sushant Lok-III, Sector 57

Gurgaon (Haryana) Contact no.-9810355569

Mail ID: [email protected] Contact No. 0124-4291036, 09899651342

mailto:[email protected]


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Index

Ch. NO. TITLE PAGE NO.

CH-1 EXECUTIVE SUMMARY

CH-2 INTRODUCTION OF THE PROJECT

CH-3 PROJECT DESCRIPTION

CH-4 SITE ANALYSIS

CH-5 PLANING BRIEF

CH-6 PROPOSED STRUCTURE

CH-7 REHABILITATION & RESETTLEMENT

CH-8 PROJECT SCHEDULE & COST ESTIMATES

CH-9 ANALYSIS PROPOSAL


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CHAPTER - I EXECUTIVE SUMMARY

1.0 Introduction

India has become the world's fourth-largest producer of crude steel. The country is slated to become the second-largest steel producer by 2020 as large public and private sector players strengthen steel production capacity in view of the rising demand. Ferro Alloy is being used for manufacturing of Alloy Steel, Super Steel, Tool Steel such as tensile, elongation etc. and for manufacturing of Corrosion Resistant and Abrasion Resistant steel.

Steel consumption is expected to grow at an average rate of 6.8 per cent to reach 104 MT by 2017 and steel production in India expected to go up to 200 MTPA by 2020 from current 70 MTPA driven by rising infrastructure development and growing demand for automotives and so will the demand of Low Carbon Ferro Alloys for specialty steel.

Project at a Glance

1 Name of the Company M/s JAMSHEDPUR CHLOROCHEM PVT. LTD.

2 Registered Office Factory& Admin Office

NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand

3 Name of the Directors

Sri Manoj Kumar Gutgutia Sri Shiv Kumar Agarwal SmtSangeeta Gutgutia Smt Sushma Agarwal

4 Proposed Sector Ferro Alloys

5 Area of plant 0.92 acres /0.37 Ha.

6 Topo Sheet No 73 J/1

7 Latitude 220 47’ 50.17” N

8 Longitude 860 07’ 17.78” E

9 Proposed Units& Total Capacity

Low Carbon Ferro Alloys& Noble Ferro Alloys –Based on Alumino-Exothermite process: 6000 TPA

10 Product & capacity LC Ferro Chrome / LC Ferro Manganese - 3600 TPA Ferro Molybdenum - 1200 TPA and Ferro Vanadium - 1200 TPA

11 Cost of Project Rs.96.20 Lakhs


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1.2 Identification of Project and Project Proponent M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys and Noble Ferro Alloys–Based on Alumino-Exothermite processwith total capacity - 6000 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkhand.

Project Promoters: M/s Jamshedpur Chlorochem Pvt. Ltd. is promoted by,

o Sri Manoj Kumar Gutgutia o Sri Shiv Kumar Agarwal o Smt Sangeeta Gutgutia o Smt Sushma Agarwal

1.3 Employment Generation - Manpower It is estimated that the total requirement of manpower of project is around 34 persons who/which include Supervisors, Skilled and semi-skilled work force.

1.4 Project Description M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys & Noble Ferro Alloys –Based on Alumino-Exothermite process with production capacity of LC Ferro Chrome / LC Ferro Manganese - 3600 TPAand Ferro Molybdenum - 1200 TPA and Ferro Vanadium - 1200 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand.

Dismantling of the existing unit of Hydrated Lime There is an existing unit of Hydrated Lime – 15000TPA within the existing premises and infrastructure. All the facilities and equipment for the existing unit will be dismantled after obtaining Environment Clearance for the Ferro Alloys. The CTE & CTO obtained for Hydrated Lime from JSPCB will be surrendered and New CTE & CTO shall be obtained for manufacturing of Low Carbon Ferro Alloys – Ferro Chrome and/or Ferro Manganese – 3600 TPA and Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA.

1.5 Site Location This project will be located at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand over an area of 0.92 acres / 0.37 Ha. The Latitude and Longitude of the proposed site is220 47’ 50.17” N & 860 07’ 17.78” E respectively. No additional land will be acquired.The availability of infrastructural facilities and logistics of operation were considered while evaluating the possible site.

1.6 Raw Material Requirement a) For Low Carbon Ferro Alloys Various raw materials will be required as per the product to be manufactured. Maximum capacity of the individual Low carbon ferro alloys or the product mix will be 3600 TPA only. The raw material requirement at max capacity will be as below:


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For Low Carbon Ferro Manganese – 3600 TPA (max):

Material Specific consumption

T/T of Product Quantity Required

TPA Roasted Mn Ore 1.730 6228.00

Aluminium 0.515 1854.00

M.S. Scrap 0.118 425.00

Fluorspar 0.115 414.00

Lime 0.150 540.00

Total 2.596 9461.00

Fuel & Consumables

Wild Babool Charcoal 0.300 1080.00 Or For Low Carbon Ferro Chrome – 3600 TPA (max):



TPA

Chrome Ore 1.800 6480.00

Aluminium 0.632 2275.00

M.S.Scrap 0.118 425.00

Total 2.550 9180.00

Fuel & Consumables (Oxidizers)

Coal 0.400 1440.00

Barium Peroxide /Sodium Nitrate

0.144 518.40


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b) For Noble Ferro Alloys Maximum capacity of the individual Noble ferro alloys will be 1200 TPA or the product mix will be 2400 TPA only. The raw material requirement at max capacity will be as below: Ferro Molybdenum -1200 TPA (Noble Ferro alloys)



TPA

Molybdic Oxide 1.020 1224.00

Aluminium Powder 0.072 86.4

Mill Scale 0.388 465.6

Iron Nails 0.163 195.6

Lime 0.041 492.00

Ferro Silicon 0.408 489.6

Total 2.092 2953.2

c) Ferro Vanadium - 1200 TPA (Noble Ferro alloys)



TPA

Vanadium Pentaoxide 1.030 1236.00

Mill Scale 0.010 12.00

Lime 0.070 84.00

Aluminium Powder 0.250 300.00

Aluminium Shots 0.500 600.00

M.S.Scrap 0.380 456.00

Flourspar 0.020 24.00

Total 2.260 2712.00

1.7 Water and Power Requirement

The total water requirement for the proposed project is estimated to be 17.5m3/day. Water requirement for the proposed plant will be met through water supply by Adityapur Industrial Area development Authority (AIADA) or Drinking water & Sanitation Department (DW&SD) Govt. of Jharkhand. The Water Connection is already available in the Unit. Necessary permission shall be obtained. A total of 133 KVA power will be required for the proposed project. The Power Connection from Jamshedpur Utility and Supply Company (JUSCO) is already available in the unit.


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1.8 Air Environment – Mitigation Measures Source of air pollution and control measures

Section Source of Pollution

Pollutants Air pollution control Measures

Chrome preheating

Burning of coal PM & gases Fume extractor followed by wet scrubber

Manganese Ore roasting

Burning of Babool charcoal

PM & gases Fume extractor followed by cyclone and Bag Filters

LC Ferro Alloys manufacturing

Reactor vessel area

Fugitive Dust & Fumes

Fume extractor followed by bag filters

Noble Ferro Alloys

Reactor vessel area


Fume extractor followed by cyclone and Bag filter

Raw material handling & sizing section

Pulverizer for grinding of raw material

Dust and particulate matter

In-built dust catcher and Bag filter

Over all Plant area

Open space Fugitive dust emission

Pucca roads within the premises, water sprinkling in dusty areas and green belt/plantation to arrest the fugitive dust emission.

• The pollution control equipment will regularly be operated and maintained. • Fugitive emission will be regularly monitored and suitable action like cleaning, water

sprinkling will be taken. 1.9 Waste Generation and Management

No use of water in the manufacturing process. However water will be used for washing of chrome ore and wet scrubber for pollution control. Water will be kept in closed circuit, but on increase in impurities it will be treated in the designated Effluent treatment plant again reused for washing, scrubbing and sprinkling. The storm water drains will be segregated and channelized to water harvesting area. Waste Water Generation and Reuse

Process Unit Quantity KLD

Source Waste water characteristics

Waste water management

Ore Washing & APCD

9.0 Washing & Scrubber

TSS, Oil, Cr, Fe & Grease etc.

Treated in ETP with facility for chrome passivation and recycled-reused in plant


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Domestic

0.8

Domestic use from plant

TSS, BOD, Oil & Grease etc.

Will be routed through septic tank & then to soak pit.

Solid Waste Generation and Management

Nature of Solid Waste Quantity Management

Slag 17 TPD Used for relining of reactor vessel & sold.

Pulveriser Bag Filter & other APCD Dust

0.6 TPD Recycle & reutilize in the manufacturing process

Hazardous waste: There is no hazardous waste from the plant except for used oil with approx quantity of 200 Liters per annum during course of production of and is also saleable to the registered recyclers and ETP Sludge Produced will be approx. 300 TPA and will be sold to the refractory manufacturers.

1.10 Site Analysis The site is within notified Industrial Area and has all the facilities for the proposed project. Also it has good connectivity with the rail and road.

1. Road Connectivity: The site for the proposed project is well connected to Tata-Kandra Road at a distance of 0.65 km.

2. Rail Connectivity: The nearest railway station is Gamharia Junction at 1.95 Km and Adityapur railway station located at a distance of 4.0 km from the proposed project site.

3. Airport: Nearest airport to the project site is Sonari, Jamshedpur at a distance of 5.22 km NE. However, nearest commercial airport is Ranchi at a distance of 95 KM NW.

1.11 Land Use Planning

Proposed approximate use of Land after installation: Land-use Breakup

SL No

Type Of Use Area

(acres) Area (ha)

1 Plant & Storage area 0.49 0.198

2 Administrative offices, canteen, security, etc. 0.06 0.024

3 Entrance, Roads and ETP Area 0.11 0.044

4 Green Belt & Open area 0.26 0 .105

TOTAL LAND 0.92 0.37


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1.12 Proposed Infrastructure a) Industrial - Plant Area

The setting up of the Main Plant Facilities, Storage, Auxiliary facilities, etc. requires0.198 ha. land out of 0.37 ha. Company will use nearest road for materials transportation and manpower connectivity.

b) Green Belt& Plantation A greenbelt & plantation development plan will be prepared and implemented along with the project. Total area for greenbelt developmentshall be 0.105 ha. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas.

c) Rehabilitation and Resettlements (R & R) Plan

No R & R involved.

1.13 Project Schedule and Cost Estimates a) Project Schedule

The total project implementation schedule is 6 months from project start date. The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance.

b) Project Cost

An indicative estimated capital cost of the proposed Plant is around Rs. 96.20 Lakh.

1.14 Analysis of Proposal The project is technically viable as located in industrial area. Also there are existing facilities which will be used by the project. Overall no negative impact on the socio economic environment is anticipated.


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CHAPTER – 02 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent

M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys –Based on Alumino-Exothermite processfor total ferro alloys manufacturing Units of 6000 TPA with production capacity of Ferro Chrome and/or Ferro Manganese - 3600 TPA and Noble Ferro Alloys - Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA.Project will be located at at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand over an area of 0.92 acres / 0.37 ha. The Latitude and Longitude of the proposed site is 220 47’ 50.17” N & 860 07’ 17.78” E respectively. No additional land will be acquired.

The availability of infrastructural facilities and logistics of operation were considered while evaluating the possible site.

Dismantling of the existing unit of Hydrated Lime Unit – Equipments & Machineries only There is an existing unit of Hydrated Lime – 15,000 TPA within the existing premises with all the manufacturing facilities and infrastructure. All the manufacturing facilities and equipment for the existing unit will be dismantled after obtaining Environment Clearance for the Ferro Alloys. The CTO for Hydrated Lime from JSPCB will be surrendered and New CTE & CTO shall de obtained for manufacturing of Low Carbon Ferro Alloys – Ferro Chrome and/or Ferro Manganese – 3600 TPA and Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA. List of plant & machineries to be dismantled enclosed as Annexure - I Project Proponent & Promoters: M/s Jamshedpur Chlorochem Pvt. Ltd. Has been promoted by following Directors:

1 Manoj Kumar Gutgutia

The promoters have good experience in the field of Ferro Alloys manufacturing through Alumino-Exothermite process and marketing of same.

2 Shiv Kumar Agarwal

3 Sangeeta Gutgutia

4 Sushma Agarwal

2.1.1 Project Details M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys –Based on Alumino-Exothermite process with production capacity of Ferro Chrome /Ferro Manganese - 3600 TPA,Ferro Molybdenum - 1200 TPA and Ferro Vanadium - 1200 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand.


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Proposed Units

Considering the potential of Ferro Alloys and the experience gained by the group in this sector, JCPL now proposes to set up the Low Carbon Ferro Alloys (LC Ferro Chrome & LC Ferro Manganese)and Noble Ferro Alloys (Ferro Molybdenum and Ferro Vanadium) to streamline its existing operation and to diversify to meet the industry demand. The various facilities proposed are:

Plant Facilities Product Total Annual Capacity (TPA)

Reactor – Furnace for LC Ferro Alloys

LC Ferro Chrome &/or LC Ferro Manganese

3600

Reactor – Furnace for Noble Ferro Alloys

Ferro Molybdenum 1200

Reactor – Furnace for Noble Ferro Alloys

Ferro Vanadium 1200

Total Ferro Alloys capacity 6000 TPA

2.2 Brief Description of Nature of the project

Manufacturing of Ferro Alloys falls into category A under primary metallurgical unit, as per EIA Notification 2006 and require prior environmental clearance from MoEF & CC.

Ferro Alloy is being used for manufacturing of Alloy Steel, Super Steel, Tool Steel such as tensile, elongation etc. and for manufacturing of Corrosion Resistant and Abrasion Resistant steel. There are three grades of Ferro Alloys as given below:

a High Carbon

b Medium Carbon

c Low Carbon

Out of these three grades, the company intends to manufacture the low carbon Ferro Chrome/Ferro Manganese and Noble Ferro Alloys viz., Ferro Molybdenum and Ferro Vanadium.

2.3 Need of the Project and its Importance to the Country and/or Region

Steel Industry in India is on an upswing because of the strong global and domestic demand. India’s rapid economic growth and soaring demand by sectors like infrastructure, real estate and automobiles, at home and abroad, has put Indian steel industry on the global map. The current status of iron ore and its future prospects have direct relationship mainly with steel production in India.


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Consumption of LC Ferro Chrome is expected to be 30000 – 36000 Tons per Annum. The manufacturing capacity is only 3600 Tons per annum in our Country. The gap is being fulfilled by Import from Russia and China.

Consumption of LC Ferro Manganese is expected to be 36000-30000 Tons per month. The manufacturing capacity is only 6000 Tons per month in our Country. The gap is being fulfilled by Import of Manganese Metal being the substitute from China.

Production of Noble Ferro Alloys was estimated at 31,308 tonnes as compared to 27,435 tonnes during the previous year, registering an increase of 14.12% during the year. Production of low carbon and medium carbon ferro manganese as well as low carbon and medium carbon silico manganese are accounted for under bulk ferro alloys production.

Steel finds wide applications in our day to day life. Various key industries like construction, transport, communication, agriculture and energy cannot sustain without steel. The manufacturing process from iron ore to finished product involves production of a large number of intermediate products. All the intermediate products have a domestic as well as a global market.

2.4 Demand – Supply Gap In addition to steel plants, several steel casting plants have been set up in the country which consumes Ferro Alloys. With a Proactive Make in India policy of Govt. of India and the consumption of Indigenously manufactured Steel in the Infrastructural Projects the demand will rise significantly and the expected projected figures may be as follows: Projected Requirement (annual)

PRODUCT DEMAND

PRESENT 2018-19 2019-20 2020-2021 beyond

LC FERRO CHROME

36000 Tons 42000 Tons 48000 Tons 54000 Tons

LC FERRO MANGANESE

30000 Tons 36000 Tons 42000 Tons 48000 Tons

There is huge gap between demand and supply which is being fulfilled by Imports. This proposed project will save Dollars by reducing Imports. The best part of this project is that the raw material is available in our Country abundantly and hence it will be complete replacement from Import.

2.5 Imports vs. Indigenous Production Consumption of LC Ferro Chrome is expected to be 30000 – 36000 Tons per Annum. The manufacturing capacity is only 3600 Tons per annum in our Country. The gap is being fulfilled by Import from Russia and China.


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Consumption of LC Ferro Manganese is expected to be 24000-30000 Tons per month. The manufacturing capacity is only 6000 Tons per month in our Country. The gap is being fulfilled by Import of Manganese Metal being the substitute from China.

2.6 Export Possibilityand Domestic/Export Market The primary markets of interest for JCPL will be essentially in the state of Jharkhand and neighboring states. Primary purpose of the project is to cater the demand of products within the country and fill gap between demand and supply.The Eastern India is the hub of manufacturing Steel. Moreover the items are High value and hence there is no factor of freight in the cost and hence the entire India is the suitable market. The entire world procures LC Ferro Chrome and Ferro Manganese from Russia and China. Since the raw material is indigenously available, our cost of production will be cheaper and can comfortably compete with Overseas manufacturer. The product can be Exported to Japan, Middle East, South Korea and Europe.

2.7 Employment Generation (Direct and Indirect) Due to the Project A wellstructured manpower is essential for uninterrupted operation and proper maintenance of plant facilities. Employment will be generated during implementation of the project. There will be permanent employment of 34 persons including Sr. Executives, Managers, Administrators, Engineers, Supervisors and Skilled Technicians. The requirement of manpower for the proposed project has been estimated keeping in view the modern concepts of automation as described below:

Manager 2 Supervisor 2

Skilled Labour 20 Semi Skilled 10

Direct Employment 34 Indirect Employment 20

Direct employment in the plant is about 34nos. but indirectly arising employment due to this proposed plant will be manifold involved in supply of raw material, disposal or sale of finished goods, handling of raw material and finished goods, transportation, loading-unloading, marketing of finished goods etc.


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CHAPTER - 3 PROJECT DESCRIPTION

3.1 Type of Project Including Interlinked & Interdependent Projects M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys –Based on Alumino-Exothermite process with production capacity of LC Ferro Chrome / LC Ferro Manganese - 3600 TPA and Ferro Molybdenum - 1200 TPA and Ferro Vanadium - 1200 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand. The plant will also be equipped with the most efficient auxiliary sub- systems, material handling facilities and pollution control equipment.

This is a Category A project as per EIA Notification and requires Environment Clearance from MoEF & CC. Project is not interlinked and interdependent. The raw material is primarily Ore being sold by State Government of Orissa. The other raw material is Aluminium Powder which is manufactured by various Companies in India.

3.2 Location Project will be located at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand over an area of 0.92 acres / 0.37 Ha. The Latitude and Longitude of the proposed site is22047’ 50.17” N&860 07’ 17.78” E respectively. No additional land will be acquired.

Fig1: Google Image of project Site


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3.2.2 Plant Layout The layout of the plant will be developed taking into following considerations:

1. Process will be consolidated into comprehensive production units.The major utilities and service facilities available for the existing unit will be used.

2. Sufficient space for storage of raw materials and finished products. 3. Green belt, plantation, RWH & space for pollution control facilities will be provided.

PLANT LAYOUT

Fig2: Layout Plan


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Fig 3: Key Plan


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3.3 Site Selection The selection of project site/location has been based on existing land in the notified industrial area and facilities like shed, electricity connection, water, manpower etc. available for the existing unit.

3.4 Size or Magnitude of Operation Project envisages installation and operation of Low Carbon Ferro Alloys –Based on Alumino-Exothermite process with production capacity of Ferro Chrome and/or Ferro Manganese - 3600 TPA.

Project will be located on the existing plot NS-88, 6th Phase Adityapur Industrial Area, Saraikela-Kharsawan over an area of 0.92 acres.

3.5 Project Description with Process Details The technology for manufacturing process is proven technology of Gold Smith Alumino Exothermite Process in which oxides of metal is reduced with proper reducers.

3.6 PROCESS DETAILS/STEPS The manufacturing process is also known as Alumino-thermite Process. Various Inputs in Predetermined quantity, which is calculated on the basis of the quality of raw material and reducers is required, hence quality of raw material is of utmost importance.

a) FOR LOW CARBON FERRO MANGANESE Roasting of Mn Ore: Mn ore received is subjected to roasting, prior to preparing the charge mix. The ore along with Wild Babool Charcoal is arranged in alternate layers in a vertical roasting furnace and ignited. The roasted Mn Ore is accumulated over the screen Grid in solid block form and small amount of ash is deposited at the bottom. The gases are passed through cyclone & bag filter to arrest the fugitive material. Sizing of Mn Ore: The roasted Mn Ore is subjected to sizing in a jaw crusher. The crusher enclosure will be provided with dust extraction system and passed through the same cyclone & bag filter to arrest the fugitive material. Grinding of Mn Ore: The sized Mn Ore is subjected to further grinding in a Pulveriser. The Pulveriser is fitted with dedicated bag filter and grinded Mn ore is collected in powdered form. Mixing and Batching of Raw Material: The powdered Mn Ore and other raw materials in desired proportion is added in the closed mixing machine and subjected to thorough mixing by rotation for obtaining homogenous mix. Reaction and product separation: After mixing the charge is collected in bins. Bins containing mixed charge is placed near to refractory lined vessels. To start the reaction initially small quantity of mixed charge is placed in the bottom of the vessel and ignite with Magnesium Ribbon.

As this kind of chain reaction, continuous addition of mixed charge on the top of melt enable to degassing process and separation of liquid slag. Smelting usually last for 30-35


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minutes in LC Ferro Manganese. After addition of complete mixed charge and reaction, vessel is left for natural cooling for about 8-10 hours.

After cooling the material is removed from vessel where product ferro alloys and slag is found in two separate layers which is separated product ferro alloy is found in the form of big buttons. Broken product will be fed to hammer mill for further reduction to granules.

Slag obtained is also crushed for reuse as reactor vessel relining or sale to outside parties.

The reaction is as follows:

LC Ferro Manganese

3MnO2 + 4Al = 3Mn + 2Al2O3

Fe2O3 + 2Al = 2Fe + Al2O3 b) FOR LOW CARBON FERRO CHROME

Washing of Chrome Ore: Chrome ore received is subjected to washing prior to preparing the charge mix. The ore has adhered mud and gangue material which is washed off on a platform by water jet through pipes. The water is kept in closed circuit through a recirculation tank set-up. On increase in impurity concentration water is treated in ETP and further recycled or reused. The washed ore is taken for drying and preheating. Pre-heating of Chrome Ore:The washed ore is taken for drying and preheating in a closed system. In this coal is usedas external fuel. The system will be provided with dust extraction system and passed through the same cyclone & bag filter to arrest the fugitive material. Chrome fumes if any will be passed through wet scrubber. Mixing and Batching of Raw Material: The heated Ore and other raw materials in desired proportion is then added to the closed mixing machine and subjected to thorough mixing by rotation for obtaining homogenous mix. Reaction and product separation: After mixing the charge is collected in bins. Bins containing mixed charge is placed near to refractory lined vessels. Vessel is filled with mix charge and a heap is created, to start the reaction initially small quantity of mixed charge is ignite with Magnesium Ribbon and the spontaneous exothermic reaction takes place immediately.

As this kind of chain reaction, continuous addition of mixed charge on the top of melt enable to degassing process and separation of liquid slag. Smelting usually last for 45-60 seconds in LC Ferro Chrome. After addition of complete mixed charge and reaction, vessel is left for natural cooling for about 12-14 hours.

After cooling the material is removed from vessel where product ferro alloys and slag is found in two separate layers which is separated product ferro alloy is found in the form


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of big buttons. Broken product will be fed to hammer mill for further reduction to granules.

Slag obtained is also crushed for reuse as reactor vessel relining or sale to outside parties.

The reaction is as follows:

LC Ferro Chrome

Cr2O3 + 2Al = Al2O3 + 2Cr

Fe2O3 + 2Al = 2Fe + Al2O3

Process Flow Chart


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c) Manufacturing of Ferro Vanadium Ferro Vanadium is smelted by the alumina thermite method in reactor vessel up to 2m in diameter; Various inputs in predetermined quantity, which is calculated on the basis of quality of raw material and reducers, are fed to a mixture machine for homogeneous mixing. After mixing the charge is collected in bins. Bins containing mixed charge are placed near to refractory lined vessels. To start the reaction initially small quantity of mixed charge is placed in bottom of the vessel and ignites with Magnesium ribbon. As this is kind of chain reaction, continuous addition of mixed charge on the top of melt enable to degassing process and separation of liquid slag. Smelting takes 45 – 60minutes. After addition of complete mixed charge and reaction, vessel is left for natural cooling for 8-10 hours.The reactions of reduction of oxides of Ferro Vanadium is presented below: Ferro Vanadium (Noble Ferro alloy)

3V2O5 + 10 Al = 6V + 5Al2O3

2Al + Fe2O3 = 2Fe + Al2O3

The mixture is mixed in double cone blender and started the smelting by bottom priming process of charging, which ensures a more uniform flow of the process; from 200 to 400 kg of prepared mixture are charged on to the shaft bottom and ignited by means of a priming mixture composed of aluminium powder and electron turnings. The priming mixture is ignited by red-hot iron rod or an electric spark.


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After the beginning of the alumino thermite process the remainder of mixture is charged from special hopper equipped with a gate and a charging pipe; care is taken to ensure that the charge is uniformly spread over the whole shaft area and the mixture is fed at a rate so that the melt surface is constantly covered with a thin layer of it. The slow charging rate causes the uncovering of melt surface and, consequently, increase heat losses.

d) Manufacturing of Ferro Molybdenum Low carbon ferromolybdenum is produced by simple and efficient off furnace silico thermite process. The reaction of reduction of oxides in smelting of ferromolybdenum are given below: Ferro Molybdenum ( Noble Ferro alloy )

MoO3 + Al = Mo + Al2O3

Fe2O3 + 2Al = 2Fe + Al2O3

Smelting is done with upper ignition (top-priming). The shaft is filled with a mixture of charge materials to a height approximately 300 mm below the upper edge, so as to prevent splashing-out. At the end of smelting, the line of slag rises only to half the height of shaft. Upon filling the shaft with charge materials, 2 or 3 craters are formed for ignition mixture. Upon ignition of the mixture, it ignites quickly, and the process of smelting occurs at a high speed. The smelting of 5000 kg of mixture takes up 30-40 minutes. With a normal run of heat, gases escape abundantly from the smelting shaft. With a cold run of heat (weak uneven evolution of gases), 15-20 kg of thermite mixture with Excess reducer is given to the charge. With a very hot run of heat and much splashing, the melt is chilled by adding pieces of alloy scrap. At the end of smelting, when no more gases rise from the melt, a holding time of 40 - 50 minutes is allowed to settle the beads of alloy. The melt accumulates as a block in the spherical recess in the hearth. After the holding time, the slag hole is open to let out the slag.


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PROCESS FLOW – NOBLE FERRO ALLOYS


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3.6 Raw Material Required Along With Estimated Quantity A) For Low Carbon Ferro Manganese – 3600 TPA:

Material Specific

consumption T/T of Product

Quantity Required TPA

Source

Roasted Mn Ore 1.730 6228.00 Odisha

Aluminium 0.515 1854.00 Imported (UAE) & /or Ahmadabad

M.S. Scrap 0.118 425.00 Local – Jamshedpur

Fluorspar 0.115 414.00 Local - Jamshedpur

Total 2.596 8921.00


Wild Babool Charcoal

0.300 1080.00 Kuchch Gujrat

Or For Low Carbon Ferro Chrome – 3600 TPA:

Material Specific

consumption T/T of Product

Quantity Required TPA

Source

Chrome Ore 1.800 6480.00 OMC, odisha

Aluminium 0.632 2275.00 Imported (UAE) & Ahmadabad

M.S.Scrap 0.118 425.00 Local , Jamshedpur

Fluorspar 0.115 414.00 Local, Jamshedpur

Total 2.783 9594.00


Coal 0.400 1440.00 Open Market

Barium Peroxide/Sodium

Nitrate 0.144 518.40 Gujrat

Washing of Chrome Orewill be done before use to reduce the adhered impurities and resultant slag generation. The water used for washing will be kept in closed circuit and will be treated in ETP before reuse.


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B) For Noble Ferro Alloys Maximum capacity of the individual Noble ferro alloys will be 1200 TPA or the product mix will be 2400 TPA only. The raw material requirement at max capacity will be as below: Ferro Molybdenum -1200 TPA (Noble Ferro alloys)

Material Quantity Required

TPA Source

Molybdic Oxide 1224.00 Imported

Aluminium Powder 86.4 Imported (UAE) &

Ahmadabad

Mill Scale 465.6 Local , Jamshedpur

Iron Nails 195.6 Local , Jamshedpur

Lime 492.00 Local , Jamshedpur

Ferro Silicon 489.6 Bhutan , North east

Total 2953.2

Ferro Vanadium - 1200 TPA (Noble Ferro alloys)

Material Quantity Required

TPA Source

Vanadium Pentaoxide 1236.00 Russia

Mill Scale 12.00 Local , Jamshedpur

Lime 84.00 Local , Jamshedpur

Aluminium Powder 300.00 Imported (UAE) &

Ahmadabad

Aluminium Shots 600.00 Imported (UAE) &

Ahmadabad

M.S.Scrap 456.00 Local , Jamshedpur

Flourspar 24.00 Local Trader

Total 2712.00


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3.7 Safety Envisaged In the Project

Fire Protection Facilities: In order to combat any occurrence of fire in plant premises the following tire protection facilities have been envisaged for the various units of the plant.

Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc will be provided with adequate number of portable fire extinguishers to be used as first aid fire appliances. The distribution and selection of extinguishers will be done in accordance with the requirement of IS: 2130-92.

Hydrant System: Internal hydrants will be provided at suitable locations and at different levels inside the major plant units. Yard hydrants will be provided normally along the road and in the close vicinity of the units to meet the additional requirement of water for existing fire.

3.8 Availability of Water Its Source, Energy/Power Requirement And Source 3.8.1 Water Requirement

The total water requirement for the proposed project is estimated to be 17.5 m3/day. Water requirement for the proposed plant will be met through water supply by Adityapur Industrial Area development Authority (AIADA) or Drinking Water & Sanitation Department (DW&SD) Govt. of Jharkhand.

Water Requirement

Unit Total make-up water (cum/day)

Washing & others 10.0

Water Scrubber 5.0

Domestic requirement & others 1.5

Dust suspension & greenbelt 1.0

TOTAL 17.5

3.8.2 Power Requirement

Total requirement of power for the unit is 133 KVA. The total power demand of the plant will be met from Jamshedpur Utility and Supply Company (JUSCO).


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3.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for Their

Management/Disposal 3.9.1 Air Environment – Mitigation Measures

Source of air pollution and control measures

Section Source of Pollution

Pollutants Air pollution control Measures

Chrome preheating

Burning of coal

PM & gases Fume extractor followed bywet scrubber

Manganese Ore roasting

Burning of Babool charcoal

PM & gases Fume extractor followed by cyclone and Bag Filters

LC Ferro Alloys manufacturing

Reactor furnace area



Noble Ferro Alloys Reactor vessel area



Raw material handling & sizing section

Pulverizer for grinding of raw material

Dust and particulate matter

In-built Dust catcher and Bag filter

Over all Plant area Open space Fugitive dust emission

Pucca roads within the premises, water sprinkling in dusty areas and green belt/plantation to arrest the fugitive dust emission.

• The pollution control equipment will regularly be operated and maintained. • Fugitive emission will be regularly monitored and suitable action like cleaning, water

sprinkling will be taken.

3.9.2 Waste water Generation and Management No use of water in the manufacturing process. However water will be used for washing of chrome ore and wet scrubber for pollution control. Water will be kept in closed circuit, but on increase in impurities it will be treated in the designated Effluent treatment plant again reused for washing, scrubbing and sprinkling. The storm water drains will be segregated and channelized to water harvesting area.


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Waste Water Generation and Reuse

Process Unit Waste water qty (m3/day)

Source Waste water characteristics

Waste water management

Ore Washing & APCD

9.0 Washing & Scrubber

TSS, Oil, Cr, Fe & Grease etc.

Treated in ETP with facility for chrome passivation and recycled-reused in plant

Domestic

0.6

Domestic use

TSS, BOD, Oil & Grease etc.

Will be routed through septic tank & soak pit.

3.9.3 Solid Waste Generation and Management

Nature of Solid Waste Quantity Management

Slag 17 TPD Used for relining of reactor vessel & sold.

Pluveriser Bag Filter Dust 0.5 TPD Recycle & reutilize in the manufacturing process

Hazardous waste: There is no hazardous waste from the plant except for used oilwith approx quantity of 200 Liters per annum ,during course of production of and is also saleable to the registered recyclers in the market & ETP Sludge Produced will be approx 300 TPA and will be sold to the refractory manufacturers.

3.9.4 Noise Levels

There is no major noise prone process except equipment for crushing, milling, separators, compressors etc. The noise control will be done in three ways namely: • By selecting low noise generating equipment, which would have below 75 dB(A) at 1m

distance. This is taken care at the equipment design stage. • By isolating the noise unit from the working personnel’s continuous exposure by providing

acoustic aids for plant personnel. • By administrative & safety measures, providing noise level monitoring, remedial

measures, providing noise safety appliances.

3.9.5 Green Belt Development The Greenbelt & plantation will be developed in 0.105 ha of plant area so as to mitigate the effects of emissions from the plant. The treated waste water from the plant will be utilized for the greenbelt development. Roads for vehicular movement will be paved and adequate mitigation measures will be provided to prevent fugitive emissions.


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3.9.6 Resource recovery – Mass Balance Material Balance for Low Carbon Ferro Manganese per 1 Ton of Product

MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)

Roasted Mn Ore 1.730 Low Carbon Ferro

Manganese 1.000

Aluminium 0.515 Slag 1.503 M.S.Scrap 0.118 Off Gases 0.093 Fluorspar 0.115 Lime 0.118

Total 2.596 Total 2.596

Material Balance for Low Carbon Ferro Chrome per 1 Ton of Product MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)

Chrome Ore 1.800 Low Carbon Ferro

Chrome 1.000

Aluminium 0.632 Slag 1.646 M.S.Scrap 0.118 Off Gases 0.137 Fluorspar 0.115 Lime 0.118

Total 2.783 Total 2.783

Material Balance for Ferro Molybdenum per 1 Ton of Product MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)

Molybdic Oxide 1.020 Ferro Molybdenum 1.000 Aluminium Powder 0.072 Slag 0.600

Mill Scale 0.388 Off Gases 0.492 Iron Nails 0.163

Lime 0.041 Ferro Silicon 0.408

Total 2.092 2.092

Material Balance for Ferro Vanadium per 1 Ton of Product MATERIAL QUANTITY (T) OUTPUT QUANTITY (T) Vanadium Pentaoxide

1.030 Ferro Vanadium 1.000

Aluminium Powder 0.250 Slag 0.900 M.S.Scrap 0.380 Off Gases 0.360 Fluorspar 0.020 Mill Scale 0.010

Aluminium shots 0.500 Lime 0.070 Total 2.260 Total 2.260


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3.9.7 Budget for Environmental Management

No. Particulars Amount in INR,

Lakhs One Time - Capital Cost

1 Installation of Air Pollution Control System

& ETP 47.00

2 Green Belt Development & RWH 2.50

Total 49.50

Recurring Cost 1 Environmental Monitoring 1.00 2 Running Cost of Pollution Control Equipments 3.80 3 Greenbelt & RWH Maintenance 1.20

Total 6.00

3.10 Schematic Representations of the Feasibility Drawing Which Give Information of EIA

Purpose.


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CHAPTER-04

SITE ANALYSIS

4.1 Connectivity

The site is within notified Industrial Area and has all the facilities for the proposed project. Also it has good connectivity with the rail and road. Road Connectivity: The site for the proposed project is well connected to Tata-

Kandra Road at a distance of 0.65 km. Rail Connectivity: The nearest railway station is Gamharia Junction at 1.95 Km and

Adityapur railway station located at a distance of 4.0 km from the proposed project site.

Airport: Nearest airport to the project site is Sonari, Jamshedpur at a distance of 5.22 km NE and commercial airport Ranchi at a distance of 110 Km NW.

About 0.92acres / 0.37 Ha. of total land is in possession, with an existing unit of Hydrated Lime – which will be dismantled on obtaining EC for the project

4.2 Land Form, Land Use and Land Ownership Total land requirement for the proposed unit is about 0.37 ha which is already in possession. The present land use is industrial,also the land is located within notified industrial area.


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4.3 Topography The topography of the land is generally flat and well suited for development of industrial projects with an elevation of 261 m above MSL. The topographic of the buffer zone is basically characterized by upland topography.

4.4 Existing Land Use Pattern

Total land requirement for the proposed unit is about 0.37 ha which is already in possession. The present land use is industrial; also the land is located within notified industrial area. with an existing unit of Hydrated Lime – which will be dismantled on obtaining EC for the project. This area does not form part of any National Park, Wild Life Sanctuary and Natural/Biosphere reserve.

4.5 Existing Infrastructure Land Total land requirement for the proposed unit is about 0.37 ha which is already in possession. Land is located in notified industrial area.

Power

Total power requirement for the project is 133 KVA, which will be met from JUSCO is available.

Water

The total water requirement for proposed plant is estimated to be 17.5 m3/day. Water will be met from supply of AIADA or DW & SD, GoJ.

Transport

The plant site is well connected by industrial area road with Tata – Kandra Road at 0.5 Km

from the project site.

Communication

Communication facilities such as telephone, tele fax and internet are available in industrial area near to the plant site.


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CHAPTER – 05 PLANNING BRIEF

5.1 Planning Concept M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro Alloys –Based on Alumino-Exothermite process with production capacity of Ferro Chrome and/or Ferro Manganese - 3600 TPA and noble ferro alloys – 2400 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand. The plant will also be equipped with the most efficient auxiliary sub- systems, material handling facilities and pollution control equipment.

5.2 Employment &Population Projection

A well structured manpower is essential for uninterrupted operation and proper maintenance of plant facilities. Employment will be generated during implementation of the project. There will be permanent employment of 34 persons including Sr. Executives, Managers, Administrators, Engineers, Supervisors and Skilled Technicians.

Manager 2

Supervisor 2

Skilled Labour 20

Semi Skilled 10

Direct Employment 34

Indirect Employment 20

5.3 Land Use Planning

Proposed approximate use of Land after installation: SL No

Type Of Use Area (acres)

Area (ha)

1 Plant & Storage area 0.49 0.198

2 Administrative offices, security, etc. 0.06 0.024

3 Entrance, Roads and PCE Area 0.11 0.044

4 Green Belt & Open area 0.26 0 .105

TOTAL LAND 0.92 0.37


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5.4 Assessment of Infrastructure Demand (Physical & Social) The existing infrastructure facility is adequate in the proposed project site. The social infrastructure like school, college, temples and play ground already exist in this area. The above infrastructure facilities need no further development for the project nor is any major change in the infrastructure envisaged due to the project. System Design for high Unit availability The high availability of the Unit and associated auxiliaries objectives will be achieved by adopting the following principles; • Use of equipment and systems of design performance and high availability which has

been fully established by a considerable record of successful operation for similar service conditions in coal fired utility stations.

• Use of only proven design concepts and conservative designs.

• Strict implementation of quality assurance norms during design, manufacture as well as installation and commissioning stage.

• Strict compliance with the project company approved pre-commissioning and commissioning procedures as well as standard checklists forming a part of commissioning documents for the project.

Sizing of critical equipment- margins & redundancy/standby Adequate margins will be provided while sizing all important auxiliaries and sub-systems to ensure operation of the Unit at full rated capacity under the worst conditions and taking into consideration normal wear & tear. Design for efficient operation Centralized maintenance system will be followed. All repairs of capital nature, heavy maintenance jobs, refractory maintenance and plant civil maintenance will be done by engaging specialized external agencies.


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CHAPTER – 06 PROPOSED INFRASTRUCTURE

6.1 Processing Area – industrial use

The processing area will comprise of various plant facilities within the premises they are – Raw material handling & processing area, reactor area, & product handling area. Thus total area of 0.198 ha will be developed as processing area.

6.2 Residential Area (Non-Processing Area)

There is no proposal of any residential colony as the required manpower will be sourced from local populace. Few highly skilled posts may be filled from outsiders for whom houses will be leased in nearby residential area. Non-processing area will comprise of facilities within the premises such as –administrative block, road & pollution control equipment area etc. over an area 0.068 ha Other social infrastructure like housing, schooling and medical facilities areaalready developed in nearby area, hence, no residential colony/township is envisaged for employees.

6.3 Green Belt

A greenbelt development plan will be prepared and implemented along with the implementation of project. Total green belt & plantation area shall be 0.105 ha. The main objective of the greenbelt is to provide a barrier between the plant and the surrounding areas. The species selection will depend upon type of soil and local species with good survival rate will be selected.

6.4 Socio-Economic Benefits &Social Infrastructure

This is an existing notified industrial area with adequate facilities. The existing infrastructure facility is adequate in the proposed project site. The social infrastructure like school, college, temples and play ground already exist in this area. The above infrastructure facilities need no further development for the project nor is any major change in the infrastructure envisaged due to the project. Only direct and indirect employment generation is envisaged.


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CHAPTER – 07 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to Be Adopted for R & R Plan With Respect To Project-NotRequired

This is an existing notified industrial area and the land has been allotted by the Adityapur Industrial Area Development Authority (AIADA) and already in industrial use. There is no displacement of any houses, habitation or livestock. Thus the project does not require any R & R plan.


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CHAPTER – 08 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

In this industry, any one of the following three alternate modes of project execution will be adopted: • Turnkey • Semi Turnkey • Packaged procurement mode Statutory Clearances The proposed project will require various statutory approvals and clearances from various authorities of the Government. Clearances required for the proposed project are identified and necessary action initiated to obtain the same.

Project Schedule It is envisaged that total project will be completed within a period of 6 months from `Go-ahead'. Land acquisition on lease is completed. The external agencies such as consultant, machinery suppliers, contractors of civil construction and equipment will be selected carefully well in advance. An effective project team has been formulated with Director as its leader.

8.2 Project Cost

An indicative estimated capital cost of the proposed Plant is Rs. 96.20 Lakhs as below:

Particulars Amount (in Rs. Lakhs)

Land - 40000 sq.ft Existing

Building& Shed - 18500 sq.ft. Existing

Plant & Machinery 35.60

Laboratory Equipment 4.60

Pollution Control Equipment 49.50

Office Equipment 2.00

Furniture & Fixture 4.50

Total 96.20


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CHAPTER – 09

ANALYSIS OF PROPOSAL

PROMOTERS M/s Jamshedpur Chlorochem Private Limited

Project Low Carbon Ferro Alloys – Ferro Chrome & Ferro Manganese

Plant location NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand

Markets Local & export

Plant capacity LC Ferro Chrome / LC Ferro Manganese – 3600 TPA Ferro Molybdenum – 1200 TPA Ferro Vanadium – 1200 TPA

Water requirement For process, domestic & others – 17.5 m3/day

Water sources Supply from AIADA or DW & SD, GoJ

Basis for assessment Per tons of finished products

Max. power demand 133 KVA from JUSCO

Main units Washing of Ore, Sizing & Mixing, Reactor

Main storages For raw materials and products – space available

Manpower 34 Nos.

Implementation period 06 months

Proposed Investment Rs. 96.20lakhs

Conclusion Based on the performance indicators, the project is technically & financially viable, Under both normal and contingent conditions.


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ANNEXURE - I

DETAILS OF PLANT AND MACHINERY TO BE DISMANTLED

HYDRATED LIME PLANT

Sl. No. Name of the Machinery Capacity

1 PULVERISER (32" CHAMBER SIZE) 2 M.T./P. Hrs 2 ROTTERY VALVE & FLOTER VALVE 5 NOS. 2 M.T./P. Hrs 3 PULVERISER (36" CHAMBER SIZE) 2.5 M.T./P. Hrs 4 HAMMER MILL (36" SIZE) 2 M.T./P. Hrs 5 HAMMER MILL (32" SIZE) 2 M.T./P. Hrs 6 BUCKET ELEVATOR 4 NOS. 2 M.T./P. Hrs 7 HYDRATOR WITH CHIMNEY 2 M.T./P. Hrs 8 SCREW CONVEYOR 3 NOS. 2 M.T./P. Hrs 9 AIR CLASSIFIER 2 M.T./P. Hrs

10 BLENDER WITH CHIMNEY 2.5 M.T./P. Hrs 11 SILO WITH CHIMNEY 12 M.T./P. Hrs 12 HOPPER 1 M.T./P. Hrs 13 BRICK KLIN 10'*20' 1 no. 14 ROASTER 2 NOS. 8'*8' 2 nos.

15 BASE, STAIR CASE, PLATFORM, PAINTING, FREIGHT & CONSUMABLES For All Plant

16 POLLUTION CONTROL EQUIPMENT (BAG FILTERS-3 NOS.) 42 Bags Filters 17 WATER TANK 8000 Ltrs.

18 TOOLS & EQUIPMENT Welding Machine

Documents

For FERRO ALLOYS MANUFACTURING – 6000 TPA PRODUCT MIX LOW CARBON …environmentclearance.nic.in/writereaddata/EC/14092018... · 2018. 9. 14. · obtaining Environment Clearance