Pre-Feasibility Report
for
Expansion / Modernization of existing facilities
of Godawari Power and Ispat Ltd.
for
Godawari Power & Ispat Ltd
428/2, Phase-I, Industrial Area,
Siltara, Raipur - 493111
1
Godawari Power & Ispat Limited
Pre-Feasibility-Report
Expansion / Modernization of existing facilities of
Godawari Power and Ispat Limited
I N D E X
CHAPTER
NO.
PARTICULARS PAGE
NOS.
1 Project Highlights / Executive Summary 1
2 Introduction of Project / Background Information 2 – 6
3 Current Request for Proposed expansion /
Modernization
7 – 13
4 Location & Site Analysis 14 – 17
5 Process Description of Iron Ore Pellet Plant 18 – 29
6 Process Description of Magnetite Powder 30 – 31
7 Process Description of Steel Billets (SMS) 31 – 41
8 Process Description of Power Plant 41 – 52
9 Environment & Green Belt 53 – 58
10 Occupational Health 59 – 60
11 Socio-Economic Development 61 – 62
12 Organization & Manpower 63
13 Project Implementation Schedule 64
14 Capital Cost 65
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
1
Pre-Feasibility-Report
Chapter - 1
Project Highlights / Executive Summary
Name of the Unit : GODAWARI POWER & ISPAT LTD.
Regd. Office : Plot No. 428/2, Phase-I
Industrial Area, Siltara,
Raipur (Chhattisgarh)
Plant Location : Within existing premises of plant at Industrial Area,
Phase-I, Siltara, Raipur.
Contact person : Shri T. Bose
Tel No. : 0091-771-4082736
Mobile No. : 09993000739
Fax No. : 0091-771-4057601
Present Proposal : 1) Enhancement in production capacity of Iron Ore Pellet
Plant from existing 2.1 MTPA (2 units) with Coal
Gasification System to 2.3 MTPA with Coal
Gasification System.
2) Change in Product mix of Pelletization plant to include
manufacture of Magnetite Powder / Heavy Media for
coal washeries (Capacity 2,00,000 TPA)
3) Modernization and enhancement in production capacity
of Steel Melting Shop (Billets) from existing 4.00 lac
TPA to 5.50 lac TPA by change in configuration of
induction furnaces.
4) Modernization of existing power plant by change in
configuration of existing 3 TG Sets [TG-1 : 9 MW,
TG-2 : 9 MW, TG-4 : 30 MW (+1 standby)] with one
new energy efficient TG set of 48 MW capacity in the
existing Power Plant.
Land Area : Within the existing land of 86.46 ha overall plant area
Raw Materials : 1) Iron Ore fines , Bentonite , Binders, Flux for Pellet Plant
and Coal/Coke, Pet coke , Furnace Oil for Fuel system
2) Magnetite Ore to manufacture Magnetite Powder
3) Sponge Iron, Scrap, Pig Iron, Silico Manganese for SMS
Project Cost : The present investment is Rs. 1724.11 Crores in the entire
existing facilities for which ECs were granted. No
additional investment is involved in Pellet expansion and
manufacture of Magnetite Powder. Further approx. Rs. 75
Crores is proposed for the expansion / modification
proposals of SMS and Rs. 70.00 Crores is envisaged for the
modernization proposal of Power Plant.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
2
Chapter – 2
Introduction of the Project / Background Information
Identification of Project Proponent and the Project
The company was incorporated on 21/09/1999 with the Registrar of Companies,
Gwalior (M.P.). The promoters of the company are the Hira Group of Industries,
which is one of the largest groups in Central India. Hira Group, integrating its
operations by setting up facilities for forward and backward integration and foraying
into higher value added projects, has diversified into Sponge Iron, Power, Steel,
Rolled Products, Ferro Alloys, Mining, Cement, Crushing, Beneficiation,
Pelletization, Renewable Energy, Technology & Real Estate. In 2017-18, the group’s
turnover is about Rs.3200 crores within which the turnover of Godawari Power &
Ispat Ltd is around Rs.2200 crores. The Group has emerged as one of the largest
entities of Chhattisgarh and also has a pronounced presence in other states.
Godawari Power and Ispat Limited (GPIL) is the flagship company of Hira Group of
Industries. The company’s integrated steel manufacturing unit is having a dominant
presence in the long products segment of the steel industry, mainly into mild steel
wires. Today, GPIL is an end-to-end manufacturer of mild steel wires. In the process,
the company manufactures iron ore pellets, sponge iron, billets, ferro-alloys, wire rods
and steel wires as also power generation.
GPIL has come a long way since it started its operation as a sponge iron manufacturer
in the year 2001. Over the last years, the company has scaled up its capacity multifold
and is today the fifth largest producer of coal based sponge iron in India and is one of
the largest players in the mild steel wires segment. Not only has the company
increased its scale during the aforesaid period, it has also moved up the value chain.
Board of Directors
The Board of GPIL comprises following Directors:
1) Mr. Bajrang Lal Agrawal
2) Mr. Dinesh Agrawal
3) Mr. Abhishek Agrawal
4) Mr. Dinesh Kumar Gandhi
5) Mr. Vinod Pillai
6) Mr. Shashi Kumar
7) Mr. B.N. Ojha
8) Mr. Biswajit Choudhuri
9) Mr. Harishankar Khandelwal
10) Ms. Bhavna G. Desai
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
3
History of the Company
Name and Address of Project Proponent:
Godawari Power & Ispat Ltd was originally incorporated as Ispat Godawari Ltd in
1999 to manufacture sponge iron, billets, and generate captive power.
The name of the company was changed to Godawari Power and Ispat Limited in
2005. GPIL was also allotted captive iron ore mines in Chhattisgarh.
GPIL successfully completed its IPO and its shares got listed on the BSE and the NSE
in April, 2006. GPIL’s first WHRB captive power plant (7 MW) also became the first
in the world to be registered with CDM Executive Board for entitlement of carbon
credits under the Kyoto Protocol.
GPIL is the first company in Chhattisgarh to be awarded the Integrated Management
System Certification by Accreditation bodies UKAS of UK and Swiss Accreditation
of Switzerland and certified by SGS India Pvt. Ltd., signify excellence in different
aspects of business.
� ISO:9001:2008 FOR Quality Management System
� ISO:14001:2004 for Environment Management System
� OHSAS ISO:18001:2007 for Occupational Health & Safety
It is worth noting that Godawari Power and Ispat Limited achieved state level
recognition in plantation and stood 2nd
in Vriksha Mitra Mahaabhiyan-2008 & 3rd
in
Open Plantation Award-2009.
Name of the Unit : Godawari Power & Ispat Limited
Date of Incorporation : 21/09/1999
Regd. Office : Plot No. 428/2, Phase-I, Industrial Area, Siltara,
RAIPUR (Chhattisgarh)
Plant Location : Industrial Area, Siltara, Raipur
Contact Person : Shri T. Bose
E-mail : [email protected]
Tel No. : 91-771-4082000, 4082736
Fax No. : 91-771-4057601
Godawari Power & Ispat Ltd Pre-Feasibility Report - Expansion/ Modernization Programme
4
Following Environment Clearances / Amendments were obtained from time to time for our existing projects at Siltara Industrial Area, Raipur,
Chhattisgarh.
Sl.
No.
Environment
Clearance
No. & Date
EC / Amendment granted for Activities
1 MoEF F. No.
J-11011/326/
2005-IA-II(I)
Dated 02/03/2006
Amendment
Letter dated
12/05/2016 &
30/06/2017
Original Sanction Amendments received Present / Proposed Status
Sponge Iron 4,95,000 TPA Capacity increased to 6,50,000 TPA
vide MoEF & CC letter dated
12/05/2016
Operational – 4,95,000 TPA. Applied for
Consent to Establish for expansion phase.
Steel Billet 4,00,000 TPA Operational - 4,00,000 TPA
(Current request for modernization and
expansion by additional production of
1,50,000 TPA.
Total capacity after expansion would be
5,50,000 TPA)
Power 53 MW Current request for amendment for
proposed change in configuration by
installation of one new energy efficient
TG Set of 48 MW in place of 3 ageing
TG sets.
Ferro Alloys or
Pig Iron
16,500 TPA or
33,000 TPA
Operational - Ferro Alloys 16,500 TPA
(TOR granted vide letter F.No. J-11011/
326/2005-IA-II(I) Dated 20th July, 2017
– Proposal No. IA/CG/IND/65739/2017)
for capacity increase to 33,000 TPA.
H.B. Wire 1,00,000 TPA Operational – No change
O2 Generation 12,00,000 NM3 Operational – No change
N2 Generation 45,00,000 NM3 Operational – No change
Fly Ash Brick 165.00 lakh Nos. Operational – No change
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
5
Plant
2 MoEF F. No.
J-11011/179/
2009-IA-II(I)
Dated 25/08/2009
Amendment
Letter dated
17/08/2015 &
Extension of
Validity of EC
was granted vide
letter dated
21/07/2017
Expansion of Steel Plant by installation of -
Iron Ore
Beneficiation Plant
10,00,000 TPA Under Commissioning Stage
Rolling Mill 3,00,000 TPA Amended the capacity to 4,00,000
TPA vide MoEF&CC letter dated
17/08/2015
Operational by end of 2018
Arc Furnace
(for Casting
Moulds)
5,000 TPA
Operational by end of 2018
Biomass Based
Power Plant
20 MW Operational
3 MoEF F. No. J-11011/216/
2014-IA-II (I)
Dated 07/04/2016
Iron Ore Pellet Plant of 2.1 MTPA capacity (2 Units : Kiln-I of 0.6 MTPA & Kiln-II of 1.5 MTPA)
Two units of 0.6 MTPA & 1.5 MTPA
Current request for –
1) Amendment for proposed
enhancement in production capacity to
23,00,000 TPA without change in plant
and machinery.
2) Change in product mix to include
manufacture of 2,00,000 TPA
Magnetite Powder
Coal Gasification System – 16,000 Nm3/hr + 1 No. Standby of 4,000 Nm
3/hr
for 0.6 MTPA Pellet Plant and 40,000 Nm3/hr + 1 No. Standby of 20,000
Nm3/hr for 1.5 TPA Pellet Plant (Total 56,000 Nm
3/hr + Standby 24,000
Nm3/hr)
Current request for -
1) Regularization of Standby Gasifiers of
24,000 Nm3/hr
2) Installation of new Gasifiers of
12,000 Nm3/hr (3 x 4000 Nm
3/hr)
Online ambient air quality monitoring system is in place regularly and compliance reports are regularly submitted to
Chhattisgarh Environment Conservation Board and MoEF Regional office, Nagpur.
Godawari Power & Ispat Ltd Pre-Feasibility Report - Expansion/ Modernization Programme
6
Additionally, we are also having the following Environment Clearances for our iron
ore mines at external locations :
Sl.
No.
Environment
Clearance
Activity
1 MoEF F. No.
J-11015/208/
2006-IA-II(M)
Dated
31/01/2007
Amendment
Letter dated
15/10/2015
Iron Ore mining at Village : Boria Tibbu, Tehsil: Mohala, Dist.
Rajnandgaon, Chhattisgarh for 7.05 lakh TPA in 110 ha mine lease
area.
Addition of Iron Ore Crushing Units of 2 x 150 TPH
2
MoEF F. No.
J-11015/339/
2006-IA-II(M)
Dated
25/06/2007
J-11015/384/
2012.IA-II(M)
Dated
12/12/2014
Amendment
Letter dated
26/05/2016
Iron Ore mining at Ari Dongri Village : Kachche, Tehsil:
Bhanupratappur, Dist. Uttar Bastar (Kanker), Chhattisgarh for 7.05
lakh TPA in 106.60 ha mine lease area.
Iron Ore mining with addition of 7.0 lakh TPA with total 14.05 lakh
TPA 138.96 ha mine lease area.
Addition of Iron Ore Crushing Unit of 400 TPH
The half yearly compliance reports of all the existing manufacturing facilities of the
above ECs are being submitted regularly to the Regional Office, MoEF, Nagpur;
Central Pollution Control Board, Bhopal and Chhattisgarh Pollution Control Board,
Raipur.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
7
Chapter - 3
Current Request - Overview
Proposed expansion / modernization
The request is for following proposed expansion / modernization in the existing plant
for enhancement in production capacity.
(i) Enhancement in production capacity of Iron Ore Pellet Plant from existing 2.1
MTPA (2 units) with Coal Gasification System to 2.3 MTPA with existing Coal
Gasification System.
The company is operating pelletizing plant of 21,00,000 TPA capacity (with 2 kilns of
6,00,000 TPA & 15,00,000 TPA) as a backward integration for utilization of iron ore
fines as pellets in the sponge iron kilns. Grate kiln technology was adopted by us for 2.1
MTPA pellet project.
We now proposes to enhance the existing capacity from 21,00,000 TPA to 23,00,000
TPA. No change in the plant & machinery or capital investment is proposed.
(ii) Change in Product mix of Pelletization plant to include manufacture of Magnetite
Powder / Heavy Media for coal washeries
The company proposes for crushing and grinding magnetite ore to magnetite powder
capacity 2,00,000 TPA in the existing grinding mill unit of Pellet Plants. The magnetite
powder has various uses and finds extensive application as heavy media in coal
washeries. The crushing and grinding of magnetite powder will be done in the excess
available capacity of grinding of existing pellet plant.
(iii) Enhancement of production capacity of from existing 4.00 lac TPA to 5.50 lac TPA
Steel Melting Shop (Billets) by change in configuration of induction furnaces.
The company is operating a Steel Melting Shop through Induction Furnace with a
capacity of 2,00,000 TPA in Phase-I and 2,00,000 TPA in Phase-II with valid
environmental clearances along with other integrated steel manufacturing facilities.
In view of the present scenario and available technology, we propose to enhance the
present capacity of SMS by changing the configuration of induction furnaces to achieve
additional annual capacity of 1,50,000 TPA with total capacity of 5,50,000 TPA
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
8
(iv) Change in configuration of existing 3 TG Sets {(9 MW + 9 MW + 30 MW) + 10
MW (standby)} with one new energy efficient TG set of 48 MW capacity in the
existing Power Plant.
The company is generating captive power plant of AFBC, WHRB and Biomass based
with total capacity of 73 MW with environmental clearances at Industrial Area, Siltara,
Dist. Raipur, Chhattisgarh along with other integrated steel manufacturing facilities.
The premise is located in the notified industrial area. The details of ECs are as under :
Sl.
No.
Environment
Clearance
Activity
1 MoEF F. No.
J-11011/326/2005-IA
II(I) Dated 02/03/2006
EC granted for power generation along with
other operations of steel plant.
Power Generation - 28 MW (Phase-I) which
includes:
Sanctioned Capacity
WHRB-1 7 MW
WHRB-2 10 MW
AFBC-1 11 MW
Power Generation - 25 MW (Phase-II) which
includes:
Sanctioned Capacity
WHRB-3 12.5 MW
WHRB-4 12.5 MW
2 MoEF F. No.
J-11011/179/2009-IA
II(I) Dated 25/08/2009
EC granted for Biomass Power along with other
operations.
Sanctioned Capacity
Biomass
Based Power
Plant
20 MW
It may be noted that the 4 Turbines (TG-1 : 9 MW, TG-2 : 9 MW, TG-4 : 30 MW and
one standby TG-3 : 10 MW) are connected to a common header.
In view of the present technology, we now propose to replace the ageing turbines TG-1, 2
& 4 with a new energy efficient Siemens Make TG set of 48 MW, without any change in
power generation.
The TG-5 with a capacity of 25 MW will remain unchanged, since it is physically
separate from the others and not connected to the common header.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
9
Need for the project and its importance to the Country / Region
Pellet
In India partly due to the sponge iron sector; the overall percentage of lumps usage in
steel making is higher than most other countries. As hard ore reserves is depleting day by
day, lump generation suitable for blast furnace operation is coming down resulting in
production of large amount of surplus fines. Alternative iron making processes for
production of steel may lead to changing pattern of use material inputs and feed stock
causing significant shift in respective share of lumps and agglomerated iron ore (pellets)
and will also enable the use of ores which could not be utilized earlier. As fines forms
considerable part of iron ore resources, value addition to the iron ore fines through
various activities such as Pelletization is the need of the hour.
The Ministry of Environment and Forest also encourages for establishment of Iron Ore
Pelletization plant to utilize the huge stock pile of iron ore fines.
Magnetite Ore
In a global perspective, magnetite has greater importance in several countries compared
to India. China, the world’s largest steel producer, uses magnetite as the major raw
material. Taconite, the principle iron ore in America, contains magnetite as the iron
bearing material. Appreciable deposits are found in Australia and many European
countries, especially Sweden. Other small deposits may be found across countries around
the world.
In India, over 90% of magnetite is found in the southern states of Karnataka (73%),
Andhra Pradesh (14%) and Tamil Nadu (5%). Rajasthan in the west accounts for another
5%. The balance is scattered over Goa, Kerela, Maharashtra, Odisha, Jharkhand,
Chhattisgarh , Assam, Nagaland & Meghalaya.
Government policies favour the beneficiation of coal. The most recent measure is
Gazette Notification G.S.R 02 (E), dated 02 January 2014 and issued by the Ministry of
Environment, Forest and Climate Change (MOEF&CC), which states that “power plants
of capacity of 100 MW or above located between 500-749 km from the pit head shall be
supplied with raw or blended or beneficiated coal with ash content not exceeding 34
percent on quarterly average basis from 05 June 2016. Further, all new coal plants have
been mandated to use supercritical technology and 144 existing plants have been
assigned mandatory efficiency targets that will require use of higher quality coal.
Steel
India was the world’s third-largest steel producer in 2016. The growth in the Indian steel
sector has been driven by domestic availability of raw materials such as iron ore and
cost-effective labour. Consequently, the steel sector has been a major contributor to
India’s manufacturing output.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
10
Though the Indian steel industry is going through a sluggish phase, the future remains
optimistic from players with backward and forward integration.
Power Plant
Captive Power refers to generation from a unit set up by industry majorly for its own
consumption. According to the exact definition as per Electricity Act 2003, it is a power
plant set up by any person to generate electricity primarily for his own use and includes a
power plant set up by any cooperative society or association of persons for generating
electricity primarily for use of members of such cooperative society or association.
Captive Power Generations have been growing at a fairly aggressive pace in India.
Industrial sector is one of the largest consumers of electrical energy in India. It consumes
about 45.9 percent of total electricity consumption in the country. The demand for
electricity in India has been continuously growing with time. Thus, to sustain and excel
in the dynamic global environment, it has become imperative for the industries to ensure
uninterrupted power supply for performance optimization which has subsequently led to
the growth in Captive Power Generations in India.
Demand and Supply
Pellet
With the rapid development of Infrastructure and manufacturing sector, the Iron and steel
industry is poised for an accelerated growth. Steel demand in the country is increasing at
an average rate of 10% and is likely to remain in 10-12% range at least for the next
decade. In order to meet the steadily growing steel demand in the country, domestic steel
producing capacity is required to be higher than 150 mtpa within next three years. Indian
economy is growing at more than 10% rate, steel demand and supply will grow in the
same way. As good quality iron ore deposits are depleting fast beneficiation/pelletization
technologies will have to be adopted to meet iron ore demand. Therefore good yield of
pellet process generally around 70% will make this technology economically viable.
� Agglomeration technologies such as Pelletization will have to be added to DRI Plant
/ Steel Plant so that concentrates can be used as feed material. Recycling of cheaper
raw material (fines) by pelletization process as feed material will result in better
Return on Investment as compared to using Iron ore as feed material.
� With superior reducibility behavior of pellets compared to lump ore efficiency of
DRI production improves.
With gradual depletion of high Iron Ore reserves, the Iron and Steel sector world over
has been looking at alternatives to utilise the low grade iron ore fines for iron making so
that there is optimal utilisation of the available iron ore resources. Growth of Steel
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
11
Industry, especially in China over the years despite the depletion of high grade Iron Ore
has taken place on the strength of technologies of Beneficiation, Sintering and
Pelletisation of Iron Ore Fines, which enhances the productivity of the blast furnaces in
Steel making and hence lowering the cost of steel production.
In the Indian context, by the year 2020, India’s production of steel is expected to touch
110 Million Tonnes and it is imperative that the fines generated in the mining of iron ore
be utilized for the production of steel. The Indian steel industry which predominantly
uses expensive lump ore is gradually moving towards usage of iron ore pellets.
The present Indian raw material scenario offers an opportunistic disposition towards
pellet making owing to the availability of large quantities of sub grade fines, slimes and
blue dust etc. at different mine heads. These materials are not suitable for sinter making.
Pelletization is the only possible route for salvaging these, otherwise waste but valuable
materials. Recent techno-economic studies indicated favorable indices for installation of
pellet plants, both small and large scale. The demand supply analysis also underlines the
need for Pelletization.
Magnetite Powder
Currently the installed capacity of coal beneficiation plants in India is 150 million tons
per annum and is targeted to increase 600 million tons per annum by the year 2025. The
consumption of Magnetite Powder is 1 Kg. per ton of beneficiated coal. Hence the
current requirement is 1.50 lac MT of Magnetite Powder annually which will increase to
6.00 lac MT per annum.
Presently the supply of Magnetite Powder is mix of indigenously manufactured
Magnetite Powder and imported.
Magnetite Powder is extensively used in coal beneficiation plant, as a process of
enriching the quality of coal and reduction of its ash content.
The better grade of coal is not available in India, which requires beneficiation. The
Ministry of Environment & Forests has already made it mandatory for use of
beneficiated coal in power plants of 100 MW capacity and above.
The intrinsic quality of Indian coal, along with the dominant practice of open cast
mining, has meant that run of the mine (ROM) Indian non-coking coal contains a huge
share of ash and other minerals. ROM coal typically has high ash content from 30-50
percent and low calorific value (2,500-5,000 kcal/kg). In general, high ash content
creates problems for coal users that include erosion, difficulty in pulverisation, poor
emissivity and flame temperature, low radiative transfer, and generation of excessive
amounts of fly-ash containing large amounts of un-burnt carbon. In addition, the
transport of ROM coal across long distances is wasteful, as it carries large quantities of
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
12
ash-forming minerals that results in misuse of rail and port capacity. The transport of
high ash coal across long distances also contributes to emission of carbon dioxide (CO2)
and other greenhouse gases (GHG) from the mode of transport (rail and road).
Steel
Production
• Steel industry was de-licensed and de-controlled in 1991 & 1992 respectively.
• India is currently the 3rd
largest producer of crude steel in the world.
• In 2016-17 (prov.), production for sale of total finished steel (alloy + non alloy)
was 100.74 mt, a growth of 10.7% over 2015-16.
• Production for sale of Pig Iron in 2016-17 (prov.) was 9.39 mt, a growth of
1.8% over 2015-16.
• India was the largest producer of sponge iron in the world during the period
2003-2015 and was the 2nd
largest producer in 2016. The coal based route
accounted for 79% of total sponge iron production in the country in 2016-17
(prov).
• Data on production / production for sale of pig iron, sponge iron and total
finished steel (alloy/stainless + non-alloy) are given below for last five years and
April-May 2017:
Indian steel industry : (in million tonnes)
Category 2012-13 2013-14 2014-15 2015-16
Pig Iron
Production for
Sale
6.870 7.950 9.694 9.228
Sponge Iron
Production
23.01 22.87 24.24 22.43
Total Finished Steel
Production for
sale
(alloy/stainless
+ non alloy)
81.68
87.67
92.16
90.98
Demand - Availability
• Industry dynamics including demand - availability of iron and steel in the
country are largely determined by market forces and gaps in demand -
availability are met mostly through imports.
• Interface with consumers exists by way of meeting of the Steel
Consumers’ Council, which is conducted on regular basis.
• Interface helps in redressing availability problems, complaints related to
quality.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
13
Global Captive Power Generation Market: Comprehensive Overview
Captive power generation is the power generation unit that has been set up by an
industry or individual for its personal consumption. The industrial sector is one of the
leading consumers of power and is also expected to contribute extensively to the
revenue of the global captive power generation market. Based on captive generation
equipment, the market can be segmented into transformers, electricity precipitators,
heating ventilation air conditioning, heat exchanger, generator, turbine, and boiler
among others. Based on technology it can be categorized into diesel, gas, coal, and
renewable.
Global Captive Power Generation Market: Key Trends
The prime forces of the global captive power generation market are growing demand
for power coupled with the prevalence of cross-subsidy charge in the cost of
generation of per unit of power. Mounting demand across the globe along with
growing urbanization and industrialization and an incessantly rising world population
is expected to boost the adoption of captive power generation. In the near future, the
global captive power generation market is expected to grow at a steady and moderate
rate. It has been anticipated that the market will be mainly driven by the growing
demand for power and the sky rocketing costs of electricity. The demand for captive
power generation is expected to intensify over the next couple of years due to the
existence of the element of cross subsidy in power tariff and rise in per unit cost of
power generation.
The market is also likely to be bolstered by the need for reliable and quality power
couple with decrease in wastes and enhancement of fuel flexibility. The industries
have been compelled to adopt captive power generation and set up their plants in
order to meet their power needs and not depend on the electric grid for power supply.
The growth of the market is also likely to be augmented by the symbiotic relation of
the manufacturing processes with the power generation technologies. Indian power
sector is undergoing a significant change that has redefined the industry outlook.
Sustained economic growth continues to drive electricity demand in India. The
Government of India’s focus on attaining ‘Power for all’ has accelerated capacity
addition in the country. At the same time, the competitive intensity is increasing at
both the market and supply sides (fuel, logistics, finances, and manpower).
Godawari Power & Ispat Ltd. Pre
Location and Site Analysis
The terrain of the land is plain. The
86.464 ha of existing land in the premises of Godawari Power & Ispat Limited, Siltara
Industrial Area, Raipur. This Industrial Area is developed by CSIDC
map showing the location of all
Detailed Layout Plan of Godawari Power & Ispat Ltd.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
14
Chapter - 4
The terrain of the land is plain. The proposed projects are located in the total area of
of existing land in the premises of Godawari Power & Ispat Limited, Siltara
. This Industrial Area is developed by CSIDC Ltd.
map showing the location of all the manufacturing units of GPIL is -
Detailed Layout Plan of Godawari Power & Ispat Ltd.
odernization Programme
are located in the total area of
of existing land in the premises of Godawari Power & Ispat Limited, Siltara
Ltd. The Layout
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
15
Overall, the land utilization is as under:
No additional land is required for the current proposals.
The requisite green belt is 28.53 ha. (33%). As against the same, the total green belt is
33.190 ha.
There are no ecologically sensitive places like national park, sanctuary, biosphere
reserve, heritage sites, archeological monuments, defense installation, health resorts,
scenic beauty etc. around 10 Kms. radius of the site. There is no route of migratory
animals within the project site. The site satisfies the criteria stipulated by the Ministry
of Environment & Forest, Government of India for setting up of industries.
Toposheet No. : F44/P/11, F44/P/15
Latitude : N 21°22’09.5" - 21°22’77.9"
Longitude : E 81°40’64.9" - 81°41’22.7"
Connectivity
The company’s existing manufacturing facilities are located at about 20 Kms in north
from Raipur, the capital of Chhattisgarh State. The project site is along the Raipur-
Bilaspur Highway and the facilities are located more than 1 Km away from the
Highway. The nearest railway station is Mandhar (around 3 Kms. south east of site)
on the Mumbai-Howrah main line. The nearest airport is located at Mana village near
Raipur at a distance of about 30 Kms. from the site.
Particulars Area
in Acres
Area in
Ha.
No. of trees
Total Land Area 213.657 86.464 -
Total Covered Area 45.078 18.242 -
Total Road Area 35.029 14.175 -
Total Green Belt Area 82.010 33.190 73439
Total Open Area 51.540 20.857 -
Godawari Power & Ispat Ltd. Pre
10 Km. Area Map on SOI Toposheet
Google Image of Project Site
Chikhli
Birgaon
Achholi
Nawadih
Padharidih
Kanhera
Kandarka
Kumhari
Bhalesur
BahesarLataHardi
Siphon
Bhimbhori
Kumhi
Devsara
Khurmuri
Dhaba
81°35'
21°25'
21°20'
STREAMS
RIVER / NALA
POND
ROAD
HABITATION
GRID
PROJECT SITE
INDEX
81°35'
KHARUN RIVER
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
16
10 Km. Area Map on SOI Toposheet
Google Image of Project Site
Tanda
SiltaraSondraChikhli
NimoraSankra
Dhaneli
Birgaon
Achholi
Kanhera
Kumhari
Bahesar
Kumhi
Barantara
Devsara
Khurmuri
Mundrethi
Dharsihwa
Tiwria
Kurra
Murra
Dhaba
PandarbhattaDevri Manohra
Meharsakha
KuthrelKukera
Raita
Kapasda
Parastarai
AkoliGidhauri
Barbandha
Mandhar
Newardih
BhurkoniSemaria
Baroda
SadduSevni daldal
Bhanpuri
Urkura
Ranwabhata
Giraud
Mandhar
Matia
TarraJarauda
PauniPatthri
TaresarKhurmuri
Mangsa
Bartori
Kadwa
Siliari
Malaud
Kurud
Nagargaon
Mohdi
Tor
Dande Kalan
Dande Khurd
Nardaha
Amasevni
Tekari
Bhaismunda
Akoli
81°40' 81°45'
21°25'
21°20'
RIVER / NALA
PROJECT SITE
RAILWAY LINE
M/s Godawari Power & Ispat Ltd. Plot No. 428/2, Phase-I, Industrial Area, Siltara,
10 KM. STUDY AREA
81°40' 81°45'
KU
LH
AN
NA
LA
CHHOKRA NALA
Raipur-493111, Chhattisgarh Plot No. 428/2, Phase-I, Industrial Area, Siltara, Raipur-493111, Chhattisgarh
odernization Programme
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
17
List of Villages within 10 Kms. Radius of GPIL
Name of Village Direction
Siltara W
Tanda E
Sarora S
Charoda – 1 NW
Dharsiwa NW
Kurud Village NE
Dhaneli Village SW
Chhapora village SSE
Bhanpuri Village SSW
Kanhera Village WSW
Kurna Village NNW
Murathi Village WNW
Akoli ESE
Bahesar WNW
Mandhar SE
Garh NE
Mohdi ENE
List of Industries within 10 Kms Radius of GPIL
Sr. No Name of the Industry Type
1 M/s. Sarda Energy & Minerals Ltd. Pellet, DRI & Power
2 M/s. Jaysawal Neco Ltd DRI & Power
3 M/s.Mahamaya Sponge Iron (P) Ltd. Sponge Iron
4 M/s. Mahendra Sponge & Power Ltd. Sponge Iron
5 M/s. Hira Ferro Alloys Ltd. Ferro Alloys
6 M/s. Vandana Global Ltd. DRI & Power
7 M/s. SKS Ispat & Power Ltd. DRI & Power
8 M/s. Euro Prateek Sponge & Iron Ltd. DRI & Power
9 M/s/ Jagdamba Power & Alloys Ltd. Power
10 M/s. Drolia Power & Ispat DRI & Power
11 M/s. Nakoda Ispat Limited DRI & Power
12 Aarati Sponge & Power Ltd. DRI & Power
13 API Ispat & Power Tech Ltd DRI & Power
14 Drolia Electrosteel (P) Ltd. DRI
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
18
15 S.K. Sarawagi & Company (P) Ltd. DRI
Chapter – 5
Project Description & Manufacturing Process
IRON ORE PELLET PLANT
Enhancement in production capacity of Iron Ore Pellet Plant from existing 21.00 lac
TPA (2 units) with Coal Gasification System to 23.00 lacs TPA with Coal
Gasification System.
The company is operating pelletizing plant of 21,00,000 TPA capacity (with 2 kilns of
6,00,000 TPA & 15,00,000 TPA) as a backward integration for utilization of iron ore
fines as pellets in the sponge iron kilns. Grate kiln technology was adopted by Godawari
Power & Ispat Limited for 21.00 lac TPA pellet project.
Now, the company proposes an increase its total production capacity from 21,00,000
TPA to 23,00,000 TPA without any change in the plant & machinery, but only by
change in the following:
1) The pellet plant was designed for utilization of Hematite ore. However, since the fines
generated from our captive mines are primarily Magnetite in nature, the raw material
mix is generally with 50% Magnetite and 50% Hematite. The heat requirement from
Hematite for production of per ton of pellet in terms of calories is more than
Magnetite. Hence, with similar heat input, higher pellet production is envisaged from
magnetite fines.
2) We are also proposing the mix of coal/coke or pet coke as pulverized fuel in the
Gasification system along with Furnace Oil.
Justification for increase in production capacity from 2.1 MTPA to 2.3 MTPA
The ratio of fuel consumption in production of iron pellets from Haematite is about
1.33 to 1.5 times than that of using from magnetite ore.
(Source: Energy & environmental profile of the US Mining Industry Ch IV, pg 9)
Accordingly, even considering the fuel consumption at the lower end of 1.33, the heat
requirement for using a blend of haematitic and magnetite ore will considerably
increase the production by using the same heat input.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
19
We must mention here that we have two operating iron ore mines of combined
capacity of 2.1 million tons per annum, the ores of which are predominantly
magnetitic.
A calculation of effective higher production on using hematite and magnetite ore is
given below:
Ratio of heat for Hematite over
Magnetite
133
At 50 : 50 Magnetite : Hematite
Magnetite Heat 50 x 1 50
Hematite Heat 50 x 1.33 66.50
Total 116.5
Hence excess production
feasible
133 .
116.5
114.16%
Say 15%
However, the proposed production restricted
for enhancement is 10%
For 6.00
lac TPA
For 15.00
lac TPA
Total
Excess Production 660000 1650000 2310000
Say 650000 1650000 2300000
Working Days 350 350
Working Hours 8400 8400
Production per Hour 77 196 274
Say 280
We propose to go for enhancement of pellet production capacity from existing
21,00,000 TPA to 23,00,000 TPA.
Grinding Mill Capacity
Grinding Mill capacity of both the Pellet Plants (TPH) 350
Working Hours 7920
Total Grinding Capacity (TPA) 2772000
Process routes and facilities
The Iron Ore from Ari Dongri mines are converted to Fines of Magnetite for Pellet
production and the ore from Boria Tibbu 5/18 mm size to sponge iron plant and -5
mm to pellet plant. In Pelletization iron ore fines is wet ground to 325 mesh (80%
passing max.).
Main technological facilities
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
20
Sl.
No. Processing step Technological facility
1 Grinding Closed Circuit Wet Ball Bill, Filter
2 Green Ball Mixer, Disk Pelletizer
3 Induration Grate-Kiln-Cooler
Reportedly, with incorporation of wet grinding of iron ore, energy consumption
would be reduced by 25% to 35% as compared to dry grinding.
Plant and Equipment
Sl.
No. Building Covered/ Open
1. Iron Ore Yard Concrete floor with
covered shed
2. Raw Material Gentry Closed
3. Iron Ore Grinding Closed
4. Mixing Closed
5. Balling Disc Closed
5. Travel Grate Closed
7. Kiln Open
8. Annular Cooler Open
9. Utilities Open/ Closed
10. Coal Gasifier System Open
Process Details
Iron Ore Pellet Plant
In order to make entire technological level, environment protection level, advanced
stage and suitable for operation and maintenance, it is designed to have some new
material, new technology, new process, new equipment and new structure, with aim at
improving reliability, reducing investment, extending life campaign, lowering
operation cost, facilitating maintenance and replacement.
Travel grate machine - Rotary kiln process features as :
� Drying, Preheating, Baking, Cooling and etc are carried on different equipments
including travel grate machine, rotary kiln and annular machine, leading to uniform
quality of product and reliable and simplified equipment.
� Each set of equipment can be controlled individually and adjusted conveniently,
which is strongly adapted for raw material, particularly hematite.
� Good adaptability for fuel. Low fuel consumption, power consumption and low
operation cost.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
21
Rotary kiln is step-less adjusted by speed reducer and AC frequency converter to
enable operation smooth and stabilized.
To adopt advanced air flow system, fully recovering sensible heat of high temperature
flue gas generated from annular cooler, making utilization of thermal energy to the
maximum extent, and lowering thermal consumption of pellet.
Main operation process are centralized controlled and adjusted by computer, main
technological process are monitored and administrated by industrious TV with high
automatic control level.
High attention is put on the protection of environment, which purify the dust
contained waste gas by use of high effective dust catcher to discharge into the air after
reaching standard discharge norm.
Dust is collected in centralized manner, which can be fully recovered and utilized.
The Iron Ore Pelletization Plant has the following major units:
Iron Ore grinding system & Filtration
The design capacity of fine grinding machine is 350 T/Hr. feeding fines of incoming
raw iron ore is around 63.5%. Granular sizes of output of iron ore after grinding is
around 70 to 90 passing though 325 mesh, subject to filtration to produce iron ore
concentrate with water content of around 9% to 10%. Preliminary iron ore grinding is
carried out in closed circuit ball mill and Wet screen.
Mixing room
Iron ore fines, Bentonite, flux, coke and ESP dust are all mixed uniformly in a mixer.
As per water content of material, some certain quantities of water is added so as to
maintain water content before balling process ranged from 9 to 10%.
Balling Room
Mixed material is transferred through belt conveyor into the high level of balling
room, where the material mix is discharged through plough-type dumper above belt
conveyor separately into 9 mixed material bunker, under which, 9 sets of Ф6.0m
balling disc are installed. Green ball produced from balling disc is transferred from
collective belt conveyor into the green ball distribution system in the travel grate
machine for material distribution.
Green ball distribution system
Green ball from balling room is fed into the distribution system through belt
conveyor. In reciprocating process, head swinging belt conveyor feed the green ball
into large ball roll screen for screening. Unqualified green ball of more than 16 mm
are separated out and then fed back into the balling room through return material
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
22
system. Green ball of less than 16mm is fed onto wide belt conveyor, which
transfers the green ball onto roll distributor through AC frequency converter.
Roll distributor fed qualified green ball of 5-16 mm onto travel grate machine.
Undersized balls less than 5 mm are recycled to the balling system.
Baking System
Travel grate machine, rotary kiln and annular circular machine are designed to
formulate baking system. Green ball are dried and preheated in the travel grate
machine, and then baked, solidified in the rotary kiln, cooled in the annular cooler.
Travel Grate Machine
Effective length of travel grate machine is 36 meters for 6.00 lac TPA & 54 meters for
15.00 lac TPA. Length of wind box is 3 meters. The travel grate machine is divided
into 4 zones each unit, which are separately for suction drying zone, preheating
zone I and preheating zone II.
Suction drying zone I & II
In suction drying zone, recoverable hot west gas suctioned by heat resistant fans
from wind boxes in preheating zone II penetrates material layer downward from up,
to keep green ball free of water and dried.
A set of main suction blower is provided to exhaust waste gas from wind box into the
air through ESP.
Preheating zone I
Hot waste gas flow in the preheating zone I is utilized to keep drying green ball
through material layer, in order to assure pellet to sustain high temperature in
Preheating Zone II.
Hot waste gas in preheating zone I is merged through main pipes at a side of wind
box with hot waste gas from suction drying zone to be discharged into air all
together through ESP, Main suction blowers and chimney.
Preheating zone II
In preheating zone II, pellet is further heated. Pellet is partially solidified and
hardened to achieve certain strength to sustain impact caused by pellet falling from
travel grate machine into the rotary kiln to avoid being crushed in process of
rotation of the kiln.
Rotary Kiln
Sizes of the kiln are Φ4.0 mtr. X 32 mtr. for 6.00 lac TPA & Φ5.0 mtr. X 42 mtr. for
15.00 lac TPA.
Pellet, after preheated by the traveling grate machine, is discharged into the end of the
kiln through scrapper and chute. The kiln is provided with HFO & producer gas
spraying gun in its head.
Godawari Power & Ispat Ltd. Pre
The well baked pellet, is discharged, after large sizes of pellet is sieved out by
fixed screen at the head of the rotary kiln, into the material receiving hopper
of annular cooler.
Annular Cooler
Effective area of annular cooler is 50 sqm for
TPA. The annular cooler consist
Frame, Upper Cover and etc. The pellet, after cooled dow
in the annular cooler, is discharged outside through discharging hopper.
Main air suction blowers
Waste gas from preheating zone I merge with those from Wind Box of Suction
drying zone is discharged through ESP an
content of waste gas to be discharged into the air is not more than 50mg/Nm3.
Finished Product Transportation System
Cooled pellet, after discharged from material discharging hopper of annular
cooler, is transferred through belt conveyor into the Junction Box, where the
cooled pellet 100 to 150 deg C is transferred through metal belt conveyor
into the finished product transportation system.
Flow Sheet of Pellet Plant
Production Programme
The production program of the Iron Ore Pelletization Plant is
annual average production hours considered is 7,920 hrs based on three 8 hrs
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
23
The well baked pellet, is discharged, after large sizes of pellet is sieved out by
fixed screen at the head of the rotary kiln, into the material receiving hopper
Effective area of annular cooler is 50 sqm for 6.00 lac TPA & 90 sqm for 15
. The annular cooler consists of Rotary mechanism, Wind Box, Driving Device,
Frame, Upper Cover and etc. The pellet, after cooled down to below 100 centigrade
in the annular cooler, is discharged outside through discharging hopper.
Main air suction blowers
Waste gas from preheating zone I merge with those from Wind Box of Suction
drying zone is discharged through ESP and main chimney into the air. Dust
content of waste gas to be discharged into the air is not more than 50mg/Nm3.
Finished Product Transportation System
Cooled pellet, after discharged from material discharging hopper of annular
transferred through belt conveyor into the Junction Box, where the
cooled pellet 100 to 150 deg C is transferred through metal belt conveyor
into the finished product transportation system.
Programme
program of the Iron Ore Pelletization Plant is 23,00,000
annual average production hours considered is 7,920 hrs based on three 8 hrs
odernization Programme
The well baked pellet, is discharged, after large sizes of pellet is sieved out by
fixed screen at the head of the rotary kiln, into the material receiving hopper
& 90 sqm for 15.00 lac
of Rotary mechanism, Wind Box, Driving Device,
n to below 100 centigrade
in the annular cooler, is discharged outside through discharging hopper.
Waste gas from preheating zone I merge with those from Wind Box of Suction
d main chimney into the air. Dust
content of waste gas to be discharged into the air is not more than 50mg/Nm3.
Cooled pellet, after discharged from material discharging hopper of annular
transferred through belt conveyor into the Junction Box, where the
cooled pellet 100 to 150 deg C is transferred through metal belt conveyor
,00,000 TPA. The
annual average production hours considered is 7,920 hrs based on three 8 hrs
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
24
shifts/day, 7 days/week and 330 d/yr of plant operation. The required production rate
is 290 tph.
Fuel Firing System
In view of better efficiency of heat in kilns and clean coal technology, the company is
adopting a pulverized Coal/Coke/Pet coke firing system along with furnace oil in both
the Pelletizing Plants in addition of coal gas.
Presently we are operating the following Gasification system in both the pellet plants
with valid consents:
• Coal Gasifiers of 16,000 Nm3/hr (4 Nos. x 4,000 Nm
3/hr) &
1 standby of 4000 Nm3/hr in 0.6 MTPA Pellet Plant
• Coal Gasifiers of 40,000 Nm3/hr (10 Nos. x 4,000 Nm
3/hr) &
1 standby of 20,000 NM3/hr in 1.5 MTPA Pellet Plant
We are running into shortage of gas requirement in the existing operating gasification
system total 56,000 Nm3/hr. Originally the coal availability was estimated at CV of
5000 Kcal. However, the present average availability of coal is only CV of 4000 Kcal
CV, hence this is resulting in lower efficiency in the gasification system.
In view of this, we now propose enhance the Gasification system as under in our
pellet plants for better plant utilization.
A) Total gas requirement for our pellet plants 92,000 Nm3
B) Existing capacity of gasifiers 56,000 Nm3
C) Short fall in gas requirement (A – B) 36,000 Nm3
D) Regularization of Consent to Operate for standby
Gasifier of 1 No. 4,000 Nm3/hr and 1 No.
20,000 Nm3/hr (Standby to be made operational)
24,000 Nm3
E) Propose to install additional Gasifier system (4 x
3000 Nm3/hr)
12,000 Nm3
Coal gasification process is one of the cleanest technologies currently available. In the
process of coal gasification, water gas is produced with zero fugitive emission. The
coal gasification process stands better in comparison to other fuels and there is about
50% reduction in the air emissions.
The Coal Gasification Facility consists of:
o Coal sizing
o Coal conveying from ground hopper to top of battery of coal Gasifiers
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
25
o Coal Gasifiers
o Gas cleaning system consisting of gravity settlers, cyclones and electrostatic tar
precipitator.
o Insulated gas piping
o Process water system
o Ash handling consisting of ash conveyor and storage hopper
o Instrumentation, automation & control for the entire facility
From environmental point view, the usage of producer gas through Coal Gasifier has
proven lowest Nox, Sox, particulate matter and lower hazardous air pollutants. Ash is
in the form of small clinkers / granules and also be slightly wet when disposed.
Therefore, it does not fly and being used for brick making. Water used in the process is
either converted into steam or re-circulated and therefore there is no waste water
stream.
Project Requirements
Raw Materials & Material Balance
Proposed Raw Material Balance
Source of raw materials
Proposed 2300000 TPA
No. of Days 350
Production per
Hour 280 TONS
INPUT OUTPUT
Item
Quantity
(Kg/ton)
Quantity
(TPA) Item
Quantity
(Kg/ton)
Quantity
(TPA)
Iron Ore Fines
DRY including
Return Fines 1040 2392000 Pellet 1000 2300000
Bentonite /
Binder 10 23000 Process Loss 1 2705
Lime Stone /
Dolomite 16 36800 LOI 23 52900
Return Fines 42 96195
Green Ball
Moisture (10%) 110 253000 Steam 110 253000
TOTAL 1176 2704800 1176 2704800
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
26
Iron ore
The requirement of iron ore fines is met from captive mines Ari Dongri & Boria
Tibbu. The shortfall in quantity is sourced from Local Market / Odisha.
Ari Dongri Iron Ore Mine & Crushers
Ari Dongri iron ore mine with crushers is located at at Ari Dongri Village : Kachche,
Tehsil: Bhanupratappur, Dist. Uttar Bastar (Kanker), Chhattisgarh The deposit has
been explored in detail and about 9 million ton reserves of iron ore have been proved.
The annual capacity is 1.405 MTPA and the ore is Magnetite.
Boria Tibbu Iron Ore Mine & Crusher
Boria Tibbu iron ore mine with crusher is located at Village : Boria Tibbu, Tehsil:
Mohala, Dist. Rajnandgaon, Chhattisgarh is The deposit has been explored in detail
and about 3.3 Million ton reserves of iron ore have been proved. The annual capacity
of these mines is 0.705 MTPA and the ore is Hematite.
The iron ore fines so produced at these mines are the feed for the Iron Ore
Pelletization Plant at M/s Godawari Power & Ispat Limited. The average quality of
fines is as follows:
Fe : 60 to 65%
SiO2 + Al2O3 : 4 to 8 %
Phos : 0.040 to 0.070 %
LOI : 0 to 4%
Bentonite
The Bentonite is sourced from Gujarat. The average quality of dolomite required is
as follows:
Chemical Properties of Kuchchh Bentonite
SiO2 : 45-52%
Al2O3 : 15-17%
Fe2O3 : 15-16%
CaO : 1.0 %
MgO : 2.5 %
LOI : 8 -9%
Dolomite
The dolomite is sourced from Local market / Maharashtra and Madhya Pradesh. The
average quality of dolomite are as follows :
CaO : 28 – 30%
MgO : 18 – 20%
SiO2 : 3 – 6%
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
27
Fe2O3+Al2O3 : 1.0 – 2.0%
LOI : 39 – 43%
Coke
The Coke / Pet coke is imported and locally sourced. The average quality of Coke
required is as follows:
Fixed Carbón : 65 to 80% Min
Size : 0 to 5 mm
Proposed Water Requirement
Unit
Proposed Water
Consumption for
6,50,000 TPA
(KL/Day)
Proposed Water
Consumption
(KL/Day)
for 16,50,000 TPA
Total for proposed
23,00,000 TPA
(KL/Day)
Iron Ore Pellet Plant 200 400 600
Gasifier Division
Existing & Post-
expansion)
120 778 898
Total 320 1178 1498
Power requirement
Presently 15 MW Power is sourced from our captive generation. The proposed power
requirement after enhanced capacity will remain the same.
Proposed Fuel Consumption in Gasification system
Proposed for 23,00,000 TPA
Fuel (Tons /per Annum)
1 Coal / Coke / Petcoke 286364
2 Furnace Oil 2300
Note : Tar produced is about 6% of coal will be consumed internally in the Pellet
Plant. Sulphur content will be significantly reduced in the proposed fuel mix of the
Gasification System. Since the gasification system is a clean process, our ESPs are
designed accordingly and the emission from the ESP is within the norms of 35
Mg/Nm3. Both the pellet plants have sufficient stack height to safe guard the
environment and all pollution control measures and equipments are in operation.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
28
Environment Management
There is no fugitive emission. The slurry water is recycled and used in the process.
The ash generated is being utilized for fly ash brick making. The tar is re-burnt in the
process. As such, there is no other solid waste.
Solid Waste Management
• The solid waste generated during gasification stage is ash and can be stored and
transported easily and utilized for fly ash brick making.
• The Tar generated from the gasification plant is mainly consumed internally in the
pellet plant and only a small quantity is being sold to outside authorized parties.
Solid Waste Generation
Proposed for 23,00,000 TPA
Ton/ Day Ton/ Annum
Ash Generation 252 88200
Tar Generation 49 KL 17250 KL
The increase in ash content is due to poor quality of coal available.
Pollution control measures
Air pollution
The measures to control the air pollution ensure the ambient air quality standards as
laid down by Central Pollution Control Board for industrial and mixed use areas. In
addition, the emission from the chimneys are kept below the permissible limits of
statutory norms for dust. Gaseous exceed ambient air quality norms due to the entire
plant.
The system for air pollution provides acceptable environment conditions in the
working areas and abates air pollution in the surrounding areas of the site. The
technological equipment and processes have been selected with the above objective.
Depending upon the quality of emissions from different sources, suitable air pollution
control systems are provided. The chimney height is as per requirement to ensure
Ground Level Concentration (GLC) of different pollutants within permissible limits
after considering the background Ground Level Concentration. Various dust
extraction and dust suppression systems are in indicated below.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
29
Dust extraction system
Sl.
No. Location / Shop Facilities
i
Flue and hot gases
from Grate-Kiln-
Cooler system
Flue gas & dust extraction system comprising of
multiclone, Electrostatic precipitators, tall chimney etc.
ii Coke & Flux
grinding system
Pulse jet type bag filter, centrifugal fan and motor, duct
work including suction hoods, duct supports, stack, dust
hopper, rotary air lock valves, dust conditioner, etc.
iii Material handling
system Water spray - dust separation system.
However, in order to meet the statutory ground level concentration limits for SO2,
NOx and other gaseous pollutants, suitable stack heights are provided for proper
dispersion. All stacks are provided with port holes and working platform so that stack
monitoring is being done as per norms.
Stacks of 65 Mtr. height & 100 Mtr. height have been provided in 6.00 lac TPA &
15.00 lac TPA Pellet Plants respectively. Sufficient numbers of Bag Filters are
installed at all the junction points / transfer points. Two Nos. ESPs are also installed
in the respective pellet plants.
The collected dust from bag filters and ESPs is recycled for continuous feeding for
production of pellets, thus, there is NO SOLID WASTE generation from the plant.
The fuel for Gasifier i.e. Coal is stored and transported as per stipulated norms.
Effluent Generation
There is no effluent generated in the Iron Ore Pelletization Plant. The plant has been
designed and equipment has been selected accordingly. Thus, the plant is designed as
ZERO DISCHARGE.
• In the grinding system the water is completely recovered and Re-circulated.
• Cooling Towers are fitted with efficient filtering system. The scale and sludge
particles arrest at filter.
• About 10 KL/Day waste water is generated from the cooling tower and the same
treated in our existing Effluent Recycling System.
• The Phenolic waste water generated from Coal Gasification is being co-processed
(Incinerated) in the after burning chamber of Sponge Iron Plant as stipulated by
the CPCB.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
30
Chapter – 6
Project Description & Manufacturing Process
MANUFACTURE OF MAGNETITE POWDER
Change in Product mix of Pelletization plant to include manufacture of
Magnetite Powder / Heavy Media for coal washeries
Magnetite Powder has miscellaneous uses and finds extensive application as heavy
media in coal washeries.
Magnetite is a black/brownish black, naturally occurring iron oxide, represented
chemically as Fe3O4. It is magnetic in nature – hence the name – a property that has
been applied extensively while dealing with the mineral. Being a source of iron, it is
the starting material for many iron & steel producers around the world. Another
application of magnetite, which should be of interest to this industry, is its use as a
heavy media in coal washeries, to separate out higher grades of coal from lower ones.
It is also used as raw material for manufacturing of magnetic tapes.
Use of Magnetite as a Heavy Media
Powdered magnetite is often mixed with a liquid to produce thick, high-density slurry
that is used for specific gravity separations. Much of the high-ash coal that is mined in
India and is floated across a slurry of magnetite. Clean coal particles have a low
specific gravity and float on the slurry. Particles contaminated with pyrite (a sulfide
mineral with a high specific gravity) sink into the high-density slurry.
Use of Magnetite as an Abrasive
The abrasive known as "emery" is a natural mixture of magnetite and corundum.
Some synthetic emery is produced by mixing magnetite with aluminum oxide
particles. The production of synthetic emery gives the manufacturer control over the
particle size and the relative abundance of aluminum oxide and magnetite in the
product. Some finely ground magnetite is also used as an abrasive in waterjet cutting.
In the past few decades, synthetic abrasives have filled many of the applications
where magnetite was previously used.
Other Uses of Magnetite
• Toner in electrophotography,
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
31
• Micronutrient in fertilizers,
• Pigment in paints,
• Aggregate in high density concentrate
Manufacturing process of Magnetite Powder / Heavy Media
The process of Magnetite Powder is as follows :
The crushed iron ore is passed through the Magnetic Separators wherein the magnetite
ore is segregated from impurities etc. This magnetite ore is then subjected to further
crushing and grinding to the desired micron size. Subsequently the magnetite ore after
being analyzed for its specifications is weighed and packed in PVC bags and supplied
to customers.
For manufacture of Magnetic Powder, the crushing & grinding of ore / fines will be
done in the Grinding mill unit of our existing 6.00 lac TPA & 15.00 lac TPA Pellet
Plants.
We propose to utilize the grinding mill unit of the pellet plant for manufacture of
Magnetite Powder upto 2,00,000 TPA. The crushing and grinding of magnetite
powder will be done in the excess available capacity of grinding of existing pellet
plant.
Availability of Raw Material - Iron Ore
Godawari Power & Ispat Ltd. is operating iron ore mines at Ari Dongri, Dist. Uttar
Bastar Kanker over an area of 138.96 hectare (with mining capacity - 14.05 lakh
TPA) & at Boria Tibbu in an area of 110 hectare (with mining capacity - 7.05 lakh
TPA). The shortfall after consumption of fines in existing/proposed Pellet Plants will
be procured from outside sources.
The ore from Ari Dongri mines is primarily magnetite in nature. The operating
capacity of this mine is 14.05 lac tons per annum. The bulk of ore is utilized for
company’s pellet plant. The company proposes to utilize the partial quantity of
magnetite ore for manufacture of Magnetite Powder.
Land
The land area of existing Pellet Plant will be utilized for manufacture of Magnetite
Powder.
Power requirement :
There is no additional power requirement as the magnetite powder will be
manufactured in the excess available capacity of grinding mill of existing pellet plant.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
32
Water requirement :
Additional water requirement will be 20,000 KL/Year or 60 KL/Day
Chapter – 7
Project Description & Manufacturing Process
STEEL MELTING SHOP (STEEL BILLETS)
Modernization of existing Steel Melting Shop by substitution with new furnaces with
resultant change in configuration and increase in production capacity from existing
4.00 lac TPA to 5.50 lac TPA.
The company is operating a Steel Melting Shop through Induction Furnace with a
capacity of 2,00,000 TPA in Phase-I and is commissioning Furnaces with capacity of
2,00,000 TPA in Phase-II
The existing configuration of SMS is as under :
Furnace
Capacity
Nos. Heats
per day
Production
Capacity /
Day
Production
Capacity /
Year
Total existing
production
capacity
Phase-I 7 ton 5 Nos. 7 245 73500
12 ton 3 Nos. 7 252 75600
15 ton 2 Nos. 7 210 63000 212100
Phase-II 30 ton
(inclusive
of LRF)
2 Nos. 10 600 198000 198000
Total 4,10,100 Say
4,00,000 TPA
In view of the enhanced sponge iron capacity and available technology, we propose to
enhance the present capacity of SMS by changing the configuration of induction
furnaces to achieve additional annual capacity 1,50,000 TPA with total capacity of
5,50,000 TPA.
Proposed Configuration :
Furnace
Capacity
Nos. Heats
per day
Production
Capacity /
Day
Production
Capacity /
Year
Total existing /
proposed
capacity
Phase-I 12 ton 3 Nos. 7 252 83160
15 ton 8 Nos. 7 840 277200 360360
Phase-II 30 ton 3 Nos. 7 630 207900 207900
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
33
(inclusive of
LRF)
Total 568260 say
550000 TPA
Process Description of the Steel Melting Shop
In this project, we have considered Induction Furnace for producing billet / ingots
and the production of billets to be used for producing structural steel (wire rod /
TMT) from the rolling mill. The furnace is run with electric power fed from the
furnace transformer. The material kept for charging on the charging conveyor is
fed inside the induction furnace and is melted and the same is discharged out of
furnace and is poured to the ladle furnace for further processing in the continuous
casting machine. Steel Billets shall be produced through Induction furnaces to
CON-CAST machines; the main raw-material is Sponge Iron. Power shall be
internally consumed; additionally Steel Scrap and Ferro Alloys as per the
requirement.
Steel melting shop is a department where the metallic scrap and the sponge iron is
being melted in induction furnace. The liquid metal thus melted is treated with
alloys additions for required final product chemistry and cast in to the Billet
through continuous casting machine.
The steel melting shop shall have complete facilities right from Weigh Bridge,
Receiving and processing yard for Raw Materials, Charging Bays, Furnace
Transformers, Cooling Towers, DM Plant, water softening plant, EOT cranes,
storage yards, conveyor systems for feeding, bin weighing system, ladles, ladle
preheater, compressor, pumps, electrical power and control system etc.
The charge mix of Sponge Iron, Steel Scrap and Ferro Alloys are charged in
Induction Furnace as per required chemical composition in the bottom part of
Induction Furnace. All the raw-materials are melted in the furnace with the help of
power and temperature is raised at 1650 to 1680
0 C and liquid metal is tapped in
Ladle. The temperature is measured with Pyrometer. The molten steel is tapped in
ladle and then fed to CONCAST (Continuous Casting Machine) through Ladle to
get the sizes of Billets as per requirement of Rolling Mills.
The manufacturing process are described under following heads :
* Raw Material
* Raw Material feeding system
* Induction Furnace
* Ladle Refining Furnace
* Continuous Casting Machine
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
34
The sponge iron is fed into the bunkers through the belt conveyor from the sponge
iron plant. From the load out center of the sponge iron plant one conveyor belt has
been considered to the induction furnace shed and a shuttle conveyor is considered
in the shed for filling the bunkers of furnace. From these bunkers each induction
furnace is fed individually through the weight feeders for uniform and regular
feeding of the raw material into the furnace and also to have a proper accounting
of the sponge iron feeding. And rest of the raw material is fed into the induction
furnace by getting it weighed in the platform scale available on the induction
furnace platform. The slag produced in the process, after cooling is sent to the
slag dump.
MECHANICAL EQUIPMENTS AND SYSTEMS
Handling Equipments: The handling equipments consist of;
i) Over head cranes / Metal handling crane: This is equipped with lifting hoists,
one for liquid handling and other hoist for auxiliary work.
ii) Raw material crane: There is overhead cranes attached with electromagnets.
These are with double hoist. Main hoist with electromagnet is used to handle the
metallic charge and transfer it to the furnace, unloading of incoming scrap
material. The auxiliary hoist is used for handling of byproduct as slag and debris,
transferring of additions during operation and production.
iii) Metal handling ladles: These are the metallic containers of adequate holding
capacity with a free board for safety. The liquid metal/steel prepared is transferred
from furnace to ladle by hydraulic tilting of furnace. The ladle is then carried by
lifting with metal handling overhead crane to continuous casting machine. The
ladles are lined with high temp withstanding refractories of suitable quality.
The Melting Furnace consists Steel Frame Furnace as per following :
Hydraulically tilted steel frame furnace constructed from steel structure to provide
higher rigidity and strength. Iron shunts prevent heating of the steel frame from
the strong magnetic field, the shunt also holds the coil and prevents the coil from
deformation.
The induction coil is placed between the special top refractory block and bottom
made out of special refractory clamped by a vertical steel channel.
The coil is made out of electrolytic hollow copper section with top and bottom
cooling turns made out of non-magnetic stainless steel. The complete steel frame
is pivoted on strong stanchions.
Each furnace includes:
1. A set of hydraulic cylinders for the hydraulic tilting of the furnace.
2. Manually operated hydraulic direction control valve for tilting.
3. Leak detector assembly with stainless steel probe wires and hardware.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
35
4. Set of flexible water cooled power leads for connection between the
power induction coil and power supply unit. Water cooled leads are
with sleeves for protection against metal splash.
Continues Casting Machine: This is the prime equipment of steel melting shop.
The machine consists of water-cooled copper mold tubes and the mechanical
design to cast the liquid metal with metallurgical parameters. The machine works
with the latent heat transformation by primary and secondary water cooling
followed by standard solidification structure. The machine is of bow type with
desired radius and allied assemblies as withdrawal, oscillation, hydraulic handlers,
etc. The hot billet thus cast through is being cut into required length by
oxyacetylene cutting torch. The hot steel Billets pass through the mill approach
roll table directly from CCM to Rolling Mill.
Mechanical Equipments:
1) Water complex: There are three water complex induction furnace and casting
machine. The complex consists of various pumps suitable for furnace cooling,
panel cooling, primary and secondary cooling of casting machine.
2) Cooling towers: Cooling towers are installed with water tanks for exchange of
heat of the hot water used for furnace water and primary and secondary after
cooling hot water. Cooling towers are of forced draft type.
3) Hydraulic power pack: The metal handling ladles are attached with hydraulic
operated slide gate system for controlled pouring of metal in secondary casting pot
at casting machine. This slide gate is being operated with this hydraulic power
pack.
4) Ladle burners: Ladle burners of suitable capacity are required for preheating
of metal handling ladles to avoid temperature difference losses.
5) Compressors: Instrument cum-service air compressors along with an air-drying
and filtration plant is provided to supply moisture free and oil-free air for
handling of dummy bar at concast, operating pneumatic cylinders of casting
machine, air cleaning of induction furnace coils, The compressors is medium
speed non-lubricated, oil free, reciprocating 2-stage equipped with all accessories .
A completely automatic control system is sequentially control the driver system to
ensure timely regeneration and service to provide dry air at the outlet at all times.
Provision is kept to supply plant air from the air receivers.
6) Raw material handling system: This system is solely made for handling the
major raw material i.e. Sponge Iron. The system consists of a ground hopper and
the hopper is assisted by suitable capacity Bucket Elevator. The bucket elevator
carries sponge vertically through buckets and transfers to conveyor horizontal
belt, to get appropriate time of maintenance. The sponge thus carried is transferred
to the day bins of individual furnaces and then directly charged into the furnace.
Weigh feeders is provided intermediate for weighing of sponge iron actually
charged in to furnace.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
36
7) The mechanical dept also looks after the various maintenance schedules of all
the accessories of induction furnaces, allied cutting and welding equipment
utilization.
Electrical Equipments:
Power Unit:
I. Electrical Panel
i) Cabinet :
Metal cabinet, duly painted fitted with panel doors which are gasketed and
equipped with locks. In addition, micro switches are provided which illuminate a
lamp on the monitor board and shut off power to prevent injury to personnel when
the lift off panel or doors are opened.
ii) Rectifier Section with Filter :
a) High power SCRs with snubbers for rectification
This rectifier is designed to minimize line harmonics compared to phase
controlled rectifier.
Instantaneous trip circuit facility is provided for the protection of the rectifier
b) Fast acting semi-conductor fuses
c) Two Nos. of Air core encapsulated current limiting reactors
d) DC capacitors located in capacitor section
This design of converter and filter section reduces losses compared to iron
core current limit reactor(s) and helps to provide constant DC voltage to the
voltage fed inverter.
This design helps to achieve the conversion efficiency not less than 96%.
i) Inverter Section
This section contains inverter panel containing high power inverter SCRs with
snubbers, anti parallel diodes and DI/DT reactors. This helps to provide full
power throughout the melt cycle.
ii) Capacitor Section
a) This section contains all the required DC filters and medium frequency AC
Capacitors.
b) One pressure switch, installed in each capacitor.
c) One indicating lamp located on the monitor board to notify the operator when
the Capacitor pressure switch has been actuated.
v) Ground/Metal Leak Detector
One sensing ground/metal leak detector ready to sense and indicate any
ground and metal leak. Consisting of indicating lamp, milliameter, probe
disconnect switch to disconnect the probe from the power supply.
vi) Control and Monitor System
a) Three direct reading instruments including frequency meter, kilowatt meter
and furnace voltmeter.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
37
b) One main control board for controlling of the equipment which eliminates
electronic complexity and simplifies maintenance. This board is located in a
compartment. A cooling fan with heat exchanger is provided for temperature
control.
c) ON/OFF push buttons are provided on the control door.
d) One power control knob is provided on the control door to set the desired
power level.
e) One circuit monitor for monitoring and indicating functional parameters,
such as water pressure, water temperature and other electrical faults.
vii) Internal Closed Water System (Inside the Cabinet)
This contains one feed manifold with temperature and pressure switches and
one drain manifold with temperature sensors for different paths of cooling
system.
viii) Internal Closed Water System (Outside the Cabinet)
This structure contains one plate type water to water heat exchanger,
expansion/air separator tank, one mono block non- ferrous pump with
starter and one deionizer cartridge for continuous purification of internal
water.
ix) Furnace Selector Switch Assembly
Furnace selector switch saves time for selecting the required furnace. For
better contact it is made out of silver plated copper blades
x) Hydraulic Power Unit
One hydraulic pumping unit (without oil and starter) to supply pressurised
fluid to the tilting cylinders complete with pump, pump motor, fluid
reservoir, pressure relief valve, pressure gauge, return line filter and filter
air breather cap all mounted on a common base with seamless pipes and
fittings
LABORATORY: A fully equipped chemical laboratory for the inspection,
analysis and quality control of incoming raw material and the product is
envisaged. The finished product called Billet is being manufactured as batch wise
as independent heat batch of each furnace. The heat has to be of specified standard
chemistry. To test the various elements range in billets the lab is to be equipped
with Spectrometer. Spectrometer is automatic computerized machine to give the
result of about 18 - 24 elements just in 5 mnts. The spectrometer works on the
light spectrum theory. As each element produces different light spectrum of
different wave length, which is captured and been analyzed as the percentage of
elements available. The laboratory is also parallely supported by manually done
weight analysis method.
Godawari Power & Ispat Ltd. Pre
Raw Materials
Material Balance for Existing SMS of 4.00 lac TPA
The raw materials required in the process of induction arc furnace are
Scrap & Ferro alloys.
Input
Material Per
T/T
Sponge Iron 1.09
Scrap 0.13
Flux 0.01
Silico Manganese
(Ferro)
0.01
Total 1.24
Slag is about 22% of billet. The same is being reprocessed through crushing and
magnetic separation plant, where about 8 to 10% of slag is being recovered as low
grade sponge iron and reused in the steel melting shop.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
38
Existing SMS of 4.00 lac TPA
The raw materials required in the process of induction arc furnace are -
Output
Per
T/T
Qty. (MT) Material Per
T/T
1.09 434,679 Steel Billets 1.00
0.13 52,570 Slag 0.23
0.01 3,401 LOI 0.01
0.01 5,986
1.24 496,636 1.24
Slag is about 22% of billet. The same is being reprocessed through crushing and
magnetic separation plant, where about 8 to 10% of slag is being recovered as low
grade sponge iron and reused in the steel melting shop.
odernization Programme
Sponge Iron,
Qty (MT)
400,000
93,235
3,401
496,636
Slag is about 22% of billet. The same is being reprocessed through crushing and
magnetic separation plant, where about 8 to 10% of slag is being recovered as low
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
39
Material Balance for total 5.50 lac TPA (Post-expansion)
Input Output
Material Per
T/T
Qty. (MT) Material Per
T/T
Qty (MT)
Sponge Iron 1.09 599,500 Steel Billets 1.00 550,000
Scrap 0.13 71,500 Slag 0.23 126,500
Flux 0.01 5,500 LOI 0.01 5,500
Silico Manganese
(Ferro)
0.01 5,500
Total 1.24 682,000 1.24 682,000
Water requirement -
Availability of water
The company has already existing reservoir and water is sourced from Chhattisgarh
Ispat Bhoomi Limited, the nodal agency for supply of water to the industrial areas.
The company had entered into an agreement for 10,000 KL/day water by Chhattisgarh
Ispat Bhoomi Limited for industrial / domestic use in its integrated steel facilities.
The overall present water consumption for the total integrated steel facilities of the
company is about 8,000 KL/Day.
Power requirement –
The power requirement for existing SMS & proposed unit is 1000 Kwh/ton, which is
be met from existing captive power generation sources.
Other Utilities
Due to a number of moving equipments, oil / lubricants are required at various stages
of the process; the consumption of the same is reduced.
Particulars
Existing Water
requirement for 4.00
lac TPA
(KL/day)
Proposed Water
Consumption for total
5.50 lac TPA
(KL/day)
Raw water requirement
for cooling Purpose 2854 3920
Domestic Water 4 5
Total : 2858 3925
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
40
Existing Infrastructure
Infrastructure available such as Administrative Building, Water Reservoir and Water
Pump house, Workshop Building, Water Storage Reservoir, etc. have already been
provided in the existing plant.
Facilities for Drinking Water, Rest Room, Toilets, Medical Unit, etc. already
installed. No additional facilities are required.
Environmental Considerations of the Steel Melting Shop
Pollution Control System
The shop is made 100% pollution free by installing state of the art Suction Hood to
individual furnace connected to high capacity suction blower. The system is further
being connected to bag filter, followed by screw conveyor and a stack of required
height.
The plant is further equipped with Natural Draft Exhaust Fans attached to shed for
remaining fumes to atmosphere. It is further to confirm that as the major raw material
is the Sponge iron which never emits any dust or smoke, it just emits heat.
Regarding Water pollution, as all the water circuits are closed loop system no water
effluents are being blown outside the premises. There is no adverse impact on either
air or water quality in and around the plant site on account of installation of the
proposed plant.
The outlet dust concentration is limited to 35 mg/Nm3 through suitable design of the
bag house. Fugitive emission from the LRF is collected using suitable fume extraction
system, connected to bag filter. The shed of casting shop is provided with sufficient
height. Ventilation system at skylight disperses uncollected emissions outside the
shed and maintains clean work environment.
The various noise generating sources in the SMS are feeding systems, casting,
transfer, lifting and placement of steel products. The operations are confined within a
covered shed with skirt boards, which prevents excessive noise from coming outside
the shed and the same is controlled at the desired levels,
The generated solid waste is not a hazardous waste; hence it can be easily disposed to
ground filling & road leveling after recovery of metal.
The measures to control the air pollution are being ensured as per the ambient air
quality standards laid down by Central Pollution Control Board for industrial areas.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
41
Solid Waste Management
Existing & Proposed
Solid Waste
generation
Existing
Quantity for
4.00 lac
(TPA)
Proposed
Quantity For 5.50
lac (TPA) –
Post-expansion
Method of Disposal
Slag
93,235
1,26,500
Slag is about 22% of billet
capacity. The same is being
reprocessed through crushing
and magnetic separation plant,
where about 8 to 10% of slag
is being recovered as low
grade sponge iron and reused
in the steel melting shop. Part
of the slag is used for land
filling.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
42
Chapter – 8
Project Description & Manufacturing Process
POWER PLANT
Change in configuration of existing 3 TG Sets {(9 MW + 9 MW + 30 MW) + 10
MW(standby)} with one new energy efficient TG set of 48 MW capacity in the existing
Power Plant
The existing TG sets of 3 TG Sets [TG-1 : 9 MW, TG-2 : 9 MW, TG-4 : 30 MW] with total
power generation capacity of 48 MW will be replaced by a single Energy Efficient TG set of
48 MW without change in power generation capacity. The process will remain same.
Reasons for Modernization
The change in configuration of existing TG capacity by installation of one new energy
efficient TG set should be viewed as modernization which replaces the existing 4 TG sets
with a new TG set of 48 MW.
This innovative measure of augmenting the capacity of the plant is primarily aimed at
improving the thermal efficiency of the plant as a whole resulting into reduction of heat rate.
Godawari Power and Ispat Ltd. is a designated consumer with Registration No. INS0032CG
with Bureau of Energy Efficiency (BEE) of Ministry of Power which has set a target of
reducing the Specific Energy Consumption by 5% in the present PAT cycle.
In the next PAT cycle, the company has to perform better to meet the more stringent targets
and hence to become more energy efficient.
As the company has covered most of the energy efficiency measures during PAT Cycle-1, to
meet the stipulated target by BEE, the proposed measure of switching over to a new energy
efficient 48 MW TG set by replacing the existing ageing 4 TG sets will go a long way in
achieving this target.
The reduction of heat rate from 3890 Kcal/Kwh to 3440 Kcal/Kwh through this measure will
amount to enhancing the energy efficiency over 10%, which will comfortably meet the target
imposed by BEE towards the reduction of specific energy consumption.
Manufacturing Process
Steam Power Plant
A steam power plant continuously converts the energy stored in fossil fuels (coal, oil,
natural gas) or hot gases into shaft work and ultimately into electricity. The working fluid is
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
43
water, which is sometime in liquid phase and sometimes in vapour phase, during its cycle
of operation. Power Plant as a bulk energy converter from fuel to electricity using water is a
working medium. Energy released by the burning of fuel is transferred to water in the
BOILER (B) to generate steam at a high pressure and temperature, which then expands in
the TURBINE (T) to a low pressure to produce shaft work. The steam leaving the turbine is
condensed into water in the CONDENSOR (C) where cooling water from cooling tower
carry away the heat released during condensation. The PUMP (P) then feeds the water
(condensate) back to the boiler, and the cycle goes on repeating itself. The working
substance water thus follows along B-T-C-P path of the cycle interacting externally. Since
the fluid is undergoing a cyclic process, there is no net change in its internal energy over
the cycle and consequently, the net energy transferred to the unit mass of fluid, as heat
during the cycle must equal the net energy transfer as work from the fluid.
WHR - The boiler is single drum, natural circulation, balanced draft, water tube and
membrane well type construction. It is a three pass WHR for recovering heat gases coming
from the sponge iron kiln at a temperature of in between 950 to 1050 deg. C.
The first pass is made up of water cooled membrane walls in view of high temperature of
flue gases which enables recovery of radiation heat component in addition to convection
component of heat transfer. The particles carried by the flue gases also add to the non-
luminous radiation heat transfer thus increasing the over all heat transfer. The flue gas
temperature reduces by about 200-250 deg. C in the first pass and enters the second pass of
WHRSG. In the second pass, the super heater coils and flag type Evaporator I bundle are
arranged. Finally the fuel gases pass through the third pass, which is made up of un-cooled
walls/steel casing and contains Evaporator II Bundle along with economizer bundles.
The upper headers of the membrane walls and the evaporator bundles I & II is connected to
the steam drum by risers. Finally, flue gases flows to ESP and steam generates.
Boiler Feed Water System
The feed water from the deaerator is pumped to the steam drum thru an economizer by
multistage feed water pumps, of which two are working and one is standby. The
economizer recovers the heat from flue gases, thereby preheating the feed water before it
enters the steam drum.
Water Circulation
The water circulation system consist of three sections viz. Imbed coils, Conv. Bank Tubes
and Water walls. The conv. bank tubes have self-adjusting circulation pattern, with a few
tubes connected to the water space, serving as down comer tubes and the remaining
serving as riser tubes. A portion of the water circulated is evaporated and the steam water
mixture rises up into steam drum where steam is separated from water. Dry steam leaves
the steam drum, while the water mixes the incoming feed water for further circulation. The
In-bed coils and water walls receive water from water drum through down comers. The
steam water mixture, rising through water wall tubes, enters the steam-drum and the dry
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
44
saturated steam leaves the drum. The steam drum is provided with suitable internals for
steam-water separation.
Super Heater
The saturated steam from the steam drum enters the convective super heater location at
furnace water walls exit, is of pendant type arranged for counter flow. The heat from the
flue gases is transferred to the steam by convective process and the super heater is suitable
designed to achieve the rated steam temperature. The steam then enters the In-bed super
heater where it is finally super heated pressure.
Combustion Air
The air for efficient combustion of fuel is supplied by primary (FD) fan and secondary
(PA) fan both the fans are provided with Dampers (manual) to regulated the air supply
from the operating platform.
Flue Gases
Fuel gases leaving the combustor; transfer the heat by radiation to the water walls by non-
luminous radiation and convection to the super heater and economizer. The flue gases
leaving the super heater pass through the economizer, which act as heat recovery units. The
gas then flow to the APH and Electrostatic Precipitator (ESP). The ash is collected in the
hoppers provided underneath APH. The hoppers are provided with rotary air lock. One
number ID fan is provided in the flue gas stream, to produce necessary draft to maintain
the furnace under low negative pressure. ID fan inlet damper can be adjusted to maintain
the furnace draft at desired level from operating platform.
Steam Turbo Generator
The steam turbine is a primary mover, which continuously converts the energy of high
pressure high temperature steam supplied by a steam exhausted to a condenser. This
energy conversation essentially occurs in two steps:
1. The high pressure, high temperature steam first expends in the nozzles and comes out
at a high velocity.
2. The high velocity jets of steam coming out the nozzles impinge on the blades
mounted on a wheel, get deflected by an angle and suffer a loss of momentum which
is absorbed by the rotating wheel in producing torque.
Condensor
A condenser, where the exhaust steam from the turbine is condensed operates at pressure
lower than atmosphere. There are two objects using a condenser in steam plant :
1. To reduce the turbine exhaust pressure so as to increase the specific output of the
turbine. If circulating water temperature in a condenser is low enough, it creates a low
backpressure for the turbine. This pressure is equal to the saturation pressure
corresponding to the condensing steam temperature, which, in turn, is a function of the
cooling water temperature. It is know that the enthalpy drop or turbine work per unit
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
45
pressure drop is much greater at a low pressure than at the high-pressure end of a
turbine. A condenser by lowering the back pressure, thus increases the plant efficiency
and reduces the steam flow for a given output. The lower the pressure the greater is the
output & efficiency. Hence, it is important to use the lowest possible cooling water
temperature. This restricts the temperature rise of cooling water in the condenser tubes
so that the tube outer surface remains low and consequently, the condensing steam
temperature is low and vacuum is high.
2. To recover high quality feed water in the form of condensate and feed it backs to the
steam generator without any further treatment. As a result, only the make-up water, to
replenish the water losses in the cyclic plants needs to be treated.
Circulating Water System
The circulating water system supplies cooling water to the turbine condenser and thus acts
as a medium through which heat is rejected from the steam cycle to the environment.
In closed loop system, warm water from the condenser is passing through a cooling device -
a cooling tower, the cooled tower, and the cooled water is than pumped back for condenser
circulation. However, a natural body of water is still necessary nearby to supply the make-
up water to replace the loss due to evaporation, blow down and so on.
Feed Water System
Condensate collected in the condenser, pumped in the deaerator through regenerative
system.
Deaerator
It is used for the purpose of deaerating the feed water. The presence of dissolved gases like
oxygen and carbon-di-oxide in water makes the water corrosive, as they react with the
metal to form Iron-oxide. The solubility of these gases in water decreases with increase in
temperature and becomes zero at the boiling or saturation temperature. These gases are
removed in the deaerator. Where feed water is heated to the saturation temperature by the
steam extracted from the turbine. Feed water after passing through a heat exchanger –
called vent condenser, is sprayed from the top so as to expose large surface area, and the
bled steam from the turbine is fed from the bottom. By contact, the steam condenses and
the feed water is heated to the saturation temperature. Dissolved oxygen and carbon-dioxide
gases get released from the water and leave along with some vapour, which is condensed
back in the vent condenser, and the gases are vented out. To neutralize the effect of residual
dissolved oxygen and carbon-di-oxide gases in water, sodium sulphite (Na2503) or
hydrazine (N2H4) is injected in suitable calculated doses into the feed water at the suction
of the boiler feed pump (BFP).
Boiler Feed Pump
Feed water after deaeration, transferred to the boiler by boiler feed water pump pressure.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
46
Advantages on installation of new Energy Efficient 48 MW TG Set in place of existing
4 Nos. TG Sets :
1) Water Conservation - About 412000 m3 water /year will be saved after installation of
48 mw Siemens turbine. Due to lower specific steam consumption of 4.15 ton
steam/mw there will be decrease in raw water consumption of plant as our old turbines
are having average specific steam consumption of 4.9 ton steam/mw, saving of about
412000 m3 of water per annum.
2) Saving of demineralised water- About 12000m3 of water/year will be saved after
installation of 48 mw Siemens turbine and will ultimately result in monetary saving.
3) Saving due to reduction of auxiliary power-we will save about 5424000 kwh/year
due to reduction in aux power above saving of auxiliary power will be achieved as we
will be having only one (1) boiler feed pump operative against presently operated four
(4) bfp.
- we will be having only one (1) condensate extraction pump operative against
presently operated three (3) CEP pumps.
- we will be having only one deareator charged against presently charged three
deareators by installation of single deareator we will be able to achieve more deareator
temperature as compared to split deareator.
- we will save steam for hogger ejector as we will be charging only single ejector
against three ejectors after installation of 48 mw single turbine.
4) Ease of plant operation
Single turbine instead of four numbers of turbine reduce the complexity of plant
operational parameters & reduce plant equipments tripping. Bleed charging availability
is for all time. It will reduce the chances of malfunctioning as well the required less
spare items. During any change in load there are no chances of load shifting from one
turbine to another turbine.
Godawari Power & Ispat Ltd. Pre
The present scenario of Captive Power generation is as under :
Boiler MCR
Boiler Steam
Generation
(MCR)
Scheme-1 with
common
header
WHRB-1
WHRB-2
AFBC-1
AFBC-2
Scheme-2 with
common
header
WHRB-3
WHRB-4
Captive Power Plant
Existing Process Flow Diagram of Power Plant
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
47
The present scenario of Captive Power generation is as under :
Boiler Steam
Generation Existing
TG Sets
Total Generation
Capacity
TG-1 (9 MW) 7 MW
TG-2 (9 MW) 10 MW
TG-3 (10 MW)
Standby 11 MW
TG-4 (30 MW) 20 MW
48 MW
TG-5 (25MW) 12.5MW
12.5MW
25MW
Grand Total 73MW
Existing Process Flow Diagram of Power Plant
odernization Programme
Total Generation
Capacity
Average
Designed
Heat Rate
Kcal/Kwh
3890
3890
3168
3168
Godawari Power & Ispat Ltd. Pre
Proposed scenario of power generation :
Boiler
MCR
Boiler Steam
Generation (MCR)
Scheme-1
with
common
header
WHRB-1
WHRB-2
AFBC-1
AFBC-2
Scheme-2
with
common
header
WHRB-3
WHRB-4
Captive Power Plant
Proposed Modification in process Flow Diagram of Power Plant after installation of
48 MW TG Set
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
48
Proposed scenario of power generation :
Boiler Steam
Generation (MCR)
Proposed
TG Sets
Total Generation
Capacity
48 MW New
Energy Efficient
TG Set
7 MW
10 MW
11 MW
20 MW
48 MW
TG-5 (25MW)
(No Change)
12.5MW
12.5MW
25MW
Grand Total 73MW
Proposed Modification in process Flow Diagram of Power Plant after installation of
odernization Programme
Average
Designed
Heat Rate
Kcal/Kwh
3440
3440
3168
3168
Proposed Modification in process Flow Diagram of Power Plant after installation of
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
49
This change in configuration will result in saving due to saving of water, reduction in
auxiliary power consumption and reduction in maintenance cost with no change in pollution
load. There will be no change in boiler steam generation; rather heat rate will be reduced.
Plant, Machinery & Equipments of Power Plant
Major Plant & Machinery proposed to be installed for new 48 MW TG Set
- Turbine, Boiler Feed System
- Deaerator System
- Steam Piping
- Auxiliary Cooling Water system, Cooling Water Pump with piping
- GRP, GCP & Synch. Panel
- HT Breaker
- GT Transformer for TG
- HT, LT & Control Cables
- AC for Control & MCC Room
Utilities
Existing & Proposed Raw Materials / Fuel
There will be no change in raw materials / fuel feed
Input Raw Materials / Fuel Average
Consumption
(TPA)
Source
Coal 113225 Coal Linkage / auction
Dolochar 2678 Generation from own Sponge
Iron Division
Rice Husk 167111 Purchase from Private Parties /
Open market
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
50
Water requirement -
Availability of water
The company has already existing reservoir and water is sourced from Chhattisgarh
Ispat Bhoomi Limited, the nodal agency for supply of water to the industrial areas.
The company had entered into an agreement for 10,000 KL/day water by Chhattisgarh
Ispat Bhoomi Limited for industrial / domestic use in its integrated steel facilities.
The overall water consumption for the total integrated steel facilities of the company
is about 8000 KL/Day.
Power requirement –
The power requirement for auxiliary consumption is met from existing captive power
generation sources.
Existing 4.1 MW
After modification 3.5 MW
Other Utilities
Due to a number of moving equipments, oil / lubricants are required at various stages
of the process; the consumption of the same will be reduced.
Existing Infrastructure
Infrastructure available such as Administrative Building, Water Reservoir and Water
Pump house, Workshop Building, Water Storage Reservoir, etc. have already been
provided in the existing plant.
Facilities for Drinking Water, Rest Room, Toilets, Medical Unit, etc. already
installed. No additional facilities are required.
Existing
Proposed
After
installation of
48 MW TG Set
Water circulation 12900 11760 M3/HR
Water evaporation loss 178 162 M3/HR
Blow down 30 27 M3/HR
Water consumption at turbine end 4.3 3.4 M3/MW
Specific water consumption after
installation of 48 MW TG Set
3.4 M3/MW
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
51
Environmental Considerations of the Power Plant
Pollution Control Measures
Being an integrated project, the gases generated from Sponge Iron project are re-used to
generate electricity. The fuel for AFBC power plant is Coal and Rice Husk. The following
pollution control measures are installed :
- At all the points, Dust Collectors are installed.
- Water sprinkling is done regularly to control the fugitive emissions.
- The waste gases are fed in the Waste Heat Recovery Boiler wherein Electro Static
Precipitator is installed.
- For handling of Ash – Ash Handling system is installed & the ash is being used as
Waste for land leveling, supply to brick manufacturers.
- All roads are concretized.
- All conveyor systems are covered.
The measures to control the air pollution are being ensured as per the ambient air quality
standards laid down by Central Pollution Control Board for industrial areas.
Solid Waste Management
Solid Waste generation
Quantity
(TPA)
Method of Disposal
Fly Ash (AFBC) 85071.20 Land filling / leveling and
supply to brick manufacturing
units/ cement plants
Pollution monitoring
GPIL is carrying out continuous monitoring of ambient air quality and stack emission
within and outside the Plant premises regularly and the data is being submitted to
CECB on regular basis.
4 Nos. Continuous ambient air quality monitoring stations have been established for
measurement of PM, SO2, NOx, CO etc.
Pollution Control Equipments of Power Plant
Sl. No. Location
Name of Pollution Control
Device Capacity
1 AFBC # 70 TPH ESP 137800 M3/Hr.
2 AFBC # 100 TPH ESP 187560 M3/Hr.
3 100 TPH BUNKER BAG FILTER 8500 M3/Hr.
4 DAY BIN HOPPER BAG FILTER 12500 M3/Hr.
5 U.G. TUNNEL BAG FILTER 16500 M3/Hr.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
52
Stack details of Power Plant
Stack
No.
Stack attached with
Height
(Meter)
Diameter
(Meter)
1 Kiln -01 (WHRB-01) + AFBC 70 TPH 74 2.2
2 Kiln - 02 (WHRB-02) + AFBC 100 TPH 74 4.2
3 Kiln-03 + Kiln-04 (WHRB-03 + WHRB-04) 74 4.2
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
53
Chapter - 9
ENVIRONMENT & GREEN BELT
Environmental Management Cell
An environmental monitoring and control cell is established. The Environmental Cell is
functioning under the control of the General Manager Mr. Mansoor Ali along with the
EMS team of the company to monitor the environmental measures.
The cell is responsible for monitoring ambient air quality, stack emission, ambient noise in
the plant and vicinity, wastewater quality and discharge, quality of water bodies receiving
effluent, workplace air quality, occupational safety and health, and maintenance of
analytical instruments. Additional responsibilities of the cell include the following:
� Conducting annual environmental audit and submit audit report to State
pollution Control Board (SPCB);
� Submit environmental monitoring report to SPCB;
� Conduct regular training programs to educate plant personnel on safety
practices to be followed in the plant;
� Conduct safety and health audits to ensure that recommended safety and
health measures are being followed; and
� Inform the management regularly about conclusions/results of monitoring and
recommend environmental protection measures.
Environmental Laboratory
To deal with environmental issues, a well-equipped laboratory has been established in
GPIL where various environmental samples have been analyzed by qualified Analysts.
The Laboratory has all the facilities required by today’s hard and fast analysis results
related to Physical, Chemical and Biological investigations. EMS laboratory has a facility
of instruments which makes the analysis and interpretation easier, these includes
Spectrophotometers, Digesters, Ovens, Sterilizers, Distillation units, HVS, RDS, Stack
Monitors, On-line dust/gas measurements, etc.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
54
Rain Water Harvesting System
SN LOCATION NO. OF TRENCHES/ WELLS
CAPACITY
TRENCHES 1 Near Reservoir Phase -I 1 Length X Depth X Width =
7m X 2m X 2m = 28m3 (each) i.e. total 112 m3. 2 Power plant, Phase - II 1
3 SID, Phase - II 1
4 6.00 lac TPA Pellet Plant 1
TOTAL 4
RECHARGE WELLS 1 ADM area 1 Dia X Depth = 0.6 m2 X 2 m =
1.2 m3 (each) i.e. total 13.2 m3 2 Power Plant, Phase - I 2
3 Power Plant, Phase - II 1
4 Near Equipment Division
1
5 Temple Garden 2
6 SMS Area 1
7 Pellet 6.00 lac TPA area
2
8 SID Phase - II area 1
TOTAL 11
Note: Four nos. of recharge trenches, 11 nos. of recharge wells and one no.
recharge pit has been established for rain water harvesting having capacity to
recharge about 200000 Ltr. water per year. Two nos. of reservoirs exists for
surface water harvesting. The details of reservoirs as under :
RESERVOIR -1 (CIRCULAR)
Capacity of reservoir 23175 CU.MTR
Depth 4.5 MTR
Dia 81 MTR
RESERVOIR -2
Capacity of reservoir 36809.158 CU.MTR
Top Length 107.072 MTR
TOP Width 67.072 MTR
Bottom Length 82.824 MTR
Bottom Width 42.824 MTR
Total Height 7 MTR
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
55
Plantation & Green belt
Adequate green belt is provided all around the plant premises. Locally available types
of trees as specified by the Chhattisgarh Environment Conservation Board have been
planted, which are resistant to pollutants are planted. The total area brought under the
greenbelt in the existing industrial complex of GPIL is 33.190 ha. GPIL has already
planted about 73500 numbers of trees in the premises and proposed to plant around
8600 plants. This includes gap filling of trees at various locations of the plant.
Every year tree plantation is undertaken in a planned manner on a massive scale. Most
of them including species having capability of pollution control and some of them are
capable to survive in high saline conditions & low fertile soil. Soil management is
also the part of us for better use of soil within the plant premises and out-sides as well.
Extensive Plantation & grassing has been carried out to check the erosion from
various plant activities. We have done mass outside plantation under various schemes
such as Vriksh-Mitra Abhiyan & Hariyar-Chhattisgarh.
Major tree species planted inside the plant premises :
S.
No.
Common name Scientific Name Saplings
planted
1. Neem Azadirachta indica, 1500
2. Amaltash Cassia fistula, 1200
3. Gulmohar Delonix regia, 6000
4. Sissoo Dalbergia sissoo 4000
5. Pipal Ficus religiosa, 150
6. Bargad Ficus bengalensis 150
7. Su-babool Laucaenea leucocephala 25000
8. Kadam Anthocephalus cadamba 1500
9. Jamun Psidium guyava 2500
10. Khamhar Gmelina arborea 1200
11. Karanj Pongamia pinnata 2500
12. Ashok Saraca indica 3500
13. Mangium Acacia mangium 2500
14. Other species like Peltaform, Kala shirish, Acacia, Casia
samea, Mini Gulmohar, Arjun, Mahogani, Erithrina,
Bakayan, Nilgiri, Paras pipal, Allestonia, Aonla, Mango,etc
21739
Total 73539
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
56
Year-wise Plantation Details of GPIL (Inside & Outside Premises)
YEAR
TOTAL
LAND
AREA
GPIL
TOTAL INSIDE AREA
COVERED
(Acre)
ROAD
SIDE/
OUT SIDE
AREA
COVERED
2006-07 213.657
Acre
7000 7.00 1000 1 KM 8000
2007-08 1166 1.16 3000 3 KM 4166
2008-09 4813 4.81 4000 4 KM 8813
2009-10 12761 12.76 7000 7 KM 19761
2010-11 9460 9.46 1000 1 KM 10460
2011-12 11229 11.22 23000 23 KM 34229
2012-13 3150 3.15 11000 11 KM 14150
2013-14 10474 10.47 14000 14 KM 24474
2014-15 4511 4.51 9000 9 KM 13511
2015-16 5475 5.47 20000
Siltara
60 ACRE 25475
2016-17 3400 3.40 17000
Siltara
40 ACRE 20400
2017-18 800 Gap filling 7000
CSIDC land
Siltara
13 Acre 7800
TOTAL 74239
Nos.
73.41 117000
Nos.
191239
Nos.
34.35 % ACRE
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
57
Photographs of Existing Plantation at GPIL
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
58
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
59
Chapter - 10
Occupational Health
GPIL is following guidelines provided by the Directorate of Industrial Health and Safety
and Labour Ministry of State which is amended time to time as directed by the authority.
GPIL has functional 24 x 7 Occupational health centre with full time factory medical
officer. Three Clinic Attendants who work in shift duties and a ward boy.
Functions of the Health Centre is :
� All the employees are examined by factory medical officer for occupational diseases
every year.
� GPIL Ensures Medical fitness of all the new employees through (Form 32) Pre
Employment Medical Examination by factory medical officer as directed by
Directorate of Industrial Health and Safety.
� GPIL maintain Health register Form 21 of all the employees working in our company
with periodical medical check-up every year.
� GPIL takes specialists services for conducting ophthalmological examination and
Pure Tone Audiometry of our employees every year. In the year 2014
ophthalmological examination of approx. 350 employees was conducted and 172
were found to have refractive errors which was corrected by giving glasses to the
employees. Similarly pure tone audiometry of 40 employees was done and 3 were
found to have NIHL report of the same was sent to directorate and further treatment
of the employees was done.
� Every 3 year X-Ray of the employees is been done. In the year 2013 X-Ray
examination of 800 employees was done and in year 2014 X-Ray examination of
1000 employees was done.
� Spirometric examination (Pulmonary function test) is done every year. In the year
2013 pulmonary function test of 232 employees was done. In the year 2014
spirometric examination of 328 employees has been done.
Facilities available at Health Centre are -
� GPIL have facility for conducting pulmonary function test , Blood sugar monitoring
and ECG for cardiac evaluation of employees at our occupational health center.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
60
� GPIL have one medium size autoclave machine for sterilization of surgical
equipments and other consumables.
� GPIL have all kind of Primary medications available in our occupational health
center like Antibiotics, Anti-inflammatory, Antacids Anti pyretic, Anti cold and
others .
� GPIL have all kind of life saving medications available in our occupational health
center including anti snake venom for any such emergency.
� All kinds of Splints and Traumatic Aids are available to give primary treatment to
trauma patients.
� GPIL have all kind of surgical equipment required for wound repair and minor
incision and drainage surgeries.
� GPIL have Two Nos. of ambulances with first aid box and 6 oxygen cylinder in each
for prompt transport to a tertiary health center as and when required.
� We have 88 First aid boxes allocated inside the plant with all the basic medication
and dressings as per the factory act.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
61
Chapter - 11
Socio-Economic Development
Godawari Power & Ispat Ltd. has been actively supporting social causes for a very
long time. The company strives to integrate social value within its daily business
decision-making process with an aim to achieve positive and sustainable outcomes
towards business, environment and the society at large. Apart from the various CSR
activities, the company has taken the social initiatives towards conservation of
environment, improvement of the social status of people in Chhattisgarh,
contributions to relief funds, etc.
Under Corporate Social Responsibility (CSR) the needs of the nearby villages and
surrounding area is being periodically addressed and GPIL is committed to further
identify and continue the same in future.
Godawari Power & Ispat Ltd. is already executing various CSR activities in following
fields.
Education a) Developing various government schools by building them further according to
need.
b) Rewarding meritorious students of Government schools to boost their morale.
c) Sponsoring the education of a lot of needy children.
d) Encouraging under privileged girls from rural communities around its operational
areas to study.
e) Organizing seminars and workshops for imparting technical education involving
soft skills especially for the people of remote regions.
f) Sponsoring salaries of the teachers teaching in rural areas in order to keep them
motivated to impart quality learning skills.
g) Providing various facilities to the schools such as furniture and computers in rural
areas.
Health a) Health Camps organized at GPIL for worker and employees- Blood donation
camp, Eye Check Camp, Hemoglobin & General Check-up, BDM Test
(Osteoporosis), Diabetes Detection Camp, Lung Function Test by Spirometer.
b) Organizing pulse polio camps in the communities near its areas of operation.
c) Provision of free medicines for the people of rural areas.
d) Providing financial aid to the patients who cannot afford the treatment for their
chronic diseases.
e) Financial assistance to Gram Panchayat, Siltara for purchasing Ambulance.
f) 5 Tri-cycle donated to for the Handicapped to CG Pichhda Varg Parishad.
g) Financial assistance to MIKKI Memorial Trust for MGM Eye Institute.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
62
h) Sponsorship of Mobile Medical Unit (MMU Van) for Helpage India. Weekly
deployment of MMU Van with Doctor and Free Medicines in nearby villages of
GPIL.
Infrastructural Development a) Maintenance of rural roads and arrangement of safe drinking water.
b) Construction of bore wells to deal with water crisis.
c) Financial aid to rural communities for their social and cultural enhancement.
d) Provision of sewing machines, clothes, chairs and ceiling fans to the needy
people.
e) Community enrichment activities such as construction of approach roads and
supporting the cultural activities by building stages etc.
Environment Conservation • 45000 plantations done under “VRIKSHA MITRA MAHAABHIYAN-2008”
• 5 kms. Plantation done near Radiant Public School, Champaran Road, Raipur.
• Plantations done in 2009-10 inside & outside the premise of GPIL, and nearby
villages of Tada & Siltara.
• 1500 plantations done at Yogshala, Siltara.
• 200 plantations at Sai Kripa Hospital, Siltara.
• 250 plantations at ITI Hathbandh.
• GPIL got 3rd
position in Open Plantation Award, 2009, given by Urla
Industrial Association.
• Further plantation is being done as per directives of State Government.
Sports • Sponsored to Mr. Satya Prakash Masih (D.F.O.), Raigarh for participation in
Asian Weight Lifting Championship held at Tashkent, Ujbekistan he won
GOLD & SILVER medal.
• Sponsored Ms. Sangeeta Rajgopalan for participation in World Badminton
Championship 2009 through C.G. Van Khel Kalyan Samiti.
• Sponsored Inter Dist. Sports Competition organized by J.L.H.S. School
Siltara.
• Sponsored Cricket tournament at Dharsiva & Bojiya
• One of the sponsors for innumerable sports events in the remote rural areas as
a form of recreation for the people and develop their skills.
• Financial assistance for Chhattisgarh State Cricket Sangh & Sports
Associations.
The expenditure on various CSR activities by the company for the last five years is :
Year Expenses (In Lac)
FY: 2013-14 147.61
FY: 2014-15 155.56
FY : 2015-16 160.94
FY : 2016-17 60.79
FY : 2017-18 119.57
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
63
Chapter - 12
Organization and Man power
GPIL is providing direct employment to more than 1500 workers. The local persons
have been given preference in employment as per the qualification and technical
competencies. Moreover, indirect employment through contractors is provided to
about 1200 workers. Necessary training has been given to the unemployed youths of
the nearby villages. Indirect employment opportunities have been created in the
periphery of the plant automatically as the project started operation in the region. The
manpower covers the top management, middle and junior level executives and other
supporting staff including workforce.
The above manpower is based on production technologies, type of requirement for
various units of the plant, level of mechanization and automation, the layout of the
plant, the number of operating shifts for the various plant units, etc. Some provisions
to accommodate, off and leave reserve requirement have been made.
In order to operate and maintain the plant facilities, including its technical general
administration needs, the manpower covers the top management, middle and junior
level executives and other supporting staff including workforce. The total manpower
of various divisions of the company are as under:
Sl.
No Name of unit Direct Indirect Total
1 Administration 330 135 465
2 Power 202 30 232
3 Pellet 331 295 626
4 SID 368 120 488
6 Ferro 43 40 83
7 Steel 213 360 573
8 Oxygen 20 25 45
9 Wire Drawing 35 100 135
10 Gasifier 97 50 147
11 Automobile 36 100 136
12 Engineering 40 20 60
Total:- 1715 1275 2990
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
64
Chapter - 13
Project Implementation Schedule
The Services of experienced consultants will be utilized for detailed planning,
preparation of techno-economic feasibility report and other associated activities.
Considering the existing expertise of the company, the company expects to adhere to
the schedule. However, the implementation of the proposed projects primarily will
depend upon statutory clearances including environmental clearances. If the
environmental clearance is taken as the zero date, then the implementation schedule
of installation & commissioning of the proposed facilities will be 12 to 18 months.
Godawari Power & Ispat Ltd. Pre-Feasibility Report - Expansion/ Modernization Programme
65
Chapter – 14
Project Cost
The present investment in the entire existing facilities is Rs.1724.11 Crores, for which
ECs were granted. There is no additional investment in Pellet expansion and
manufacture of Magnetite Powder.
Further approx. Rs. 75 Crores is proposed for the proposed expansion / modification
of SMS and Rs. 70 crores in the modernization of Power Plant for change of TG set.
Form - 1
for
Expansion / Modernization of existing facilities
of Godawari Power and Ispat Ltd.
for
Godawari Power & Ispat Ltd
428/2, Phase-I, Industrial Area,
Siltara, Raipur - 493111
FORM -1
APPLICATION FOR OBTAINING ENVIRONMENTAL CLEARANCE VIDE PARA
6 OF S.O.1533 OF MoEF NOTIFICATION DATED 14th
SEPTEMBER 2006
(I) Basic Information
Sl.
No.
Item Details
1 Name of the project Expansion / Modernization of existing
facilities of Godawari Power and Ispat Ltd.
2 Sl. No. of the schedule As per EIA Notification dated 14th
September 2006, the project activity falls
under Category ‘A’, S. No. 3 (a).
3 Proposed capacity / area / length/ tonnage
to be handled/ command area/ lease
area/number of wells to be drilled
1) Enhancement in production capacity of
Iron Ore Pellet Plant from existing 2.1
MTPA (2 units) with Coal Gasification
System to 2.3 MTPA with Coal
Gasification System.
2) Change in Product mix of Pelletization
plant to include manufacture of
Magnetite Powder / Heavy Media for
coal washeries (Capacity 2,00,000 TPA)
3) Modernization and enhancement in
production capacity of Steel Melting
Shop (Billets) from existing 4.00 lac
TPA to 5.50 lac TPA by change in
configuration of induction furnaces.
4) Modernization of existing power plant
by change in configuration of existing 3
TG Sets [TG-1 : 9 MW, TG-2 : 9 MW,
TG-4 : 30 MW (+1 standby)] with one
new energy efficient TG set of 48 MW
capacity in the existing Power Plant.
4 New/Expansion/Modernization Expansion / Modernization
5 Existing Capacity/Area etc. 1) Sponge Iron – 6,50,000 TPA
2) Steel Billet - 4,00,000 TPA
3) Power - 53 MW (AFBC/WHRB)
4) Ferro Alloys or Pig Iron - 16,500
TPA {TOR granted vide letter F. No.
J-11011/326/2005-IA-II(I) Dated
20th
July, 2017}
5) H.B. Wire - 1,00,000 TPA
6) O2 Generation - 12,00,000 NM3
7) N2 Generation - 45,00,000 NM3
8) Fly Ash Brick Plant - 165.00 lakh
Nos/Annum
Godawari Power & Ispat Limited Form -I
2
9) Iron Ore Beneficiation Plant -
10,00,000 TPA
10) Rolling Mill - 4,00,000 TPA
11) Arc Furnace - 5,000 TPA
12) Biomass Based Power Plant-20 MW
13) Iron Ore Pellet Plant of 2.1 MTPA
capacity (2 Units : Kiln-I of 0.6
MTPA & Kiln-II of 1.5 MTPA)
6 Category of the Project i.e. ‘A’ or ‘B’ As per EIA Notification dated 14th
September 2006, the project activity falls
under Category ‘A’
7 Does it attract the general condition? If
yes, please specify.
Yes, location of the plant is within 10 Km
of polluted area
8 Does it attract the specific condition? If
yes, please specify.
No, it does not attract the specific condition.
9 Location
Plot/Survey/Khasra No. 428/2, Phase-I, Industrial Area
Village Siltara
Tehsil Dharsiwa
District Raipur
State Chhattisgarh
10 Nearest railway station/ airport along with
distance in kms.
Railway Station : Mandhar (3 Kms.)
Airport : Mana, Raipur (30 Kms.)
11 Nearest Town, City, District Headquarters
along with distance in kms.
Raipur (20 Kms.)
12 Village Panchayats, Zilla Parishad,
Municipal Corporation, Local body
(complete postal addresses with telephone
nos. to be given)
Village Panchayats : Tada - Siltara
Zilla Parish]ad : Raipur
Municipal Corporation : Raipur
White House, Near Mahila Thana,
Chotapara, Raipur
13 Name of the Applicant M/s.Godawari Power & Ispat Limited
14 Registered Address 428/2, Phase-I, Industrial Area,
Siltara,
Raipur - 493111 (Chhattisgarh)
15 Address for Correspondence: Project Proponent
Name T. Bose
Designation (Owner/ Partner/ CEO) Head (Corporate Affairs)
Address Hira Arcade, First Floor, Pandri, Raipur,
Chhattisgarh
Pin Code 492001
E-mail [email protected]
Telephone No. 0771-4082000/ 4082001
Fax No. 0771-4057601
16 Details of Alternative Sites examined, if
any. Location of these sites should be
shown on a topo sheet
Not applicable as it is expansion /
modernization of existing units of the plant.
17 Interlinked Projects Sponge Iron 6,50,000 TPA
Ferro Alloys 16,500 TPA
Godawari Power & Ispat Limited Form -I
3
HB Wires 1,00,000 TPA
Oxygen Gas 12,00,000 m3 per Annum
Nitrogen Gas 45,00,000 M3 per Annum
Fly Ash Brick 1,65,00,000 nos per Annum
Iron Ore Mining 21,10,000 TPA
Iron Ore Beneficiation 10,00,000 TPA
(Under Commissioning Stage)
Rolling Mill 4,00,000 TPA
(Under Commissioning Stage)
18 Whether separate application of
interlinked project has been submitted?
Yes, Proposal submitted vide No.
IA/CG/IND/65739/2017 for Ferro Alloys
expansion for which TOR was granted vide
F. No. J-11011/326/2005-IA-II (I) dated
20/07/2017. Request to consider the present
proposal as amendment to the TOR granted.
19 If yes, date of submission 29/06/2017
20 If no, reason Already obtained EC for interlinked
projects.
21 Whether the proposal involves
approval/clearance under: if yes, details of
the same and their status to be given.
a) The forest (conservation) Act,
1980?
b) The Wildlife (protection) Act,
1972?
c) The C.R.Z Notification, 1991?
The proposal does not involve any
approval/clearance under any act as
mentioned in the condition.
No
No
No
22 Whether there is any Government
Order/Policy relevant/relating to the site?
No Government Order/Policy is issued
relevant for the project site.
23 Forest land involved (hectares) None.
24 Whether there is any litigation pending
against the project and/or land in which
the project is proposed to be set up?
a) Name of the Court
b) Case no.
c) Orders/directions of the Court, if
any and its relevance with the
proposed project
No
Godawari Power & Ispat Limited Form -I
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving
actions, which will cause physical changes in the locality (topography, land
use, changes in water bodies, etc.)
Sr. No.
Information/Checklist
confirmation
Yes/No
Details thereof (with approximate
quantities /rates, wherever possible) with
source of information data
1.1 Permanent or temporary change in
land use, land cover or topography
including increase in intensity of
land use (with respect to local
land use plan)
No The existing projects are established within
the premises of GPIL which is within
industrial area of CSIDC land. The land
use planning is done as per the regulation.
However, land cover has been improved
with increased green belt / cover by
additional plantation.
1.2 Clearance of existing land,
vegetation and buildings? No
Not applicable, as the proposed expansion/
modernization is within existing plant
premises
1.3 Creation of new land uses?
No
Not applicable, as the proposed expansion/
modernization is within existing plant
premises
1.4 Pre-construction investigations e.g.
bore houses, soil testing? No
Not applicable, as the proposed expansion/
modernization is within existing plant
premises
1.5 Construction works?
Yes
Replacing the existing induction furnaces
with new induction furnaces of SMS unit
1.6 Demolition works? Yes
Replacing the existing induction furnaces
with new induction furnaces of SMS unit
1.7 Temporary sites used for
construction works or housing of
construction workers? No
As the workers are coming form nearby
villages and accommodation for
supervisory construction staff is being
provided in the temporary accommodation
within plant premises.
1.8 Above ground buildings, structures
or earthworks including linear
structures, cut and fill or
excavations.
No
As the same is existing within the plant
premises, there is no change in topography,
land use etc.
1.9 Underground works including
mining or tunneling? No Not applicable
1.10 Reclamation works? No Not applicable
1.11 Dredging?
No Not applicable
1.12 Offshore structures? No Not applicable
Godawari Power & Ispat Limited Form -I
5
1.13 Production and manufacturing
processes?
Yes
1) Enhancement in production capacity of
Iron Ore Pellet Plant from existing 2.1
MTPA (2 units) with Coal Gasification
System to 2.3 MTPA with Coal
Gasification System without change in the
plant and machinery.
2) Change in Product mix of Pelletization
plant to include manufacture of Magnetite
Powder / Heavy Media for coal washeries
i.e. crushing and grinding the magnetite ore
to magnetite powder of capacity 2,00,000
TPA.
3) Modernization and enhancement in
production capacity of Steel Melting Shop
(Billets) from existing 4.00 lac TPA to 5.50
lac TPA by change in configuration of
induction furnaces.
4) Modernization of existing power plant
by change in configuration of existing 3
TG Sets [TG-1 : 9 MW, TG-2 : 9 MW,
TG-4 : 30 MW (+1 standby)] with one new
energy efficient TG set of 48 MW capacity
in the existing Power Plant.
Detailed Process Description and flowchart
are incorporated in the Pre-Feasibility
Report.
1.14 Facilities for storage of goods or
materials?
Yes
Adequate storage facilities for additional
raw materials are in place. The raw
materials are kept under covered storage
shed in each division of the plant.
1.15 Facilities for treatment or disposal
of solid waste or liquid effluents?
Yes
1) Pellet Plant :
Ash is being used for brick manufacturing
units.
Tar is internally consumed and re-burnt in
the process and a small quantity is being
sold to outside authorized parties.
2) Steel Plant
Slag will be reprocessed through crushing
and magnetic separation plant, about 8 to
10% of slag is being recovered as low
grade sponge iron and reused in the steel
melting shop. Part of the slag is used for
land filling.
3) Power Plant :
The generated solid waste i.e Fly Ash from
Godawari Power & Ispat Limited Form -I
6
the AFBC Boilers is being used for land
filling / leveling and supply to brick
manufacturing / cement units.
There is no effluent water from the process.
Domestic effluent if any is being taken to
effluent recycling system and reused in dust
suppression/green belt.
1.16 Facilities for long term housing of
operational workers? No Not applicable
1.17 New road, rail or sea traffic during
construction or operation? No
Not applicable, as this is expansion/
modernization of existing unit. The road
network is very well established in the
project area.
1.18 New road, rail, air waterborne or
other transport infrastructure
including new or altered routes and
stations, ports, airports etc?
No Not applicable
1.19 Closure or diversion of existing
transport routes or infrastructure
leading to changes in traffic
movements?
No Not applicable
1.20 New or diverted transmission
lines or pipelines? No Not applicable
1.21 Impoundment, damming,
culverting, realignment or other
changes to the hydrology of
watercourses or aquifers?
No Not applicable
1.22 Stream crossings? No Not applicable
1.23 Abstraction or transfers of water
form ground or surface waters? No Not applicable
1.24 Changes in water bodies or the land
surface affecting drainage or run-
off?
No
As the proposed expansion/modernization
activity is within existing plant premises so
there is no change in water body and land
surface affecting drainage or runoff. The
existing plant premises has already
established time tested drainage or runoff
system.
1.25 Transport of personnel or materials
for construction, operation or
decommissioning?
Yes
Transport of personnel or materials for
operation is being done by well established
transportation network.
1.26 Long-term dismantling or
decommissioning or restoration
works?
No Not applicable
1.27 Ongoing activity during
decommissioning which could have
an impact on the environment?
No Not applicable
1.28 Influx of people to an area in either
temporarily or permanently? Yes
Influx of people as marginal and temporary
workers/labours is seen and provided
employment in the area.
Godawari Power & Ispat Limited Form -I
7
1.29 Introduction of alien species? No Not applicable
1.30 Loss of native species or genetic
diversity? No Not applicable
1.31 Any other actions?
No Not applicable
2. Use of Natural resources for construction or operation of the Project (such as land,
water, materials or energy, especially any resources which are non-renewable or in
short supply):
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates, wherever
possible) with source of information data
2.1 Land especially undeveloped or
agricultural land (ha) No
Not applicable, as the operational projects
are within CSIDC land/free hold land. No
additional land is required.
2.2 Water (expected source and
competing users) unit: MGD
Yes
1) Pellet Plant & Gasification System
Proposed - 1498 KL/Day (After expansion)
2) Magnetite Powder
Proposed - 60 KL/Day
3) SMS (After Expansion) : 3925 KLD
4) Power Plant
Proposed - 11760 KL/Day (After
modernization - reduction of 1140 KL/day)
Source : Chhattisgarh Ispat Bhoomi Ltd.
(Sanctioned allotment of water is 10,000
KL/Day)
2.3 Minerals (MT)
Yes
1) Pellet Plant (After expansion)
Iron Ore Fines – 23,92,000 TPA
Bentonite/Binder – 23,000 TPA
Lime Stone/Dolomite – 36,800 TPA
Coal/Coke/Pet Coke for Gasifiers –
2,86,364 TPA
2) Magnetite Powder (Proposed)
Magnetite Ore – 2,00,000 TPA
3) Steel Plant
Sponge Iron - 5,99,500 TPA
Scrap – 71,500 TPA
Flux – 5,500 TPA
Silico Manganese (Ferro) – 5,500 TPA
4) Power Plant (After modernization)
There will be no change in the existing &
proposed raw materials / fuel.
The average consumption of Raw
materials/ Fuel is :
Coal - 1,13,225 TPA
Dolochar - 2,678 TPA
Rice Husk - 1,67,111 TPA
Godawari Power & Ispat Limited Form -I
8
2.4 Construction material – stone,
aggregates, sand / soil (expected
source – MT)
No
Not applicable, as the proposed expansion /
modernization is within the respective
existing plants
2.5 Forests and timber (source – MT) No Not applicable
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel
(MT), energy (MW)
Yes
1) Pellet Plant (After expansion)
Electricity : 15 MW (No change)
HFO : 2300 KL/annum
2) Magnetite Powder
No additional power requirement as the
product will be manufactured within
existing pellet plant.
3) The power requirement for existing
SMS & proposed unit is 1000 Kwh/ton
Source : Existing captive generation
4) Power Plant Auxiliary consumption will
be 3.5 MW. At present it is 4.1 MW.
2.7 Any other natural resources (use
appropriate standard units) No Not applicable
3. Use, storage, transport, handling or production of substances or materials, which
could be harmful to human health or the environment or raise concerns about actual or
perceived risks to human health.
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates, wherever
possible) with source of information
data
3.1 Use of substances or materials, which
are hazardous (as per MSIHC rules) to
human health or the environment
(flora, fauna, and water supplies)
No Not applicable
3.2 Changes in occurrence of disease or
affect disease vectors (e.g. insect or
water borne diseases)
No Not applicable
3.3 Affect the welfare of people e.g. by
changing living conditions? Yes
Operation of the expanded units
significantly contributed to the social
upliftment of the people in the
surrounding area.
3.4 Vulnerable groups of people who
could be affected by the project e.g.
hospital patients, children, the elderly
etc.,
No Not applicable
3.5 Any other causes No Not applicable
Godawari Power & Ispat Limited Form -I
9
4. Production of solid wastes during construction or operation or decommissioning
(MT/month)
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with approximate
quantities /rates, wherever possible)
with source of information data
4.1 Soil, overburden or mine wastes No Not applicable
4.2 Municipal waste (domestic and or
commercial wastes)
Yes The source of domestic waste water is
only from the office toilets of the plant
are being completely disposed off into
the soak pit via septic tank. Now it is
proposed to provide Packaged Type STP.
4.3
Hazardous wastes (as per Hazardous
Waste Management Rules)
Yes The hazardous waste is Used oil
generated from all the units. Permission
for generation is granted by State
Pollution Control Board.
Permission has also been obtained for tar
and phenolic waste waster generation
from Gasification System of Pellet Plant.
4.4 Other industrial process wastes No Not applicable
4.5 Surplus product No Not applicable
4.6 Sewage sludge or other sludge from
effluent Treatment No Not applicable.
4.7 Construction or demolition wastes
No
Not applicable, as the proposed
expansion/modernization is within the
respective units, there is no construction
or demolition wastes.
4.8 Redundant machinery or equipment No Not applicable
4.9 Contaminated soils or other materials No Not applicable
4.10 Agricultural wastes No Not applicable
4.11 Other solid wastes No Not applicable.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates,
wherever possible) with source of
information data
5.1 Emissions from combustion of fossil
fuels from stationary or mobile
sources
Yes
The emission of gases (PM, SO2, NO2)
may be accounted due to project
activities, vehicles, etc. The vehicles are
being undergoing regular maintenance;
plant is having EPS, Bag Filters and
appropriate stack height as per the
guidelines of Central Pollution Control
Board (CPCB).
Godawari Power & Ispat Limited Form -I
10
Better maintenance of equipments and
proper mitigation measures helped us to
reduce and keep pollution level with in
the permissible limit.
5.2 Emissions from production processes
Yes
Emission from the entire process is being
reduced by means of proper
Environmental Pollution Control
measures such as bag filters, ESP, proper
stack height, adequate greenbelt
development, water sprinkling etc
5.3 Emissions from materials handling
including storage or transport Yes
Emission from handling of raw materials
and transportation is being minimized
through water sprinkling system.
5.4 Emissions from construction
activities including plant and
equipment
No
Not applicable, these are operational
plants.
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste
No
Not applicable, these are operational
plants.
5.6 Emissions from incineration of waste No Not applicable
5.7 Emissions from burning of waste in
open air (e.g. slash materials,
construction debris)
No Not applicable
5.8 Emissions from any other sources No Not applicable
6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates,
wherever possible) with source of
information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
No
During the operation of the plant, the
noise level is maintained at less than 75
dBA at the plant boundary. Necessary
protective measures have been taken to
minimize the noise level at every point.
6.2 From industrial or similar processes
Yes
There is noise generation due to the
running of the machinery. Proper
mitigation measures has been taken for
the reduction of noise levels, such as
provision of acoustic lagging for the
equipment and suction side silencers,
selection of low noise equipment, dense
greenbelt development, personal
protective equipment, maintenance of
vehicles etc.
6.3 From construction or demolition No Not applicable
6.4 From blasting or piling No Not applicable
6.5 From construction or operational No Not applicable
Godawari Power & Ispat Limited Form -I
11
traffic
6.6 From lighting or cooling systems No Not applicable
6.7 From any other sources No Not applicable
7. Risks of contamination of land or water from releases of pollutants into the ground or
into sewers, surface waters, groundwater, coastal waters or the sea:
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates,
wherever possible) with source of
information data
7.1 From handling, storage, use or
spillage of hazardous materials
No
The fuel is Heavy Furnace Oil which is
being stored and transported as per
stipulated norms. HFO is being brought
in road tankers and unloaded by means of
pumps. HFO is being supplied to Kiln
and Travel Grate of Pellet Plant.
Necessary unloading platform, pump
house, unloading header, pumps,
pipelines, etc. are provided.
Also due care has been taken during its
use for lubrication of external part of
equipment, that nothing falls on ground
to contaminate soil. The Tar generated
during gas cleaning is internally
consumed / re-burnt in the process and
part quantity is sold to outside authorized
industries.
7.2 From discharge of sewage or other
effluents to water or the land
(expected mode and place of
discharge)
No Not applicable
7.3 By deposition of pollutants emitted to
air into the land or into water No Zero waste discharge
7.4 From any other sources No Not applicable
7.5 Is there a risk of long term build up of
pollutants in the environment from
these sources?
No Not applicable
Godawari Power & Ispat Limited Form -I
12
8. Risk of accidents during construction or operation of the Project, which could
affect human health or the environment
Sl.No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates,
wherever possible) with source of
information data
8.1 From explosions, spillages, fires etc
from storage, handling, use or
production of hazardous substances
No Not applicable
8.2 From any other causes No Not applicable
8.3 Could the project be affected by
natural disasters causing
environmental damage (e.g. floods,
earthquakes, landslides, cloudburst
etc)?
No The project site falls in Seismic Zone –II.
9. Factors which should be considered (such as consequential development) which could
lead to environmental effects or the potential for cumulative impacts with other existing
or planned activities in the locality
Sl.
No
Information/checklist confirmation
Yes/No
Details thereof (with
approximate quantities /rates,
wherever possible) with source of
information data
9.1 Lead to development of supporting.
facilities, ancillary development or
development stimulated by the
project which could have impact on
the environment e.g.:
• Supporting infrastructure (roads,
power supply, waste or waste water
treatment, etc.)
• housing development
• extractive industries
• supply industries
• other
Yes
� Reinforcement of supporting
infrastructure- road, transport,
communication, drinking water,
sanitation etc.
� Development of housing infrastructure
due to increased income and
employment.
� Development ancillary industry to
support to plant requirements.
� Employment will increase as per the
requirement of workers for the project
and local people are being preferred.
This contributes in raising the socio-
economic status and standard of living
of the nearby villagers.
9.2 Lead to after-use of the site, which
could have an impact on the
environment
No
This is established unit, within a notified
industrial area and no other after-use is
envisaged.
9.3 Set a precedent for later
developments No Not applicable
9.4 Have cumulative effects due to No Not applicable
Godawari Power & Ispat Limited Form -I
13
proximity to other existing or planned
projects with similar effects
III Environmental Sensitivity
S.
No.
Areas
Name/
Identity
Aerial distance (within 15 km.) Proposed
project location boundary
1
Areas protected under international
conventions, national or local legislation
for their ecological, landscape, cultural or other related value
No None
2
Areas which are important or sensitive for
ecological reasons - Wetlands,
watercourses or other water bodies, coastal
zone, biospheres, mountains, forests
No Water Bodies:
Chhokra Nala : 5.0 km SE
Kharun River : 6.0 km NE
Kulhan Nala : 4.0 km NW
.
3
Areas used by protected, important
or sensitive species of flora or fauna for
breeding, nesting, foraging, resting,
over wintering, migration
No None
4
Inland, coastal, marine or
underground waters
No None
5 State, National boundaries No None
6
Routes or facilities used by the public for
access to recreation or other tourist,
pilgrim areas
No None
7 Defence installations No None
8 Densely populated or built-up area Yes Siltara – 1.5 Km (W)
9 Areas occupied by sensitive man-
made land uses (hospitals, schools,
places of worship, community facilities)
Yes Primary health centers and schools exist in 15
km radius area.
10 Areas containing important, high quality
or scarce resources (ground water
resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)
No None.
11 Areas already subjected to pollution
or environmental damage, (those where existing legal environmental
standards are exceeded)
Yes
Godawari Power & Ispat Limited Form -I
14
S.
No.
Areas
Name/
Identity
Aerial distance (within 15 km.) Proposed
project location boundary
12
Areas susceptible to natural hazard which
could cause the project to present
environmental problems
(earthquakes, subsidence, landslides,
erosion, flooding or extreme or adverse
climatic conditions)
No None
(IV) Proposed Terms of Reference for EIA studies
(1) Expansion of Pellet Plant -
a) Increase in production capacity of existing Pellet plant and
b) Change in Product Mix in Pellet Plant i.e. manufacture of Magnetite Powder
(2) Expansion & Modernization of existing Steel Melting Shop
(3) Modernization of existing Power Plant by change in configuration of TG set.
Standard Terms of Reference will be followed. It is requested to amend the TOR issued
vide Letter no. F. No. J-11011/326/2005-IA-II (I) dated 20/07/2017 by incorporating
the above 4 activities under consideration.
A combined EIA report will be prepared as per amended TOR for further consideration.