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FOR
(CAPACITY-2X1200 TPD)
VILLAGE: PARAGHAT
TEHSIL: MASTURI
DISTRICT: BILASPUR
CHHATTISGARH
SUBMITTED BY
1
INTRODUCTION
PROJECT AT A GLANCE
The Rashi Steel And Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari Halka
No. - 38 Village : Paraghat Tehsil - Masturi and DistrictBilaspur, in Chhattisgarh
State.
Tehsil : Masturi
2
Product & Production Capacity:
Land for Green Belt : 11.25 Acres (33%of total land area)
Raw Materials :
3
Water Requirement
(A) Source : From Bore well and River
(B) Annual Requirement : 1,32,000 KL per Annum (400.00 KLD)
(C) Rainwater harvesting : Will be provided to recharge the ground
water.
(A)Palletization Plant : Iron Ore Fine Dust: 343 TPD /1,13,256 TPA)
Reused in Palletization Plant
4
PROJECT COST
PARTICULARS AMOUNT IN
LACS
(i) Land & Site Development and 550.00
Infrastructure
MEANS OF FINANCE
PARTICULARS AMOUNT IN
LACS
(i) Share Capital 5160.00
(i i) Unsecured Loan 2640.00
(iii) Tearm Loan 7200.00
Grand-Total 15000.00
5
OVERVIEW OF THE COMPANY
Preamble: Steel a basic commodity for all industrial activities, quantum of its
consumption is considered an index of industrial prosperity. Since
independence, there has been a substantial growth in the steel sector in India
from 1.5 Million Tons in 1950-51 to about 31 Million Tons at present. Additional
Steel making capacity of about 8 to 10 Million TonsNear exists in the
secondary steel sector. Further, with nearly 20% of the world population,
India's contribution is only of the order of 3.4% of world steel production.
Hence, short term and long term strategies are necessary in planning the
development of the steel industry in the country to improve the level of per
capita steel consumption. It is expected that with the measures taken by Govt.
of India for promotion consumption of iron and steel and expected growth of
Indian economy the requirement of steel will significantly increase and
accordingly the domestic manufacturing capacity needs to be increase.
Considering the potential of iron and steel in India and the experience gained
by the group in this sector, M/s RASHI STEEL AND POWER LTD (RSPL) has
decided to install pallet plant in the state of Chhatisgarh.
Brief Profile: Promoters of the company belong from erudite families of Raipur.
The management of the company believes that "Successful operation,
performance and long term viability of any business depends on a continuous
sequence of sound decision made individually or collectively by the
management team. Everyone of this decisions ultimately causes for better or
worse, an economic impact on the business. In essence, the process
managing any enterprise amounts to making an on going series of economic
choices, every time trading off costs or benefits."
Shri Ashok Agrawal, S/o Late Gajanand Agrawal hails from an illustrious and
prominent family of Chhattisgarh. He is extremely hard working, dynamic and
intelligent businessman. Ashok Agrawal has gained business experience in
last 15 years and presently Director of many companies like Rukmani
Infrastructure Pvt. Ltd., Hotel ANS international Ltd. And also partners in Dadu
Buiders and Developers. Having sharpened his business acumen in the above
referred company, he is being taken in as promoter director in the new venture
of the family.
6
Mr. Rakesh Jindal, Promoter / Director
Mr. Agrawal, aged 47 years, is a B Com. Graduate. His business interest varies
from Ferro Alloys, Power, and Infrastructure to Logistics etc. He is the key
strategist for the new venture i.e. Integrated Steel Plant. He has extensively
traveled to USA, China & Middle East, Africa etc. He is known for his foresight
ness and resourcefulness. He is presently successfully running a 15 MW
thermal power plant at Raigarh (CG).
Mr. Gupta, aged 43 years is an Engineer- Mechanical has very vast experience
in Power and Steel Sector. He has good knowledge of the technology for
making steel through sponge iron. He has rendered his services in various
organizations in last 17 years. His last service with Scania Steel & Power Ltd.,
Raigarh as a General Manager, Technical & Production.
SL. NO. 1 2 3 4 5
DESIGNATION DIRECTOR DIRECTOR DIRECTOR DIRECTOR DIRECTOR
NAME MAHESH RAKESH ASHOK KUMAR AMAR ASHOK KUMAR
GUPTA JINDAL AGRAWAL AGRAWAL AGRAWAL
FATER NAME Lt. GIAN Lt. ANAND Lt. JAGMOHAN Shri Lt. GAJANAND
CHAND GUPTA SURUP DAS AGRAWAL SATYANARAYAN AGRAWAL
AGRAWAL
CITIZENSHIP INDIAN INDIAN INDIAN INDIAN INDIAN
PAN NO AFEPG0838D ACHPJ2881P ADLPA9437H ADPPA3753Q ACHPA9792L
PASSPORTNO J0219069 H5763011 G7859009 G1014283 G2258565
MOBILE NO 09993520981 07752-408405 07752-408405 07752-408405 07752-408405
EMAIL ID maheshgp70@ rakeshjindal88 bilaspur@mail. amar.rrenergy@ ashokkumaragrawal@
yahoo.co.in @gmail.com com gmail.com live.com
House No. 25, B-1 Jindal Piteshwar krishna vihar, House No. 10/45,
Ring Road No Nagar, Jindal P/34B, Jain dhimrapur Dabhra Road, Kharsia
2, Mahima Steel & Power Mandir Road chowk, 496661, Chhattisgarh
Vihar, Bilaspur Ltd. Kranti Nagar raigarh-496001 District: Raigarh (C.G.)
District: sh-63, Bilaspur, C.G. District: Raigarh
Bilaspur (C.G.) Chhendipada 495001 (C.G.)
Road, Nisa, District:
ADDRESS Jindal Nagar Bilaspur (C.G.)
Post Office,
Angul-759111
ADDRESS DETAILS
Corporate Office: Registered Office: Site Office:
M/s Rashi Steel and Power Ltd. M/s Rashi Steel and Power Ltd. M/s Rashi Steel and Power Ltd.
BF-1, First Floor, Rajiv Plaza A-184, First Floor, Meera Bagh Village: Paraghat/Beltukri
Opposite Axis Bank, New Delhi, 110087 Near Lilagar River Bridge,
Bilaspur C.G. 495001 Tehsil Masturi ,Post Off: Jairamnagar,
District: Bilaspur C.G.
a)
8
PROJECT DESCRIPTION
SITE LOCATION
The Rashi Steel and Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari Halka
No. - 38 Village: Paraghat Tehsil - Masturi and District - Bilaspur, in Chhattisgarh
State.
The project location is well connected by road and rail. The nearest railway station
is Bilaspur, which is at a distance of 22 km from the site. The nearest airport is
Raipur and sea port is Paradeep - Orissa.
There are no ecological sensitive places like national park, Sanctuary, biosphere
reserves, heritage site, archeological monuments, defense installation, health
resorts, scenic beauty, etc. around 10 kms of the site. There is no route of
migratory animals within the project site.
METEOROLOGICAL DATA
Maximum dry bulb temperature Minimum dry bulb temperature Design dry bulb
9
WIND AND SEISMIC DATA
DETAILS
The Rashi Steel And Power Limited is going for installation of 2xO.4 = 0.8 Million
TPA Palletization Plant, keeping in view the present demand of Steel Plant. The
proposed Steel plant of Rashi Steel And Power Limited is located at Patwari
Chhattisgarh State.
The proposed Steel Plant is at National Highway connecting Raipur, Bilaspur NH-
200. A connecting road from the plant site to the highway has been constructed
by State Govt.
I AREA in
S.NO. PARTICULARS
Acres
4 Parking 01.87
Rail
Project site is connected via S.E.C. Railway line between Raipur and
Rourkela, which is main line between Mumbai and Howrah.
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Airport
The nearest civilian airport is at Mana, Raipur, and the capital of
Chhattisgarh at about 120 Km from the plant site.
Our country has been progressing very fast requiring inter alias, high
production of steel. Steel plays a very important role in improving the economic
condition of any country. Thus, the project will improve the economic condition
of the country to a great extent.
JUSTIFICATION OF PROJECT
11
PELLETISATION PLANT (2 X 0.4 MilLION TPA CAPACITY)
INTRODUCTION
The proposed 2 x 0.4 Million TPA Pelletisation Plant will be established based
on the requirement of the raw material for the present established plant.
Considering the scenario in the state and projected requirement of MIs RSPl is
setting up of a 2 x 0.4 Million TPA pelletisation plant. Adequate land is available
for the project. For plant cooling, services and potable water requirement, the
source of water will be from ground water. Product of the proposed plant will be
sold to local market of Sponge Iron Plant and later on for self consumption in
the proposed plant.
M/s RSPL will be implementing the project through loan requirements from
financial institutions and internal accruals and investments from promoters. The
plant. will be executed through package wise system and unit is proposed to be
commissioned in 12 months from zero date.
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PROPOSED PROJECT: 0.8 (2 x 0.4) Million TPA Pelletisation Plant
A power station requires a number of basic inputs such as land, fuel, water
etc. for setting up of power station and is primarily governed by the following
basic considerations:
a) Availability of land
b) Rail/road accessibility
c) Availability of fuel and proximity to source
d) Availability of water and proximity to source
e) Load demand and proximity to the grid
f) Environmental consideration
g) Suitability of the land from topography and geological aspects These
factors have been found very favorable to establish and operate the
project.
Land selected for this project is coming under Paraghat village, Masturi -Block,
Bilaspur, CG. Required land is already in the possession of M/s Rashi Steel
And Power Limited. Nearest town is Masturi which is around 10 kms from the
project site. Nearest Railway station is Bilaspur which is around 22 kms from
the project site. Commercial Airport is Raipur and
nearest port is Vishakapattanam.
Availability of Land
Adequate land is available in project site. The site terrain is generally plain
requiring minimum efforts to grade them. The land is currently not in use and
there are no inhabitants requiring rehabilitation or resettlement. The topsoil is
clayey soil. Suitable foundation, based on soil investigation results, will be
adopted. Entire land is under the possession of the company.
13
Details of Land : 34.12 Acres Khasra No. and area is enclosed as issued by
revenue department.
a) Accessibility
b) Finished Product:
In Bilaspur area sponge Iron plant is situated about 25 km. radius from RSPl
plant site, which is at a distance of around 25 km by road. Finished product of
pelletisation plant will be utilized in the sponge iron division as raw material.
later on in own Sponge Iron plant which is under consideration.
c) Water Requirement
Requirement of raw water is estimated as 400 m3/day only. The required water
will be from surface water i.e. from near by River and ground water also.
d) Power Requirement
e) Environmental Consideration
The land for the proposed pelletisation plant site is already in possession of MIs
Rashi Steel And Power Limited. The site will be developed based on the
recommendations of the state environmental authorities, as well as the
guidelines of MOEF. Suitable provisions will be incorporated in the design of
buildings, structures, and selection of equipment so that there are no adverse
effects due to emissions, noise, and contamination of soil, water and air.
14
PELLETISATION PLANT (2 X 0.4 MILLION TPA CAPACITY)
(1) Drying and preheating roasting and cooling proceed in grate kiln and
annular cooler respectively so its equipment is sample and reliable and
product quality is even.
(2) The equipment of roasting system with high adaptability to raw material
can be individually controlled and flexibly regulated.
Main Workshop:
The main workshop of this pellet production line stockyard proportioning room
drying room damp mill room pelletizer room grate oven building (including
screening and distribution of green pellets), rotary kiln annular cooler air flow
system spillage return system (including spillage lifting) fuel preparation room.
15
Stockyard and Proportioning System
Drying Room:
This is a drum like structure of dimension 3x20 m for drying purpose.
Mixture of proportioned concentrate and bentonite is sent to drier drum for
the purpose of heating and drying with the help of flue gas with temperature
of 700°C supplied by a combustion furnace. After heating the end gas with
a temperature of 1200°C is discharged through the chimney. The initial
water content of the mixture is about 11.0% and after drying it comes to
7.0~8.0%.
The dried mixture is then discharged through a chute to a belt conveyer, and
then transported to damp grinding room. The drier has normal processing
capacity of 90 tons per hour.
Grinding Room:
In normal state, the dried blended mix is distributed to belt conveyor by disc
16
feeder and conveyed to a blended bin located at damp mill room by belt
conveyer. Then it is filled into the damp mill through a charging conveyer for
mixing, homogenizing and grinding. The grinded material is transferred to a
pallefizin9 belt and then to a blending bin at palletizer house.
Palletiser House:
Dimension of palletiser house covers 15x34.4 m2• The mixture is sent to upper
part of the pelletiser house by belt conveyor then separately discharged to three
bins with level gauges. Each blended mix bin has an effective content of 60 m3
under them tight type belt conveyor are laid respective to 36.0 m disk palletiser.
The speed of tight type belt conveyor can be regulated by a frequency variable
controller, and their speed is matched with that of disk palletizer. Each palletiser
has a production capacity of 50 T/hr. Generally during normal operation two
sets are in operation and the third one is on standby. During palletizing an
amount of water is added to the mixture so that it can have optimal water
content for palletizing. Green pellets from the palletizer are collected and
shipped to screening and distribution system through palletisation belt.
Grate oven
The plant building for grate oven covers 14 x 59 m2 and the effective width and
length of grate oven is respectively 2.8m and 36m, the depth of pellets
17
distribution on the grate oven bed is 120-180mm. The grate oven is divided into
four chambers from inside with whole preheating section I, II.
In this section circling hot air is at about 150°C. Mixed air is blast through pellet
bed, so that circulating hot air at dewatered and get dried. The main heat
source is wasting heat from section III of annular cooler. The air can be give out
directly a lot of steam and mini-dust.
Preheating section I
The hot air from annular cool section II connects the preheating section I by hot
air pipe. The lacking heat is supplies by hot air from preheating section II to get
the hot air temperature of 900°C.
h)
This preheats the pellet from the downdraft section. The wasting hot air is
collected by collecting main pipe in the side blast box and into
Preheating section II
In the preheating section II, pellets are further heated under hot air of 1100°C,
at the same time partially become hardened. These partial hardened pellets
can bear the impact of drifting-down from grate oven to rotary kiln, and will not
break during rotation of the kiln. Heat sources in this section comes from hot
flue of the kiln tail, end the lacking heat is supplied hood of the section, a flue
and a relief valve are fixed for the lacking heat is supplied hood of the section,
a flue or additional burner. Over the top part of furnace hood of the section, a
flue and a relief valve are fixed for baking furnaces and emergency operation.
18
Green pellets dried and preheated totally about 28 minutes, with enough
strength, are sent into the rotary kiln by way of a shovel and a chute at tail end
of the kiln.
Rotary kiln
The kiln is supported by 2 lintel girders. Compound precast bricks and high
strength heat insulation castable are resistance to wear and thermal insulation,
which can decrease temperature of the kiln's surface and extend its working
life.
The preheated pellets are loaded at feed end of rotary kiln by a shovel and
chute. A special designed collapsible spray gun is mounted at kiln discharge.
Combustion intensity and flame profile can be regulated by means of extension
and contraction of the collapsible spray gun as well as adjustment of blast
volume. Roasting temperature in the kiln is 13001350 °C and rotating speed
and position of the kiln can be controlled. The discharge hood is sealed by a
device, which is protected by a structural cooling blower.
Annular cooler
The baked and roasted pellets from rotary kiln, fall into the receiving bin
(capacity-50m3) of annular cooler through the kiln discharge hood. And then
leveled off on pellets cars of the annular cooler by help of a roller pusher and
cooled by air blast. Its processing capacity is 80t/h, while its cooling time is
around 45 minutes at a normal depth of 680-760 mm of pellets. The annular
cooler is divided into three cooling sections, each equipped with cooling fans,
partition wall and the receiving bin.
The fume hood of the cooler is divided into four areas. In the area i.e. blowe air
to chills the pellets and its heated to 1000-1100°C then directly returns to the
rotary kiln through the kiln discharge hood over the receiving bin and the
parallel fume duct. This hot fume is used to increase temperature and oxygen
content of kiln and change the flame profile from the spray gun. In the second
area, i.e. section II cold blasted and further cools the section I at the same time.
19
The temperature increases to 400-600°C then is right led to drying section I of
the grate oven via a hot air pipe, for further drying and preheating of green
pellets. In section II & IV, the pellets should be cooled to 1500°C and collected
by a buffer bin and then sent out by a heat resistant belt conveyer. Air
temperature in cooling section III is 35000C and is introduced to Drying
Section. Air temperature in cooling section is at 90-100 °C and fume is directly
freed through the chimney of the annular cooler. Blast volume of blowers is
automatically adjusted by a throttle installed in the blast inlet, which is used to
control hot air temperature, so that the most part of heat volume recovered
from pellet cooling can be utilized for palletizing production process.
The hot air from annular cooler section II lead to great oven preheating
section I. 'Hot air circling' is the process in which waste hot air grate oven
preheating section I, II to blower drying section and downdraught drying is that
wasting hot air of downdraught drying section give out through static de-
duster and main draught fan and chimney. The dust content off wasting hot air
is less than 50mg/Nm3, the dust collected by multi-cyclone and static de-
duster is returned to damp mill room through spillage system.
Fuel:
The various types of fuels like liquid, solid and gaseous fuels are available as
a heating source in industrial use. The selection of right type of fuel depends
on various factors such as availability, storage, handling, pollution and landed
cost of fuel. Keeping the pollution status of proposed Pelletisation plant, Coal
Gas has been selected as heating fuel in the process. The knowledge of the
fuel properties helps in selecting the right fuel for the right purpose and
efficient use of the fuel.
It can be potentially hazardous to store furnace oil in barrels. A better practice is to store it
in cylindrical tanks, either above or below the ground. Furnace oil, that is delivered, may
contain dust, water and other contaminants.
As a certain amount of settlement of solids and sludge will occur in tanks over
time, cleaning should be carried out at regular intervals annually for fuels. A
little care should be taken when oil is decanted from the tanker to storage tank.
All leaks from joints, flanges and pipelines must be attended at the earliest.
Fuel oil should be free from possible contaminants such as dirt, sludge and
water before it is fed to the combustion system.
The physical properties and chemical composition of the raw material and fuel
used in production, and those of finished product must be checked in
21
accordance with those items list.
The following are the major raw material required for the manufacturing of
Iron Ore Pellets.
Bentonite:
Si02 : 66.70%
AI203 : 28.30%
CaO : 1.50%
MgO : 3.50%
H20 : 5.00%
Coal:
Fixed carbon : 45% plus.
Volatile matter : 35% plus.
Ash : 35 to 45%.
Sulphur : 0.1 max.
G.C.V : 3500 (k.cal/kg)/min
Ash fusion temperature: 2000 °C/1600 °C (min)
Size : 0 to 300mm/200mm.
22
Moisture : 10 to 15 % max.
Input Output
Iron Ore Fines 1.1000 Tons B.F. Sinter 1.0 Tons
Coal 0.02883 Tons Input Return Fine 0.143 Tons
Betonite 0.0150 Tons Dust
Total Input 1.143 Tons Total Output 1.143 Tons
Power Requirement:
Manpower Requirement:
23
TYPICAL FLOW DIAGRAM OF IRON ORE PELLETIZING PLANT
24
TECHNICAL ASPECTS
CIVIL WORKS:
This proposed project envisages various civil works related to complete plant
apart from other facilities like construction of road, culverts, rest house, canteen,
water works etc. Further there is no past history of flood in the area. The project
also provides, in view of socio economic development of the surrounding
areas/villages, construction of roads, culverts, Primary health centre, School,
Community Hall, Water works etc as per requirement.
Control Room area shall have Brick wall on external face, over which un-
insulated single Metal Cladding shall be provided. ESP, Control Room Building,
Air Washer Building and all other facilities buildings shall be of RCC I Steel
frame structure within-fill Brickwork I Insulated Metal Cladding.
ARCHITECTURAL CONCEPTS
Layout of the plant area shall have definite hierarchy of road network ;
25
depending upon its usage, aesthetic, visual sensibilities for creating road vistas,
focal points, building back drops, building frames. General layout shall be
evolved taking over the basis of landform & local climate and due consideration
shall be given to orientation & wind direction. Overall emphasis shall be on
developing eco-friendly architecture, merging with the nature with its own
sustainable energy management systems .
CHIMNEY
A reinforced concrete I MS chimney of 60 m height with steel liner shall be
provided for the project. The liner shall essentially be constructed from
structural steel and shall be of the hung type (with multiple point liner support
systems). The liners shall be provided with resin bonded wool type thermal
insulation. The portion of the liners projecting above the chimney roof,
however, shall be constructed of stainless steel liners over the roof slab of the
chimney. Internal platforms shall be provided for enabling access to various
elevations of the stack and to provide support to the steel liner. External
platforms shall also be provided.
The water is pumped from the pump house to the condenser through steel
lined concrete r encased pipe for each unit. Hot water from condenser shall
also be conveyed through a similar pipe of same size to induced draught
cooling towers.
26
The cooling towers (2 Nos.) shall be of induced draught type, which includes
cooling water basin made up of RCC of grade M 25 with suitable foundation
system.
The cold water discharge from cooling tower shall flow by gravity to the CW
pump house fore bay through RCC open channel. The concrete grade for the
open channel shall be M25. All gates, stop logs and trash racks shall be of
structural steel, which shall be hot double dip galvanized and I or epoxy
painted.
A firewater tank and pump house shall be provided. Superstructure of the pump
house shall be of ReC with in-filled brick masonry a panel wall. Foundation for
firewater tanks shall also be provided.
CRUSHER HOUSE
Crusher house shall be of structural steel with permanently colour coated steel
sheet cladding. Floors and roof slabs shall be of RCC. Crushers shall be
supported on RCC deck slab, which in turn will rest on Vibration Isolation
System consisting of springs & dampers. IPS flooring has been considered for
floors.
DRAINS
Drains shall be constructed on both sides of roads. In a well planned manner as
well as integrated with the existing drain facilities overall grid system of main
drains l artillery drains are to be provided , designed to dispose off by gravity to
the main drain.
SEWERAGE
R.C.C. concrete pipes' C.1. pipes shall be used for sewage disposal and t or to
be extended to the existing system to match the future requirement. Extended
aeration type permanent sewage treatment plant shall be provided for
treatments of sewage disposal system including Central Monitoring Basin
(CMB) as per applicable local bylaws l environmental standard l conditions of
State and l or Central authorities.
Auto -changeover between the low and high capacity aux. PRDS stations
depending on the station auxiliary steam requirement is also envisaged. Each
unit will have its own auxiliary steam header whereas for station services a
common station auxiliary steam header is also proposed. A high temperature
station auxiliary steam header taking its tap off from the auxiliary PRD station
before the de-superheater will also be provided, to take care of the mill fire
fighting and air heater soot blowing.
28
ELECTROSTATIC PRECIPITATOR
ESP with high efficiency will be used to limits the outlet emission to 50 mg/Nm3
and will be designed and modified later as per the desired requirement.
ESP transformer rectifier sets will use high fire point oil as the cooling medium.
The dust collection hoppers at all strategic locations will have a minimum
storage capacity of eight (8) hours. The hoppers will have heating
arrangements to prevent ash sticking to the sloping sides and down pipes.
Level indicators to indicate and trip the ESP in case of high ash levels in the
ash hoppers, which will jeopardize the safety of ESP otherwise.
In order to meet the environment norms and maintain the sustained efficiency of
ESP, it shall be adequately designed with sufficient margins for all operating
conditions. The Electrostatic Precipitator Management System (EPMS) in
conjunction with opacity monitor shall continuously monitor and maintain the
optimum energy level to achieve higher efficiency of ESP. For obtaining the
sustained high efficiency and availability of other equipment, it shall be
designed for low NOx formation by adopting the appropriate burners, high
efficiency at part load, flexibility to fuel within the range specified, quick startup
and two shift operation capability, adequately sized furnace for burning and low
flue gas velocities to minimize erosion.
Control rooms
Telecommunication rooms
UPS Rooms
Conference room
Relay rooms
Control room, water and fuel analysis room, instruments room, ESP etc.
30
VENTILATION SYSTEM
Ventilation system shall be designed to supply fresh outdoor air and shall be
selected for maintaining inside conditions for those areas where close control of
temperature is not required, but nevertheless have a stipulated maximum
temperature.
DDCMIS SYSTEM
In line with current practices, microprocessor based digital control, monitoring &
Information System would be provided for the safe, reliable and efficient
operation of the equipments and their auxiliaries.
COMMUNICATION SYSTEM
For effective communication within and outside the plant, an
intercommunication system will be provided and distributed throughout the
plant. The major components of the system are:
CONSTRUCTION POWER
The construction power required for the construction of the power plant wiI be
derived from the nearest CSEB's 33 kV source as per the requirement in a
32
phased manner.
SOURCES OF POLLUTION
The major sources of pollution from a project can be classified under the following
heads:
Fugitive dust generated during solid fuel handling and processing.Fugitive dust
generated during conveying, storage and disposal etc.
Thermal pollution
Noise pollution
The various measures proposed to mitigate the impact of these pollution sources
on the environment are discussed below:
33
POLLUTION CONTROL MEASURES AIR POLLUTION
High efficiency electrostatic precipitators (ESPs) will be installed to limit the
particulate emission to 50 mg/Nm3 in line with the State Govt. Policy. To facilitate wider
dispersion of remaining particulates and gaseous pollutants (SO2 and NOX), a chimney of
suitable height will be provided. The chimney will be provided with personal
access for monitoring of stack emissions.
For control of fugitive dust emissions within and around the raw material handling and
finished product handling areas, dust extraction and suppression systems would be
provided. Dust suppression system shall be installed at all requisite points in the plant.
WATER POLLUTION
An effluent management scheme, consisting of collection, treatment,
recirculation and disposal of effluents, shall be implemented in order to optimize
the make up water requirement as well as liquid effluent generation. The details
of water system for the project is described as follows:
• Recirculation type C.W. system with induced draft cooling towers, with
C.W. blow down from cold water side to ensure that there is no thermal
pollution.
NOISE POLLUTION
The major noise generating sources are those pumps, fans, handling plant etc.
from where noise is continuously generated. Acoustic enclosures shall be
provided wherever required to control the noise level below 75 dB (A). Wherever
it is not possible technically to meet the required noise levels, the personal
protection appliances shall be provided.
34
SOLID WASTE MANAGEMENT
The solid waste management scheme for solid waste generated from project
shall involve collection, supply to entrepreneurs for utilization, promoting solid
waste utilization and safe disposal.
CONSTRUCTION PHASE
Air Environment
The installation of plant during construction phase would result in the increase of
SPM concentrations due to fugitive dust. Frequent water sprinkling in the vicinity of
the construction sites would be undertaken and will be continued after the
completion of plant construction, as there is scope for heavy truck mobility. It will be
ensured that both gasoline and diesel powered vehicles are properly maintained to
comply with exhaust emission requirements.
Noise Environment
There will be marginal increase in noise levels during construction phase, which is
temporary. No construction activities are planned during night time, which may
contribute to the existing baseline.
Water Environment
Land Environment
Generally cutting of herbaceous vegetation, during the construction phase results in
35
the loosening of the top soil. There is no such removal of vegetation in the proposed
site. Further plantation measures would help in preventing soil erosion.
Any hazardous material required for constructional activity will be sorted as per
safety norms. Further construction site will be provided with suitable toilet and
treatment facilities etc for maintaining hygienic conditions.
Socio-economic Environment
Any construction activity will benefit the local population in a number of ways. The
company management shall give preference to local people through both direct and
indirect employment. It shall provide ample opportunity to the locals to up-lift their
living standards by organizing events that propagate mutual benefits to all, such as
health camps, awareness campaigns, donations to poorer sections of society and
downtrodden. Educational needs of the region should be improved by encouraging
the workers to allow their children to attend schools. Sufficient funds shall be
allocated for these and other emergency needs. Compensation packages to the kin
of those workers who loose I disable their working ability due to any accident.
OPERATIONAL PHASE
Air Environment
The dust generated from the various conveyors points, crushing etc, will be
controlled by covering the conveyor belt and approaching the transfer points
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and then installing one centralized dust extraction system which extract all the
dust from various points. These dust later be trapped by ESP .
Noise Environment
The following are the noise control measures proposed to be undertaken in the
proposed plant.
• A thick greenbelt will be developed all around the plant boundary to act as
noise attenuator.
• In addition personnel working near high noise level generating sources will
be provided with ear muffs.
• Proper and suitable acoustic barrier will also be provided around areas
generating high noise to maintain noise levels below 90 dB (A).
• Storm rain water drainage will be routed through a silting tank, for arresting
of silt. Rain water will be used during the rains for the purpose of the plant
water requirement.
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An independent plant affluent drainage system is proposed to ensure that
plant effluent doesn't contaminate storm water drains. After individual
treatment of effluents, these will be disposed off through a central monitoring
basin. Efficient operation of various treatment schemes will be ensured to
conform quality of treated effluents to relevant discharge standards.
The sewage from plant will be directed to STP. The capacity of STP will be
adequate and the treated effluent would be either utilised for plantation
purposes or will be discharged.
In general, the storm water run-off is often polluted through dust, garbage and
unprotected solid wastes. Hence, primary treatment in setting tanks is
essential in order to minimize the pollution to a significant level before the
disposal of these waters into natural environment.
Rainwater Harvesting
Underground sewers are preferable to collect the storm waters, storm waters
of open road drains are often misused as open sewers for the discharge of
industrial and domestic wastewater and as well as dumps for disposal of solid
wastes. Rainwater Harvesting technique will be adopted by the industry as per
guideline of the MoEF and CGWB.
The disposal of solid waste is planned by utilising safe and scientific procedures its
handling, storage and disposal activities. Solid waste generated will be disposed
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Few measures are further elaborated below, which would promote sustainable
development in this expansion activity.
i. Water blanket will be maintained over material heaps, and other dust
ii. Thick green belt will be developed all around the periphery of the plant and
some free areas within the premises so as to reduce the pollution and improve
the aesthetics of the area.
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POST OPERATIONAL MONITORING PROGRAM
Regular monitoring of pollutants in different environmental disciplines like air,
water, noise etc will be conducted for proposed units and the data will be
regularly submitted to Chhattisgarh Environmental Conservation Board.
INSTITUTIONAL SET-UP
The post operational monitoring program will be under the supervision of the
Environmental Management Group (EM G) at the project site. The EMG at site
will interact with state Environment Conservation Board for all environmental
related issues during operation of the station.
STATUTORY CLEARANCES
A comprehensive study is in process to prepare Environmental Impact
Assessment report for this project. After receipt for No Objection Certificate
from Chhattisgarh Environmental Conservation Board, Ministry of
Environmental & Forests will be approached for obtaining Environmental
Clearance. This will be in accordance with the procedure laid down in the EIA
Notification 2006 and its subsequent amendments.
PERFORMANCE GUARANTEES
The plant and facilities will be designed, engineered, manufactured, tested,
erected and commissioned ensuring compliance to international standards
and incorporating state of the art technology. Quality assurance programs will
be implemented meticulously to ensure high quality for the equipments and
systems. At every stage right from the selection of raw materials till
conductance of performance guarantee tests, inspection shall be carried out
at every stage of manufacture and tests such as type tests and routine tests
will be carried out on the components, equipment and systems so as to
ensure that the plant will give integrated optimal performance. While it is not
the intent to elaborate all the inspection, testing and performance guarantee
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tests involved, the following specific guarantees will be adhered to:
a. Review of actual performance of each unit vis-a-vis targets and norms for key
operating parameters.
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problems and related difficulties.
MAINTENANCE PHILOSOPHY
With a view to build up to required expertise and institute the best maintenance
practices, initially for the first few years, major overhauls and maintenance of
major equipments will be carried out directly by the respective equipment
manufacturers or their licensed representative. The overhaul and maintenance
procedures will then be tuned suitably to have an optimal customized
maintenance system for the equipment and systems covered under the plant.
The maintenance procedure aims at maximizing the availability of generating
units while ensuring minimum maintenance cost and safety of plant and
personnel.
TRAINING
Depending on the level and experience of O&M staff, training programs will be
designed and implemented by contractor in association with O&M contractor and
the owner. The covered includes the following:
- Training at operating plants in India and abroad where similar equipment are in
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operation.
- Maintenance training.
- Simulator training.
- Workshops.
TRAINING POLICY:
An appropriate training policy would be adopted at the outset aiming to fulfill the
main objectives of improving the organizational efficiency & effectiveness as a
whole and also to maintain a high technological status and develop an
understanding of the importance of cooperation & teamwork.
AFFORESTATION
The project envisages a good quantum of afforestation glvmg it the highest
priority to maintain as a pollution free area as far as possible. Afforestation and
green belt development activities would be implemented in a massive way for
which specific land is also separately proposed. Extensive plantation program will
be commenced right from the procurement of the land so that the trees are
appreciably grown up till the plant is commissioned.
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Factors for selection of plant species for green belt development; fast growing,
perennial and ever green, thick canopy cover, large leaf area index, resistant to
specific air pollutants, preferably indigenous, will maintain regional ecological
balance and soil and hydrological conditions of the region. The species to be
planted will be selected based on the available land soil quality and the quantum
of water available. The following aspects would be considered in the placement of
plants.
(i) Trees growing up to two meters or more in height with thick canopy cover
and perennial foliage will be planted around the installation.
(ii) Planting of trees will be done is rows (minimum three rows) while planting
trees care will be taken so that the green envelop would conceal the installation
when observed from outside the premises. For preventing the horizontal
dispersion pollutants if any, the trees planted in alternative row will fall in straight
line.
(iv) Sensitive species like magnifera indica will be planted in patches along the
entire green belt to work as an indicator of pollution potential.
SOCIO-ECONOMIC DEVELOPMENT:
The project provides full opportunity for local people/village to get employment
directly or indirectly and helps in the up-liftment of socioeconomic status of the
area, which is one of the most essential factors. The project envisages
involvement of social activities of the surrounding community by planning
betterment of neighboring social conditions through awareness and welfare
programs that will ensure improved relations. The commitment of management
includes upIiftment of social, health, basic needs of drinking water supply and
provision of educational facilities. Many of the beneficiaries of such programs
shall include own employees as well. Goodwill of the local population can never
be ignored. The channels employed may vary either through direct contact or by
means of local organizations. Another important fact of social environment
identified by the project proponents is a green appearance; hence the
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management will develop a green belt towards aesthetic beautification, as the
same is necessary to be considered as a responsible, social neighbor.
PROJECT MANAGEMENT
Project management covering various aspects of the project will be implemented
following appropriate systems for which experienced Personal and suitable
management tools specially developed for the purpose will be deployed. The
project management activities are ammged in phases and accordingly project co-
ordination procedures will be developed in association with contractor.
Computerized systems with advanced software will he followed for materials
management, cost control, budgetary control, finance management, scheduling,
resource allocation, monitoring etc. An integrated project management and
control system is envisaged for the project planning, scheduling, monitoring and
control. This system encompasses all areas of engineering management,
contract, management, construction and commissioning management. This
system would envisage development of a master network, which is the overall
program of the project.
PROJECT CONTRACTING
The main features of the project contracting followed by VVL would be as
follows:
All the plant and works involved in this project including detailed design,
engineering, procurement, construction, testing and commissioning of the plant
to a performance specification consistent with International standards, and in
accordance with the current Indian Legislation will be carried out by a single
contractor. This approach minimizes contractual interfaces,shortens project
implementation time scale and places design and contraction risks with the
party best able to manage them. Detailed engineering co-ordination and sub-
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contracting activities are all simplified and shortened.
ENGINEERING MANAGEMENT
The project engineering activities will be planned to schedule within the time
frame specified for the engineering milestones in the master network schedule.
QUALITY MANAGEMENT
The Quality Management will be implemented through various system and
procedure, which shall follow the model of ISO 9000. The apex document for
the Quality Management shall be a Quality program which shall cover system
& procedure for various activities which may have effect on Quality like design
control, document and data control, document and data control, process
control inspection and testing,corrective and preventive actions, quality audit,
control of document and records etc.
This Quality program will include detailed quality control plans for major
equipment & services and it will ensure that the equipment & services under
the scope of contract whether manufactured or performed within the
contractor's works or subcontractor's works or at site, are in accordance with
the contract specification, codes and standards, statutory requirements, etc.
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CONTRACTOR
The contractor will have dedicated team headed by a Project Manager who
will be the chief coordinator for the Project, and will be responsible for the
project execution. The project ream of Contractor will have sufficient
technical personnel for various areas like engineering, procurement,
execution, quality, finance etc. to co-ordinate all matters pertaining to the
Project.
The Civil works contractor will carry out all civil works required for the project
including all detailed design work. However EPC contractor will carry out the
basic design.
• Ensuring all safety features in the equipment, system and layout in the
design stage itself.
Rashi Steel and Power Limited are planning to have a system of rainwater harvesting at
village Paraghat and Beltukri, district Bilaspur, Chhattisgarh. Rainwater harvesting is
primarily dependent on various site characteristics such as soil property, catchments
characteristics; rainfall characteristics, and ground water tables etc.
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There are artificial as well as natural rainwater harvesting systems. The collecting system
can be implemented for i) Individual units and ii) Centralized collection system
Scheme II: Construction of rainwater filter bed at centralized place where water from
individual unit as well as storm water from open area shall be diverted
The reference is hydrological data of Bilaspur from the IMD. The maximum rainfall in july
in the year of 2011-12 is 300.3 mm. The yearly rainfall is 1041 mm in 2011-12 and 1100
mm is the average rainfall in the last five year from 2008 to 2012. 1,01,700 m3 maximum
water will be collected from the rain fall in the rain water harvesting pond in a month.
Approximately 3,52,899 m3 water will be collected from the rain fall in the rain water
harvesting pond, which will fulfill the 47 days requirement of the plant.
Total Storm water Load on the site for 1 mm rain fall 339
Considering maximum rainfall in the month of july is 300 mm, So the total 101700
storm water load
Total storm water load on the site for 1041 mm rain fall 352899
101700 m3 is the maximum capacity of the rain water harvesting pond and the water which we
collect within the project premises in a month.
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PROJECT FINANCIAL, COST ESTIMATION ETC.
The cost of the Iron Ore Palletisation Plant covers all the costs associated
with the construction of the plant, and includes the civil construction cost, cost of
equipment for production, cost of auxiliaries utilities. The total project cost is
arrived at by adding to this cost, the pre operative expenses inclusive of
project design and engineering, sa-t-up and training expenses, interest during
construction and the margin money to meet the working capital requirements. The
table given below gives the details of the Project Works Civil, Mechanical and Electrical
Cost estimate and the overall project cost estimate.
PROJECT COST
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MEANS OF FINANCE
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