EVMIVHLOEarth Stahl PFR

EARTHSTAHL & ALLOYS PVT. LTD.
* EXISTING SUBMERGED ARC FURNACE (1X3.6MVA) by

changing product Mix of 10500 TPA of C.I. Lumps /Ball to
9200 TPA of Ferro Alloys.
* EXISTING INDUCTION FURNACE 1x550 KW of 3600 TPA for

Casting & Forging of Iron & Steel.
* PROPOSED INDUCTION FURNACE 1x750 KW + 1x2250KW

for 8400 TPA for Casting & Forging of Iron & Steel.
* PROPOSED SUBMERGED ARC FURNACE 1x5.4MVA for

13,800 TPA of Ferro Alloys
* PROPOSED INDUCTION FURNACE of 1x550 KW + 1x750 KW

+ 1x2250KW of 12000 TPA for Casting & Forging/Billets
/Ingots of Iron & Steel.
* PROPOSED ROLLING MILL 18000 TPA for MS Strip/Round

Bar/Square with Coal Gasifier 1750Nm3/Hr.
* PROPOSED IRON ORE WASHING of 5,00,000 TPA

CAPACITY.
EarthStahl & Alloys Pvt. Ltd.

5B, Merlin Jayshree Vihar,
Pandrai Tarai, Mandi Gate, Raipur (C.G)
Email – info@earthstahl.com
Phone +91 8120666664
1
Table of Content
Chapter-1
Executive Summary
1.1 Executive Summary 5
1.2 Project at a Glance 6-8
Chapter-2
Introduction of the project / Background information
2.1 Company Background 9-10
2.2 Management 11
2.3 Banker 12
2.4 Need for the project and its importance to the country 12
and or region
2.5 Demand -Supply Gap 12-13
2.6 Cost of Project 13-14
2.7 Employment Generation (Direct and Indirect) due to 14
Project
2.8 Manpower Estimate 14-15
Chapter-3
Project Description
3.1 Type of project 16
3.2 Location (map showing general location, specific location, 17-19
and project boundary and project site layout) with
coordinates
3.3 Details of alternate sites considered and the basis of 20-21
selecting the proposed site, particularly the
environmental considerations gone into should be
highlighted
3.4 Project Area description 21-22
3.5 Mechanical Equipments And Process Flow Diagram of all 23-60
existing & proposed project.
3.6 Raw material & other utilities 61-70
3.7 Fuel 71
3.8 Availability of water its source, Energy/Power 72-75
requirement and source should be given
3.9 Quantity of wastes to be generated (liquid and solid) and 76
scheme for their Management/disposal
3.10 Air Pollution 77-78
3.11 Water Pollution 79
3.12 Noise Abatement 80
3.13 Green Belt development 80
2
3.14 Occupational health & safety 80

3.15 Socio –economic environment 80
Chapter-4
Site Analysis
4.1 Connectivity 81
4.2 Land Form, Land use and Land ownership 81
4.3 Topography (along with map) 81
4.4 Existing land use pattern (agriculture, non-agriculture, 84
forest, water bodies (agriculture, non-agriculture, forest,
water bodies (including area under CRZ)), shortest
distances from the periphery of the project to periphery of
the forests, national park, wild life sanctuary, eco
sensitive areas, water bodies (distance from the HFL of
the river), CRZ.
4.5 Existing Infrastructure 84
4.6 Soil classification 84
4.7 Climatic data from secondary sources 85
4.8 Social Infrastructure available 85
Chapter-5
Planning Brief
5.1 Planning concept 86
5.2 Population Projection 86
5.3 Land use planning (breakup along with green belt etc.) 86-87
5.4 Assessment of Infrastructure Demand (physical & social). 88
5.5 Amenities/Facilities 88
Chapter-6
Proposed Infrastructure
6.1 Industrial Area 89
6.2 Green Belt 89
6.3 Social Infrastructure 89
6.4 Drinking Water Management 89-90
6.5 Sewerage system 90
Chapter-7
Rehabilitation and Resettlement (R & R) Plan 91
Chapter-8
Project Schedule and Cost Estimates
8.1 Likely date of start of construction and likely date of 92-93
completion
3
8.2 Estimated project cost along with analysis in terms of 92-93

economic viability of the project
Chapter-9
Analysis of proposal (Final Recommendations)
9.1 Financial and social benefits with special emphasis on 94-95
the benefits to the local people including tribal
population, if any, in the area
4
CHAPTER-I
Executive Summary
1.1 Executive Summary
M/s. Earth Stahl & Alloys Pvt. Ltd., has been promoted by first generation
entrepreneurs and technocrats with diverse and wide industrial and
commercial experience. The company was incorporated in 2009 by Mr. Rajesh
Somani and Prawin Somani.
The basis of selection of major equipment including a review of

technologies and their evaluation is indicated in the report. The chapter
in the report also deals with the annual requirement of raw material.
The project report also covers the plant facilities and plant description
for the Submerged Arc Furnace, Induction Furnace, Rolling Mill along
with Coal Gasifier and Iron Ore Washing Plant.
The detailed process description of all the system has been covered in
the project report.
The chapter in the project report deals with the facilities provided for the
plant water system and other utilities such as fuel etc. The pollution
control measures proposed to be adopted in the Submerged Arc Furnace,
Induction furnace, Rolling Mill along with Coal Gasifier and Iron Ore
washing Plant also described in the chapter of the report.
The chapter of the report also includes the organization and estimated
manpower for the Submerged Arc Furnace, Induction furnace, Rolling
Mill along with Coal Gasifier and Iron Ore washing Plant. The estimates
of capital cost and the financial analysis of the project are presented in
the report.
5
1.2 Project at a Glance
Company details
Name : Earthstahl & Alloys Pvt. Ltd.
Registered Office : 5B, Merlin Jayshree Vihar, Pandrai Tarai, mandi

Gate,Raipur (C.G)
Factory : Village – Duldula, Simga, Distt – Baloda Bazaar,

Chhattisgarh
List of Directors : 1) Mr. Rajesh Somani
2) Mr. Ravi Laddha
3) Mr. Praveen Somani
Site Details
Sr. Particulars Details

No.
1. Latitude 21o38’47.4” N
2. Longitude 81o44’17.2” E
3. Altitude 276 m above MSL
4. Toposheet 64G/10 (F44P10)
5. Seismicity Area falls under least affected earthquakes

zone II
as per IS 1893 – 1984
7. Climatic condition Ambient Air temp 7oC to 46oC

(Annual Average) Avg. annual rainfall 1200 mm
8. Nearest village Harim Bhatta
9. Nearest town Simga
6
10. Nearest railway station Tilda (14 KM)
11. Nearest airport Raipur (55 KM)
12. Streams / Rivers Seonath River - 6 kms SW
ChitawarNala: 2Km East
GadariaNala :8Km South
13. Sanctuaries /National Nil

Parks/ Biospheres, etc.
14. Topography Gently sloping
15. Defense Installations Nil
16. Historical Places Nil
17. Road Access NH 200 (3 KM)
Project Details
Existing & proposed project and change in Product mix at Village –
Duldala, District - Baloda Bazaar, Chhattisgarh – State. The details are
as under :-
S Furnace Type Description Capacity Existing Status Proposed Proposed

N (MT/An Products Change in New
num Product Mix Capacity
/ Product of (MT/Ann
Proposed um
Project
1 Sub-merged Arc 3.6MVA-SAF 10500 CI Existing Ferro Alloys 9200
Furnace lumps/Balls under
operation
2 Induction Furnace 1x550 KW 3600 Castings Existing Castings and 3600
. and forging under forging of
of iron & operation Iron& Steel
steel
3 Induction Furnace 1x750KW 8400 Castings CTE issued Castings and 8400
1x2250KW and forging by CECB. forging of
of Iron and (Proposed Iron& Steel
steel as per Project)
CTE.
4 Ferro Alloys Plant 5.4 MVA - - Proposed Ferro Alloys 13800
(Sub-merged Arc
Furnace)
5 Induction Furnace 1x550KW - - Proposed Castings & 12000
7
Induction Furnace 1x750KW - - forgings of

Induction Furnace 1x2250KW - - Iron &
steel/Ingots/
Billets
6 Rolling Mill - - Proposed MS Strip/ 18000
Round/
Square/ Bar
7 Coal Gasifier 1x1750Nm3/ - - Proposed Producer Gas 1750Nm3
hr /hr
8 Iron Ore Washing - - - Proposed Washed Ore 500000
Plant
Financial Details of the Project (Capital Cost)
Sr. No. DESCRIPTION Rs.

(In Lacs)
1 3.6 MVA Submerged Arc Furnace 1400.00
2 1x 550 KW Induction Furnace 1100.00
3 1x750 KW and 1 x 2250 KW Induction Furnace 2400.00
4 1x 550 KW, 1x750 KW, 1 x 2250 KW Induction furnace 3500.00
6 Rolling Mill with Coal Gasifier 600.00
8 Iron Ore Washing plant 500.00
TOTAL COST 10600.00
8
CHAPTER – 2
Project Introduction / Company Background
2.1 Introduction & Company Background
M/s. Earth Stahl & Alloys Pvt. Ltd. has been promoted by first generation
entrepreneurs and technocrats with diverse and wide industrial and
commercial experience. The company was incorporated in 2009 by Mr. Rajesh
Somani and Prawin Somani.
The company had obtained Consent to Establish vide CECB letter no

3952/TS/CECB/2010 dated 11.10.2010 for 26,250 TPA Submerged Arc
Furnaces for Production of C. I. Lumps/Balls. The Project was to be
established in a Phased manner i.e In Phase-I 1x3.6 MVA Submerged Arc
Furnace (Capacity - 15,750 TPA) and in Phase-II 1x5.4 MVA Submerged Arc
Furnace (Capacity - 26,250 TPA).
Having such consent for the proposed projects the company has established
and operated the Phase – I facility i.e. 1x3.6 MVA Submerged Arc Furnace for
production of 10,500 TPA C.I. Balls and lumps after obtaining Consent to
Operate from CECB vide letter no 7120/TS/CECB/2012 under Water Act and
7122/TS/CECB/2012 under Air Act dt 22.02.2012.
Further, the company has surrendered the Phase – II Facility (5.4 MVA
Submerged Arc Furnace for production of 15,750 TPA C.I. Balls and lumps and
obtained amended CTE from CECB vide its letter no 5306/TS/CECB/2014
dated 21.11.2014 for installation of 3 Nos Induction Furnaces in two phases
i.e. Phase-I (1x 550 KW) for production of 3,600 TPA of Casting & Forging
9
of Iron & Steel and in Phase-II (1x750 KW + 1x2250 KW) capacity 8,400
TPA of Casting & Forging of Iron & Steel in the same premises.
Having such Consent the company has initially installed one number
Induction furnace (550 KW) of phase-I project for production of 3,600
TPA of Casting & Forging of Iron & Steel and for which consent to
operate is issued by CECB vide its letter no 6504/TS/CECB/2016 dated
30.3.2016 under water Act and 6506/TS/CECB/2016 dated 30.3.2016
under Air Act.
Now the company has plan to further expand the existing submerged
arc furnace (1x5.4MVA)for production of 10500 tpa C.I.Lumps /Balls and
Induction Furnace (550KW) for production of castings & forging of Iron
& Steel by adding :
Submerged Arc furnace (1x5.4MVA for production of Ferro Alloys 10800
TPA and Induction Furnace (1x550KW, 2x750KW & 2x2250KW) for
production of castings of Iron & Steel, Ingots / Billets and also change in
products Mix of existing Submerged Arc Furnace (1x3.6MVA) from 10500
TPA C.I. Lumps/Balls by reducing to 7200 TPA Ferro Alloys . The
Company is also proposed to install a Rolling mill of capacity-18000 TPA
for production of MS strips/ Round/ Square/Bar etc. A Coal Gasifier of
capacity-1750Nm3/hr. for production of Producer of Gas and also
proposed to install a Iron Ore Washing Plant of capacity – 0.5MTPA in
the existing premises at Village-Duldula, Tehsil –Simga, District –
Balodabazar (C.G).
As per EIA Notification 2006, in case of secondary metallurgical

processing Industrial units, production capacity more than or equal
30000 TPA and also change in product mix of existing plant would
10
require environment clearance from MOEF&CC, Government of India,

New Delhi.
2.2 Directors
The company has been promoted by Mr. Rajesh Somani, Mr. Prawin Somani
and Mr. Ravi Laddha who are directors on the board of the company.
Mr. Ravi Laddha, aged 40 is an Executive Director with SARDA ENERGY &
MINERALS LTD, a listed company having interests in steel, power and ferro
alloys with a turnover of Rs. 1200 cr. He has over 15 years of experience with
ESAPL having headed projects and operations. Steel, sponge iron, pellet and
thermal power projects with investments in excess of Rs. 1000 cr have been
executed under his direct supervision and control. Presently he is heading
projects, real estate and mining operations of the Sarda group. The company
has received benefit of his technical expertise and experience in execution /
operation of projects. He has also visited European countries & China to study
the latest technical developments in the field of steel, real estate and power
sector.
Mr. Rajesh Somani, aged 42 years has been in the steel business for last 17
years through his venture M/s Shree Balaji Iron & Steel Company and Aayush
Steel Co. Private Limited, operating from Vizag. He has excellent contacts with
Iron & Steel producers & traders and is in charge for marketing of the
company’s products.
Mr. Prawin Somani, aged 36 years is an industrialist with 12 years of

experience. He is having Ore/Coke Briquette manufacturing plant in Siltara
Industrial Growth Centre Raipur. He also has interests in scrap & steel waste
products business. He is looking after procurement and plant operation.
11
2.3 Bankers
Company is banking with Bank of India.
2.4 Need for the project and its importance to the country
and/or region
The need for Ferro alloys, Casting & forging of Iron & Steel Rolling mill will
grow with the Infrastructure development of the Country. Iron ore washing
plant as a part of the iron making facility is required due to the runaway
increase in iron ore prices and shortage of Iron ore in the recent year in India.
Chhattisgarh state has abundant raw minerals resulting in a major steel
producer state, it also has surplus power which is a major requirement for
Ferro alloys. There being many big PSUs and other major steel producers, for
them Ferro alloys is the major consumable item and these Plants also have a
regular requirement of Casting and forging.
In view of the above, M/s EarthStahl & Alloys Pvt Ltd. has decided to setup
the above said project.
2.5 Demand -Supply Gap

Steel Industry in India is on an upswing because of the strong global and
domestic demand. India’s rapid economic growth and soaring demand by
sectors like infrastructure, real estate and automobiles, at home and abroad,
has put Indian steel industry on the global map. According to the latest report
by International Iron and Steel Institute (IISI), India is the seventh largest steel
producer in the world. The current status of iron ore and its future prospects
have direct relationship mainly with steel production in India. The total iron
ore resources in India are approximately 25,249 Million tonnes (out of which
Hematite constitutes 14,630 MT and Magnetite constitutes 10,619 MT). Out of
12
the total production, 56% of iron ore production comes out as fines and 44% as
boulders which have to be sized to 10-30 mm for blast furnaces and 6-18 mm
for sponge iron plants. Iron ore in a finely ground state is not easily
transported or readily processed .Thus it is necessary to agglomerate the fine
ground ore into pellet using binders.
2.6 Cost of the Project

Since the report includes a project which is already under operation the Cost
of Project, Thus, for the established unit the Gross capital made has been
considered as cost of project and for the others it is estimated based on
enquires floated, quotations received. The financing and pre-operative cost has
been considered based on the proposed financial package.
The existing project cost is Rs.25.00 Crores and estimated cost of the
proposed project is Rs.81.00 Crores, the total cost thus evaluated to be
Rs.92.00 Crores including pre-operative expenses and margin money for
working capital requirements. The details of the cost are under given.
EXISTING
SN Particular Capacity Amount

(Rs. in Crores)
1. Sub-merged Arc Furnace 3.6 MVA 14.00

3.6 MVA
1. Induction Furnace 1 x 550 KW 11.00
PROPOSED EXPANSION
(Rs. in Crores)
1. Induction Furnace 1 x 750 KW
24.00
13

(Rs. in Crores)
1. Sun-merged Arc Furnace 5.4 MVA 11.00
3. Induction Furnace 1 x 750 KW 35.00
5. Rolling Mill 18000 TPA

6.00
6. Coal Gasifier 1 x 750Nm3/hr
7 Iron Ore washing Plant 0.5 MTPA 5.00
2.7 Employment Generation (Direct and Indirect) due to

Project
The major benefit of project will be in the sphere of generating employment for
about 188 persons in that area. The project will benefit local population. The
manpower requirements for the operational phase of the Plant will be about
188 people. In addition, there will be an indirect employment for skilled/ semi
skilled people during project life. All attempts will be made to employ suitable,
locally available, skilled personnel from the nearby area. In case of non-
availability of skilled persons, people will be employed from outside area.
2.8 Manpower Estimate
It is estimated that the total requirement of manpower for the whole

organization will be approximate 188. Department-wise /division-wise
manpower is given as under.
The manpower has been divided into the following categories:
 Managerial
14
 Executive
 Supervisory
 Skilled (SK) / Unskilled
Name of Project Managerial Tech. Supervis Skilled / Total

Executive ory Unskilled
Administrative Tech.
Management
3.6MVA Submerged 02 05 08 15 20 50
Arc Furnace
5.4MVA Submerged 03 04 10 15 32
Arc Furnace
2x750 KW Induction 02 02 08 08 20 40
Furnace
2x550 KW Induction
Furnace
2x2250KW Induction
furnace
Rolling Mill with Coal 02 01 04 02 20 29
Gasifier
Iron ore Washing 01 01 02 03 30 37
Plant
Total 07 12 26 38 105 188
15
CHAPTER - 3
Project Description
3.1 Type of Project

Existing, proposed project and change in Product mix at Village –
Duldala, District - Baloda Bazaar, Chhattisgarh – State. The details are
as under :-
S Furnace Type Descripti Capacit Existing Status Proposed Propose

N on y Products Change in d New
(MT/An Product Mix / Capacity
num Product of (MT/An
Proposed num
Project
1 Sub-merged Arc 3.6MVA- 10500 CI Existing Ferro Alloys 9200
Furnace SAF lumps/Balls under
operation
2 Induction Furnace 1x550 3600 Castings and CTE & CTO Castings and 3600
. KW forging of issued by forging of
iron & steel CECB. Iron& Steel
3 Induction Furnace 1x750KW 8400 Castings and CTE issued Castings and 8400
1x2250K forging of by forging of
W Iron and CECB.(Propo Iron& Steel
steel sed Project)
4 Ferro Alloys Plant 5.4 MVA - - Proposed Ferro Alloys 13800

(Sub-merged Arc
Furnace)
5 Induction Furnace 1x550KW - - Proposed Castings & 12000
Induction Furnace 1x750KW - - forgings of Iron
Induction Furnace 1x2250K - - &
W steel/Ingots/B
illets
6 Rolling Mill - - Proposed MS Strip/ 18000
Round/
Square/ Bar
7 Coal Gasifier 1x1750N - - Proposed Producer Gas 1750Nm
m3/hr 3/hr
8 Iron Ore Washing Plant - - - Proposed Washed Ore 500000
16
3.2 Location (map showing general location, specific location,

project boundary and project site layout) with coordinates.
Company has acquired 13 acres of private land in the village of Duldula from
land owners and for 4 acres agreement has been signed and additional 14
acres of land are under process of acquisition for proposed expansion projects
(Ferro alloys, Rolling Mill with Coal Gasifier & Iron ore washing plant etc.).
Hence total land required for existing and proposed is 31 Acres of land. Out of
which 10.5 Acres of land will be reserved for green belt development. The site is
located within 21o38’48.20” North Latitude and 81o44’16.03” East longitude. It
is located centrally vis-à-vis source of raw materials and consuming Industry.
The map showing general location of the proposed Project and Project site
layout plan is shown below.
17
18 MAP
LOCATION
LAYOUT PLAN
19
3.3 Details of alternate sites considered and the basis of

selecting the proposed site, particularly the environmental
considerations
The proposed expansion project site is situated at Village – Duldula, Tehsil –

Simga, District: Baloda Bazaar, Chhattisgarh State. The Plant is located about
50km from Raipur and is just 3kms away from Raipur – Bilaspur National
highway. The proposed expansion is in existing premises of Earthstahl & Alloys
Pvt. Ltd. Hence, no alternative site is considered.
The following are the factors in favor of selection of site at village Duldula :
_ Easily availability of raw material.
_ Availability of power.
_ Availability of adequate water.
_ Availability of adequate land for locating the plant with approach roads.
_ Suitability of land from topography and geological aspects.
_ Proximity of National Highways & Transport of heavy equipments.
The environmental consideration of the site is tabulated below:
Sr. Particulars Details

No.
1. Latitude 21o38’47.4” N
2. Longitude 81o44’17.2” E
3. Altitude 276 m above MSL
4. Toposheet 64G/10 (F44P10)
5. Seismicity Area falls under least affected earthquakes

zone II
as per IS 1893 – 1984
7. Climatic condition Ambient Air temp 7oC to 46oC

(Annual Average) Avg. annual rainfall 1200 mm
8. Nearest village Harim Bhatta
20
9. Nearest town Simga
10. Nearest railway station Tilda (14 KM)
11. Nearest airport Raipur (55 KM)
12. Streams / Rivers Shivnath
13. Sanctuaries /National Nil

Parks/ Biospheres, etc.
14. Topography Gently sloping
15. Defense Installations Nil
16. Historical Places Nil
17. Road Access NH 200 (3 KM)
3.4 Project Area description Plant Site
Company has acquired 13.0 acres of private land in the village of Duldula from
land owners and for 4.0 acres agreement has been signed and additional 14.0
Hence total land required for existing and proposed expansion is 31 Acres. Out
of which 10.50 Acres of land will be reserved for green belt development. It is
located centrally vis-à-vis source of raw materials and consuming Industry.
21
Statement of Area
The details of land area for existing and proposed expansion projects are as
given below:-
Composite Area Statement

S.N Facility Existing Proposed Total
expansion
Area in Acres
1. Sub-merged Arc Furnace 2.00 - 2.00
3.6 MVA
2. Induction Furnace – Existing 0.50 - 0.50
3. Ferro Alloys Plant - 2.00 2.00

(Sub-merged Arc Furnace)
4. Induction Furnaces (1 x5) - 1.50 1.50
5. Rolling Mill with Coal Gasifier - 2.00 2.00
6. Iron Ore Washing Plant - 5.50 5.50
7. Raw materials Yard 1.0 0.50 1.50
8. finished goods Yard 1.0 0.50 1.50
9. Administrative building , 0.50 - 0.50
Security , weigh bridge etc
10. Roads , open area, others 3.50 - 3.50
utilities
11. Green Belt 4.00 6.50 10.50
Total 12.50 18.50 31.00
(5.05 Ha) (7.48 Ha) (12.54 Ha)
22
3.5 Mechanical Equipments and Process Flow Diagram
Plant & Machinery for Ferro Alloys Plant

Presently, the Company has 3.6MVA Sub-merged Arc Furnace, which is used
to produce CI lumps and CI balls. Now it is proposed to convert the production
into Ferro Alloys.
SN Description 3.6MVA 5.4MVA

(Existing) (Proposed)
1. Furnace Shell Diameter 6000 mm 6750mm
2. Electrode Diameter 700 mm 820mm

3. Smoke Hood Low Hood Low Hood
4. Furnace Transformer rating 4000 KVA 6000 KVA
5. Method of Tap Change O.L.T.C O.L.T.C
6 Furnace Height 3600 mm 3700mm
Details of 3.6MVA Sub-merged Arc Furnace (Existing)
1. Furnace Shell
Cylindrical casing and bottom constructed from thick plates around 16 mm
boiler plates and 20 mm rolled steel sections. Heavy stiffener rings and flat will
be provided to ensure the maintenance of the shell shape during operation and
in spite of high thermal and mechanical stresses. Three spouts at the hearth
level at 120 degrees apart will be attached to the shell for tapping purpose. The
diameter of the furnace is 6000 mm.
2. Exhaust Hood
The top portion of the hood will be fabricated out of 8/6 mm MS material. The
side wall of the hood will be fabricated out of 5 mm thick rolled sheets. The top
portion of the hood & supporting structure is water cooled. The entire side wall
& top portion of the hood will be supported on structural pillars fabricated out
of structural channels.
23
3. Connecting Duct and Chimney

One number of connecting duct and one number of chimney will be fabricated
from MS sheets. The chimney will be approximately 1270mm dia & 32 meters
in height from the ground level which is required as per the pollution control
authority’s rules and regulations.
4. Electrode System
Three numbers of self baking electrodes which is fabricated with MS sheet of 3
mm rolled and filled with CPC based carbon paste. The diameter of electrode is
700 mm.
5. Suspension Frame
Three sets of fabricated mantle box dully assembled with cooling blowers.
6. Mantle Frame / Cooling Shield

Mantles are fabricated with 8 mm thick MS/SS plate will be provided, which
will surround the electrode. The bottom flange of the mantle will be holding
pressure ring and contact shoe. The cooling shield s fitted in out side of the
mantle for to protect the copper tubes from direct heat. It is fabricated with 10
mm thick SS plate & highly insulated. Guide rolls are provided for to maintain
the balance of the mantle & cooling shield.
7. Pressure Ring
MS fabricated Pressure Ring duly machined & pressure tested; with water
cooling arrangements will be provided to press the contact pad to the electrode.
Pressure ring will be complete with springs & bolt assembly.
24
8. Refrectories
The furnace shell will be lined with cpc (calcined petroleum coke) based
tamping paste from inside. This will be backed by the layers of high Alumina
bricks and IS-8 bricks. Tapping holes will be provided at the hearth level in the
refractories which will make out of silicon carbide bricks. The bottom lining will
be thick layer of tamping level in the refractories with Alumina bricks of 45%
and 70%.
9. Copper
Water cooled copper condact pad will be provided which will be suspended
from mantle. Water cooled bus-tubes drawn form electrolytic copper material
will be used to supply the current from terminal block to the contact shoe.
Terminal block with flexible plate will be provided on the side of the
connections coming from the sides of furnace transformer. The bus tubes
coming from the furnace and the bus tubes coming from transformer is
connected with flexible copper cables. All copper items will be highly insulated
with mica tubes, Cynthania & etc
10. HYDRAULIC POWER PACK

This system using for the movement of electrodes & slipping mechanism. The
Hydraulic system will be complete with power pack, cylinders, remote operated
solenoid valve, non-conductivity flexible hydraulic hoses, pipes, valves & etc.
11. SLIPPING MECHANISM

Electrode slipping device will be provided for each electrode. This will facilitate
to slip the electrode downwards when the length of the electrode reduced due
to consumption in operation. The mechanism will be two-ring and will operate
on hydraulic force.
25
12. TAPPING ARRANGEMENTS

This will comprise the swivel type tap hole arcing device moving on monorails
around the furnace. Electrical connection to the arcing device should be
manually connected after it is in position. Normally oxygen and lancing pipe is
using to tapping the metal.
13. CONTROL PANEL

The control panel consists of side ventilating lowers, double rear door with
lock, completely shop assembled, wired, tested and painted. The apparatus and
instruments like voltmeter, ammeter, MDC meter, various indicating lamps,
push buttons, auxiliary contactors, protection fuses etc. And one number
power distribution control panel, MCC panel & hydraulic control panel for to
distribute the power supply from the auxiliary transformer.
14. SUB STATION
The 33 sub station consists of 3 no VCB, relay panels, auxiliary transformer,
current transformer (CT), potential transformer (PT), lightning arrester (LA),
Capacitor bank, A.B. switches, disc and pin insulators & etc. XLP cables are
using for to connect from breaker to furnace transformer.
15. BATCHING SYSTEM

Incoming raw materials are stored separately in their respective stockyards.
Daily requirements of these materials are transported from the stockyards to a
ground level hopper. There after, an elaborate raw-material handling system is
provided to feed the correct pre-weighed mixture to the furnace. This system
will consist of the following:
1] Feed hopper of 15-ton capacity
2] Belt conveyor 600 mm width, 30-cub.Mtr/hr. x 100 mtr capacity
3] 12 numbers of day bunkers will be fabricated out of steel structure
4] Vibratory feeders.
26
5] Weigh hopper with load cell arrangement with digital panel.
6] Shuttle conveyer 800 mm width x 18 mtr, 30-cub.Mtr/hr. capacity.
7] 3 ton capacity Monorail hoist.
8] Charging bins with 7 numbers of chutes with slide gate.
Automatic control panel for weighing & batching & necessary MCC
merged in the furnace control panel.
15(A) WEIGHING & BATCHING OPERATION

12 No Day bunkers shall be provided for 8 different raw materials. Vibrating
feeders shall be provided below the day bunkers. The vibrating feeders shall
have 2 modes of operations viz. Coarse & fine. Two number of weigh hopper
will receive raw material separately from separate 12 nos. of Day bunkers.
Each weigh hopper shall be supported on 4 nos. of load cells. Vibrating feeders
shall also be provided below the weigh hopper. Material duly weighed in the
weigh hopper shall fall on a conveyor below the weigh hopper, after switching
on the vibrating feeders below the weigh hopper. The material shall get dumped
in to a surge hopper with vibrating feeder.
15(B) FURNACE FEEDING SYSTEM

The weighed raw materials from surge hopper will collected in a conveyor belt
& lifted to third floor of furnace building.
6 nos. of charging bins and 1 no. of correction bin, which are located around
the circumference of furnace. With the help of mono-rail all charge bins are
filled with raw materials.
The charging bins will extend further in the form of a chute of 300 mm dia, up
to the furnace. Pneumatically operated gates will be provided in each chute.
These gates will be operated from the furnace platform.
27
16. FINISHING PRODUCT HANDLING

Finished goods are collected in C.I. pots / sand bed. One EOT crane-7.5 ton
capacity is using for handling the finished products.
17. FURNACE TRANSFORMER

Furnace transformer has a rating of 4000 KVA with O.L.T.C. Primary input is
33 KV & secondary out put is 70-100-140 V. 4 terminal in each phase on
secondary side. The furnace transformer is in two tanks ie Auto transformer
with OLTC in one tank and the main transformer in second tank. The auto
transformer is kept in ground floor & the main transformer in first floor. Both
transformers interconnected with XLP cable.
20. MISC.
The other components like stuffing box, softener plant, guide assemblies, all
cooling motors, manifold onwards for bus-tubes & hydraulic as well as water
with necessary fittings, flexible hoses etc.
21. POLUTION EQUIPMENT

Pollution equipment consists of I.D.fan, bag filter unit, ducting pipes, spark
arrester, pulse jet, dust collector & etc.
23. PUMP ROOM

The pump room consists of two pump & motors for water cool the copper bus
tubes, transformer & etc. Cooling tower is using for to cool the hot water which
is coming from furnace instruments. To full fill the vapour loss, water will
pump from bore-well through softener plant – which is used to reduce the
hardness of raw water. One number of pump & motor for to operate the
softener plant.
28
Details of 5.4MVA Sub-merged Arc Furnace (Proposed)
1. FURNACE SHELL
Cylindrical casing and bottom constructed from thick plates around 16 mm
and 20 mm rolled boiler steel sections. Heavy stiffener rings and flat will be
provided to ensure the maintenance of the shell shape during operation and in
spite of high thermal and mechanical stresses. Three spouts at the hearth level
at 120 degrees apart will be attached to the shell for tapping purpose. The
diameter of the furnace is 6750 mm.
2. EXHAUST HOOD
The top portion of the hood will be fabricated out of 8/6 mm MS material. The
side wall of the hood will be fabricated out of 4 mm thick rolled sheets. The top
portion of the hood & supporting structure is water cooled. The entire side wall
& top portion of the hood will be supported on structural pillars fabricated out
of structural channels.
3. CONNECTING DUCT AND CHIMNEY

One number of connecting duct and one number of chimney will be fabricated
from MS sheets. The chimney will be approximately 1500mm dia & 32 meters
in height from the ground level which is required as per the pollution control
authority’s rules and regulations.
4. ELECTRODE SYSTEM
Three numbers of self baking electrodes which is fabricated with MS sheet of 3
mm rolled and filled with carbon paste. The diameter of electrode is 820 mm.
29
5. SUSPENSION FRAME
Three sets of fabricated mantle box dully assembled with cooling blowers.
6. MANTLE FRAME/ COOLING SHIELD

Mantles are fabricated with 8 mm thick MS/SS plate will be provided, which
will surround the electrode. The bottom flange of the mantle will be holding
pressure ring and contact shoe. The cooling shield s fitted in out side of the
mantle for to protect the copper tubes from direct heat. It is fabricated with 10
mm thick SS plate & highly insulated. Guide rolls are provided for to maintain
the balance of the mantle & cooling shield.
7. PRESSURE RING
MS fabricated Pressure Ring duly machined & pressure tested; with water
cooling arrangements will be provided to press the contact pad to the electrode.
Pressure ring will be complete with springs & bolt assembly.
8. REFRECTORIES
The furnace shell will be lined with ECA based tamping paste from inside. This
will be backed by the layers of high Alumina bricks. Tapping holes will be
provided at the hearth level in the refractories which will make out of silicon
carbide bricks. The bottom lining will be thick layer of tamping level in the
refractories with Alumina bricks of 45% and 70%.
9. COPPER
Water cooled copper conduct pad will be provided which will be suspended
from mantle. Water cooled bus-tubes drawn from electrolytic copper material
will be used to supply the current from terminal block to the contact shoe.
30
Terminal block with flexible plate will be provided on the side of the
connections coming from the sides of furnace transformer. The bus tubes
coming from the furnace and the bus tubes coming from transformer is
connected with flexible copper cables. All copper items will be highly insulated
with mica tubes, Cynthiana & etc.
10. HYDRAULIC POWER PACK

This system using for the movement of electrodes & slipping mechanism. The
Hydraulic system will be complete with power pack, cylinders, remote operated
solenoid valve, non-conductivity flexible hydraulic hoses, pipes, valves & etc.
11. SLIPPING MECHANISM

Electrode slipping device will be provided for each electrode. This will facilitate
to slip the electrode downwards when the length of the electrode reduced due
to consumption in operation. The mechanism will be two-ring and will operate
on hydraulic force.
12. TAPPING ARRANGEMENTS (optional)
This will comprise the swivel type tap hole arcing device moving on monorails
around the furnace. Electrical connection to the arcing device should be
manually connected after it is in position. Normally oxygen and lancing pipe is
using for to tap the material from the furnace.
13. CONTROL PANEL

The control panel consists of side ventilating lowers, double rear door with
lock, completely shop assembled, wired, tested and painted. The apparatus and
instruments like voltmeter, ammeter, MDC meter, various indicating lamps,
push buttons, auxiliary contactors, protection fuses etc. And one number
31
distribution control panel, FPC panel & hydraulic control panel for to distribute
the power supply from the L.T transformer.
14. SUB STATION

The 33 sub station consists of 3 no VCB, relay panels, auxiliary transformer,
current transformer (CT), volt transformer (PT), lightning arrester (LA),
Capacitor bank, A.B. switches, disc and pin insulators & etc. XLP cables are
using for to connect from breaker to furnace transformer.
15. BATCHING SYSTEM

Incoming raw materials are stored separately in their respective stockyards.
Daily requirements of these materials are transported from the stockyards to a
ground level hopper. There after, an elaborate raw-material handling system is
provided to feed the correct pre-weighed mixture to the furnace. This system
will consist of the following:
1] Feed hopper of 15-ton capacity
2] Belt conveyor 600 mm width, 30-cub.Mtr/hr. x 100 mtr capacity
3] 12 numbers of day bunkers will be fabricated out of steel structure
4] Vibratory feeders.
5] Weigh hopper with load cell arrangement with digital panel.
6] Shuttle conveyer 800 mm width x 18 mtr, 30-cub.Mtr/hr. capacity.
7] 3 ton capacity Monorail hoist.
8] Charging bins with 7 numbers of chutes with slide gate.
Automatic control panel for weighing & batching & necessary MCC
merged in the furnace control panel.
32
15 (A) WEIGHING & BATCHING OPERATION

12 No Day bunkers shall be provided for 8 different raw materials. Vibrating
feeders shall be provided below the day bunkers. The vibrating feeders shall
have 2 modes of operations viz. Coarse & fine. Two number of weigh hopper
will receive raw material separately from separate 12 nos. of Day bunkers.
Each weigh hopper shall be supported on 4 nos. of load cells. Vibrating feeders
shall also be provided below the weigh hopper. Material duly weighed in the
weigh hopper shall fall on a conveyor below the weigh hopper, after switching
on the vibrating feeders below the weigh hopper. The material shall get dumped
in to a surge hopper with vibrating feeder.
15(B) FURNACE FEEDING SYSTEM

The weighed raw materials from surge hopper will collected in a conveyor belt
& lifted to third floor of furnace building.
6 nos. of charging bins and 1 no. of correction bin, which are located around
the circumference of furnace. With the help of mono-rail all charge bins are
filled with raw materials.
The charging bins will extend further in the form of a chute of 400 mm dia, up
to the furnace. Pneumatically operated gates will be provided in each chute.
These gates will be operated from the furnace platform.
16. FINISHING PRODUCT HANDLING

Finished goods are collected in C.I. pots / sand bed. One EOT crane-7.5 ton
capacity is using for handling the finished products.
17. FURNACE TRANSFORMER
Furnace transformer has a rating of 6000 KVA with O.L.T.C. Primary input is
33 KV & secondary out put is 70-110-140 V. 4 terminal in each phase on
secondary side.
The transformer is in two part ie Auto transformer & OLTC in one tank and the
main transformer with secondary side in another tank. Both transformers are
33
inter connected with XLP cable. The auto transformer is installed in ground
floor & the main transformer in 2nd floor.
18. MISC.
The other components like stuffing box, softener plant, guide assemblies, all
cooling motors, manifold onwards for bus-tubes & hydraulic as well as water
with necessary fittings, flexible hoses etc.
19. POLLUTION CONTROL EQUIPMENT

Pollution equipment consists of I.D.fan, filter bag unit, ducting pipes, spark
arrester, pulse jet, dust collector & etc.
20. PUMP ROOM

The pump room consists of two pump & motors for water cool the copper bus
tubes, transformer. Cooling tower is using for to cool the hot water which is
returned from furnace. To full fill the vapour loss, water will pump from bore-
well through softener plant. One number of pump & motor for to operate the
softener plant. One electric panel is also used to operate the pumps.
34
MANUFACTURING PROCESS OF FERRO ALLOYS
PROCESS OF SILICO MANGANESE / FERRO MANGANESE

MANUFACTURE
Production of Silico Manganese / Ferro Manganese in submerged arc electric
furnace is a process of smelting (reduction of oxide and melting of alloy and
slag) of manganese flux. The gangue in the ore is slagged off with dolomite as
flux.
Reduction of oxides of manganese and iron (present in Mn ore) and quartz is

carbothermic process. Which results in formation of respective carbides
necessitating fixed carbon input in the form of coke. Impurities such as
phosphorus, sulphur etc. also get reduced into the metal. The flue gas will let
out through the chimney.
The manufacturing process is continuous. Pre-mixed raw materials are fed

continuously into the furnace in required proportions through overhead
storage hoppers.
The liquid metal and slag are tapped out at regular intervals through common
tap holes. The metal is timed into cast iron moulds and the slag granulated for
disposal.
The metal, after stripping from the moulds are sized according to the
customers requirement and dispatched as loose in bulk or packed in gunny
bags.
Process Hazards:-
The whole process shall be carried out at higher temperature involving liquid
metal and slag.
35
36
Plant & Machinery for Existing & Proposed INDUCTION

FURNACES (Casting & Forging of Iron & Steel)
TECHNICAL SPECIFICATIONS
S.N. DESCRIPTION QTY.
1. 1 x 500 KW ( Existing )
500 KW E- Series solid state power 1 No.

supply unit with DM Water circulating
unit.
500 Kg ET- Alumin-SL Melting furnace 2 Nos.
with Hydraulic Tilting arrangement, Bus
bar, water cooled cables and
hydraulically operated furnace lid.
Hydraulic Power pack 1 No.
Furnace Transformer 1 No.
2. 1 x 750 KW (Proposed)
unit .
3. 1 x 2250 KW (Proposed)
unit .
- Furnace Transformer 1 No.
37
BOILER SPECIFICATIONS
For fulfilling requirement of steam in the Casting & Forging unit we have
installed a (1 x1 TPH) Grate / FBC Boiler. Detailed specifications is as under :-
No. of Boiler 1 No.
Type Grate
Make Thermax / CL / CBL / IBL
Capacity (Max.) 1 TPH
Working pressure 10Kg/cm2
Temperature 180oC
Operating Hr. 8 Hr. in a Day

300 days in a year
Fuel Requirement 0.25 TPH / 2 TPD
Fuel Type Coal
Auxiliary associated with Boiler Feed Boiler Feed Pump
Stack 30MTR. Stack of MS

Pollution Control unit Dust Collector
38
Plant & Machinery for Proposed INDUCTION FURNACES

(Casting & Forging of Iron & Steel, Ingots / Billets production)
TECHNICAL SPECIFICATIONS
S.N. DESCRIPTION QTY.
1. 1 x 500 KW

unit.
2. 1 x 750 KW
unit .
3. 1 x 2250 KW
unit .
- Furnace Transformer 1 No.
39
BOILER SPECIFICATIONS
For fulfilling requirement of steam in the Casting & Forging unit we propose to
install a (1 x1 TPH) Grate / FBC Boiler. Detailed specifications is as under :-
No. of Boiler 1 No.
Type Grate
Make Thermax / CL / CBL / IBL
Capacity (Max.) 1 TPH
Working pressure 10Kg/cm2
Temperature 180oC
Operating Hr. 8 Hr. in a Day

300 days in a year
Fuel Requirement 0.25 TPH / 2 TPD
Fuel Type Coal
Auxiliary associated with Boiler Feed Boiler Feed Pump
Stack 30MTR. Stack of MS

Pollution Control unit Dust Collector
PROCESS OF MANUFACTURE
We intend to setup a Foundry based on lost foam casting process to

manufacture Grey Iron, Ductile iron, Steel and Alloy Steel Castings. The target
is to manufacture small castings between 0.2 kg to 200 kg and cater the needs
of Steel Plants, Pallet Plants, cement plants, Sinter Plants, Railway Coach
Factories, Pump, Agriculture equipment, Automobile and valve Industries.
The Lost foam Casting Process

The project envisages creating facilities of modern foundry methods using Lost
Foam casting process where a high density polystyrene or styro foam pattern is
40
used. The pattern is dipped into special refractory paint which forms coating.
This enables near net shape castings which can be made more cost-effectively
than by the sand moulding process. The process has got following distinct
advantages.
High Integrity Castings with, Exceptional Surface Finish:
This being a ceramic molding process, inclusions, gas, hot tears and other
casting defects associated with sand molding are avoided. It also gives the
products exceptional surface finish that is at par with that of products made by
the investment process.
41
Process Flow Chart
The process flow with details of each step is described in detail hereunder :-
PRE MOULDING ASSEMB COATING

EXPANSIO LY
N
DRIER SAND COMPACTION POURING

FILLING
SHAKE- FETTL CLEANING MACHINING

OUT INGG
42
Pre-expansion
The tiny spherical polystyrene beads are expanded to about 30-40 times their
original size using a small quantity of pentane (typically 5% by weight) as a
blowing agent. This process involves the heating of beads, using a flow of
steam, which causes the blowing agent to boil and thus a honeycomb of closed
cells is formed. As the material cools the pentane liquefies and a partial
vacuum is formed inside the bead. It takes about 45 minutes. The beads are
returned to a holding tank for approximately twelve hours to allow the reassure
differential to equalize, giving a stabilized granule.
Raw Materials for the manufacture of Castings
1. Cast Iron 6. FeMn

2. Pig Iron (Fdy. Grade) 7. SiMn
3. Steel Scrap 8. Inoculin
4. Dolomite 9. Cored wire Mg. / Fesi Mg.
5. FeSi
Raw materials like Pig Iron Steel, Ferro Alloys etc. are melted in Induction
Furnace with Fesi, FeMn, Cast iron (liquid metal available), the melted metal
is adjusted in the Induction Furnace for its composition super heated to the
require temperature. The metal is then tapped, inoculated and poured into
mould already prepared. Necessary lab, chemical and physical checks are
carried out for adequacy.
The moulds are prepared this way:-
A pattern is made as per the requirements of the drawing of the customer. It is

then fitted in a match plate, mounted on to moulder machines and is
prepared with Bentonite, coal dust and water in sand conditioning plant
as per requirement. A moulding base is placed on to the match plate on the
machine and prepared silica sand is fed into the box.
43
The casting thus poured is shot blasted, fettled. Dimensional checks, hydraulic
testing, machining etc. is done as per requirement. Heat treatment and
tempering is done on casting wherever necessary. As per market requirement
forging will also be done with proper capacity of press. After doing final
inspection the castings are painted, packed and dispatched.
This iron is chosen because of its remarkable combination of strength,

toughness and wears resistance. Its outstanding features are good corrosion
resistance and oxidation resistance. Magnetic properties, strength and
dimensional stability at elevated temperature are its very good features.
These properties are developed by a closely controlled heat treatment

operation called austempering which develops a union matrix structure of
bainitic ferrite (60%) and retained (high carbon) austenite. This is thermally
stable at extremely low temperatures but is work hardanable and will locally
transform into martin site under suitable conditions of stress. This phase is
extremely hard.
44
Plant & Machinery for Proposed ROLLING MILL along with

COAL GASIFIER
TECHNOLOGICAL PARAMETERS
1 Reheating Furnace 8 MT/ hour
2 Rolling Mill 60 MT / Day
3 Cooling bed 8 MT/hour
4 CRANES CAP 5 ton
5 WATER SOFTENING PLANT 500 LITRE CAP, TYRE RESIN NA
6 COOLING TOWER ERP COUNTER FLOW BOTTLE

SHAPE
7 OTHER EQUIPEMNTS VIZ CHARGING CAR AND BUCKETS,

magnet etc ELECTRICALS ETC.
8 Coal Gasifier 1 No.
MANUFACTURING PROCESS OF ROLLING MILL
The capacities of the proposed facilities are given below:
PRODUCT PROPOSED CAPACITY

(METRIC TON)
MS strip/round /square 18,000 TPA
45
The proposed project will be based on the steel rolling through Coal
Gasifier/pulveriser, Reheating furnace, rolling mill, cooling bed This route of
steel making has the following benefits:
 Very high on quality
 Lower Power Consumption,
 Environment friendly process as compared to other processes of Steel
Making.
Under this process, company will have the ability to produce MS strip/round
/square. The product-wise capacity is flexible, and can be adjusted based
upon the prevailing market conditions.
PRODUCT- MIX
The product mix envisaged for the proposed plant is given in the following table
keeping in the view the group’s internal consumption pattern and down ward
market requirements. The promoters in consultation with technical
consultants are planning the following product-mix:
S Item Qty Uses
N
1 MS strip/round 18000 MT Building construction and
/square / Bar manufacturing domestic use Chanel
gates machine Parts,nails, pins, &
many othe products.
TECHNOLOGICAL CONSIDERATION FOR PROCESS ROUTE

AND PLANT CAPACITY
Production of iron and steel is highly technology oriented. The technological

consideration for the different process considered for this plant has been
analyzed.
46
The choice of various technologies and plants are based on the following broad
considerations.
 The plant to be based 60 TPD rolling mill , Producer gas/coal base
reheating furnace, & cooling bed
 The plant capacity will be 18000 TPA
 Optimization of productivity and efficiency of overall plant with a view to
optimize the plant investment and operating cost.
GENERAL LAYOUT
The layout of the plant has been planned considering the plant capacity of
18000 TPA of MS strip/round /square / Bar Total area required for the
proposed steel plant is 2 acre . The general layout of the plant has been
planned by taking in to account road entries, natural terrain of the site,
rational flow materials, maximum utilization of the area, shortest possible lead
for communication network and predominant direction of wind. The layout
plan is enclosed at the end of this report.
RAW MATERIALS
The requirement of major raw material as considered for this report are given
in the table below:
Description Annual Requirement
(MT)
1 Billet 18460
2 Coal 3700
The raw material can be sourced locally.
47
STEEL ROLLING
The billets, are heated at 1200°C to make metal malleable and then rolled into
finished products. There are different rolling mills for different products.
Rolling mill for long products such as bars, angles, structural etc. can be part
of steel making plant or an independent small-scale industry. Flat product
rolling mills are capital intensive, as they have to meet strict quality
parameters.
1 Machine type Automatic
2 Configuration
Roughing Mill
Intermediate Mill
Finishing Mill
3 Installed capacity / year 18000 MT
4 Shift 1 Shift 10 Hours
5 Working days / year 300
6 Finished Products MS strip/round /square/Bar
7 Average weight of billet/bloom 50 Kgs

charge
48
STEEL ROLLING PROCESS FLOW CHART
Coal
Coal gasifier
Poducer Gas
Billet
Reheating Furnace
Rolling Mill
Cooling Bed/
Inspection Bed
MS strip/round /square
49
Manufacturing Process of Rolling mill for production MS

strip/Round/Square/Bar.
Re Heating Furnace
The billets (Raw Material) are charged on the Billet charging bed (reheating
furnace)by the billet yard crane and then charge through back charging door
by Mechanical Pusher inside the furnace and the heated billets are discharged
from reheating furnace through side discharging door by mechanical ejector
and processed through roughing mill train
Pusher-Type Furnaces
Continuous pusher-type furnaces were designed initially for heating billets and
small bloom sections. The hearths were relatively short in length and were
sloped downward longitudinally towards the discharge end to permit an easy
movement of billets through the furnace. Pushers were used to push forward
the charge of cold billets.
Longer furnaces generally are constructed now. Some have hearths about 24.5
metres (80feet) long, with top and bottom firing, and contain preheating,
heating and soaking zones. Recuperators are utilized to provide waste-heat
recovery. Multiple-zone furnace (e.g. five-zone slab heating furnace) have been
evolved from one-zone furnace in the early designs. to the modern five-zone
slab heating furnace.
The steel to be heated in a continuous furnace can be charged either from the
end or through a side door. In either case, the steel is moved through the
furnace by pushing the last piece charged with a pusher at the charging end.
As each cold piece is pushed into the furnace against the continuous line of
material, a heated piece is removed. The heated piece is discharged by several
methods, such as through an end door by gravity upon a roller table which
feeds the mill, or pushed through a side door to the mill table by suitable
manual or mechanical means or withdrawn through the end door by a
mechanical extractor.
50
Advantages of the pusher-type furnaces are collected as follows:

 High production per dollar investment, high hearth area efficiency, and
high production per square foot of ground space occupied.
 Low maintenance, ease in charging and drawing steel, less trouble from
temperature inequalities between each succeeding piece drawn.
 Better means for controlling the rate of heating at all temperature levels.
Gradual rise in temperature permits charging all grades of cold steel
without cooling furnace.
 Can be built for any reasonable length of piece to be heated, resulting in
higher mill yield.
Rolling Mill
The Rolling Mill comprises a roughing mill, a intermediate mill , & three
finishing mill for producing various sizes. TMT machine for producing TMT
quality bars, cooling bed for maintain the uniform quality.
51
Cooling Bed
On the cooling bed, products are cooled down to desired temperature, while
maintaining the straightness.
Cutting & finishing system (For deformed bar & section)

Those products are then discharged from the cooling bed and further processed
by cutting and finishing system.
All products are cut to length by cold shear transferred to receiving conveyor.
At the end of the conveyor, a conveyed table is located which transfer the
products to bundling area then to shipping are.
Electrical
The Rolling Mill plant need mains input power source voltage level shall be
4500KW
52
TECHNICAL SPECIFICATION OF COAL GASIFIER
Sr. Requirement Solution

No.
1 No of Gasifier 01
2 Type Hot gas
3 capacity 1750 cu.m/hr
4 Coal required 3700 ton
5 Make up water 750 ltr/ton
6 Heat required /ton 300000 Kcal/to
7 GVC of Fuel 1200 Kcal/M3
8 Gas required 1500 M3 / hour
7 Finish steel output 6ton/hour
8 Ash generation 40% of coal used
9 Tar generation 100 kg- 360kg/day
10 Stack 40 mtr height & 600 dia

at top- 1200 dia at
bottom
11 Pollution control equipment Recuperator
Bag filters
53
MANUFACTURING PROCESS OF COAL GASIFIER – PRODUCER

GAS
The Single Stage Gasifier is required for industries where the production is
based on mechanism with hot gas. The Gasifier is equipped with a mono-
bucket coal lifting crane and bunker. The coal feeder is dual roller coal feeder
and the wet revolving ash-pan drive is used to take the ash out of the Gasifier.
The system of coal gasification is simply incomplete oxidation of carbon in the
coal to produce mixture of gases mainly carbon mono oxide and methane.
These gases are taken to the combustion in re- furnace to produce heat on
complete oxidation.
The coal is feed from above and a mixture of steam and air is charged from
below. The resulting gas generated is tapped from above.
Coal gas is produced by the reaction of gasification agent, which is mixture of
steam and air, which goes through red - hot fixed burning bed of the carbon in
form of coal.
The oxygen content in the air and steam react with the carbon in the fuel,
generating the coal gas.
54
COAL GASIFIER PROCESS FLOW CHART
AIR POWER RE-

HEAT
F/C
COAL GASIFIER CYCLONE BURNER
GAS DUCT
GAS
BLOWER
WATER ASH
R
HOT AIR
CHIMNEY
RECUPERATOR
55
Plant & Machinery for Proposed Iron Ore Washing Plant
Main Characteristics of Process Technique & Level of

Equipment
Screening arrangement will be incorporated to screen our fines (-8mmsize) from

the calibrated ore. Screening of -8mm fines will be done to separate -1mm &
+1mm to -8mm fines. The float ore contains lot of quartzite,
BHQ and other gangue material. The ore from the mine has about 50% fines
which will be also screened here to -1mm & +1mm to -8mm sizes.
The undersize & fines are sent to fine master where by the help of cyclones
washed fines of -1mm separated by screen. Below – 50 micron is pumped to
Thickener and dozing of flocculants helps to clear the water for reuse.
At all the transfer point of conveyor belt water sprinkling in adequate quantity
will be done. The hopper where fines / ROM is fed is also provided with
sprinkler to prevent dust dispersion.
The calibrated iron ore & fines will be sold in the local marked. The -50 micron
fraction containing gangue material shall be pressure filtered for squeezing
water and used for brick making and sold to cement plants.
SN Description Unit Qty

1 Ground Hopper Feeder & Conveyor set 1
2. Power Rinser – 1400 voltas make set 1
3 Screen & oversize conveyor set 1
4 Pressure filter No 2
5. Product conveyor & Hopper Nos 6
6 Attrition Scrubber Nos 2
7 Slurry pumps Nos 4
8 Fine Master – 120 & Twin conveyors set 2
9 Thickner Nos 2
10 Pumps & fittings Nos 6
11 Bag filter Nos 2
12 Submersible pump Nos 4
56
13 Weigh Bridge – 100 ton Nos 2

14 Pay loader 2.3 Cum No 2
15 Water sprinkling & mister All transfer points
1. Iron ore size:- - 8 mm
- 8 mm fines are of low grade. These fines need to be washed to make it

suitable feed to Blast furnace / DRI plant.
The Iron Ore (- 8 mm) typically has following Chemical analysis.
Fe :- 58%
SiO2:- 8 to 12%
Al2O3:- 1.5 to 2.5%
The proposed Iron Ore washing plant shall have basically following sections to
upgrade the ore to Minimum 63.5% Fe & SiO2 + Al2O3 less than 5%.
1. Wet scrubbing & screening.

2. Attrition scrubber to remove sticking Al2O3 & SiO2.
3. Fine master with hydro cyclones to further remove impurities.
4. Thickener(s) to thicken the slurry and separate water for recirculation in the
system.
6. Filtration of tailings to dewater it.
1. Wet Screening
-8 mm fines shall be passed through wet screens to remove surface stuck

laterite, alumina etc. The ore will be separated in to different sizes of
lumps & fines after screening.
57
2. Power Scrubber
Fines and sized ore will pass through power scrubber to liberate sticking
alumina and silica by scrubbing the ore.
3. Attrition Scrubber
Fines of +1 mm and –8 mm will be given churning effect by electrically

driven equipment where sticking fines will further get liberated from
alumina & Silica.
4. Fine Master
Fines -1 mm and +1 mm to –8 mm from attrition scrubber will pass

through fine master where hydro cyclone will separated silica and
alumina.
5. Slurry Pump Box
The liberated alumina and silica along with water is accumulated in

slurry pump box from where it is pumped to thickener.
6. Thickener
Silt is allowed to settle by adding flocculent and clean water is siphoned

to raw water tank from where it re-circulates for washing purpose.
7. Pressure filter / Ceramic filter
The silt from the thickener will be pumped to pressure filter for
dewatering purpose, which will be used for brick making and sold to
cement plants.
The input and output quality of Iron ore washing from Input of 58 Fe
Grade to 63.5 Fe Grade output.
58
59
3.6 Raw Material & Other Utilities
MATERIAL BALANCE OF PROPOSED FERRO ALLOYS PLANT

(Ferro Manganese)
PER TON OF PRODUCT
Considering Power consumption as 3000 units / MT
S. N. NAME OF MATERIAL QUANTITY OUTPUT QUANTITY
01 Manganese Ore 2.35 Metal 1.0
02 Pearl Coke 0.6 Slag 1.0
03 Dolomite 0.36 Burning 1.31

losses
Total 3.31 3.31
ANNUAL REQUIREMENT FOR PRODUCTION OF FERRO MANGANESE
S. NAME OF 3.6 MVA Submerged Arc 5.4 MVA Submerged Arc Total Raw
N. RAW Furnace furnace Material
MATERIAL ANNUAL PRODUCTION ANNUAL PRODUCTION requirement
OF 9200 MT OF 13800 MT
QTY OUTPUT QTY QTY OUTPUT QTY QTY
1 Manganese 21620 Metal 9200 32430 Metal 13800 54050
Ore
2 Pearl Coke 5520 Slag 9200 8280 Slag 13800 13800
3 Dolomite 3312 Burning 12052 4968 Burning 18078 8280
Loss Loss
TOTAL 30452 30452 45678 45678
60
MATERIAL BALANCE OF PROPOSED FERRO ALLOYS PLANT

(Silico Manganese)
PER TON OF PRODUCT
Considering Power consumption as 4000 units / MT.
S. N. NAME OF MATERIAL QUANTITY OUTPUT QUANTITY
01 Manganese Ore 1.8 Metal 1.0
02 Manganese Slag 0.6 Slag 0.9
03 Pearl Coke 0.31 Burning 1.32

Loss
04 Steam Coal 0.21
05 Quartz 0.21
06 Dolomite 0.095
Total 3.22 3.22
ANNUAL REQUIREMENT FOR PRODUCTION OF SILICO MANGANESE
S. NAME OF 3.6 MVA Submerged Arc 5.4 MVA Submerged Arc

N. MATERIAL Furnace furnace
ANNUAL PRODUCTION OF ANNUAL PRODUCTION OF
6900 MT 10300 MT
QTY OUTPUT QTY QTY OUTPUT QTY
1 Manganese Ore 12420 Metal 6900 18540 Metal 10300
2 Manganese Slag 4140 Slag 6210 6180 Slag 9270
3 Pearl Coke 2139 Burning 9143 3193 Burning 13648

Loss Loss
4 Steam coal 1449 2163
5 Quartz 1449 2163
6 Dolomite 656 979

Total 22253 22253 33218 33218
61
MATERIAL BALANCE OF INDUCTION FURNACE FOR THE

PRODUCTION OF DUCTILE IRON CASTING & FORGING
PER TON OF PRODUCT
FOR 1.0T DUCTILE IRON CASTING

C=3.4-3.7%, Mn=≤0.60%, Si =2.0-2.2%, S=≤0.02%, P=≤0.04%, Mg =0.03-0.045%,
Cu=≤0.5%
QTY. UNIT
A RAW MATERIAL
1 CRCA SCRAP 940 kg
2 PIG IRON (STEEL GRADE) 300 kg
3 CARBURIZER 40 kg
4 FERRO SILICON 30 kg
5 FERRO-SILICON-MAGNESIUM 20 kg
6 H/C FERRO-MANGANESE 3 kg
7 COPPER 7 kg
8 INNOCULANT 6 kg
Total 1346 kg
FOUNDRY RETURN (against 13.25% gating system) after 3%

B burning loss 178 kg
C FOUNDRY RETURN (against 10% rejection) after 3% burning loss 134 kg
Total Return 312 kg
D Total charge 1346 kg

E Total Return as foundry return (including rejection) 312 kg
F Burning loss 12 kg
G Slag 22 kg
H Total casting 1000 kg
62
ANNUAL REQUIREMENT FOR PRODUCTION OF DUCTILE IRON
S. NAME OF 1X550 KW INDUCTIN 1X750KW & 1X2250KW

N. RAW FURNACE (EXISTING) INDUCTION FURNACE
MATERIAL ANNUAL (PROPOSED)
PRODUCTION OF ANNUAL PRODUCTION
3600 MT OF 8400 MT
INPUT QTY OUTPUT QTY QTY OUTPUT QTY
1 CRCA Scrap 3384 Metal 3600 7896 Metal 8400
2 Pig Iron 1080 Slag 79 2520 Slag 184
(steel grade)
3 Carburizer 144 Burning 43 336 Burning 101
Loss Loss
4 Ferro 108 Foundry 1124 252 Foundry 2621
Silicon return return
5 Ferro- 72 168
Silicon-
Magnesium
6 H/C Ferro- 11 25
Magnesium
7 Copper 25 59
8 Innoculant 22 50
TOTAL 4846 4846 11306 11306
S. NAME OF 1X550 KW & 1X750KW & TOTAL RAW

N. RAW 1X2250KW INDUCTION MATERIAL
MATERIAL FURNACE (PROPOSED) REQUIREMENT
ANNUAL PRODUCTION OF FOR
12000 MT EXISTING,
PROPOSED
INDUCTION
FURNACES
INPUT QTY OUTPUT QTY INPUT
1 CRCA 11280 Metal 12000 22560
Scrap
2 Pig Iron 3600 Slag 263 7200
(steel
grade)
3 Carburizer 480 Burning 144 960
Loss
4 Ferro 360 Foundry 3745 720
Silicon return
5 Ferro- 240 480
Silicon-
63
Magnesium
6 H/C Ferro- 36 72
Magnesium
7 Copper 84 168
8 Innoculant 72 144
TOTAL 16152 16152 32304
PER TON OF PRODUCT
FOR 1.0T CAST IRON CASTING

C=3.0-3.7%, Mn=≤0.60%, Si =1.4-1.8%, S=≤0.10%, P=≤0.150%,
QTY. UNIT
A RAW MATERIAL
1 PIG IRON (STEEL GRADE) 1000 kg
2 M.S. STEEL 260 kg
3 FERRO SILICON 17 kg
4 HIGH CARBON FERRO-MANGANESE 3 kg
Total 1280 kg
B FOUNDRY RETURN (against 10% gating system) 128 kg

C FOUNDRY RETURN (against 10% rejection) 128 kg
Total Return 256 kg
D Total charge 1280 kg

E Total Return as foundry return (including rejection) 256 kg
F Burning Loss 10 kg
G Slag 14 kg
H Total casting 1000 kg
64
ANNUAL REQUIREMENT FOR PRODUCTION OF CAST IRON
S. NAME OF 1X550 KW 1X750KW & 1X2250KW

N. RAW INDUCTION FURNACE INDUCTION FURNACE
MATERIAL (EXISTING) (PROPOSED)
ANNUAL ANNUAL PRODUCTION
PRODUCTION OF OF 8400 MT
3600 MT
INPUT QTY OUTPUT QTY QTY OUTPUT QTY
2 Pig Iron 3600 Slag 50 8400 Slag 118
(steel grade)
3 MS Steel 936 Burning 36 2184 Burning 84
Loss Loss
4 Ferro 61 Foundry 922 143 Foundry 2150
Silicon return return
5 High 11 Metal 3600 25 Metal 8400
Carbon
Ferro
Manganese
8
TOTAL 4608 4608 10752 10752
S. NAME OF 1X550 KW & 1X750KW & TOTAL RAW

N. RAW 1X2250KW INDUCTION MATERIAL
MATERIAL FURNACE (PROPOSED) REQUIREMENT
ANNUAL PRODUCTION OF FOR
12000 MT EXISTING,
PROPOSED
INDUCTION
FURNACES
INPUT QTY OUTPUT QTY
1 Pig Iron 12000 Metal 12000 24000
(steel
grade)
2 MS Steel 3120 Slag 168 6240
3 Ferro 204 Burning 120 408
Silicon Loss
4 High 36 Foundry 3072 72
Carbon return
Ferro
Manganese
TOTAL 15360 15360 30720
65
RAW MATERIALS REQUIREMENT FOR 18000 TPA ROLLING

MILL FOR PRODUCTION OF MS STRIPS / ROUNDS / SQUARE /
BAR
The requirement of major raw material as considered for this report are given
in the table below:
Description Annual Requirement
(MT)
1 Billet 18500
Coal
(Required for production of
2 Producer Gas) 3700
66
Material Balance Flow Chart of Rolling mill
B/loss – 2 %
369 MT
Billet 18000
MT
18460
MT End cutting – 0.5%
91 MT
67
Material Balance of Coal Gasifier
14800000 M3
Reheating furnace
Producer gas
Land filling & brick

Coal-3700 ash
manufacturing
(1480 ton)
Tar- 60 ton Sale to Authorised

vendor in market
68
Material Balance for 0.5 MTPA Washing Plant
(Taking 300 operational days)
INPUT QTY (MT) OUTPUT QTY. (MT)

PER ANNUM PER ANNUM
Iron Ore Fines (-8mm) 500000 Iron ore 350000

Fe58 Fe>63.5%
Tailings * 150000
500000 500000
* Tailings will be sold to cement plant in the local market and also used for
bricks making.
69
3.7 FUEL
LDO / HFO shall be used in Induction furnace and Coal shall be used in
Boilers and Producer gas will be used in Reheating furnace of Rolling Mill. The
details are given below :
SN Type of fuel Facility Qty /annum
1. LDO / HFO Induction Furnace 5 KL

4. Coal / Reheating furnace of 3700 MT or
Producer Gas Rolling Mill 1750 cum/hr.
5. Coal Boiler (Two nos.) at 1200
Induction furnace
70
3.8 WATER REQUIREMENT
Water is required in the plant mainly for the purpose of equipment cooling, in
Ferro alloys, Induction furnace and Iron Ore washing purpose. Water is also
required for drinking, sanitary, and firefighting purposes. In order to conserve
water and minimize the make-up water requirement, it is proposed to adopt re-
circulating system after proper treatment for the equipment cooling. In re-
circulating system same water re-circulate again and again and some make
water is added for evaporation losses. The outflow from the toilets of the plant
buildings shall be led to various septic tanks in respective areas through
separate drains and the run-off of them will be connected to sock pits
/dispersion trenches. The total water balance for the plant is shown in the
following tables :-
WATER BALANCE FOR FERRO ALLOYS
SN INPUT QTY. IN KL/ DAY
3.6 MVA 5.4 MVA TOTAL
A 1. Cooling system 17 25.5 42.5
2. Spray 1.0 1.5 2.5
3. Softener Regeneration 2.0 3.0 5.0
4. Domestic 1.0 2.0 3.0
Total 21 32 53
B Evaporation loss and consumed water details
1. Cooling system 16.2 24.3 40.5
2. Spray 1.0 1.5 2.5
71
4. Domestic 0.5 0.5 1.0
Total 17.9 27.1 44.5
C Wastewater
Generation
2. Spray - - -
4. Domestic 0.4 1.5 1.9
Total 3.0 5.4 8.4
WATER BALANCE FOR INDUCTION FURNACE
The water requirement is very low is only 34 KLD for Existing & proposed
induction furnaces including the requirement for Domestic purpose. Water will
be mainly required for the purpose of cooling the processed materials. The
existing source is sufficient to meet our increased water requirement.
SN INPUT QTY. IN KL/ DAY Total
Existing Proposed
A Cooling system 2 12 14
1.
2. Boiler 8 8 16
3. Domestic 0.6 3.4 4
Total 10.6 23.4 34
B Evaporation loss and consumed water details
72
1. Cooling system 3 10.3 13.3
2. Boiler 3 9 12
3. Domestic 0.5 0.5 1
Total 6.5 19.8 26.3
C Wastewater
Generation
2. Boiler Blow down 1 3 4
3. Domestic 0.5 2.5 3
Total 1.6 6.1 7.7
WATER BALANCE FOR ROLLING MILL ALONGWITH GASIFIER
SN FACILITY TOTAL
A INPUT
1. Cooling system including Gasifier 20.0
2. Dust Suppression 3.0
3. Domestic 5.0
4. Plantation 5.0
Total 33.0
B EVAPORATION LOSS AND CONSUMED WATER DETAILS
1. Cooling system 19.0
2. Dust Suppression 3.0
3. Domestic 3.0
4. Plantation 5.0
73
Total 30.
C Wastewater Generation
1. Cooling system 1.0
2. Dust Suppression Nil
3. Domestic 2.0
4. Plantation Nil
Total 3.0
WATER BALANCE FOR IRON ORE WASHING PLANT

The total water requirement for the Iron Ore washing plant will be
approximately 200 KL/Day. About 40% water will be lost and the rest
60% will be recycled. The overall water balance is mentioned bellow:-
Details Process System Waste Water Uses

Loss Generation
Process 190 76 114 Recycle
Miscellaneous 9.80 9.80 -- --

(Spraying &
Plantation)
Domestic 0.20 0.10 0.10 Septic tanks

& soak Pit
Total 200.00 85.90 114.10
74
3.9 Quantity of wastes to be generated (liquid and solid) and

scheme for their Management / Disposal.
3.9.1 Solid Waste Management
The quantity of solid waste generation and its utilization / disposal shall be
mentioned below in the table:
SN Solid waste Source Quantity Utilization / Disposal

TPA
1. Ferro / Silico Ferro 13800 100% Ferro manganese slag will be
Manganese Alloys used in Plant for production of
Slag Plant Silico manganese. In case silico
manganese will be produced then
the slag will be sold to brick plant
& used for road making.
2 Runner Induction 7490 100% re-used in the plant itself as

Riser/ furnace a raw material.
Foundry
Return
(considering
DI casting)
3 Induction Induction 526 For making of road and filling of

furnace Slag furnace low laying area in the premises
(Considering and also sold to bricks / blocks
DI casting) manufacturing plant
4. Ash Coal Boiler 600 Will be sold to brick

manufacturing plant
5. Burnt Sand Induction 34 Will be sold to brick
furnace manufacturing plant.
6. End cutting Rolling mill 91 End cutting will be recycled back

& Mill scale in the Induction furnace and Mill
scale will be sold in the market.
7. Tar Gasifier 60 It will be sold to authorized vendor
in the market.
8. Ash & cinder Gasifier 1480 Will be sold to brick
manufacturing plant.
7 Tailings Iron ore 150000 Tailings will be sold to cement
washing plant in the local market.
plant.
75
3.10 AIR POLLUTION
There will be two major source of air pollution in the plant, fugitive emissions
from various material handling and transfer points and from flue gases
generated from various combustion units. In order to control the air pollution
in the Induction Furnace, Submerged Arc furnace, Shot blasting machine and
Boilers etc. The Dust extraction systems will be installed, it consists of suction
hood, cyclones, Bag filters. Suction hood mounts on the head of the furnace,
the flue gases will be sucked through the hood.
The blower sucks the flue gases through hood along with pipe, which is
connected to the cyclone. The cool and fresh air will be exhausting through the
30/40 meter stack, in which the dust concentration will be less than the
prescribed standard.
Flue gas discharge facilities of existing plant and proposed project are as
under :-
UNIT AIR POLLUTION EFFIC STACK NO OF

CONTROL SYSTEM IENC HEIGHT STACKS
Y
3.6MVA Bag house with online 99.5% 30M ( as per 01

Submerged Arc emission monitoring CPCB
furnace (Existing) system (OPACITY guidelines)
METER )
Induction Furnace Dust Extraction 99.5% 30M ( as per 01
(1x550 KW) system with Suction CPCB
(Existing) Hood, Cyclone guidelines)
Grate Boiler Dust Collector 99.5% 30M ( as per 01

(Existing) CPCB
guidelines)
Induction Furnace Dust Extraction 99.5% - do- 01

(1x750KW + 1 x system with Suction
2250 KW) Hood, Cyclone.
(Proposed)
76
5.4MVA Bag house with online 99.5% 30M ( as per 01

Submerged Arc emission monitoring CPCB
furnace(Proposed) system (OPACITY guidelines)
METER )
Grate Boiler Dust Collector 99.5% 30M ( as per 01
(Proposed) CPCB
guidelines
Induction Furnace Dust Extraction 99.5% 30M each ( as 02

1x550 KW system with Suction per CPCB
1x750KW Hood, Cyclone. guidelines
1 x 2250 KW
Proposed
Reheating Furnace Bag house & Heat 99.5% 40M 01

for Rolling Mill with recuperator and online
Gasifier emission monitoring
(Proposed) system.
77
3.11 WATER POLLUTION
Water is required in the plant mainly for the purpose of equipment cooling, in
Ferro alloys, Induction furnace and Iron Ore washing purpose. Water is also
required for drinking, sanitary, and firefighting purposes. In order to conserve
water and minimize the make-up water requirement, it is proposed to adopt re-
circulating system after proper treatment for the equipment cooling. In re-
circulating system same water re-circulate again and again and some make
water is added for evaporation losses. The outflow from the toilets of the plant
buildings shall be led to various septic tanks in respective areas through
separate drains and the run-off of them will be connected to sock pits
/dispersion trenches.
Out of the total water requirement of 320 KLD for the existing as well as
proposed plants only 133.3 KLD waste water will be generated. The disposal of
this will be done as under:-
Sn Type of waste water Quantity Treatment / Disposal Methodology

(in KLD)
1. Domestic 7 Treated in septic tank attached with
soak pit
2. Back wash & 4.5 Will be utilized for spraying and dust
Softener suppression and plantation.
Regeneration
3 Process of Washing 114.10 Re-cycle in the respective plant.

plant.
4. Cooling system 3.7 Re-cycle in cooling
5. Boiler Blow down 4 Will be utilized for spraying and dust

suppression and plantation.
Total 133.3
78
3.12 NOISE ABATEMENT
Noises from compressor, fans, centrifugal pumps, electrical motors etc. will be
kept in control so that the ambient noise level shall not exceed 75dBA during
daytime and 70dBA during nighttime. Noise pollution control measures will be
provided in respective departments by way of providing silencers soundproofs
cubicles / covers and proper selection of less noise prone machinery and by
development of green belt.
3.13 GREEN BELT DEVELOPMENT
The plantation and green belt development has been taken care in and the
space reserved for plantation is more than 33% of the total plant area. The
company has developed extensive green belt around the plant by planting
suitable species of evergreen trees which will be extended further. Adequate
plantation will substantially abate the dust pollution, filter the polluted air,
reduce the noise and ameliorate the plant environment. The total plantation
area is 10.5 acre.
3.14 OCCUPATIONAL HEALTH AND SAFETY

Besides the above, the operating and maintenance personnel will be provided
with all the necessary safety equipment such as hand gloves, gum boots,
aprons, helmets, protective glasses, ear muffs etc. Workers training will focus
on reduction of wastes, utilization of wastes and generally maintaining a clean
and healthy environment.
3.15 SOCIO-ECONOMIC ENVIRONMENT

The implementation of the project will have the following positive impacts over
the surrounding area.
-Increase in job opportunities for local as well as population in the surrounding

area.
-Increase in business opportunities for the local people, due to which economic
status of the community would increase.
79
CHAPTER-4
Site Analysis
4.1 Connectivity
The proposed expansion by adding Submerged Arc Furnace and Induction

furnaces, Rolling mill along with Gasifier and Iron ore washing plant to be
installed at existing site which is located at village: Duldula, Tehsil: Simga,
Dist: Baloda Bazaar, Chhattisgarh-State. The nearest city from the site is
Simga which is around 3 KM. The nearest Railway station is Tilda on Mumbai –
Howrah main line which is around 14 KM. Nearest air port is at Raipur which
is 55 KM from site. The nearby sea port is Vizag – 650 KM.
The site is connected to National Highway-200 which is 3 KM from Site.
4.2 Land Form, Land use and Land ownership
EASPL holds 13 acres of lands for which the land is diverted to industrial and
agreement for 4 acre has been finalized. The company proposes to acquire 13
acres of land which is available alongside the existing land.
4.3 Topography
The project site is fairly flat with trees/shrubs present at some places. There
will not be any cutting and filling required for the proposed project. The
topographical Map of 10KM Radius of the proposed site is give bellow;
80
FIG : 10 KM REDIUS GOOGLE MAP
Google map of 10 km radius of the proposed site.
81
FIG : TOPOGRAPHICAL MAP
82
4.4 Existing land use pattern (agriculture, non-agriculture, forest, water

bodies (including area under CRZ)), shortest distances from the periphery
of the project to periphery of the forests, national park, wild life
sanctuary, eco sensitive areas, water bodies (distance from the HFL of the
river), CRZ.
Company is having 13 acres of land at Duldula which is diverted to industrial

land. The physical changes in respect of topography and land use, though
permanent, shall be compensated by developing green belt around the project
site.
There is no National Park, Wildlife Sanctuaries, and Forests in 10 KM radius

from our existing plant / site.
Nearby Eco-sensitive zones- Nil
Nearby Elephant/Tiger Reserves-Nil
Migratory Routes- No
4.5 Existing Infrastructure
Good infrastructure is available in the vicinity of Plant; some of the key

features are listed below:
1. Availability of NH-200 which is 3 KM away from the existing and

proposed site. Same can be used for transportation of all kind of Plant
Equipment, Raw material etc.
2. Availability of adequate Water Resources.

3. 33 kV switch yard already exists in the plant premises for taking
electricity supply from CSPDCL.
4.6 Soil classification
Physical characteristics of soil are delineated through specific parameters viz.

particle size distribution, bulk density, porosity, water holding capacity and
texture.
The bulk density of the soil in the site ranged between 1.32 to 1.47 g/cc which
indicates favorable physical condition for plant growth. The porosity and water
holding capacity of the soils are in the range of 26.21 % to 33.27 % and
24.88% to 31.65% respectively. The soil in the impact zone has clayey
structure with moderate water holding capacity.
83
4.7 Climatic data from secondary sources
Climatically data collected from Secondary source i.e. IMD Raipur. The details
of data are tabulated below:-
Temperature (o c) Relative Humidity (%) Rain-fall
Month Min Max Min Max Mean
January 27.7 13.5 62 39 12.2
February 30.3 16.2 55 31 20.4
March 34.7 20.5 41 24 23.3
April 39.2 25.1 36 21 15.1
May 42.3 28.9 35 22 16.8
June 37.5 26.8 61 49 193.6
July 30.3 24.1 85 73 391.8
August 30.1 24.1 86 73 393.6
September 31.0 24.1 82 74 249.4
October 31.2 21.5 73 60 62.4
November 29.1 16.0 63 46 7.8
December 27.5 13.2 62 43 1.8
The maximum wind speed of the area is 60 km/hr.
4.8 Social Infrastructure available
Simga is the nearest town to the plant. General social infrastructure like
Samudayik Bhawan, School, hospital etc. is available in the town.
84
CHAPTER-5
Planning brief
5.1 Planning concept

Type of industry: Ferro Alloys, Induction Furnace, Rolling Mill along with coal
gasifier and Iron Ore washing Plant.
Transportation Facilities: National Highway-200 for transportation which is
about 3 KM from Plant site connected by internal roads. Tilda railway station is
about 14 KM from proposed plant site.
Town and Country planning/Development authority: Gram Panchayat
5.2 Population Projection

Total Population in 10 KM radius of site is estimated, approx. to 72400.
5.3 Land use planning (breakup along with green belt etc.)
Company has acquired 13.0 acres of private land in the village of Duldula from
land owners and for 4.0 acres agreement has been signed and additional 14.0
Hence total land required for existing and proposed expansion is 31 Acres. Out
of which 10.50 Acres of land will be reserved for green belt development. It is
located centrally vis-à-vis source of raw materials and consuming Industry.
85
Statement of Area
The details of land area for existing and proposed expansion projects are as
given below:-
Composite Area Statement
S.N Facility Existing Proposed Total

expansion
Area in Acres
1. Sub-merged Arc Furnace 2.00 - 2.00
3.6 MVA
2. Induction Furnace – Existing 0.50 - 0.50
3. Ferro Alloys Plant - 2.00 2.00

(Sub-merged Arc Furnace)
4. Induction Furnaces (1 x5) - 1.50 1.50
5. Rolling Mill with Coal Gasifier - 2.00 2.00
6. Iron Ore Washing Plant - 5.50 5.50
7. Raw materials Yard 1.0 0.50 1.50
8. finished goods Yard 1.0 0.50 1.50
9. Administrative building , 0.50 - 0.50
Security , weigh bridge etc
10. Roads , open area, others 3.50 - 3.50
utilities
11. Green Belt 4.00 6.50 10.50
Total 12.50 18.50 31.00
(5.05 Ha) (7.45 Ha) (12.54 Ha)
The plantation and green belt development will also be taken care in the plant
and the space reserved for plantation will be more than 33% of the total plant
area. Adequate plantation will substantially abate the dust pollution, filter the
polluted air, reduce the noise and ameliorate the plant environment.
86
5.4 Assessment of Infrastructure Demand (physical & social).

Basic infrastructure demand for nearby area would be first to have internal
roads, availability of clean and pure drinking water, availability of good
schools, availability of Hospitals, community halls, Sulabh Shauchalaya , easy
and faster means of transportation and connectivity to nearby town and city,
availability of uninterrupted electricity etc. are the present assessed demands
for sustained and healthy growth of nearby area of site. Most of the
infrastructure demand mentioned above comes automatically when industry of
this magnitude comes in such area, systematic efforts shall be made to bring
such facility in the surrounding area for all round physical and social
development.
5.5 Amenities / Facilities

For the social development in the area the company has planned to provide
drinking water etc. time to time the company will also organize free eye check
up, cataract camp, free distribution of spectacles etc.
87
CHAPTER-6
Proposed Infrastructure
6.1 Industrial / Residential Area -
Our existing unit is located at village- Duldula, Tehsil : Simga, District-Baloda

Bazaar, Chhattisgarh.
Our proposed project is in existing premises of Submerged Arc furnace &
Induction furnace, which is located at village- Duldula, Tehsil : Simga, District-
Baloda Bazaar, Chhattisgarh.
6.2 Green Belt

The plantation and green belt development will also be taken care in the plant
and the space reserved for plantation will be more than 33% of the total plant
area. Adequate plantation will substantially abate the dust pollution, filter the
polluted air, reduce the noise and ameliorate the plant environment.
6.3 Social Infrastructure
For the social development in the area the company has planned to provide
drinking water etc. time to time the company will also organize free eye check
up, cataract camp, free distribution of spectacles etc. For the economical
development the company will provide the employment as per requirement and
individual’s qualification & eligibility.
6.4 Drinking Water Management

Bore well water will be used in the plant for drinking purpose. to maintain
the water level water harvesting pond is constructed at various points of the
plant site. The water system will cater to the drinking and sanitary
requirements of plant personnel as well as laboratory and contingent users.
88
The required water will be pumped by two pumps (including one stand-by).
The treated water will be chlorinated and stored in the overhead tank for
distribution as drinking water.
6.5 Sewerage system

It is proposed to collect fecal sewerage through sewerage network from
the plant and lead it to the sewerage treatment plant. The treatment
plant shall consist of screen grit separator, primary sedimentation tank,
activated sludge plant, secondary clarifier, sludge recirculation pump
house etc. The treated effluent quality shall confirm to the Indian
Standard for discharge to surface water.
89
CHAPTER – 7
Rehabilitation and Resettlement (R&R)

Plant
The total land requirement for the project is 31 acres, out of which 13 acres is
under possession, for 4 acres agreement has been done and the balance land of
14 acres is proposed to purchase. Land is available at adjoining the existing
land. There will be no displacement of people including home oustees, land
oustees and landless laborers, thus R&R issue are not applicable.
90
CHAPTER-8
Project Schedule and Cost Estimates
8.1 Likely date of start of construction and likely date of completion
Likely date of start of construction: December, 2016.

Likely date of completion: December, 2018.
Construction Schedule
The schedule has been developed considering mostly the supply of plant and
equipment, as well as volume of work for Construction /Erection of the plant
and other local conditions at site.
8.2 Estimated project cost along with analysis in terms of economic

viability of the project
Cost of Project
The total cost for existing & estimated proposed project is Rs.106.0 Crores
including pre-operative expenses and margin money for working capital
requirements. The cost has been estimated based on enquiries floated,
quotations received. The financing and pre-operative cost has been considered
based on the proposed financial package

(In Lacs)
2 1x 550 KW Induction Furnace 1100.00
3 1x750 KW and 1 x 2250 KW Induction Furnace 2400.00
91

(In Lacs)
4 1x 550 KW, 1x750 KW, 1 x 2250 KW Induction furnace 3500.00
6 Rolling Mill with Coal Gasifier 600.00
8 Iron Ore Washing plant 500.00
TOTAL COST 10600.00
.
Means of Finance
The promoters contribution will be met out of Capital Requirements and

shortfall, if any, would be met out of unsecured loans (interest free)
brought in by the promoters.
92
CHAPTER-9
Analysis of proposal
(Final Recommendations)
9.1 Financial and social benefits with special emphasis on the benefits to
the local people including tribal population
The proposed project will result in improvement of infrastructure as well as

upliftment of social structure in the area. The people residing in the nearby
areas will be benefited directly and indirectly. It is anticipated that the
proposed plant will provide benefits for the local people in two phases i.e.
during construction phase as well as during operational stage of the plant.
1. Construction Phase
Employment
The major benefit due to the proposed project will be in the sphere of
generating employment for people of that area. The proposed project will
benefit local population.
2. Operational Phase
Community Services
ESAPL will employ local people to the extent possible for avoiding
creation of additional infrastructure. ESAPL will develop medical facilities
for catering to the needs of the project personnel. These facilities will also
be extended to the local community in due course.
3. Education
ESAPL will initiate action for social upliftment in the area like female
education, vocational training. Financial support will also be extended to
strength education infrastructure in the region.
93
4. Employment
The manpower requirements for the operational phase of the Ferro Alloys Plant,
Induction Furnace, Rolling Mill along with Coal gasifier and Iron Ore Washing
Plant will be about 188 people. In addition, there will be an indirect
employment for skilled/ semi skilled people during project life. All attempts will
be made to employ suitable, locally available, skilled personnel from the nearby
area. In case of non-availability of skilled persons, people will be employed from
outside area.
5. Transportation
There will also be small increase in the vehicular traffic due to passenger
transport. This increase in traffic will not have any consequence to warrant
special mention. One should expect that the increased passenger load in the
sector would prompt the state government/ private movers to start new and
frequent public transport services to this area, bringing upliftment to the whole
locality.
6. Other Benefits
ESAPL is equally conscious for the all round socio-economic development and
is committed to raise the quality of life and social well being of communities
where it operates..
------------------------------00-------------------------------
94

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EARTHSTAHL & ALLOYS PVT. LTD.

* EXISTING SUBMERGED ARC FURNACE (1X3.6MVA) by

* EXISTING INDUCTION FURNACE 1x550 KW of 3600 TPA for

* PROPOSED INDUCTION FURNACE 1x750 KW + 1x2250KW

* PROPOSED SUBMERGED ARC FURNACE 1x5.4MVA for

* PROPOSED INDUCTION FURNACE of 1x550 KW + 1x750 KW

* PROPOSED ROLLING MILL 18000 TPA for MS Strip/Round

* PROPOSED IRON ORE WASHING of 5,00,000 TPA

EarthStahl & Alloys Pvt. Ltd.

3.14 Occupational health & safety 80

8.2 Estimated project cost along with analysis in terms of 92-93

1.1 Executive Summary

The basis of selection of major equipment including a review of

1.2 Project at a Glance

Name : Earthstahl & Alloys Pvt. Ltd.

Registered Office : 5B, Merlin Jayshree Vihar, Pandrai Tarai, mandi

Factory : Village – Duldula, Simga, Distt – Baloda Bazaar,

List of Directors : 1) Mr. Rajesh Somani

2) Mr. Ravi Laddha

3) Mr. Praveen Somani

Sr. Particulars Details

3. Altitude 276 m above MSL

4. Toposheet 64G/10 (F44P10)

5. Seismicity Area falls under least affected earthquakes

7. Climatic condition Ambient Air temp 7oC to 46oC

8. Nearest village Harim Bhatta

9. Nearest town Simga

10. Nearest railway station Tilda (14 KM)

11. Nearest airport Raipur (55 KM)

12. Streams / Rivers Seonath River - 6 kms SW

ChitawarNala: 2Km East

GadariaNala :8Km South

13. Sanctuaries /National Nil

14. Topography Gently sloping

15. Defense Installations Nil

16. Historical Places Nil

17. Road Access NH 200 (3 KM)

S Furnace Type Description Capacity Existing Status Proposed Proposed

Induction Furnace 1x750KW - - forgings of

Financial Details of the Project (Capital Cost)

Sr. No. DESCRIPTION Rs.

TOTAL COST 10600.00

Project Introduction / Company Background

2.1 Introduction & Company Background

The company had obtained Consent to Establish vide CECB letter no

As per EIA Notification 2006, in case of secondary metallurgical

require environment clearance from MOEF&CC, Government of India,

Mr. Prawin Somani, aged 36 years is an industrialist with 12 years of

Company is banking with Bank of India.

2.5 Demand -Supply Gap

2.6 Cost of the Project

SN Particular Capacity Amount

1. Sub-merged Arc Furnace 3.6 MVA 14.00

1. Induction Furnace 1 x 550 KW 11.00

SN Particular Capacity Amount

2. Induction Furnace 1 x 550 KW

3. Induction Furnace 1 x 750 KW 35.00

4. Induction Furnace 1 x 2250 KW

5. Rolling Mill 18000 TPA

7 Iron Ore washing Plant 0.5 MTPA 5.00

2.7 Employment Generation (Direct and Indirect) due to

2.8 Manpower Estimate

It is estimated that the total requirement of manpower for the whole