01+$ 233- 1 454236environmentclearance.nic.in/writereaddata/modification/PreviousTOR… · Village : Eklari, Taluka : Moh adi District: Bhandara, Maharashtra Pincode 441 905 email

FORM – 1 (REVISED)

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JUNE, 2018 (Issue 01, Rev 0)

Submitted by:

M/s. Sunflag Iron & Steel Co. Limited

Village Eklari, Taluka Mohadi District Bhandara, Maharashtra

Form 1 - Amendment in configuration of EC dated 02.05.2017 of SISCL 1

FORM 1 (Issue 01, Rev 0, June 2018)

APPLICATION SEEKING PRIOR ENVIRONMENTAL CLEARANCE FOR

AMENDMENT IN CONFIGURATION SANCTIONED VIDE EC LETTER NO. J-11011/355/2004-IA II(I) DATED 02.05.2017

WITHOUT ANY CHANGE IN TOTAL PRODUCTION

(I) Basic Information 1 Name of the Project/s Amendment in configuration of

Integrated steel plant sanctioned vide MOEF&CC’s EC letter no. J-11011/355/2004-IA II(I) dated 02.05.2017 without any change in total production of M/s Sunflag Iron & Steel Company Ltd.

2 S. No. in the Schedule 3(a), 1(d), 2(a), 4(b) 3 Proposed capacity /area/length/

tonnage to be handled /command area / lease area / Number of wells to be drilled

The Area (200 ha) and total steel production (1.0 MTPA) remain same but there are configuration changes proposed as per Annexure-1 to achieve different forms of same product.

4 New/Expansion/Modernization Amendment & addition in configuration 5 Existing Capacity/ Area Area- 200 ha

Steel production - 1.0 MTPA EC granted vide letter no. J-11011/355/2004-IA.II(I) dated 21.02.2006, amendment dated 12.01.2012 and 02.05.2017 (refer Annexure-2(a), 2(b) and 2(c))

6 Category of the Project “A” or “B” “A” 7 Does it attract the general

conditions? If Yes, please specify Yes. It is within 10 km radius of a sanctuary but outside its ecosensitive zone.

8 Does it attract the specific

conditions? If Yes, please specify No

9 Location Refer Annexure-3 for location plan Plot/ Survey/ Khasra no. Refer Annexure-4 for list of khasras Village Warthi, Sirsi & Eklari Tehsil Mohadi


District Bhandara State Maharashtra 10 Nearest railway station/ airport

along with distance in kms Bhandara Railway Station, 0.5 km, ENE Nagpur Airport, 61 km, WSW

11 Nearest town, city, district head

quarters along with distance in kms Nearest town and District Head quarter : Bhandara, 7.4 km, SSE.

12 Village panchayats, Zila parishads,

Municipal Corporation, local body (Complete postal address with telephone nos. to be given)

Village Panchayat – Eklari Grampanchayat, P.O. Bhandara Road, Tehsil- Mohadi, Dist.- Bhandara

13 Name of the Applicant M/s Sunflag Iron & Steel Co. Limited

(hereafter referred to as SISCL) 14 Registered Address M/s. Sunflag Iron & Steel Co. Limited

Village: Eklari, Taluka: Mohadi District : Bhandara, Maharashtra

15 Address for Correspondence Name Mr. S. K. Arora Designation(Owner/Partner/CEO) Senior Vice President (Works) Address

M/s. Sunflag Iron & Steel Co. Limited Village : Eklari, Taluka : Mohadi District: Bhandara, Maharashtra

Pincode 441 905 email admin@ sunflagsteel.com,

[email protected] Telephone Number 07184 - 285551 to 55 Fax Number 07184 - 285570 16 Details of Alternatives sites

Examined, if any, Locations of these sites should be shown on the toposheet

Not Applicable (as this is an under expansion plant, in which changes in configuration are proposed without any change in total capacity).

17 Interlinked Projects Nil 18 Whether separate application of the

interlinked project has been submitted

Not Applicable

19 If Yes, date of application Not Applicable 20 If No, reason Not Applicable


21 Whether the proposal requires

approval/clearance, if Yes the details of the same to be given

Not Applicable

a) Forest Conservation Act – 1980?

Not applicable since no forest land within project area.

b) Wild life protection Act – 1972? Not applicable as not within Eco-sensitive zone of Koka WLS (nearest WLS)

c) CRZ Notification – 1991? Not applicable as it is not near sea shore.

22 Whether there is any Government

Order/ Policy relevant/ relating to the site?

No

23 Forest land involved (hectares) Nil 24 Whether there is any litigation

pending against the project and/or land in which the project is proposed to be set up?

No

(a) Name of Court Not applicable (b) Case No. Not applicable (c) Orders/ directions of the Court,

if any and its relevance with the proposed project

Not applicable

(II) Activity 1. Construction, operation or decommissioning of the Project involving

actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)

Sl. No.

Information/ Checklist confirmation

Yes/No

Details thereof (with approximate quantities /rates, wherever possible)

with source of information data 1.1 Permanent or temporary change

in land use land cover or topography including increase in intensity of land use (with respect to local land use plan

No There will be no change in overall landform/land use of 200 ha as the plant is an existing plant since several decades. There will be a change in configuration without any enhancement in production in the existing units. The new units will be adjusted within the existing sheds, existing solid waste yard and only 0.5 ha area from open area shall be required for them.


Sl. No.


Yes/No


with source of information data 1.2 Clearance of existing land,

vegetation and buildings? Yes No clearance of existing land,

vegetation and buildings is envisaged except cryogenic oxygen plant

1.3 Creation of new land uses? No The 200 ha is already under industrial use and will continue as same. Open area (0.5 ha only) within the existing plant will be utilised for installation of additional units.

1.4 Pre-construction investigations e.g. bore houses, soil testing?

No Soil testing for the existing set up of SISCL has already been carried out. The proposed expansion will be executed in the existing premises of SISCL.

1.5 Construction works? Yes Yes, construction of the additional units as listed in Annexure-1 will be carried out

1.6 Demolition works? Yes Demolition of old cryogenic oxygen plant.

1.7 Temporary sites used for construction works or housing of construction workers

Yes Majority of construction workers will be local and temporary sheds facility will be provided for workers

1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations

Yes In the existing premises of SISCL, above ground buildings and structures are existing. The new structures for expansion as per EC dt 02.05.2017 shall be installed and structures required as per proposed amendment shall be installed after amendment. The associated earthwork for the construction of buildings shall also be carried out.

1.9 Underground works including mining or tunneling?

No No underground work is involved.

1.10 Reclamation works? No No reclamation work is involved 1.11 Dredging? No No dredging is to be adopted 1.12 Offshore structures? No Not applicable 1.13 Production and manufacturing

processes? Yes DRI and MBF routes, both are being

followed for steel production in the existing plant. The overall processes as per EC dt. 02.05.2017 shall remain same but there will be changes/ addition in process as listed in Annexure 1.

1.14 Facilities for storage of goods or materials

Yes The same storage areas for goods and materials will be utilized.


Sl. No.


Yes/No


with source of information data 1.15 Facilities for treatment or

disposal of solid waste or liquid effluents?

Yes SOLID WASTE: In addition to the facilities for which EC was granted on 02.05.2017, the following additional solid waste management measures are envisaged: 130 TPD of Dolo Char will be

reduced during the shut down of DRP-1.

17 TPD waste in the overall plant will

be recovered and reused due to installation of metal slag recovery plant (1.26 MTPA). Thus, about 3% of slag from Ingot/Billet production will be reduced.

11 kg/Ton of solid waste will be

generated from Electro Slag Refining (ESR) furnace which will be sent to Metal Slag Recovery Plant. There will be no solid waste generation from Vacuum Arc Remelting (VAR) furnace. By assuming 300 working days solid waste generated from ESR will be 0.374 T/T production.

3.5 TPD solid waste will be

generated from Ingot heating/ soaking pit furnace at Blooming mill. Fine dust generated will be consumed in sinter plant and chips and scrap will be used in SMS.

Additional 15 TPD (350 TPM from

bright bar and 25 TPM from heat treatment, assuming 25 working days) will be generated from bright bar and heat treatment. Fine dust generated will be consumed in sinter plant and chips and scrap will be used in SMS.

61 TPD of ash will be generated

from combustor operation during shut down of DRP-1 which will be


Sl. No.


Yes/No


with source of information data used in low lying areas, backfilling and brick making.

LIQUID EFFLUENT: A. 7 KLD effluent will be reduced

during the shut down of DRP-1. B. No effluent will be generated from

Metal Slag Recovery Plant. C. The following additional effluent will

be generated which will be sent to existing ETP & used in cooling tower, sinter plant, pig cast machine and slag quenching : 33 KLD from ESR & VAR 25 KLD from Vacuum

Induction Melting (VIM) Furnace.

13.5 KLD from SMS Vacuum degassing.

16.2 KLD from Ladle Refining Furnace.

3.5 KLD from Ingot Heating/ Soaking pit furnace.

D. The effluent generated (20 KLD)

from the PSA oxygen plant will replace the effluent generated from cryogenic oxygen plant, which will be dismantled.

1.16 Facilities for long term housing of operational workers?

No No additional housing construction will be there as colony is already existing within the plant boundary. The required man power as per EC dated 02.05.2017 is 2535. There will be no additional man power requirement as the excess manpower from the existing units will be shifted to the proposed units.

1.17 New road, rail or sea traffic during construction or operation?

Yes As additional construction is involved, additional traffic during construction phase in form of trucks bringing In construction material. During operation phase, no additional raw material(coal) for the overall plant


Sl. No.


Yes/No


with source of information data will be there. It will reduce when combustor operates then 250 TPD coal will be consumed instead of 725 TPD for DRP-1. FO consumption for BSM will get eliminated due to PGP while intermediate products will be inputs to the proposed additional/amended units. Hence, no additional traffic on account of raw material, products or solid waste will be there.

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

No Not required since existing infrastructure will be adequate for the proposed transportation

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

No Not Applicable, as proposed configuration change is within existing facility & infrastructure.

1.20 New or diverted transmission lines or pipelines?

No Not required

1.21 Impoundment, damming, culverting, Realignment or other changes to the hydrology of watercourses or aquifers?

No Not required

1.22 Stream crossings? No Not required as proposed configuration change is within existing (and under establishment) facilities & infrastructure.

1.23 Abstraction or transfers of water form ground or surface waters?

No No additional abstraction or transfer of water from sanctioned source (Wainganga river - 15098 cum/day) will take place because company has implemented water conservation measures in last two years, thereby creating spare water capacity. SISCL has already having permission for drawl of water from Wainganga river and also harvests and stores the rainwater runoff in separate pond from where it is transferred to raw water reservoir. The water requirement as sanctioned in EC dated 02.05.2017 is 15098 cum/day. The total additional water requirement will be for :


Sl. No.


Yes/No


with source of information data Remelting furnace for super alloys

(135 KLD) Vacuum Induction Melting Furnace

(100 KLD) Metal slag recovery plant (5 KLD) SMS Vacuum Degassing (54 KLD) VD Boiler (160 KLD) Ladle Refining Furnace (64.8 KLD) Ingot Heating/ soaking pit furnace

at Blooming Mill (14 KLD) Bright bar and heat treatment (108

KLD) Sinter Boiler (151.2 KLD) Total of above = 792 KLD The water requirement (100 KLD) of cryogenic oxygen plant will be replaced by same water requirement for PSA oxygen plant. There can be two scenarios for additional water requirement : 1) When combustor is not operating then the additional water requirement will be 792 KLD 2) When combustor will be operational, the DRP-1 water requirement of 125 KLD will become zero but combustor requirement of 2 KLD will be there in addition to above units. Therefore the total additional water requirement will be 669 KLD.

1.24 Changes in water bodies or the land surface affecting drainage or run-off?

Yes No change in water bodies is envisaged. Open areas (0.5 ha) within the plant will be used for installation of additional units and they will be provided with storm water drainage system.

1.25 Transport of personnel or materials for Construction, operation or decommissioning?

Yes There will be marginal increase in traffic mainly due to movement of trucks, machinery, and work force during construction. During operation, there will be no increase in road or rail traffic. No


Sl. No.


Yes/No


with source of information data additional manpower is envisaged, hence, no additional traffic on account of personnel is envisaged.

1.26 Long-term dismantling or decommissioning or restoration works?

No Not Required.

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

No No significant impact is envisaged during decommissioning of old cryogenic oxygen plant.

1.28 Influx of people to an area in either temporarily or permanently?

Yes During construction, local workers will be given priority and temporary housing arrangement at site for outside workers will be provided. During operation, there will be no increase in man power as the excess manpower from the existing units will be shifted to the proposed units.

1.29 Introduction of alien species? No - 1.30 Loss of native species or genetic

diversity? No -

1.31 Any other actions? No - 2. Use of Natural resources for construction or operation of the Project

(such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):

Sl. No.


Yes/No

Details thereof (with approximate quantities /rates, wherever

possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

Yes No additional land requirement will be there as the configuration change will occur in the same premises of SISCL without increase in total production. Open area (0.5 ha) within the plant will be brought under the proposed additional units.

2.2 Water (expected source & competing users) unit: KLD

Described in point 1.23 earlier

2.3 Minerals (MT)

No Combustor will be in operation when DRP 1 will be shut down. Coal consumption for DRP-1 is 725 TPD while for combustor, it will be 250 TPD. Thus, 475 TPD coal consumption will decrease on the


days combustor operates. FO consumption for BSM will reduce since PGP will become operational and supply producer gas in future. There will be no increase in Iron ore, coke, limestone, dolomite, manganese ore etc.

2.4 Construction material – stone, aggregates, sand / soil (expected source – MT)

Yes Construction material such as stone, aggregates, sand, steel shall be required

2.5 Forests and timber (source – MT)

No Use of timber is not envisaged. Doors and windows made of materials other than wood will be used

2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes The additional electricity required (15.945 MW) for operation of additional/amended units shall be as follows: DRP1 shut down = -3 MW Remelting furnace for super alloys

= +7 MW Vacuum Induction Melting

Furnace = +2 MW Metal Slag recovery plant = +0.32

MW SMS Vacuum Degassing = +0.06

MW VD Boiler = +0.65 MW Ladle Refining furnace = +0.16

MW Ingot Heating/ soaking pit furnace

at Blooming Mil = +0.2 MW Bright Bar and Heat Treatment =

+6 MW and 400 kg/hr LPG for heat treatment furnaces

Producer Gas Plant for Bar Section Mill = +1.7 MW

Sinter Boiler =+ 0.06 MW Combuster = +1.4 MW Oxygen plant = -3.63 MW PSA Oxygen Plant = +1.7 MW LPG Storage = +0.125 MW Coal Drier = +1.2 MW

2.7 Any other natural resources (use appropriate standard units)

No Nil


3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.

Sl. No.


Yes/No



3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

Yes 10 KL Fuel Oil will be used during start-up (light up) of the combustor. 400 kg/hr LPG for heat treatment furnaces.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases)

No Not anticipated since no water logging is anticipated. The waste water will be treated and reutilised.

3.3 Affect the welfare of people e.g. by changing living conditions?

Yes Betterment of the people in the surrounding areas is envisaged as the performance of the industry will improve without any infrastructural change.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

No Impact on vulnerable groups of people is not envisaged due to the proposed changes in project as these will be located within the existing factory premises and adequate pollution control arrangements will be provided to abate air, noise, water, land pollution due to project activities.

3.5 Any other causes No - 4. Production of solid wastes during construction or operation or

decommissioning (MT/month)

Sl. No.


Yes/No



4.1 Spoil, overburden or mine wastes No Not applicable 4.2 Municipal waste (domestic and or

commercial wastes) No No additional solid waste will be

generated as there is no increase in the manpower

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

Yes 1. Used oil is generated from the equipment operation in existing plant (EC dated 21.02.2006) and will be additionally generated from the units to be installed as per EC amendment dated 12.01.2012 and EC dated


Sl. No.


Yes/No



02.05.2017 In the current proposal, where the additional equipment will be used in lieu of the existing equipment, the generation will remain unchanged. However, new units such as ESR & VAR, VIM, metal slag recovery plant, Expansion of bright bar and heat treatment, combustor, etc. will generate additional used oil. FO sludge will also be generated. As per existing consent to operate issued from State board vide consent order no.BO/CAC-Cell/UAN No :- 0000026674-17/CAC/1709000929 date 26.9.17, valid upto 31.5.2022 Hazardous waste is used at our Sinter plant and used oil is used in furnace by mixing with furnace oil. Similarly at CPP, regeneration of DM Plant will be carried out periodically using acid and sodium hydroxide. This will generate hazardous waste termed as chemical sludge. Chemical sludge generated from waste water treatment plant will be temporarily stored and used at Sinter plant as per consent to operate issued from State board vide consent order no.BO/CAC-Cell/UAN No :- 0000026674-17/CAC/1709000929 date 26.9.17, valid upto 31.5.2022. Coal tar will be generated from PGP which will be carried along with producer gas and burnt in furnace.

4.4 Other industrial process wastes

No The various wastes materials generating from technical processes would be reutilized to the maximum extent possible. Other wastes which


Sl. No.


Yes/No



cannot be used will be either dumped or disposed off as per norms. Annexure 5 gives the project solid waste and its management.

4.5 Surplus product No - 4.6 Sewage sludge or other sludge

from effluent treatment No There will be marginal increase in

sludge due to additional 84.2 KLD effluent throughput. This additional sludge will be utilized in sinter plant after dewatering, hence, no additional waste for disposal shall be there.

4.7 Construction or demolition wastes

Yes Minor additional construction work is involved and negligible waste generated will be reused for filling low lying areas inside and around the plant.

4.8 Redundant machinery or equipment

No -

4.9 Contaminated soils or other materials

No -

4.10 Agricultural wastes No Not Applicable 4.11 Other solid wastes No - 5. Release of pollutants or any hazardous, toxic or noxious substances to

air (Kg/hr)

Sl. No.


Yes/No


with source of information data 5.1 Emissions from combustion of

fossil fuels from stationary or mobile sources

Yes Emissions will be due to combustion of fossil fuels. As can be seen in Annexure 5, despite the proposed changes in plant configuration to achieve different finishing of the products, there will be no overall increase in the fossil fuels, and consequently no increase in overall emissions from the plant.

5.2 Emissions from production processes

Yes As above

5.3 Emissions from materials Yes Emission from material handling,


Sl. No.


Yes/No


with source of information data handling including storage or transport

storage or transport for raw material handling plant including lime crusher, for Combustor, Metal Recovery plant, ESR, VAR, VIM etc will be controlled through Bag filters, High pressure fogging system, dust suppression system etc. to maintain within the norm.

5.4 Emissions from construction activities including plant & Equipment

Yes Minimum construction activities are involved which will require dust control measure through sprinkling etc.

5.5 Dust or odours from handling of materials including construction materials, sewage and waste

Yes Dust will be controlled by existing dust extraction system, dust suppression system, road cleaning by Sweeper machine, Water spray by tanker etc. No odours are anticipated from processes.

5.6 Emissions from incineration of waste

No Not applicable

5.7 Emissions from burning of waste in open air (e.g. slash materials, construction debris)

No No waste material will be burned in open air

5.8 Emissions from any other sources

No -

6. Generation of Noise and Vibration, and Emissions of Light and Heat:

Sl. No.


Yes/No



6.1 From operation of equipment e.g. engines, ventilation plant, crushers

Yes Noise level will be maintained within acceptable limits. Operation of equipment, gearbox etc. are the source of Noise. Adequate noise control measures have already been taken inside the plant including enclosures, barriers, signage and PPEs.

6.2 From industrial or similar processes

Yes Same as above

6.3 From construction or demolition

Yes Some noise will be generated construction machinery and civil work


Sl. No.


Yes/No



activities 6.4 From blasting or piling No No blasting is involved. 6.5 From construction or

operational traffic Yes Small magnitude of construction job

will be involved. No major additional traffic is envisaged

6.6 From lighting or cooling systems

Yes Cooling Tower is there, which has some localized effect in its vicinity. The natural movement of air will ensure rapid dispersal and build up is not envisaged. However, due to lighting or cooling systems, noise pollution will be insignificant.

6.7 From any other sources No - 7. Risks of contamination of land or water from releases of pollutants into

the ground or into sewers, surface waters, groundwater, coastal waters or the sea:

Sl. No.


Yes/No



7.1 From handling, storage, use or spillage of hazardous materials

No Used oil generated from equipment, is stored on impervious covered area before selling to authorized recyclers or before use in furnaces by mixing with Furnace oil. HSD is stored in a licensed underground storage tank.

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

Yes SISCL has ‘zero’ water discharge plant. 100% water is recycled back to process, used for dust suppression, ash quenching, garden maintenance, cooling tower make up, etc. STP water is used for dump yard dust suppression purpose and gardening purpose.

7.3 By deposition of pollutants emitted to air into the land or into water

No The deposition of pollutants emitted to air, on land or into water will be minimized due to dispersion achieved by stacks height criteria for proposed expansion project. Besides provision of air pollution control systems like ESPs, Bag Filters, to all fugitive


Sl. No.


Yes/No



emission sources will restrict the emissions below stipulated norms.

7.4 From any other sources No -

7.5 Is there a risk of long term build up of pollutants in the environment from these sources?

No -

8. Risk of accidents during construction or operation of the Project, which

could affect human health or the environment Sl. No.


Yes/No



8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

No In the captive power plant & Steel plant, handling/use or production of hazardous substances will not be carried out. Chances of explosions, spillages, fires will be negligible. However all precautionary measures will be taken to avoid such incidents. Fire hydrant system with alarm system, fire tender & extinguishers at various locations will be provided. However, on site & off site emergency plan will be prepared prior to proposed expansion project plant operation. Periodic emergency preparedness training will be given during proposed expansion project operation.

8.2 From any other causes Yes Fire and electrical short circuit may occur due to accidental event/s. Strict safety observation & monitoring will be done to overcome such risk.

8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?

No SISCL Plant falls under Seismic Zone II as per IS 1893-2002 and the area is not prone to earthquakes, floods etc. The chance of occurrence of flood is remote. Also the area is far away from the sea.


9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality

Sl. No.


Yes/No

Details thereof (with approximate quantities /rates,

wherever possible) with source of information data

9.1

Lead to development of supporting ancillary development or development stimulated by the project which could have impact on the environment e.g.: Supporting infrastructure

(roads, power supply, waste or waste water treatment, etc.)

housing development• extractive industries

supply industries other

Yes It is intended to outsource the repair and fabrication jobs. In order to do that, the company envisions to support surrounding small entrepreneurs and therefore a growth will be seen in the supply industry in surroundings.

9.2 Lead to after-use of the site, which could have an impact on the environment

No Not Applicable

9.3 Set a precedent for later developments

No -

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

No Not envisaged, as the production will remain unchanged within capacity sanctioned in EC dated 02.05.2017. Minor modification is proposed as given in Annexure-1.

(III) Environmental Sensitivity

Sl. No.

Areas Name/Identity Aerial distance within 15 kms )

Proposed Project location boundary

1. Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

Listed in Annexure 6 Listed in Annexure 6

2. Areas which are important or sensitive for ecological reasons - Wetlands,



Sl. No.

Areas Name/Identity Aerial distance within 15 kms )

Proposed Project location boundary

watercourses or other water bodies, coastal zone, biospheres, mountains, forests

3. Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration


4. Inland, coastal, marine or underground waters


5. State, National boundaries Madhya Pradesh 34.5, N 6. Routes or facilities used by the

public for access to recreation or other tourist, pilgrim areas


7. Defence installations Nil - 8. Densely populated or built-up

area Bhandara 7.4 km, SSE

9. Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)

Hospitals, Schools, Community facilities are present within 10 km of the study area. List of amenities in Villages in 10 km is given in Annexure 7

10. Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals


11 Areas already subjected to pollution environmental damage. (those where existing legal environmental standards are exceeded

Nil -

12. Areas susceptible to natural hazard which could cause the project to present environmental Problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions

The Plant area falls in seismic Zone – II, which is not an active seismic zone. The project is not likely to be affected by floods, landslides, cloudburst etc.

-

I hereby give undertaking that the data and information given in the application andenclosures are true to the best of my knowledge and belief and I am aware that ifany part of the data and information submitted is found to be false or misleading atany stage, the project will be rejected and clearance given, if any to the project willbe revoked at our risk and cost.

Date: 14.06.2018Place: Eklari, Maharashtra. lC-

(Project Proponent I Authorized Signatory)

NameDesignationAddress

S. K. AroraSenior Vice President (Works)Mis. Sunflag Iron & Steel Co. LimitedVillage Eklari, Taluka MohadiDistrict Bhandara, Maharashtra

Submit document supporting claim of authorized signatory for the specific project.(Refer Annexure-B)

LIST OF ANNEXURES

Annexure No. Description

1 Proposed change in configuration

2 a. Environmental clearance letter, 2006b. EC amendment letter, 2012c. Environmental clearance letter, 2017

3 Location plan4 Land schedule (List of khasras)5 Summary table listing changes in raw material, water

consumption, effluent generation, solid waste, power andfuel for proposed amendments

6 Map showing 15 km radius around project site along withlist of forests, water bodies & other features

7 List of amenities within 10 km radius8 Authorization to signatory9 Pre-feasibility report

Form 1-Amendment in configuration of EC dated 02.05.2017 of SISCL 19

ANNEXURES

ANNEXURE : 1

[1]

PROPOSED CHANGE IN CONFIGURATION

Sl. No.

Products Production & configuration for which

EC granted dt 02.05.2017

Proposed amendment

(current application)

Total

1 Direct Reduced Iron 1.0 Million TPA (4x350 TPD & 4x500 TPD Kilns)

No change 1.0 Million TPA (4x350 TPD & 4x500 TPD Kilns)

2 Pig Iron / Hot Metal 0.6 Million TPA (2 X 0.30 Million TPA MBF)

No change 0.6 Million TPA (2 X 0.30 Million TPA MBF)

3 Ingots / Billets 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF & 1x50/60 + 1x50 TPH EAF)

No change 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF & 1x50/60 + 1x50 TPH EAF)

3.a.* Remelting Furnace for Super Alloys i.e. Electro Slag Refining (ESR) & Vacuum Arc Remelting (VAR) furnace with their auxiliary equipments

Nil ESR- 25 T/Batch, 3T/Batch & VAR -15 T/Batch, 3T/Batch (annual capacity - 18000 T/Annum)

ESR- 25 T/Batch, 3T/Batch & VAR -15 T/Batch, 3T/Batch (annual capacity 18000 T/Annum)

3.b.* Vacuum Induction Melting Furnace (VIM)

Nil 6T/ Batch ( annual capacity 6000 T/Annum)

6T/ Batch ( annual capacity 6000 T/Annum)

3.c.* Metal slag recovery plant (100 TPH + 50 TPH plant)

Nil 12,60,000 TPA 12,60,000 TPA

3.d.* SMS Vacuum Degassing

Unit -1 (mentioned in EIA) 60 T/Batch

Unit-2 - 60 T/Batch, Unit - 3 (standby)- 60 T/Batch

Unit-1, 2 & 3 Total = 60 +60 T/Batch (& 60 T/Batch standby)

3.e.* VD boiler 1X 16 TPH 1X 16 TPH 2X 16 TPH 3.f.* LRF (Ladle Refining

Furnace) for SMS of 60T steel ladle

Unit -1 & 2 (mentioned in EIA) 60 T/Batch

Unit- 3 60 T/Batch Unit-1, 2 & 3 Total = 60 + 60 T/Batch (1 standby)

4 Rolled Steel Products 1.0 Million TPA (2x70 TPH, 2x60 TPH, 2x14 TPH)

No change 1.0 Million TPA (2x70 TPH, 2x60 TPH, 2x14 TPH)

4.a.* Ingot Heating/ soaking pit furnace at Blooming Mill (02 Nos)

Nil No addition in capacity of total rolled products, since product will either be reheated in 2X70TPH RHF of Blooming Mill sanctioned in EC or in ingot heating RHF (0.32 MTPA)

No addition of capacity of total rolled products

4.b.* Bright Bar and Heat Treatment

Bright Bar : 2500 TPM (30,000 TPA) and Heat treatment : 3000 TPM (36,000 TPA)

Bright Bar : 2500 TPM (30,000 TPA) and Heat treatment : 3500 TPM (42,000 TPA) Change in product configuration as per

BBU : 5000 TPM (i.e 60,000 TPA); Heat Treatment (Coil & Rod) : 6500 TPM ( i.e.78,000 TPA)

ANNEXURE : 1 Contd..

[2]

Sl. No.

Products Production & configuration for which


Proposed amendment

(current application)

Total

demand with no increase in overall steel production of 1.0 MTPA

4.c. Producer Gas plant (gasifier) for Rolling mill

11000 Nm3/hr, 350 days operation (EC amendment dt. 12.01.2012)

Nil 11000 Nm3/hr, 350 days operation

5 Sinter 0.85 Million TPA (0.45 + 0.4 MTPA)

Same 0.85 Million TPA (0.45 + 0.4 MTPA)

5.a. Sinter Boiler Nil 1 X 5.7 TPH @10kg/cm2

1

6 Electricity 90 MW Same 90 MW 6.a.* Combuster with coal

crusher and coal handling plant

Nil Hot flue gas generation for Steam generation @45 TPH for Power generation @ capacity : 9.5 MW

9.5 MW

7 Coke 0.25 Million TPA Same 0.25 Million TPA 8.a. Oxygen / Nitrogen /

Argon Plant 45000 TPA Same 45000 TPA

8.b. Oxygen Plant 15000 TPA Will be dismantled 0 8.c.* PSA Oxygen Plant NIL 140 TPD 140 TPD 9 Washery 750 TPD Same 750 TPD 10 Crusher Not mentioned separately,

but integral to raw material handling system

Mention required: 150 T/hr, 350 days operation

150 T/hr, 350 days operation

11* LPG Storage Nil 60,228 Kg storage capacity

60,228 Kg storage capacity

12* Coal Drier Nil 300 TPD 300 TPD

Note:- * New units 1. Change in product configuration in Bright Bar and Heat Treatment:

500 TPM for 15- 40mm. (Bar to Bar peeling) 300 TPM for 12- 25mm (Coil to Bar peeling) 100 TPM for 5.5 - 16mm (Coil to Bar peeling) 1000 TPM (Induction Hardening & Tempering line in existing shed) 2000 TPM (Coil annealing capacity by installing Bell annealing furnaces) 1000 TPM (Bar annealing capacity by installing Spherodising bar annealing

furnaces) 2000 TPM (Grinding capacity for dia .6 - 30mm) 400 TPM (Eddy current testing) Chamfering machines (1000 TPM)

ANNEXURE : 2(a)

ANNEXURE : 2(a) Contd..




ANNEXURE : 2(b)

ANNEXURE : 2(b) Contd..

ANNEXURE : 2(b) Contd..

ANNEXURE : 2(c)

ANNEXURE : 2(c) Contd..








Khasra List 1

LIST OF KHASARA NOs. UNDER EXISTING SISCO LTD.

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 1 428 0.24 EKLARI 2 429 0.23 EKLARI 3 432/1 0.24 EKLARI 4 439 0.56 EKLARI 5 440 0.71 EKLARI 6 441 0.25 EKLARI 7 448 0.66 EKLARI 8 459 0.52 EKLARI 9 463 0.15 EKLARI

10 423/2 0.09 EKLARI 11 430 0.08 EKLARI 12 312 0.52 EKLARI 13 313 0.27 EKLARI 14 479 0.51 EKLARI 15 476 0.47 EKLARI 16 454 0.03 EKLARI 17 391/1 1.39 EKLARI 18 436 0.11 EKLARI 19 240/5 0.36 EKLARI 20 339/4 0.05 EKLARI 21 464 0.20 EKLARI 22 431 0.33 EKLARI 23 435 0.41 EKLARI 24 437 0.10 EKLARI 25 451 0.15 EKLARI 26 452/1 0.42 EKLARI 27 414 0.38 EKLARI 28 456 0.40 EKLARI 29 339/1 0.19 EKLARI 30 424 0.62 EKLARI 31 239/3 0.28 EKLARI 32 461 0.17 EKLARI 33 455/1 2.05 EKLARI 34 376 7.30 EKLARI 35 339/2 0.46 EKLARI 36 340/2 0.07 EKLARI 37 458 0.45 EKLARI 38 420 0.31 EKLARI 39 472 0.67 EKLARI 40 478 0.44 EKLARI 41 427 0.52 EKLARI 42 434 0.30 EKLARI 43 450 0.36 EKLARI 44 462 0.13 EKLARI 45 320 0.18 EKLARI 46 321 0.06 EKLARI


Khasra List 2

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 47 415 0.70 EKLARI 48 467 0.41 EKLARI 49 426 0.44 EKLARI 50 433 0.30 EKLARI 51 438 0.14 EKLARI 52 449 0.33 EKLARI 53 452/2 0.14 EKLARI 54 453 0.18 EKLARI 55 275 0.52 EKLARI 56 217 0.78 EKLARI 57 220 0.52 EKLARI 58 237/1 0.18 EKLARI 59 229/2 0.24 EKLARI 60 295 0.07 EKLARI 61 298 0.71 EKLARI 62 396/4 0.49 EKLARI 63 396/4 1.54 EKLARI 64 396/1 0.31 EKLARI 65 396/2 2.73 EKLARI 66 396/3 2.03 EKLARI 67 396/5 2.03 EKLARI 68 337 1.21 EKLARI 69 343 0.12 EKLARI 70 297 0.97 EKLARI 71 418/1 0.04 EKLARI 72 418/2 0.84 EKLARI 73 422/3 0.25 EKLARI 74 255/2 0.67 EKLARI 75 409 0.93 EKLARI 76 410 0.95 EKLARI 77 411 0.90 EKLARI 78 471/1 0.59 EKLARI 79 475 0.22 EKLARI 80 204 0.65 EKLARI 81 205 1.02 EKLARI 82 202 1.64 EKLARI 83 203 0.90 EKLARI 84 471/2 0.40 EKLARI 85 447 0.57 EKLARI 86 378/1 2.81 EKLARI 87 219 0.09 EKLARI 88 222 0.61 EKLARI 89 391/2 0.37 EKLARI 90 432/2 0.40 EKLARI 91 372 0.22 EKLARI 92 351 0.30 EKLARI 93 360 0.23 EKLARI 94 390 2.07 EKLARI


Khasra List 3

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 95 359 0.16 EKLARI 96 365 0.12 EKLARI 97 371 0.12 EKLARI 98 364 0.16 EKLARI 99 373 0.32 EKLARI

100 421 0.20 EKLARI 101 314 0.30 EKLARI 102 416 0.80 EKLARI 103 221 0.26 EKLARI 104 323 0.20 EKLARI 105 324 0.62 EKLARI 106 471/3 0.10 EKLARI 107 206/2 1.38 EKLARI 108 206/3 0.28 EKLARI 109 208 0.24 EKLARI 110 210 1.16 EKLARI 111 206/1 1.38 EKLARI 112 291 0.54 EKLARI 113 218 0.24 EKLARI 114 23 1.05 EKLARI 115 24 0.14 EKLARI 116 237/3 2.09 EKLARI 117 292 0.50 EKLARI 118 477 0.39 EKLARI 119 228 2.80 EKLARI 120 356 0.18 EKLARI 121 357 0.10 EKLARI 122 366 0.14 EKLARI 123 358 0.16 EKLARI 124 225/2 1.84 EKLARI 125 341 0.17 EKLARI 126 367 0.07 EKLARI 127 353 0.28 EKLARI 128 368 0.31 EKLARI 129 455/3 0.36 EKLARI 130 224 0.18 EKLARI 131 226 0.42 EKLARI 132 355 0.30 EKLARI 133 370 0.18 EKLARI 134 342 0.13 EKLARI 135 369 0.14 EKLARI 136 338 0.09 EKLARI 137 466 0.46 EKLARI 138 352 0.31 EKLARI 139 468 0.05 EKLARI 140 469 4.43 EKLARI 141 407/2 6.44 EKLARI 142 470 0.18 EKLARI


Khasra List 4

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 143 209 1.08 EKLARI 144 213 0.46 EKLARI 145 213/1 1.01 EKLARI 146 286 1.15 EKLARI 147 308/1 0.25 EKLARI 148 308/2 0.06 EKLARI 149 309 0.09 EKLARI 150 285 0.76 EKLARI 151 307 0.40 EKLARI 152 227 0.44 EKLARI 153 412 0.47 EKLARI 154 212 0.36 EKLARI 155 212/1 0.44 EKLARI 156 207/1 0.22 EKLARI 157 237/2 0.81 EKLARI 158 223 0.28 EKLARI 159 425 0.63 EKLARI 160 424/3 0.02 EKLARI 161 393 0.37 EKLARI 162 394 0.13 EKLARI 163 207 0.84 EKLARI 164 315/1 0.33 EKLARI 165 315/2 0.26 EKLARI 166 250 0.62 EKLARI 167 256/1 0.10 EKLARI 168 256/2 0.52 EKLARI 169 381 1.64 EKLARI 170 273/1 0.43 EKLARI 171 280 0.71 EKLARI 172 311 0.45 EKLARI 173 336 0.10 EKLARI 174 385 0.42 EKLARI 175 254/2 0.66 EKLARI 176 255 0.62 EKLARI 177 263/1 0.96 EKLARI 178 379 1.19 EKLARI 179 302 0.74 EKLARI 180 306 0.12 EKLARI 181 300 0.60 EKLARI 182 301 0.55 EKLARI 183 303 0.23 EKLARI 184 326 0.24 EKLARI 185 331 0.29 EKLARI 186 282 0.69 EKLARI 187 419 0.28 EKLARI 188 473 0.35 EKLARI 189 474 0.10 EKLARI 190 334 0.16 EKLARI


Khasra List 5

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 191 279 0.64 EKLARI 192 283 0.82 EKLARI 193 296 0.49 EKLARI 194 335 0.52 EKLARI 195 382 0.75 EKLARI 196 384 0.40 EKLARI 197 386 0.02 EKLARI 198 387 0.35 EKLARI 199 388 2.32 EKLARI 200 389 2.86 EKLARI 201 294 0.57 EKLARI 202 305 0.12 EKLARI 203 304 0.13 EKLARI 204 325 0.74 EKLARI 205 327 0.15 EKLARI 206 251 0.42 EKLARI 207 347 0.37 EKLARI 208 270 2.42 EKLARI 209 271 0.40 EKLARI 210 272 0.48 EKLARI 211 274 0.45 EKLARI 212 281 0.68 EKLARI 213 318 0.30 EKLARI 214 383 0.49 EKLARI 215 253 0.33 EKLARI 216 254/1 0.10 EKLARI 217 330 0.18 EKLARI 218 344 0.36 EKLARI 219 345 0.51 EKLARI 220 349 1.53 EKLARI 221 361 0.43 EKLARI 222 374 0.20 EKLARI 223 377 0.20 EKLARI 224 267 0.64 EKLARI 225 277 1.12 EKLARI 226 310 0.37 EKLARI 227 322 0.65 EKLARI 228 252/2 0.60 EKLARI 229 252/1 0.20 EKLARI 230 268/1 0.62 EKLARI 231 278 0.69 EKLARI 232 288 0.54 EKLARI 233 317 0.52 EKLARI 234 237/4 1.62 EKLARI 235 299 0.70 EKLARI 236 329 0.09 EKLARI 237 332 0.08 EKLARI 238 348 0.91 EKLARI


Khasra List 6

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 239 350 0.28 EKLARI 240 362 0.23 EKLARI 241 363 0.44 EKLARI 242 375 0.13 EKLARI 243 269 2.93 EKLARI 244 257 0.35 EKLARI 245 258/1 0.21 EKLARI 246 266/2 0.06 EKLARI 247 328 0.14 EKLARI 248 346 1.22 EKLARI 249 380 0.97 EKLARI 250 276 0.19 EKLARI 251 284 1.19 EKLARI 252 290 0.52 EKLARI 253 316 0.29 EKLARI 254 319 0.76 EKLARI 255 319/1 0.06 EKLARI 256 460 0.16 EKLARI 257 340/1 0.05 EKLARI 258 457 0.86 EKLARI 259 465 0.40 EKLARI 260 216 1.05 EKLARI 261 249/6 0.76 EKLARI 262 422/1 0.21 EKLARI 263 422/2 0.20 EKLARI 264 423/3 0.20 EKLARI 265 392 0.43 EKLARI 266 249/2 0.75 EKLARI 267 249/4 0.76 EKLARI 268 249/7 0.76 EKLARI 269 249/3 0.75 EKLARI 270 287 0.46 EKLARI 271 395 6.38 EKLARI 272 413 0.89 EKLARI 273 249/5 0.76 EKLARI 274 249/1 0.75 EKLARI 275 333 0.78 EKLARI 276 249/8 0.76 EKLARI 277 293 0.45 EKLARI 278 378/2 0.40 EKLARI 279 444 0.77 EKLARI 280 445 0.11 EKLARI 281 443 0.21 EKLARI 282 446 0.31 EKLARI 283 420/2 0.19 EKLARI 284 207/2 0.84 EKLARI 285 259 0.89 EKLARI 286 260 0.96 EKLARI


Khasra List 7

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 287 261 0.81 EKLARI 288 262 0.84 EKLARI 289 263/2 0.45 EKLARI 290 396/6 0.49 EKLARI 291 407/1 0.85 EKLARI 292 442 2.27 EKLARI 293 455/2 0.67 EKLARI 294 459/1 0.17 EKLARI 295 459/2 0.28 EKLARI 296 419/2 0.16 EKLARI 297 417 0.44 EKLARI 298 421 0.36 EKLARI 299 423/1 0.20 EKLARI 300 417/2 0.26 EKLARI 301 258/2 0.20 EKLARI 302 339/3 0.23 EKLARI 303 354 0.14 EKLARI 304 215 0.44 EKLARI 305 211 0.70 EKLARI 306 214 0.20 EKLARI 307 264/1 0.65 EKLARI 308 264/2 0.59 EKLARI 309 264/3 0.59 EKLARI 310 74/2 0.18 SIRSI 311 422/2 0.60 WARTHI 312 422/1 0.05 WARTHI 313 487 0.10 WARTHI 314 488 0.28 WARTHI 315 486 0.08 WARTHI 316 485 0.11 WARTHI 317 422/3 0.16 WARTHI 318 482/2 6.73 WARTHI 319 476 0.10 WARTHI 320 477 0.20 WARTHI 321 479 0.22 WARTHI 322 480 0.06 WARTHI 323 496 0.27 WARTHI 324 475/2 0.03 WARTHI 325 478 0.41 WARTHI 326 489 0.61 WARTHI 27 484 0.43 WARTHI

328 493 0.07 WARTHI 329 495 0.05 WARTHI 330 492 0.06 WARTHI 331 494 0.16 WARTHI 332 491 0.12 WARTHI 333 490 1.60 WARTHI 334 471 0.17 WARTHI


Khasra List 8

SR NO. GAT NO./ Khasra No. TOTAL HR LOCATION 335 470 0.05 WARTHI 336 473 0.08 WARTHI 337 467/2 0.03 WARTHI 338 472 0.02 WARTHI 339 468/1 0.12 WARTHI 340 469/2 0.07 WARTHI 341 474/2 0.40 WARTHI 342 289 1.90 WARTHI 343 408 2.54 WARTHI 344 397/1 0.54 WARTHI

ANNEXURE : 5EC AMENDMENT DATA TO BE SUBMITTED TO MOEFCC

Power (MW) Cost (RS) in Lakhs Project Completed By/ Commencement of unit

Sl. No. Products Production & configuration for which


Proposed amendment (current application)

Total Quantity (TPD)

Remark EC obtained

Amendment proposed

Total Remark EC obtained

Amendment Proposed

Total Remarks/ Management EC obtained

(MT)

Amendment Proposed

(MT)

Total (MT) Remarks/ Management EC obtain

ed

Amend-ment

Proposed

Quantity Remark EC obtained

Amendment Proposed

Quantity Remark

1 Direct Reduced Iron 1.0 Million TPA (4x350 TPD & 4x500 TPD Kilns)

No change 1.0 Million TPA (4x350 TPD & 4x500 TPD Kilns)

-1070 Raw Material like Iron ore and dolomite will not be consumed during DRP-1 shut down (iron ore @ 1.915 MT/Ton of DRI and dolomite @0.225 MT/Ton of DRI)

125 -125 0 DRP-1 will be shutdown during combustor operation

7 -7 0 DRP-1 will be shutdown during combustor operation

130 -130 0 TPD of Dolo Char solid waste will not generate during shut down of DRP-1

-3 725 -725 0 TPD of coal reduced due to DRP-1 shut down

No change

2 Pig Iron / Hot Metal 0.6 Million TPA (2 X 0.30 Million TPA MBF)

No change 0.6 Million TPA (2 X 0.30 Million TPA MBF)

0 No change No change No change No change No change No change

3 Ingots / Billets 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF & 1x50/60 + 1x50 TPH

EAF)

No change 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF &

1x50/60 + 1x50 TPH EAF)

No change No change No change No change No change No change No change No change


Nil ESR- 25 T/Batch, 3T/Batch & VAR -15 T/Batch, 3T/Batch (annual

capacity 18000 T/Annum)

ESR- 25 T/Batch, 3T/Batch & VAR -15

T/Batch, 3T/Batch (annual capacity 18000 T/Annum)

0 No change, as intermediate product will be input

0 135 135 0 33 33 Generated effluent will be used in Existing centralised ETP & Cooling Tower make up water

0 0.374 0.374 11kg/Ton solid waste generated from ESR and therewill be no solid waste generation from the VAR. Byassuming 300 working days solid waste generated fromESR will be @ 0.374 T/T Production by consideringESR production 10200 T/A, this solid waste will be sentto Metal slag recovery plant.

7 No change No change ESR-25 T/Batch, ESR-3T/Batch , VAR-15

T/Batch, VAR-3T/Batch -- All Total cost - 93.84

Crore

ESR-25T/batch- Mar-20, ESR 3T/batch-- Dec--19, VAR 15T/Batch-

Mar-20, VAR3T/Batch-Dec-19


Nil 6T/ Batch ( annual capacity 6000 T/Annum)

6T/ Batch ( annual capacity 6000 T/Annum)

0 No change, as intermediate product will be input


0 0 0 No generation 2 No change No change 18 Crore Mar-20


Nil 12,60,000 TPA 12,60,000 TPA 0 No change as metal slag waste from plant will be input

0 5 5 0 0 0 0 -17 -17 97% (i.e.1,89,760 TPA (0.97*195629 TPA)) non-metallic slag waste will be generated, sent to Paver block manufacturer, road making and filling in low lying area. AS per EC of dtd 02.05.2017 EAF & convertor slag generation permitted @ 1,95,629 TPA for 10,25,000 TPA billet production, metal recovery for this will be @ 6000 TPA. (3% of 195629 TPA) Assuming 350 working days

0.32 No change No change 2 Crore 18-Dec

3.d.* SMS Vacuum Degassing

Unit -1 (mentioned in EIA) 60 T/Batch

Unit-2 - 60 T/Batch, Unit 3 (standby)- 60 T/Batch

Unit-1, 2 & 3 Total = 60 +60 T/Batch (&60 T standby)

0 No change as intermediate product will be input

54 54 108 Only two units out of three will operate.One unit will be stand by

13.5 13.5 27 Only two units out of three will operate.One unit will be stand by

0 0 0 No solid waste 0.06 No change No change 4.5 Crore VD-2 - Dec-18 & VD-3 Dec-20

3.e.* VD boiler 1X 16 TPH 1X 16 TPH 2X 16 TPH 0 160 160 320 0 Steam generation 0 0 0 No solid waste 0.65 No change 4.2 4.2 8.4 TPD additional 8 Crore Dec-203.f.* LRF (Ladle Refining

Furnace) for SMS of 60T steel ladle

Unit -1 & 2 (mentioned in EIA) 60 T/Batch

Unit- 3 60 T/Batch Unit-1, 2 & 3 Total = 60 + 60 T/Batch (1 standby)

64.8 64.8 129.6 Only two units out of three will operate.One unit will be stand by

16.2 16.2 32.4 Only two units out of three will operate.One unit will be stand by

0 0 0 No solid waste 0.16 No change No change 10 Crore Dec-20

4 Rolled Steel Products 1.0 Million TPA (2x70 TPH, 2x60 TPH, 2x14

TPH)


No change No change No change No change No change 61 -25.72 35.28 Existing 1X70 TPH Reheating furnace (RHF) of blooming mill (sanctioned in EC 2012) now consumes FO @21 KL per day against @ 61 KL per day (as approved in EC) since it has a dual fired burner operated on FO & MBF gas. Use of MBF gas has reduced FO consumption. Out of the FO saved (40 KLD), 8 KLD will be used by ingot heating RHF (0.32 MTPA).


Nil No addition in capacity of total rolled products, since product will either be reheated in 2X70TPH

RHF of Blooming Mill sanctioned in EC or in ingot heating RHF (0.32

MTPA)


0 Inhouse, no additional raw material 0 14 14 0 3.5 3.5 Effluent generated from 70 TPH or Ingot Furnaces due to Blow

down water. Generated effluent will be used in Existing

centralised ETP & Cooling Tower make up water

0 3.5 3.5 Mill Scale - 1% of RM & 1% of Billet input, which will be used in sinter plant/sms. Fine dust - sinter plant, Chips & scraps - sms

0.2 No change 0 6.72 6.72 4.0 Crore Dec-18


Bright Bar : 2500 TPM (30,000 TPA) and Heat treatment : 3000 TPM

(36,000 TPA)

Change in product configuration asper demand with no increase inoverall steel production of 1.0MTPA

BBU : 5000 TPM (i.e 60,000 TPA); Heat Treatment (Coil

& Rod) : 6500 TPM ( i.e.78,000 TPA)

0 No change as intermediate product will be input

108 108 216 0 0 0 15 15 30 From Bright Bar - 700 TPM, heat treat ment- 50 TPM. will be used in Fine dust - sinter plant, Chips & scraps - sms

6 No change Electrical furnace 90 Crore 20-Dec

4.c.* Producer Gas plant (gasifier) for Bar & Section Mill (BSM)

11000 Nm3/hr, 350 days operation (EC amendment dt.

12.01.2012)


0 only coal required which is accounted in fuel


60 0 60 assuming 40% ash in 150 TPD coal consumed. Sale to brick manufacturing units. Coal Tar produced will be reused for heat recovery

1.7 150 0 150 No change. TPD of coal as per EC amendment dated

12.01.2012

No change 6.0 crore Dec-22

5 Sinter 0.85 Million TPA (0.45 + 0.4 MTPA)

Same 0.85 Million TPA (0.45 + 0.4 MTPA)

0 No change No change No change 0 0 0 No change No change No change

5a Sinter Boiler Nil 1 X 5.7 TPH @10kg/cm2 1 Only fuel required 0 151.2 151.2 0 0 0 Steam generation 0 0 0 No Solid waste as BF gas & HFO will be used 0.06 0 0 0 No coal 0 11.256 11.256 Max for 24 hrs FHO consumption at startup. Additionally BF gas (quantiy-6194 Nm3/hr) will be there, reducing HFO consumption

2.2 Crores 18-Dec

6 Electricity 90 MW Same 90 MW 0 No change No change No change 0 0 0 No change No change No change6.a.* Combuster with coal

crusher and coal handling plant

Nil Steam generation @45 TPH Power generation capacity :9.5 MW

9.5 MW 0 only coal required which is accounted in fuel

0 2 2 During the shut down of DRP-1, combustor will be in operation

0 0 0 0 61 61 61 TPD ash generation utilised in brick & paver manufacturing

1.4 0 250 250 475 TPD Coal saving will be obtained due to DRP-1

shutdown and running of combustor (DRP-1

consumes 725 Ton and consumption in combustor

250 Ton / day)

No change 12 Crore Dec-18

7 Coke 0.25 Million TPA Same 0.25 Million TPA 0 No change No change No change 0 0 0 No change No change No change8.a Oxygen / Nitrogen /

Argon Plant45000 TPA Same 45000 TPA 0 No change No change No change 0 0 0 No change No change No change

8.b. Oxygen Plant 15000 TPA Will be dismantled 0 0 Will be dismantled 100 -100 0 20 -20 0 0 0 0 Will be dismantled -3.63 No change No change8.c.* PSA Oxygen Plant NIL 140 TPD 140 TPD 0 Atmospheric air is the input 0 100 100 0 20 20 0 0 0 No solid waste generation 1.7 No change No change9 Washery 750 TPD Same 750 TPD 0 No change No change No change 0 0 0 No change No change No change10 Lime Crusher Not mentioned

separately, but integral to raw material handling

Mention required: 150 T/hr, 350 days operation


0 No change No change No change 0 0 0 No change No change No change

11 LPG Storage Nil 60,228 Kg storage capacity 60,228 Kg storage capacity Nil Nil Nil Nil 0.125 Nil Nil

12 Coal Drier at DRP 300 TPD 300 ton per day capacity coal drier

312 % moisture reduction by 4-6%. nil nil nil 12 in the form of water vapour nil nil nil NA 1.2 mw /day NIL NIL NIL NIL 01 KL/DAY

heat only for drying not for reactions 13.6 LAKHS 18-Dec

TOTAL -1070 661.8 669 1330.8 Total consumption is 8589 KLD for the enitre plant, which will remain unchanged as the

water conservation measures* implemented in last 2 years are to the tune of 850 KLD

66.7 84.2 150.9 205 -67.126 137.874 3685.55 is total solid waste generation. but disposal is zero since metal is being recoverd from the waste and non-metallic waste is being reused.

14.745 875 -475 400 65.2 -3.544 61.656 250.676 Crores

*WATER CONSERVATION MEASURES has been taken to take care of Extra water consumption @ 669 m3 per day1. Drift losses in cooling tower were reduced by replacing with latest technology cooling tower (fix type/ honeycomb fills type Cooling tower replaced by optical grid type cooling tower).2. Paving of roads has reduced the water consumption in road sprinkling.3. Reduction in cooling tower makeup water by doing automation of cooling tower fans on-off with respect to outlet temperature. This has also lead to energy/Power conservation.

Fuel (Coal) (MT / DAY) Fuel (Oil) (TPd)

4. Specific water consumption has been reduced.

Raw Material (excluding fuel such as coal) Additional Water Consumption (KLD) Effluent Genertaion (KLD) Solid Waste (TPD)

ANNEXURE : 6

[1]

LIST OF FEATURES IN STUDY AREA (15 KM RADIUS) OF EXPANSION OF INTEGRATED STEEL PLANT FROM 0.5 MTPA TO 1.0 MTPA

AT SUNFLAG IRON & STEEL CO. LTD., P.O. WARTHI, TA. MOHADI, DISTT. BHANDARA

Sl. No.

Name Distance (km)

Direction

I. RIVER, NALA AND DRAIN 1. Canal originated from Ramtek canal Within 2. Neri Minor 1.1 W 3. Reservoir South of project 0.9 S 4. Khursapur Reservoir 2.7 SSW 5. Sur River 2.9 E 6. Ganeshpuram Nala 3.4 S 7. Wainganga River 4.8 ESE 8. Hantidohi Canal 4.9 SW 9. Bhosa minor 4.9 WNW 10. Morgaon Minor No.2 6.4 NW 11. Gaimukh Nadi 6.4 NE 12. Dharmapuri Minor 9.0 WNW 13. Pond near Neri 2.3 NW 14. Reservoir near Satone 2.8 W 15. Pond near Pahuni 5.2 W 16. Reservoir near Sirsi 1.2 SSE 17. Pond in Bhandara 6.1 SSE 18. Reservoir in Bhandara 5.7 SSE 19. Pond near Tavepar 3.6 SSW 20. Pond near Sakh 6.5 SW 21. Pond near Moregaon 8.1 SW 22. Pond near Shahpur 9.2 SW 23. Reservoir near Yanarwani 10.3 SW 24. Pond near Hantidahi 5.7 WSW 25. Pond near Khat 7.5 WNW 26. Pond near Chorkhumari 6.7 NW 27. Pond near Khutsawni 6.8 NNW 28. Pond near Hardeli 8.0 NNE 29. Pond near Sitepur 7.7 NW 30. Pond near Pondharbari 10.5 NW 31. Pond near Panchgaon 2.6 N 32. Pond near Bhandara road RS 0.2 E 33. Pond near Kitari 8.9 ESE 34. Pond near Surewara 9.0 SE 35. Chinta Nala 14.2 N


[2]

Sl. No.

Name Distance (km)

Direction

36. Shri Khanda Canal 11.7 NW 37. Shri Khanala Sirsoli Canal 12.4 NW 38. Nawa Talav 13.2 N 39. Mota Talav 13.3 NNE 40. Chichbori Talav 12.2 NNE 41. Lohar Talav 11.1 NNE II. ROADS 1. NH-6, Nagpur to Lakhani 7.4 S 2. SH-252 ,Dhasmapuri & Bhandara 2.5 SW 3. SH-271, Mohadi to Bhandara Adjoining E 4. SH-254, Kardha to Adyal 10.2 SSE

III. RAILWAY LINE 1. Bhandara Road Rs. To Jawaharnagar 1.5 E 2. Rewral to Tumsar Road 0.01 N

IV. RAILWAY STATION 1. Bhandara Road Rs. 1.1 E

V. FOREST, NATIONAL PARK AND SANCTUARY 1. Matora R.F. 8.7 E 2. Kola WLS 8.7 E 3. Navegaon N.P. 47.5 SE

VI. INDUSTRIES 1. MIEPL Neri 2.4 WNW 2. Rajnandgaon Oil Pvt. Ltd. 5.0 NE 3. Kasan Distilleries 6.6 SW 4. Maharashtra Metal Powders Ltd. 7.4 SW 5. Shri Metal Pvt. Ltd. 8.4 SSW 6. Ordnance factory Jawaharnagar 13.4 SSW

VII. STATE BOUNDARY 1. Madhya Pradesh 34.5 N

VIII. INTERNATIONAL BOUNDARY 1. Bangladesh 965 ENE

IX CRITICALLY POLLUTED AREA 1. Tadali 140 SSW 2. MIDC, Chandrapur 144 SSW

X. DISTRICT HEADQUARTER 1. Bhandara 7.4 SSE

XI HISTORICAL PLACES 1. Andhalgaon 13.5 N 2. Maa Chandeshwari Devi Temple 8.2 NNE 3. Korambhi Devi Temple 10.5 S 4. Pandey Mahel 6.7 SSE


[3]

TOPOGRAPHY AND DRAINAGE MAP OF 15 KM RADIUS

SUMMARY OF AMENITIES AVAILABLE (CENSUS 2011) IN VILLAGES WITHIN THE STUDY AREA OF INTEGRATED STEEL PLANT OF M/S SUNFLAG AT EKLARI

AMENITIES NOS. AMENITIES NOS. AMENITIES NOS.

EDUCATION FACILITIES DRINKING WATER FACILITY APPROACH TO VILLAGE

PPS (Pre-Primary School) 209 TWT (Tap Water-Treated) 34 NH (National Highway) 10

PS (Primary school) 103 TWUT (Tap Water Untreated) 26 SH (State Highway) 25

MS (Middle school) 71 CW (Covered Well) 27 MDR (Major District Road) 33

SS (Secondary school) 26 UW (Uncovered Well) 87 ODR (Other District Road) 67

SSS (Sr. Sec. School) 15 HP (Hand Pump) 86 BTPR (Black Topped (pucca) Road) 68

DCAS (Deg. College Arts & Science only) 0 TW/ BW (Tube Wells/Borehole) 39 GCR (Gravel (kuchha) Roads) 60

EC ( Engg. College) 0 S (Spring) 0 WBM (Water Bounded Macadam) 79

MC (Medicine College) 0 R/C (River/Canal) 36 AWR (All Weather Road) 86

MI (Management Institute) 0 T/P (Tank/Pond/Lake) 22 NWR/C (Navigable Waterways (River/Canal)) 0

P (Polytechnic) 0 WO (Others) 0 FP (Foot Path) 89

VTS/ITI (Vocational Trg School/ITI) 2

NFTC (Non Formal Training Centre) 0 COMMUNICATION SYSTEM BANKS AND COMMERCIAL SOCIETIES

SFD (School For Disabled) 0 PO (Post Office) 15 ATM (ATM) 0

EO (Others) 0 SPO (Sub Post Office) 11 CB (Commercial bank) 4

P&T (Post & Telegraph office) 15 COB (Co-operative bank) 6

MEDICAL FACILITIES PIN (Village PIN code) 89 ACS (Agricultural Crredit Societies) 42

CHC (Community Health Centres ) 1 T (Telephone (landline)) 73 SHG (Self-Help Group (SHG)) 67

PHC (Primary Health Centre) 4 PCO (Public Call Office/ Mobile PCO) 52 PDS (Public Distribution System (PDS)) 66

PHSC (Primary Health Sub-Centre) 18 MPC (Mobile phone coverage) 80 M/RM (Mandis/Regular Market) 2

MCWC (Maternity And Child Welfare Centre) 5 IC/CSC (Internet Cafes/Common Service Centre) 3 WH (Weekly Haat) 5

TBC (TB Clinic) 5 PCF (Private Courier Facility) 3 AMS (Agricultural Marketing Society) 84

HA (Hospital Allopathic) 5 NCICDS (Nutritional Centres-ICDS) 84

HAM (Hospiltal Alternative Medicine) 0 TRANSPORT SYSTEM NCAC (Nutritional Centres-Anganwadi Centre) 84

D (Dispensary) 7 PBS (Public Bus Service) 62 NCO (Nutritional Centres-Others) 89

VH (Veterinary Hospital) 8 PvtBS (Private Bus Service) 3 ASHA (ASHA) 84

MHC (Mobile Health Clinic) 0 RS (Railway station) 2 CC-TV (Community Centre with/without TV) 18

FWC (Family Welfare Centre) 4 MA (Auto/Modified Autos) 70

NGMF-OP (Non Govt. Med. facilities Out Patient) 7 Taxi (Taxi) 29 SPORTS AND ENTERTAINMENT

NGMF-IOP (Non Govt. Med. facilities In And Out Patient) 0 Van (Vans) 3 SF (Sports Field) 5

NGMF-C (Non Govt. Med. facilities Charitable) 0 T (Tractors) 0 SC/RC (Sports Club/Recreation Centre) 5

AN

NE

XU

RE

: 7

NGMF-MBBS (Non Govt. Med. facilities Medical

Prctitioner with MBBS Degree )

0 CPR-Man (Cycle-pulled Rickshaws (manual driven)) 0 C/VH (Cinema/Video Hall) 5

CPR-Mec (Cycle-pulled Rickshaws (machine driven)) 0 PL (Public Library) 19

NGMF-OD (Non Govt. Med. facilities Medical Prctitioner

with other Degree )

7 CDA (Carts Drivens by Animals) 0 PRR (Public Reading Room) 19

S/R/FS (Sea/River/Ferry Service) 0 DNS (Daily Newspaper Supply) 19

NGMF-ND (Non Govt. Med. facilities Medical Practitioner

with no Degree )

10 APS (Assembly Polling Station) 19

POWER SUPPLY BDRO (Birth and Death Registration Office) 75

NGMF-TPFH (Non Govt. Med. facilities Traditional

Practitioner and Faith Healer )

3 PSDU (Power Supply For Domestic Use) 87

PSIAU (Power Supply ForAgriculture Use) 86

NGMF-MS (Non Govt. Med. facilities Medicine Shop ) 7 PSCU (Power Supply For Commercial Use) 0

NGMF-O (Non Govt. Med. facilities Others) 0 PSALL (Power Supply For All Users) 84

SUMMARY OF AMENITIES AVAILABLE (CENSUS 2011) IN TOWNS WITHIN THE STUDY AREA OF INTEGRATED STEEL PLANT OF M/S SUNFLAG AT EKLARI

AMENITIES NOS. AMENITIES NOS. AMENITIES NOS.

EDUCATION Private-MS Office (Nos.) 7 WATER SUPPLY AND SANITATION

Govt. Primary School (Nos.) 38 Govt.-Desk Top Publishing (Nos.)) 0 Latrines-Pit (Nos.) 16276

Private Primary School (Nos.) 28 Private-Desk Top Publishing (Nos.) 1 Latrines-Flush/Pour Flush (Nos.) 6898

Govt. Middle School (Nos.) 34 Govt.-Vocational(Others) (Nos.)) 0 Latrines-Service (Nos.) 0

Private Middle School (Nos.) 18 Private-Vocational(Others) (Nos.) 5 Latrines-Others (Nos.) 55

Govt. Secondary School (Nos.) 20 Govt.-Non Formal Education (Nos.)) 1 Protected Water Supply Source-1 0

Private Secondary School (Nos.) 11 Private-Non Formal Education (Nos.) 0 Capacity Source-1 (KL) 6050

Govt. Senior Secondary School (Nos.) 14 Govt.-Special School for Disabled (Nos.)) 1 Protected Water Supply Source-2 0

Private Senior Secondary School (Nos.) 4 Private-Special School for Disabled (Nos.) 1 Capacity Source-2 (KL) 0

Govt. Degree College-Art Only (Nos.) 0 Govt.-Others(Specify) (Nos.)) 0 Protected Water Supply Source-3 0

Private Degree College-Art Only (Nos.) 0 Private-Others(Specify) (Nos.) 0 Capacity Source-3 (KL) 0

Govt. Degree College-Science Only (Nos.) 0 MEDICAL Protected Water Supply Source-4 0

Private Degree College-Science Only (Nos.) 0 Hospital Allopathic (Nos.) 2 Capacity Source-4 (KL) 0

Govt. Degree College-Commerce Only (Nos.)) 0 Hospital Alternative Medicine (Nos.) 0 Protected Water Supply Source-5 0

Private Degree College-Commerce Only (Nos.) 0 Dispensary/Health Centre (Nos.) 2 Capacity Source-5 (KL) 0

Govt. Degree College-Art and Science Only (Nos.)) 0 Family Welfare Centre (Nos.) 3 TRANSPORT

Private Degree College-Art and Science Only (Nos.) 0 Maternity and Child Welfare Centre (Nos.) 3 Bus Route Road Distance (in kms.) 0

Govt. Degree College-Art and Commerce Only (Nos.)) 0 Maternity Home (Nos.) 2 Pucca Road Length (in kms.) 198.0

Private Degree College-Art and Commerce Only (Nos.) 0 Maternity Home Nearest facility Distance (in kms.) 76 Kutcha Road Length (in kms.) 68.065

Govt. Degree College-Art,Science and Commerce (Nos.)) 0 T.B. Hospital/ Clinic (Nos.) 1 ENTERTAINMENT AND COMMODITY

Private Degree College-Art,Science and Commerce (Nos.) 15 Nursing Home (Nos.) 1 Govt.-Stadium (Nos.)) 3

Govt. Degree College-Law (Nos.)) 0 Veterinary Hospital (Nos.) 4 Private-Stadium (Nos.) 0

Private Degree College-Law (Nos.) 2 Mobile Health Clinic (Nos.) 0 Govt.-Cinema Theatre (Nos.)) 0

Govt. Degree College-University (Nos.)) 0 Others (Nos.) 0 Private-Cinema Theatre (Nos.) 3

Private Degree College-University (Nos.) 0 Non-Government Out-Patient (Nos.) 82 Govt.-Auditorium/Community Hall (Nos.)) 4

Govt. Degree College-Others (Nos.)) 0 Non-Government In and Out Patient (Nos.) 70 Private-Auditorium/Community Hall (Nos.) 16

Private Degree College-Others (Nos.) 0 Non-Government Charitable-Hospital/Nursing Home (Nos.)4 Govt.-Public Library (Nos.)) 5

Govt.-Medical College (Nos.)) 0 Non-Government Medicine Shop (Nos.) 106 Private-Public Library (Nos.) 0

Private-Medical College (Nos.) 0 ELECTRICITY Govt.-Public Reading Room (Nos.)) 0

Govt.-Engineering College (Nos.)) 0 Electricity-Domestic Connection (Nos.) 25900 Private-Public Reading Room (Nos.) 8

Private-Engineering College (Nos.) 0 Electricity-Industrial Connection (Nos.) 319 Manufactured Commodity (First) 0

Govt.-Management Institute (Nos.)) 0 Electricity-Commercial Connection (Nos.) 3620 Manufactured Commodity (Second) 0

AN

NE

XU

RE

: 7

Private-Management Institute (Nos.) 0 Electricity-Road Lighting Connection (Nos.) 1067 Manufactured Commodity (Third) 0

Govt.-Polytechnic (Nos.)) 1 Electricity-Others Connection (Nos.) 201 HELP HOMES

Private-Polytechnic (Nos.) 5 FINANCIAL Govt.-Orphanage Home (Nos.)) 0

Govt.-Shorthand (Nos.)) 0 Nationalised Bank (Nos.) 14 Private-Orphanage Home (Nos.) 2

Private-Shorthand (Nos.) 0 Private Commercial Bank (Nos.) 4 Govt.-Working Women's Hostel (Nos.)) 0

Govt.-Typewriting (Nos.)) 0 Co-operative Bank (Nos.) 5 Private-Working Women's Hostel (Nos.) 2

Private-Typewriting (Nos.) 7 Agricultural Credit Society (Nos.) 5 Govt.-Old Age Home (Nos.)) 0

Govt.-Shorthand and Typewriting (Nos.)) 0 Non-Agricultural Credit Society (Nos.) 42 Private-Old Age Home (Nos.) 3

Private-Shorthand and Typewriting (Nos.) 29 FIRE FIGHTING

Govt.-MS Office (Nos.)) 0 Fire Fighting Service (Status A(1)/NA(2)) 0

ANNEXURE : 8





PRE-FEASIBILITY REPORT

FFOORR

AAMMEENNDDMMEENNTT IINN CCOONNFFIIGGUURRAATTIIOONN SSAACCTTIIOONN IINN

EENNVVIIRROONNMMEENNTTAALL CCLLEEAARRAANNCCEE OOFF

IINNTTEEGGRRAATTEEDD SSTTEEEELL PPLLAANNTT

(VIDE EC LETTER NO. J-11011/355/2004-IA II(I) DATED 02.05.2017)

AATT

VVIILLLLAAGGEESS WWAARRTTHHII,, SSIIRRSSII && EEKKLLAARRII,,

TTEEHHSSIILL MMOOHHAADDII,, DDIISSTTRRIICCTT BBHHAANNDDAARRAA,,

MMAAHHAARRAASSHHTTRRAA

(1.0 MTPA STEEL, AREA: 200 HA)

JUNE, 2018 (Issue 01, Rev. 0)

Submitted by:

M/s. Sunflag Iron & Steel Co. Limited

Village Eklari, Taluka Mohadi District Bhandara, Maharashtra

ANNEXURE : 9

Pre-feasibility Report - Amendment in configuration of EC dated 02.05.2017 of SISCL i

CONTENTS Sl. No. Description Page No. 1.0 Executive summary 1 2.0 Introduction 2

2.1 Identification of project and project proponent 2 2.2 Brief description of nature of the project 2 2.3 Need for the project and its importance to the country and or

region 2

2.4 Demand-supply gap 2 2.5 Imports vs. indigenous production 2 2.6 Export possibility 3 2.7 Domestic / export markets 3 2.8 Employment generation (direct and indirect) 3

3.0 Project description 3

3.1 Type of project including interlinked and interdependent projects

3

3.2 Location with coordinates 3 3.3 Details of alternate sites & environmental considerations 3 3.4 Size or magnitude of operation 5 3.5 Project description with process details 7

4.0 Site analysis 22

4.1 Connectivity 22 4.2 Land form, land use and land ownership 23 4.3 Topography 23 4.4 Existing land use pattern 23 4.5 Existing infrastructure 24 4.6 Soil classification 24 4.7 Climatic data from secondary sources 25 4.8 Social infrastructure available 26

5.0 Planning brief 26

5.1 Planning concept 26 5.2 Population projection 26 5.3 Land use planning (break up along with green belt etc.) 26 5.4 Assessment of infrastructure demand (physical & social) 26 5.5 Amenities / facilities 27

Pre-feasibility Report - Amendment in configuration of EC dated 02.05.2017 of SISCL ii

Sl. No. Description Page No. 6.0 Proposed infrastructure 27

6.1 Industrial area (processing area) 27 6.2 Residential area (non processing area) 27 6.3 Green belt 27 6.4 Social infrastructure 27 6.5 Connectivity 27 6.6 Water management (quantity & source of water) 27 6.7 Sewarage system & Industrial waste management 28 6.8 Solid waste management 28 6.9 Power requirement & supply / source 29

7.0 Rehabilitation and resettlement plan 30 8.0 Project schedule & cost estimates 30

8.1 Project schedule 30 8.2 Cost of the project 30

9.0 Analysis of proposal (final recommendations) 30

LIST OF TABLES

Table No. Description Page No.

1 Distance and direction (within 15 km) of water bodies, forests from project boundary

3

2 Break up of land use 23 3 Soil test result 24 4 Monthly average relative humidity at Nagpur (2005-2015) 25 5 Fuel oil consumption 30

LIST OF FIGURES

Fig No. Description Page No.

1 Process flow diagram of pig iron manufacturing by MBF route 9 2 Process flow diagram of vacuum degassing plant 13 3 Process flow diagram of captive power plant 18

Pre-feasibility Report - Amendment in configuration of EC dated 02.05.2017 of SISCL 1

1.0 EXECUTIVE SUMMARY

Project name Amendment in configuration of Integrated steel plant sanctioned vide MOEF’s EC letter no. J-11011/355/2004-IA II(I) dated 02.05.2017 without any change in total production of steel

Project Proponent M/s Sunflag Iron & Steel Ltd.

Location Villages Warthi, Sirsi & Eklari, Tehsil Mohadi, District Bhandara, Maharashtra

Total Area 200 ha

Present Land status

Industrial Use

Product Existing: DRI, Pig Iron, Ingots/Billets, Rolled Steel, Bright Bar of Coil & Rod

Additional: Super Alloys

Rated capacity Existing: DRI - 1.0 MTPA, Pig Iron - 0.6 MTPA, Ingots/Billets - 1.025 MTPA, Rolled Steel - 1.0 MTPA, Bright Bar - 0.03 MTPA and Heat treatment of Coil & Rod - 0.036 MTPA, PGP - 11000 Nm3/hr, Sinter - 0.85 MTPA, Oxygen/ nitorgen /Argon Plant - 0.045 MTPA and Crusher - 150 T/hr

Additional: Super Alloys - 0.018 MTPA (Post Ingot/Billet, pre-rolling), Vacuum Induction Melting(VIM) Furnace - 0.006 MTPA, Metal slag Recovery Plant - 1.26 MTPA, Bright Bar - 0.03 MTPA and Heat treatment of Coil & Rod - 0.042 MTPA, Combustor - 9.5 MW and LPG Storage - 60,228 kg

Replacement: Cryogenic oxygen plant (0.015 MTPA) will be replaced by PSA oxygen plant (140 TPD)

Working days Unit wise variable, maximum 350 days per annum

Manpower No additional manpower. Only construction labours will be additional temporarily.

Implementation Schedule

54 Months

Cost of the project Rs. 250.676 crores

Water requirement Additional : 792 KLD (when DRP-1 operates) and 669 KLD (when combustor operates)

Sanctioned : 8589 KLD, which will remain unchanged because the water conservation measures implemented in last 2 years have lead to water savings against which above additional demand is adjusted.

Source of water Wainganga river

Power Requirement

Additional : 15.945 MW

Power source Maharashtra State Electricity Distribution Company Ltd (MSEDCL) (Ex.MSEB)


2.0 INTRODUCTION 2.1 Identification of project and project proponent Sunflag Iron & Steel Company Limited is a prestigious unit of the reputed

Sunflag Group with set up of a state of art Integrated Steel plant at Bhandara district of Maharashtra. The plant has capacity to produce 0.50 MTPA of high quality special steel using Iron ore and non-coking coal as basic inputs. In 2017, the plant has received permission to expand to 1.0 MTPA from MoEF&CC. The products have wide application in automobile and auto parts manufacturing industry and over the years Sunflag has established a good customer base both in OEM segment and Auto components manufacturers. The demand for these products is very good in domestic as-well-as international market. Out of the total sales about 20% comes from export sale.

Sunflag is a professionally managed company and having experienced

executives at the top level who are techno commercial wizards in their respective fields.

2.2 Brief description of nature of the project The nature of the project is ferrous metallurgical industries and fall under

the category of 1(d) due to CTPP, 2 (a) due to washery, 3(a) due to metallurgical operations and 4(b) due to coke oven plant under the category “A” of the schedule of EIA Notification, 2006.

2.3 Need for the project and its importance to the country and/or region India’s economic growth is contingent upon the growth of the Indian Steel

Industry. Consumption of steel is taken to be an indicator of economic development. While steel continues to have a strong hold in traditional sectors such as construction, housing and ground transportation, special steels are increasingly used in engineering industries such as power generation, petrochemicals, fertilizers, Automobile, Railway etc,

2.4 Demand-supply gap The Indian Steel industry has entered into new development stage from

2005-2006 riding high on the resurgent economy and rising demand of Steel. Rapid rise in production has resulted in India to become 5th largest producer of steel. It is estimated that, India’s Steel consumption will continue to grow at nearly 16% rate annually, fuelled by the demand of construction project. The National Steel Policy envisaged steel production to reach 110 million tonnes by 2020. So considering the huge demand of steel, this project is important for partially fulfilling of demand.

2.5 Imports vs. indigenous production Indigenous production is envisaged.


2.6 Export possibility Out of the total sales about 20% comes from export sale. 2.7 Domestic / Export markets Sponge Iron will be used as raw material from within house for producing

steel. The steel shall be sold in domestic market as well as exported. 2.8 Employment generation (Direct and Indirect) The required man power as per EC dated 02.05.2017 is 2535. There is no

additional man power requirement as the excess manpower from the existing units will be shifted to the proposed units. During construction phase, additional man power will be required temporarily.

3.0 PROJECT DESCRIPTION 3.1 Type of project including interlinked and interdependent projects Nil. 3.2 Location with Coordinates District & State : Bhandara, Maharashtra Village : Warthi, Sirsi & Eklari Latitude : 21°13’30” to 21°14’16” E Longitude : 79°37’11” to 79°38’26” N Location map showing general location, specific location and project

boundary enclosed as Annexure - 3.

3.3 Details of Alternate Sites & Environmental Considerations No alternatives under consideration. The amendment of the project will be

incorporated within the existing plot (200 ha).

Environmental considerations: There are several water bodies and forest present within the study area of the project. The distance to various water bodies, forest, etc. are given in Table 1.

TABLE 1

DISTANCE AND DIRECTION (WITHIN 15 KM) OF WATER BODIES, FORESTS FROM PROJECT BOUNDARY

Name Distance Direction

RIVER, NALA AND DRAIN :

Canal originated from Ramtek canal Within

Neri Minor 1.1 W

Reservoir South of project 0.9 S


Name Distance Direction

Khursapur Reservoir 2.7 SSW

Sur River 2.9 E

Ganeshpuram Nala 3.4 S

Wainganga River 4.8 ESE

Hantidohi Canal 4.9 SW

Bhosa minor 4.9 WNW

Morgaon Minor No.2 6.4 NW

Gaimukh Nadi 6.4 NE

Dharmapuri Minor 9.0 WNW

Pond near Neri 2.3 NW

Reservoir near Satone 2.8 W

Pond near Pahuni 5.2 W

Reservoir near Sirsi 1.2 SSE

Pond in Bhandara 6.1 SSE

Reservoir in Bhandara 5.7 SSE

Pond near Tavepar 3.6 SSW

Pond near Sakh 6.5 SW

Pond near Moregaon 8.1 SW

Pond near Shahpur 9.2 SW

Reservoir near Yanarwani 10.3 SW

Pond near Hantidahi 5.7 WSW

Pond near Khat 7.5 WNW

Pond near Chorkhumari 6.7 NW

Pond near Khutsawni 6.8 NNW

Pond near Hardeli 8.0 NNE

Pond near Sitepur 7.7 NW

Pond near Pondharbari 10.5 NW

Pond near Panchgaon 2.6 N

Pond near Bhandara road RS 0.2 E

Pond near Kitari 8.9 ESE

Pond near Surewara 9.0 SE

Chinta Nala 14.2 N

Shri Khanda Canal 11.7 NW

Shri Khanala Sirsoli Canal 12.4 NW

Nawa Talav 13.2 N

Mota Talav 13.3 NNE

Chichbori Talav 12.2 NNE

Lohar Talav 11.1 NNE

FOREST, NATIONAL PARK AND SANCTUARY :

Matora R.F. 8.7 E

Kola WLS 8.7 E

Navegaon N.P. 47.5 SE


3.4 Size/Magnitude of operation Plant area: 200 ha Manufacturing facilities for which EC granted by MOEF&CC Government of

India vide Letter no. J-11011/335/2004-IA.II(I) dated 02.05.2017 are:

Products Existing Capacity Proposed Capacity Total Production after Expansion

Direct Reduced Iron 0.28 Million TPA (1x350 TPD and 1x500 TPD Kilns)

0.72 Million TPA (3x350 TPD & 3x500 TPD Kilns)

1.0 Million TPA

Pig Iron / Hot Metal 0.25 Million TPA (0.3 Million TPA MBF)

0.35 Million TPA (0.30 Million TPA MBF + 0.05 Million TPA Existing Capacity Utilization)

0.60 Million TPA

Ingots / Billets 0.525 Million TPA (1x50/60 TPH EAF & 75 TPH AOD)

0.5 Million TPA (2x25 TPH IF & 1x50 TPH EAF)

1.025 Million TPA

Rolled Steel Products

0.5 Million TPA (1x70 TPH, 1x60 TPH, 1x14 TPH)

0.5 Million TPA (1x70 TPH, 1x60 TPH, 1x14 TPH)

1.0 Million TPA

Sinter 0.25 Million TPA (0.48 Million TPA Sinter Plant)

0.60 Million TPA (0.40 Million TPA Sinter Plant + 0.20 Million TPA existing capacity utilization)

0.85 Million TPA

Electricity 30 MW CPP (WHRB and FBC based boilers)

60 MW (4x15 MW CPP)

90 MW

Coke -- 0.25 Million TPA (Coke Oven Plant)

0.25 Million TPA

Oxygen Plant 15000 TPA -- 15000 TPA

Oxygen / Nitrogen / Argon Plant

45000 TPA -- 45000 TPA

Washery 750 TPD -- 750 TPD

Source : Table 1.2 of Final EIA/EMP report (0.5 to 1.0 MTPA), August 2016

Proposed Manufacturing facilities amendment and upgradation are: Proposed change in configuration

Sl. No.

Products Production & configuration for which EC granted dated 02.05.2017

Proposed amendment (current

application)

Total

1 Direct Reduced Iron 1.0 Million TPA (4x350 TPD & 4x500

TPD Kilns)

No change 1.0 Million TPA (4x350 TPD &

4x500 TPD Kilns)

2 Pig Iron / Hot Metal 0.6 Million TPA (2 X 0.30 Million TPA

MBF)

No change 0.6 Million TPA (2 X 0.30 Million TPA

MBF)


Sl. No.



application)

Total

3 Ingots / Billets 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF & 1x50/60 + 1x50

TPH EAF)

No change 1.025 Million TPA (75 TPH AOD, 2x25 TPH IF & 1x50/60 + 1x50

TPH EAF)


Nil ESR- 25 T/Batch, 3T/Batch & VAR -15 T/Batch, 3T/Batch (annual capacity 18000 T/Annum)

ESR- 25 T/Batch, 3T/Batch & VAR -

15 T/Batch, 3T/Batch (annual capacity 18000

T/Annum)


Nil 6T/ Batch ( annual capacity 6000

T/Annum)

6T/ Batch ( annual capacity 6000

T/Annum)


Nil 12,60,000 TPA 12,60,000 TPA

3.d.* SMS Vacuum Degassing Unit -1 (mentioned in EIA) 60 T/Batch

Unit-2 - 60 T/Batch, Unit 3 (standby)- 60

T/Batch

Unit-1, 2 & 3 Total = 60 +60 T/Batch (&60 T standby)

3.e.* VD boiler 1X 16 TPH 1X 16 TPH 2X 16 TPH

3.f.* LRF (Ladle Refining Furnace) for SMS of 60T steel ladle

Unit -1 & 2 (mentioned in EIA)

60 T/Batch

Unit- 3 - 60 T/Batch Unit-1, 2 & 3 Total = 60 + 60 T/Batch

(1 standby)

4 Rolled Steel Products 1.0 Million TPA (2x70 TPH, 2x60 TPH,

2x14 TPH)



Nil No addition in capacity of total rolled

products, since product will either be reheated in 2X70TPH RHF of Blooming Mill sanctioned in EC or in

ingot heating RHF (0.32 MTPA)



Bright Bar : 2500 TPM (30,000 TPA)

and Heat treatment : 3000 TPM (36,000

TPA)

Bright Bar : 2500 TPM (30,000 TPA) and Heat treatment : 3500 TPM (42,000 TPA) Change in product configuration as per demand with no increase in overall steel production of 1.0 MTPA

BBU : 5000 TPM (i.e 60,000 TPA); Heat Treatment (Coil & Rod) :

6500 TPM ( i.e.78,000 TPA)

4.c. Producer Gas plant (gasifier) for Rolling Mill

11000 Nm3/hr, 350 days operation (EC

amendment dt. 12.01.2012)


5 Sinter 0.85 Million TPA Same 0.85 Million TPA


Sl. No.



application)

Total

(0.45 + 0.4 MTPA) (0.45 + 0.4 MTPA)

5a Sinter Boiler Nil 1 X 5.7 TPH @10kg/cm2

1

6 Electricity 90 MW Same 90 MW

6.a.* Combuster with coal crusher and coal handling plant

Nil Hot flue gas generation for Steam generation @45 TPH for Power generation @ capacity : 9.5 MW

9.5 MW

7 Coke 0.25 Million TPA Same 0.25 Million TPA

8.a Oxygen / Nitrogen / Argon Plant

45000 TPA Same 45000 TPA

8.b. Oxygen Plant 15000 TPA Will be dismantled 0

8.c.* PSA Oxygen Plant NIL 140 TPD 140 TPD

9 Washery 750 TPD Same 750 TPD

10 Crusher Not mentioned separately, but integral to raw

material handling system

Mention required: 150 T/hr, 350 days

operation


11* LPG Storage Nil 60,228 Kg storage capacity

60,228 Kg storage capacity

12* Coal Drier Nil 300 TPD 300 TPD

Note:

* New Units

1. Change in product configuration in Bright Bar and Heat Treatment:

� 500 TPM for 15- 40mm. (Bar to Bar peeling)

� 300 TPM for 12- 25mm (Coil to Bar peeling)

� 100 TPM for 5.5 - 16mm (Coil to Bar peeling)

� 1000 TPM (Induction Hardening & Tempering line in existing shed)

� 2000 TPM (Coil annealing capacity by installing Bell annealing furnaces)

� 1000 TPM (Bar annealing capacity by installing Spherodising bar annealing furnaces)

� 2000 TPM (Grinding capacity for dia. 6 - 30mm)

� 400 TPM (Eddy current testing)

� Chamfering machines (1000 TPM) 3.5 Project description with process details 3.5.1 Direct Reduced Iron (EC obtained for 1.0 MTPA) The direct reduced iron process reduces the iron oxide in the mined iron ore

using non-coking coal, air and fluxes like dolomite. The direct reduced iron


contains 94% iron and iron oxide, the balance being gangue materials like oxides of aluminium, silicon and manganese.

The reduction is carried out in an inclined horizontal rotary kiln, which

rotates at a pre-determined speed. DRI gases flow counter-current to the kiln feed. The temperature at the product discharge end in a rotary kiln is about 950-1050°C compared to 750-900°C towards the feed end. The counter-current flow of hot DRI gases enables it to remove the moisture content from feed. The hot DRI gases contains huge amount of fine dust comprising oxides and unburnt carbon and toxic carbon monoxide. The flue gas coming out from the rotary kiln passes through a dust settling chamber, in which the heavier dust is settled down (15-20%). The bottom of the dust settling chamber is immersed in the wet scrapper water which is working as the sealing to avoid the gas leakage and false air entry. The gas next passes through the After Burning Chamber (A.B.C.) in which the carbon monoxide and un-burnt carbon are burnt completely. This conversion process is exothermic and the temperature of gases rises to 1000-1050°C.

The flue gas is taken to the Waste Heat Recovery Boiler (WHRB), where

the recoverable heat is utilized for generation of high pressure steam. The flue gas is next passed through an Electro Static Precipitator (ESP), where the gas is cleaned up to maximum level. The settled particles on electrodes are scrapped from the electrostatic precipitator and disposed in the earmarked area using dumpers as ESP dust. The cooled and cleaned flue gases are released to atmosphere by forced draft stack.

Later the sponge iron is screened into two size fractions i.e. –3 mm & +3

mm. +3 mm fraction directly goes for usage, -3 mm fraction can be either used directly where ever it is possible or is to be briquetted by using molasses and hydrated lime as binders.

The basic reactions in this process are as given below:

C + O2 = CO2 CO2 + C = 2CO Fe2O3 + CO = Fe3O4 + CO2 Fe3O4 + CO = FeO + CO2 FeO + CO = Fe + CO2

The reduced iron is discharged into coolers where it is cooled by spraying water and conveyed through conveyors for magnetic separation and subsequent storage/ consumption.

3.5.2 Pig Iron/ Hot Metal (EC obtained for 0.6 MTPA)

Mini Blast Furnace is a vertical shaft where the raw material mix i.e. Coke,

Iron Ore and fluxes travels down the shaft, while air is blown in, at pressure, up the shaft. The molten iron and slag (by-product) is withdrawn from the bottom of the furnace.


The mini blast furnace consists of i) Raw material handling and storage system, ii) Burden preparation system, iii) Top pressurizing and sealing system, iv) Hot blast supply, v) Blast pre heater, vi) Gas scrubbing and cleaning system, vii) Cast house slag granulation, viii) The blast furnace lined with refractory, ix) Hot metal handling and casting system, x) Utilities, xi) Power supply and xii) Instrumentation and control system.

The raw materials, i.e. Sinter, Iron Ore, coke, dolomite, limestone, quartzite

and manganese ore are received in the raw materials storage yard and conveyed to the stock house by ground hopper and conveyors. All the required raw materials are stored in day bins. Iron ore and coke is screened. The raw material is fed from the top by a charging conveyor through a top charging system, which also distributes the charge uniformly in the furnace and also performs the task of sealing the furnace from the atmosphere.

The blast for the mini blast furnace (MBF) is generated through a system of

fans connected in series in such a way that any number of fans can be operated at a time. The cold blast is preheated in hot blast stoves, which consists of continuous checkers shaped bricks, which is preheated by blast furnace gas to deliver a blast at temperature of upto 1200oC. The main blast furnace is built of structural steel plate, which is cooled by stave coolers.

The furnace has one tap hole from where both hot metal and slag are taken

out. A skimmer plate separates the slag. The hot metal flows into a ladle, while the slag is conveyed to the slag granulation system from where the slag is removed by a front-end loader. The hot metal is taken away in the ladle to the steel melting shop. The process flow diagram is shown in Fig 1.

FIG 1: PROCESS FLOW DIAGRAM OF PIG IRON MANUFACTURING

BY MBF ROUTE

2 3 1 Granulation plant

Hot metal

G.C.P

Day bins Iron ore Coke Flux

To power plant

BF Gas Flare Stack

Hot blast

MBF 350 m3

Transfer to

Charging conveyor

Clean gas main


Sinter will be used to the maximum extent in MBF after expansion. The capacity of sinter plant will also be enhanced suitably. Advantages of use of sinter in blast furnace are, improved permeability, elimination of 60 – 70% sulphur from ore during sintering, increase in softening temperature and narrowing down of the softening range, elimination of moisture, hydrated water and other volatiles. Modern high-performance blast furnaces achieve improved performance by prior physical and metallurgical preparation of the burden, which improves permeability and reducibility.

3.5.3 Ingot/ Billets (EC obtained for 1.025 MTPA)

3.5.3.1 Remelting Furnace for Super Alloys (ESR and VAR) Electro Slag Refining (25 T/Batch and 3 T/Batch): Electro slag refining is

well established worldwide as an extremely effective thermal process for chemically and metallurgically refining special metals. Materials to be remelted by this process are first air or vacuum melted and cast into electrodes.

The process consists of gradually remelting an electrode through a layer of

molten slag which serves several purposes. In molten form the slag is electrically conductive, producing resistive heating in response to electrical current. During refining single phase AC current flows through the molten slag from the electrode, the lower extremity of which is just immersed into the molten slag. Heat generated by the slag melts the tip of the electrode at the slag to metal interface.

Drops of molten metal fall through the slag to coalesce and solidify forming

the restructured metal ingot. The molten slag refines the metal and protects it from reaction with the atmosphere.

The 1,030 mm ESR furnace is a modern system incorporating the latest

generation of ESR Technology. Electro slag Remelt Furnaces are designed to produce ingots by remelting a single electrode in a static crucible. The furnace design greatly facilitates ESR melt shop operations, as well as yielding superior quality ingots, due to its unsurpassed, proven engineering design features.

Vacuum Arc Remelting (15 T/Batch and 3T/Batch): The new Vacuum Arc

Remelting furnace consists of 1 head and 2 stations co-axial furnace arrangement. The system will be capable to handle crucibles of 1,050 mm Φ x 4,300 mm long. The purpose of VAR is to make more clean steel or super alloys by remelting of cast material in the form of Bloom, Billet, Ingot, rolled, scrap, etc. Remelting process is to be carried out of Electrode into Crucible to cast Ingot which is more clean steel.

Vacuum Systems are designed for reliable, efficient service. Vacuum

pumps and components are carefully selected to produce a well-integrated, economical, low maintenance system. Pump down times will be within a range of 10 minutes for a clean, dry and empty furnace, for a chamber


pressure better than 5 x 10-3 mbar. The vacuum system is equipped with all the necessary pumps, valves, filter screen and controls.

The vacuum pumps comprises the following:

� 4,000 liters/sec oil vapor booster pumps with holding pump (03 nos)

� 9,800 m3/hr roots type blower (01 no.)

� 500 m3/hr rotary piston mechanical pump (02 nos.)

The holding pump and rotary piston pump will come equipped with an oil mist eliminator.

3.5.3.2 Vacuum Induction Melting (VIM) Furnace (6,000 TPA) The VIM furnace consists of :

� Melting chamber complete with rollaway head

� Interchangeable 6.0 Tonne Induction melting coils

� Vacuum isolated mould chamber with turntable mechanism

� Overmelt bulk charging chamber that includes immersion thermocouple and sampling

� Pre-heated tundish charging chamber complete with isolation valve Operation of the VIM furnace is achieved from the main furnace platform

level or from the control room. The molten metal is poured from the induction coil into the electrode mould

assemblies via a pre heated ceramic tundish assembly. The tundish charging chamber is complete with two vacuum gate valves that isolate it from the melting chamber.

The tundish drive mechanism transports the tundish into the top of the

mould chamber, in a position between the two gate valves, so that the pouring distance from the tundish to the moulds is kept to an absolute minimum. During operation, the vacuum isolated mould chamber allows tundishes and moulds to be loaded and unloaded during a melt campaign without breaking vacuum in the melting chamber.

The mould chamber is positioned directly beside the melting chamber and

connected via vacuum gate valve assembly. A large rollaway door mounted on support rails provides full access to the mould chamber. A hydraulically driven mould turntable assembly is provided for pouring multiple moulds. With the trolley rolled to the outer loading/unloading position full access to the moulds is available with the shop crane.


A vacuum pumping system is used to evacuate the furnace from atmospheric pressure. The melt chamber after evacation can also be back filled with inert gas up to control the charge boiling and evaporation.

Interchangeable melting units can be mounted on an interla hydraulic tiling

framework supported from the base of the melt chamber rollway door. This assembly provides forward tilting of 95° backward tilting up to 10°.

Unidirectional stirring is also provided.

3.5.3.3 Metal Slag Recovery Plant (Proposed: 1.26 MTPA)

Metal slag removed from Steel melt shop will be used in Metal slag recovery

plant as a Raw material. First the metal slag will be crushed up to size 0 to 300 mm and then sent to vibrating Grizzly feeder where screen vibrates and separates the metal slag up to 150 mm slag bolder. 150 mm slag bolder will be sent to electromagnetic drum separator where non magnetic slag gets separated. Then the material goes to metallic single deck vibrating screen which separates the waste fines upto 0 to 6 mm particles and above 6 to 150 mm particles are sent to rotary drum scrubber. The 0 to 6 mm particles are further separated into waste fines and metal slag. From rotary drum scrubber, metal slag is sent to single deck vibrating screen which separates the waste fines into 0-6 mm and 6-150 mm. The product generated from metal slag will be used in the furnace.

3.5.3.4 SMS Vacuum Degassing (Existing : 60 T/Batch, Proposed : 60 +60

T/Batch )

One SMS Vacuum Degassing unit is existing. Two additional units are proposed. Out of all the three units only two will be operational at a time and one will remain at stand by. An additional VD boiler is also proposed for the operation of additional unit.

The Vacuum Degassing Plant has been installed to improve the quality of

steel further. The main tasks accomplished with the Vacuum Degassing (VD) Plant are hydrogen removal, nitrogen removal, exact analysis trimming, improvement of steel cleanliness and improvement in casting conditions.

At VD Plant, a ladle of molten steel, with sufficient superheat above the

melting point of the steel, is placed in the vacuum chamber. A connection of inert gas is made to the ladle and the steel is stirred gently by purging inert gas through the liquid steel bath.

Thereafter, the chamber is closed and vacuum is applied to the ladle of

steel using steam ejector vacuum pumps. The desired pressure of about 1 milli bar is reached in a few minutes. The inert gas purging is increased to that allowable without spilling of the liquid metal and the liquid steel is held in this way till the requisite time has elapsed.


The purging under vacuum homogenizes the liquid steel and expels hydrogen and nitrogen from the steel. After the treatment is over in about 15 to 20 minutes, the vacuum is broken by removing the chamber cover. At the same time, the steel is sampled & temperature taken and alloy addition is done through cored wire after VD to fine tune, so as to deliver steel of the desired composition. This operation is called trimming addition.

The steel is now ready to be cast into billets. The hose pipe delivering the

inert gas is disconnected and the ladle of steel is sent for casting. The sequence of events is as follows: Crane operation and preparation of sample → Setting of ladle into chamber

→ Connecting of inert gas purging → Start of inert gas purging → Moving cover into place→Reduction of pressure→Holding inside chamber→ Opening of cover→Sampling→Measurement of temperature→Ferro-alloy addition→Disconnection of inert gas→Lifting of ladle from chamber.

The process flow diagram of Vacuum Degassing Plant is given in Fig 2. FIG 2: PROCESS FLOW DIAGRAM OF VACUUM DEGASSING PLANT

3.5.3.5 Ladle Refining Furnace (LRF) (Existing : 60 + 60 T/Batch, Proposed :

60 T/Batch) The liquid steel in the ladle is further refined and the desired chemistry of

steel is obtained by adding alloying elements. For homogenization of the


liquid steel, inert gas argon is purged through the liquid steel and the flue gases are removed from the top of the ladle through cooled ducting, bag filter and released to atmosphere after cooling and cleaning the gases for particulate matter through chimney.

Two LRF units are existing. One additional unit is proposed. Out of all the

three units only two will be operational at a time and one will remain at stand by.

3.5.4 Rolled Steel Products (EC obtained for 1 MTPA) 3.5.4.1 Blooming Mill

Sunflag have the blooming mill facility to make bigger round of size ranging

from 60 mm to 160mm and round corner square (RCS) size ranging from 63mm to 160mm. 70 TPH capacity walking beam furnace, High pressure descaler, Two high reversible stand are supported by turn over cooling bed.

3.5.4.2 Bright Bar and Heat Treatment

EC obtained: BBU - 2500 TPM (30,000 TPA) & Heat Treatment (Coil &

Rod) - 3000 TPM (36,000 TPA) Proposed: BBU - 2500 TPM (30,000 TPA) & Heat Treatment (Coil & Rod) -

3500 TPM (42,000 TPA) Peeling is the process involves pre straightening of bar then peel-off the

surface material and then again re straightening the bar. Peeling of bar at desired depth can be achieved depending upon depth of defect on the surface and customer requirement. In this process metal chips are formed which can be used for remelting.

The following will be the changes in the configuration of peeling:

� Bar to Bar peeling capacity of existing to be increase by 500T/month for dia. 15- 40mm.

� Coil to Bar peeling capacity of existing to be increase by 300T/month for dia. 12- 25mm.

� Coil to Bar peeling (5.5 - 16mm) capacity of 100T/month Induction Hardening & Tempering line of 1000T/month to be installed in our

existing shed. In this process bar are heated upto 1000 degree C temperature by induction

coils & then quenching is carried out by showering in quenching area before tempering to get the desired hardness. This equipment can be for bar dia 10 to 120 mm and bar length up to 7 mtrs.


Coil annealing capacity to be increased upto 2000 T/month by installing Bell annealing furnaces. Annealing is the process required for achieving the desired hardness of the coil which uses LPG as fuel. Flue gases formed are discharged to the atmosphere by proper chimney by transferring the heat from flue to combustion air through a Recuperator.

Bar annealing capacity to be increased upto 1000 T/month by installing

Spherodising bar annealing furnaces. Annealing is the process required for achieving the desired hardness of the coil. Flue gases formed are discharged to the atmosphere by proper chimney by transferring the heat from flue to combustion air through a Recuperator.

Chamfering machines to be installed to achieve the capacity of 1000

T/month. It is the process of removing sharp edges of bars. In this process metal burrs/ grinded metal particles are formed which can be used for remelting.

Grinding capacity to be increased upto 2000 T/month for dia. 6-30mm. It is

the process of grinding the bar with the help of grinding wheels to achieve the desired surface finish. In this process metal burrs/ grinded metal particles are formed which can be used for remelting.

Eddy current testing capacity of 400 T/month to be installed. It is the

process of testing the defects in the bars with the help of magnetic field. 3.5.4.3 Producer Gas Plant (EC obtained : 11,000 Nm3/hr) Producer Gas plant(gasifier) of total capacity 11000 Nm3/hr is being

installed at BSM reheating Furnace. Temperature of the gas will be 400-500 deg.C.

The produced gas will be used as a fuel in BSM reheating Furnace. This will

reduce existing HFO & BF Gas being used in furnace.

It is a reactor and its main body is composed of head cap, coal distributor, water jacket, fire grate, ash tray device, air inlet duct. Other components are Coal storage hopper, stoker and Bell type valve, cyclone separator, water seal for producer gas, air blower, vapour drum and gas duct.

In this process, coal as a fuel is used in the range of 13~25 mm or 25~50

mm. Coal through belt conveyor is charged to the coal hopper which is then fed to Gasifier reactor in a controlled way.

In this, coal enters pre-heating, drying and distillation zone where coal

comes in contact with gas and gets dried up and volatile matter enters the gas phase. Later coal enters the secondary reduction zone and following reaction takes place.


C+O2--->2CO

CO+H2O-->CO2+H2

Primary reduction Zone:-

C+H2O-->CO+H2

C+2H2O-->CO2+2H2

C+CO2-->2CO Oxidation Zone:- Coal burning takes place in this zone with oxidation of carbon and

generation of CO2

C+O2-->CO2

By-product of this plant is Ash which will be collected from bottom of gasifier.

The fuel consumption will be 150 TPD for 11,000 nm3/hr from 2 gasifiers. Ash generation will be approx. 60 TPD

Soft water consumption will be 50 KLD.

Nitrogen Gas shall be used for purging of Gas duct during maintenance

along with the steam.

The plant will be provided with safety instruments for gas and control room for operation and monitoring.

This plant will supply Producer gas through duct up to the BSM reheating

Furnace for Firing into Burners. Existing chimney of BSM furnace will be used for handling Flue gases.

3.5.5 Sinter Plant (EC obtained for 0.85 MTPA) The Sinter Plant was commissioned in the last quarter of financial year

2009-10, and thereafter Sunflag is able to manufacture hot metal economically using sinter in Mini Blast Furnace upto 75% of total iron ore requirement. With this sintering plant of 33 m2 annular type, Sunflag has ability to reuse all the waste/ undersize material generated out of MBF for making of sinter.

The production of iron and steel generates various types of waste materials

containing oxides, carbon, and flux material. Usually, these materials are land filled at the plant site or are hauled away for disposal. The recycling of waste materials via the sintering process has helped to achieve a saving in


the cost of the raw materials (for example, fuels and ore) and reduction in pollution.

The iron bearing material used in this 1 X 33 m2 Sinter Plant is hematite ore

fines with size of 0 to 8 mm and majority of solid wastes of existing plant. In order to improve the quality of agglomeration, available iron-bearing material in raw material yard is used. The mixing ore is composed of hematite ore fines, EAF, GCP dust & Mill Scale. Dolomite (or Limestone) and quicklime are used as flux. The solid fuel for sinter plant is coke breeze.

The gas fuel for sinter plant is BF gas which is used as ignition fuel for pre-

heating ignition furnace. Its heat generation value is 750 – 800 Kcal/m3 and is sent by pipes to the sinter plant under the pressure of 5000 Pa and dust density of less than 10 mg/m3 at connecting point.

Sintering involves mixing the iron-bearing material such as ore fines, flue

dust; concentrate with fuel. The mixture is then spread on surface beds, which are ignited by gas burners.

The high temperature heating process, at approximately 1100°C fuses the

fine particles. The resulting product is lumpy material known as sinter. The sinter is sized and the fines are recycled.

In addition to the already installed unit, 1X25 m2 sinter plant will be installed

to reach to the sanctioned capacity of 0.85 MTPA. 3.5.6 Captive Power Plant (EC obtained for 90 MW) Process flow diagram of the captive power plant is given in Fig 3. The

waste gases from the DRI kiln exhaust are passed through WHR Boiler that is top supported and is a three pass natural circulation boiler.

The approximate quantity of the heat available in these waste gases is

about 36.7 million kcal/hr. WHR Boiler utilizes heat of about 29.7 million kcal/hr for generating steam. FBC boiler of 50 TPH, 64 kg/sq. cm, 485°C consumes as fuel the dolochar generated in DRI Plant with addition of coal fines/ coal. The total heat input required for this boiler is about 39 million kcal/hr.

The existing power plant is of 30 MW capacity and the additional 60 MW will

be put up as per the sanctioned received in EC 02.05.2017. However, consent to estabilish from MSPCB vide letter no. PCBBO/RO/P&P/CE/CC-07 dated 20.09.2005 for 24 MW had been obtained out of which 5 MW had already been commissioned. Thus, balance 19 MW is available, which would take the total power generation from the entire plant to 109 MW.


FIG 3: PROCESS FLOW DIAGRAM OF CAPTIVE POWER PLANT

Electric Power

Stacks

FBC Boilers

Turbine Generators with Alternators &

Condensers

D.M. Plant

ESPs

Ash Handling

Plant

Disposal

T.G.

Condensate

Flue Gas to

Atmosphere

Raw

Water

Feed

Water

Steam

WHRBs

Waste Heat from Sponge

Iron Kilns

Steam

Bunker (Coal/Coal Fines/

dolochar)

Crusher

Vibrating Screen

Bag filters

Raw Coal

Over Sized

Coal

Bag filters

Coal Washery


3.5.6.1 Combuster (Proposed : 9.5 MW) The manufacturing process of Direct Reduced Iron Plant after modification

by installing AFBC (Combustor) is given below: AFBC is as equipment, where combustion takes place by burning of coal

and generation of flue gases upto 1100 deg.C. High temperataure flue gas will be supplied to WHRSG, where steam generation at the rate of 45 tons/hour by feeding coal at the rate of 250 tons/day will take place. This AFBC is a spare equipment for Kiln of DRI Plant-I (DRP-1).

The flue gases from the AFBC containing carbon monoxide and unburnt

coal fines are burnt in the Waste Heat Recovery Steam Generator (WHRSG). The burnt flues gases get cooled in heat exchanger of the WHRSG. These flue gases are then cleaned to remove particulate matter through electrostatic precipitator. The settled particles on electrodes are scrapped from the electrostatic precipitator and disposed in the earmarked area using dumpers as ESP dust.

The cooled and cleaned flue gases are released to atmosphere by forced

draft stack of 55 m height.

Coal consumption in existing manufacturing process (DRP-1) is 725 Metric tonne/day and after modification by addition of combustor, the coal consumption will be 250 tonne/day, Hence there is a reduction in coal consumption and the pollution load after modification will be also reduced. This is a case of only minor modification & there is no change in existing products and quantity.

It is planned to either operate existing DRP-I Kiln or modified AFBC.

Block Diagram of Direct Reduced Iron Process with AFBC

Atmospheric Fluidised Bed Combustor (AFBC)

DRP-1 After Burn Chamber

(ABC)

Waste Heat Recovery

Steam Generator (WHRSG)

Electrostatic Precipitator

(ESP)

Chimney


3.5.7 Coke Oven Plant (EC obtained for 0.25 MTPA) Coke is an essential raw material for manufacturing of iron in Mini Blast

Furnace. The total requirement of coke is about 650 Kgs. per 1000 Kgs. of Iron/ Hot Metal produced in Mini Blast Furnace. The market scenario of metallurgical grade coke with respect to price and availability is extremely volatile at present because of insufficient production capacity in India and worldwide. The present demand surge of Coke had made the scenario even worse in last couple of years. In view of the same Sunflag has envisaged installing a coke oven plant of 2,50,000 TPA capacity. The main advantages of the same are as below:

Insulate company from any coke price shocks, ensure continuous supply of

quality coke to Mini Blast Furnace for smooth/uninterrupted operations and Further improve cost efficiency of Mini Blast Furnaces.

The non recovery type of coke oven, also known as bee-hive type, is

proposed. In this system coal is heated at 1100 -1200°C in presence of restricted supply of air. Thus, coal yields only coke and the volatile matter are burnt to generate heat. This heat is then utilized for carbonization of the coal inside the oven and the burnt flue gas is released in the atmosphere. Hence, besides the above advantages Sunflag has an option to utilize the flue gases of Coke Oven plant for generation of electricity in future.

Considering the need of Sunflag as well the availability of various types of

coal and also verifying the supplier’s capabilities, the technology being offered by China is found to be best and most suitable. The distinct advantage is clean and pollution free operating process, freedom to use non-coking coal and weakly coking coal, low capital investment and option to use waste heat for generation of electricity. The need of pollution free operation is obvious and latest pollution free technology will have longer useful life. The need for using other than coking coal is for the reasons of cost control and supply management, the coking coal as compared to anthracite is not only costlier by about 25 % but also difficult to get in large quantities. The initial capital cost is also low as compared to the conventional beehive type Coke ovens. More so the Coke ovens designed by this technology can be of any size starting from capacity 50,000 TPA, whereas the conventional Coke ovens used to be around one million tonnes.

3.5.8 PSA Oxygen Plant (Proposed : 125 TPD) Principle:- The proprietary molecular sieve is the advanced technology

which separates compressed air into oxygen enriched and nitrogen enriched streams. The molecular sieve is packed in adsorption vessels for contacting with an ambient compressed air feed stream. The properties of the molecular sieve are specifically tailored to remove gases, such as water, carbon dioxide and nitrogen. These gases preferentially diffuse and adsorb into the molecular sieve pore structure. Thus, they are selectively removed as the compressed feed air travels upward through the adsorption vessel.


The resultant product from the separation process is an enriched oxygen stream.

Process Description:- Compressed ambient air is fed to the VSA System

at the minimum inlet pressure required in order to achieve the specified product capacity. The compressed air is fed, via the air blower, to one of the adsorption vessels where the oxygen and nitrogen are preferentially separated by the proprietary molecular sieve. The air is dried as it passes upward through the adsorption bed. The nitrogen is then removed as the dried air continues upward through the molecular sieve. Nitrogen diffuses through the molecular sieve pore structure and preferentially adheres to the molecular sieve at a considerably higher density than oxygen. Therefore, most of the nitrogen is retained in the molecular sieve while the oxygen tends to flow on through more freely.

Air separation occurs in one vessel and at the end of the adsorption cycle,

pressure is rapidly equalized between the vessels. The feed air is then switched to the second vessel where the adsorption process continues. The first vessel is further depressurized down to atmospheric pressure and then evacuated by a vacuum blower. This depressurization/evacuation regenerates the molecular sieve by allowing water and nitrogen to devolve from its pore structure; thus, conditioning the molecular sieve for another adsorption cycle.

Diversion of the inlet air stream from one vessel to the other is controlled by

pneumatically actuated process control valves. The valves are precisely sequenced by a solid state programmable controller; thus, providing the cycle uniformity and repeatability necessary for consistent quality product oxygen. The solid-state controller allows for reliable, operator-free, system operation. All system functions and safety interlocks are constantly monitored by the controller. The oxygen product passes through a low-pressure oxygen buffer vessel and is then compressed by an Oxygen Compressor to the specified product delivery pressure.

3.5.9 Coal Washery (EC obtained for 750 TPD)

In order to beneficiate the crushed coal, a coal washery has been installed

wherein crushed coal undergoes sieve screening for removal of stones etc., water washing for removal of dust and coal powder, separation of coal and water by centrifugal force in centrifuge, thickener & filter press. The washed coal is then conveyed to coal bunkers of DRI plant for its use as fuel and coal fines/ rejects recovered at coal washery are taken to CPP for use as fuel.

3.5.10 Coal Drier (Proposed 300 TPD) Presently in DR Plant, wet coal is fed during rainy season which hampers

productivity. To minimise this, it is intended to install one drier so that part of coal fed can be dried. Drying will be done inside the rotary drum where moisture removal will take place with the help of heat provided by furnace


oil / LDO / HSD. This drier will be used only during rainy season when moisture content in coal exceed by around 8%.

4.0 SITE ANALYSIS 4.1 Connectivity The proposed site for plant is located in villages Eklari, Warthi and Sirsi,

Tehsil Mohadi, district Bhandara, Maharashtra and is shown in Annexure-3 to Form-1. The location of plant can be seen in Survey of India Open Series Map No. F44N12. The coordinates of four corners of the plant including the ash dumping area (located within it) are as follows:

Corners Latitude Longitude

A 21°13’30’’ 79°37’58”

B 21°13’45’’ 79°38’32’’

C 21°14’16’’ 79°38’26’’

D 21°14’05’’ 79°37’11’’

Road link

The proposed plant is accessible by all weather roads from the district head

quarter Bhandara which is located at a distance of 7.4 km, SSE. The site is located near to the SH-252 Ramtek to Bhandara road, which is at an aerial distance of 2.7 km, SW. The nearest National Highway no. 6 is at located 7.5 km, S aerially.

Rail link

The nearest Railway station is Bhandara Railway Station, 0.5 km, away in

ENE direction aerially.

Air link

The nearest airport is at Nagpur, which is at about 61 km, WSW from the project site.


4.2 Land form, land use and land ownership No additional land is required, as existing land will be utilized for installation

of the above plants and facilities. Therefore, cost of land is not envisaged. 4.3 Topography The plant location is a flat land devoid of any significant topographical

features. The elevation of the plant area varies from 261 to 275 m above mean sea level (amsl). There is a canal and two seasonal nalas through the project site which are largely undistrubed except for straightening of some portion of one seasonal nala. There is no other natural water body within the plant site area. Rain water run off is through sheet flow joining the natural drainage. As the plant is constructed, storm water drains have been made in the plant area to ensure the evacuation of rain water. Rainwater runoff is also stored in a separate pond from where it is transferred to raw water reservoir.

4.4 Existing land use pattern

The existing plant occupies an area of 200 ha covering factory, colony and

amenities. No additional land is required for the proposed amendment. The existing plant comprises of DRI Plant, Mini Blast Furnace, Electric Arc Furnace, Ladle Heating Furnace, SS Converter, VD Plant, CCM, Rolling Mills, Coiler, Bright Bar Section, Oxygen Plant, Centralized Pickling Plant, Coinage Plant, Coal Washery, Brick Plant, Captive Power Plant etc. Open area (0.5 ha) within the existing plant will be utilised for installation of additional units. The breakup of land use is given in Table 2.

TABLE 2

BREAK UP OF LAND USE

Sl. No.

Particular Sanctioned Land Use as

per EC dt. 02.05.2017 (Ha)

Proposed Changes in Land Use

Resultant Proposed Land use

Resultant % break

up

1. Steel Plant Area 70.20 (+) 0.5 70.70 35.35

2. Power Plant Area 1.06 - 1.06 0.53

3. Raw Materials Storage Area

8.00 - 8.00 4.00

4. Coal Yard Area 0.90 - 0.90 0.45

5. Raw Water Reservoir Area 7.70 - 7.70 3.85

6. Green Belt Area 72.00 - 72.00 36.00

7. Open Area 20.54 (-) 0.5 20.04 10.02

8. Roads & Other Facilities 15.00 - 15.00 7.50

9. Colony (including Sunflag School Area & related facilities)

4.60 - 4.60 2.30

Total Area 200.00 - 200.00 100


4.5 Existing infrastructure

The following infrastructure has been provided for existing plant, which is under expansion as per EC dated 02.05.2017:

1. Water: The fresh water requirement of the entire plant is and will be

met from Wainganga river and rain water harvesting. For this propose pipe line infrastructure, pond for storing rain water and raw water reservoir have been constructed.

2. Power: To meet the power requirement of the entire plant, an existing 30 MW CPP is there. Additional 60 MW will be installed in due course and balance obtained from the MSEB till then. The company has a separate sanction MSPCB for 24 MW out of which 5 MW had already been installed.

3. Solid Waste: The plant has extensive arrangements for management of solid waste. The waste generated from the project at present and in future, will be nearly 90% re-used in various sub-units such as AFBC, sinter plant, road making, sale to cement plants brick manufacturers and local parties and balance approx. 10% will be dumped in the earmarked dump yard. It has been envisaged that an area of 72 ha will be developed as green belt around the project site to attenuate the noise levels and trap the dust generated due to the project development activities.

4. Housing: There is an existing colony within the project which houses the employees and their families.

4.6 Soil classification During the preparation of EIA/EMP report for obtaining EC (Dated

02.05.2017), soil analysis was carried out in and around the project with the following outcome:

TABLE 3

SOIL TEST RESULT

Parameters Project site

Bothli village

Neri village

Mahdura village

Sirsi village

pH 7.57 7.48 7.48 7.53 7.5

E.C (µmho/cm) 463 454 401 317 363

CaCO3 (% by mass) 21.9 19.7 19.5 19.4 21.3

Bulk Density (g/cm3) 1.4 1.5 1.5 1.5 1.5

Moisture (% by mass) 10.89 9.42 4.76 14.45 13.70

Organic Carbon

(% by mass)

0.50 0.38 0.51 0.36 0.26

Organic Matter

(% by mass)

0.86 0.66 0.88 0.62 0.45


Parameters Project site

Bothli village

Neri village

Mahdura village

Sirsi village

Chloride (% by mass) 0.5 2.5 2.0 2.0 2.5

Sulphate (% by mass) 0.31 0.76 0.56 0.41 0.33

Phosphorous (mg/kg) 0.12 1.12 1.15 1 0.19

Nitrate (mg/kg) 16.67 45.42 52.92 89.58 14.58

Iron (mg/kg) 40.226 33.97 16.108 43.868 63.98

Sodium (% by mass) 0.0188 0.0211 0.0118 0.0103 0.0115

Potassium (% by mass) 0.0207 0.0148 0.0116 0.0184 0.0096 Source: Min Mec R&D Laboratory’s Report no. MMS/02-15/14 dated 25.02.2015

The soil samples test results shows that the pH is nearly neutral.

Conductivity is normal, and organic matter is deficient in soils. The grain size analysis has been carried out for the samples and it was

found that all of them are predominantly medium sand as per IS classification and sandy loam as per USPRA Classification.

4.7 Climatic data from secondary sources

Temperature As per the nearest IMD station, Nagpur. The monthly mean of minimum

temperature ranges from 12.95°C in December to 27.86°C in May. The monthly mean of maximum temperature ranges from 29.44°C in January to 43.43°C in May.

Rainfall The rainfall does not show any cyclic occurrences and shows wide and

erratic variations, ranging from 977.7 mm in 2008 to 1666.5 mm in 2013. The average annual rainfall for the period 2005 to 2014 is 1171.8 mm.

Relative Humidity The average daily relative humidity data, obtained from IMD station Nagpur

is given Table 4.

TABLE 4 MONTHLY AVERAGE RELATIVE HUMIDITY AT NAGPUR (2005-2015)

Months Relative humidity (%)

At 0830 hrs At 1730 hrs

January 68 44

February 58 34

March 47 28

April 39 25

May 37 27

June 62 50


Months Relative humidity (%)

At 0830 hrs At 1730 hrs

July 86 79

August 88 79

September 86 77

October 73 63

November 73 59

December 71 82

Average 65 52

4.8 Social infrastructure available Hospitals, school, community facilities are present in the villages in buffer

zone within 10 Km of study area. Social infrastructures existing as per Census 2011 is given in as Annexure 7 to the Form 1.

5.0 PLANNING BRIEF 5.1 Planning concept Due to the impetus provided by the “Make in India” scheme of Govt of India,

the demand for such high quality steel has risen and the company intends to upgrade the plant to meet the market demand. The proposed amendments will lead to additional refining steps in the production line which will change the quality of the end product making it suitable for aeronautical, space, automobile and power generating turbine. Therefore, the company has planned the proposal.

5.2 Population projection The required man power as per EC dated 02.05.2017 is 2535. There will be

no additional man power requirement as the excess manpower from the existing units will be shifted to the proposed units.

5.3 Land use planning (break up along with green belt etc.)

Refer Section 4.4 for present and proposed planning of land use break up

5.4 Assessment of infrastructure demand (physical & social)

No additional housing construction will be there as colony is already existing

within the plant boundary. Since no addition man power is required, no additional housing will be required. The additional water requirement of the proposed new units or enhanced capacity of intermediate units will be met from the existing water recirculation system without any need for enhancement. The proposal to install metal slag recovery plant will require physical infrastructure to be constructed in addition to construction of sub-units like VIM, ESR, VAR, Ingot RHF, LPG storage, etc.


5.5 Amenities / facilities

Education, Hospitals, drinking water, power supply, post and telegraph, banks, communication and approach roads are present in the villages in buffer zone within 15 Km of study area. The same is attached as Annexure-7 of Form-1.

6.0 PROPOSED INFRASTRUCTURE

6.1 Industrial area (processing area) The existing plant occupies an area of 200 ha covering factory, colony and

amenities. No additional land is required for the proposed amendment. Open area (0.5 ha) within the existing plant will be utilised for installation of additional units. Refer section 4.4, 4.5 and 5.4 earlier for more details.

6.2 Residential area (non processing area) No additional residential colony is proposed. 6.3 Green belt The green belt equivalent to 33% of the plot area has been developed. 6.4 Social infrastructure Refer section 4.8 and 5.4 6.5 Connectivity

Refer Section 4.1

6.6 Water management (Quantity & source of water)

With respect to the proposed amendments, there can be two scenarios for

additional water requirement:

i. When combustor is not operating then the additional water requirement will be 792 KLD

ii. When combustor will be operational, the DRP-1 water requirement of

125 KLD will become zero but combustor requirement of 2 KLD will be there in addition to above units. Therefore the total additional water requirement will be 669 KLD.

Even though the water requirement is increasing due to additional units, the total consumption of the entire plant i.e. 8589 KLD will remain unchanged,. This is because, several water conservation measures have been implemented in last 2 years, leading to water savings to the tune of 850 KLD. These conservation measures were as follows:


1. Drift losses in cooling tower were reduced 2. Paving of roads has reduced the water consumption in sprinkling 3. Reduction in cooling tower makeup water 4. Specific water consumption has reduced

6.7 Sewerage system & industrial waste management

With respect to the proposed amendments, liquid effluent will be

generated from the following:

A. 7 KLD effluent will be reduced during the shutdown of DRP-1. B. No effluent will be generated from Metal Slag Recovery Plant. C. The following effluent will be generated which will be sent to existing

ETP & used in cooling tower, sinter plant, pig cast machine and slag quenching:

� 33 KLD from ESR & VAR � 25 KLD from Vacuum Induction Melting (VIM) Furnace. � Additional 13.5 KLD from SMS Vacuum degassing. � Additional 16.2 KLD from Ladle Refining Furnace. � 3.5 KLD from Ingot Heating/ Soaking pit furnace.

D. The effluent generated(20 KLD) from the PSA oxygen plant will

replace the effluent generated from cryogenic oxygen plant, which will be dismantled 84.2 KLD additional effluent will be generated which will be sent to the existing ETP (Capacity: 26,664 KLD), which has excess capacity to be able to accommodate this additional 0.32% effluent. The treated effluent will be used in cooling tower, sinter plant, pig cast machine and slag quenching.

6.8 Solid waste management

In addition to the facilities for which EC was granted on 02.05.2017, the

following additional solid waste management measures are envisaged:

� 130 TPD of Dolo Char will be reduced during the shut down of DRP-1.

� 17 TPD waste in the overall plant will be recovered and reused due to installation of metal slag recovery plant (1.26 MTPA). Thus, about 3% of slag from Ingot/Billet production will be reduced.

� 11 kg/Ton of solid waste will be generated from Electro Slag Refining (ESR) which will be sent to Metal Slag Recovery Plant. There will be no solid waste generation from Vacuum Arc Remelting (VAR). By assuming 300 working days solid waste generated from ESR will be 0.374 T/T production.


� 3.5 TPD solid waste will be generated from Ingot heating/ soaking pit furnace at Blooming mill. Fine dust generated will be consumed in sinter plant and chips and scraps will be used in SMS.

� Additional 15 TPD (350 TPM from bright bar and 25 TPM from heat treatment, assuming 25 working days) will be generated bright bar and heat treatment. Fine dust generated will be consumed in sinter plant and chips and scraps will be used in SMS.

� 61 TPD of ash will be generated from combustor operation during shut down of DRP-1 which will be used in low lying areas, backfilling and brick making.

6.9 Power requirement & supply / source The additional electricity required (15.945 MW) for operation of

additional/amended units shall be as follows:

� DRP1 shut down = -3 MW

� Remelting furnace for super alloys = +7 MW

� Vacuum Induction Melting Furnace = +2 MW

� Metal Slag recovery plant = +0.32 MW

� SMS Vacuum Degassing = +0.06 MW

� VD Boiler = +0.65 MW

� Ladle Refining furnace = +0.16 MW

� Ingot Heating/ soaking pit furnace at Blooming Mil = +0.2 MW

� Bright Bar and Heat Treatment = +6 MW and 400 kg/hr LPG for heat treatment furnaces

� Producer Gas Plant for Bar Section Mill = +1.7 MW

� Sinter Boiler =+ 0.06 MW

� Combuster = +1.4 MW

� Oxygen plant = -3.63 MW

� PSA Oxygen Plant = +1.7 MW

� LPG Storage = +0.125 MW

� Coal Drier = +1.2 MW

The additional power requirement will be sourced from MSEB.


7.0 REHABILITATION AND RESETTLEMENT PLAN There will be no rehabilitation and resettlement as the proposed

amendments are within the existing plant.

8.0 PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

The project will be completed within 54 months after the grant of EC.

8.2 Cost of the Project

The total project cost works to Rs 250.676 crores

9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)

With respect to the environmental impact from the overall plant, based on table given in Annexure 5 of enclosed Form 1, the following are the conclusions:

1. Manpower - No change will be there as excess manpower from other

sections of the steel plant shall be utilized in the additional/alternate units stated above.

2. Raw Material - There will be reduction by 1070 TPD (~54 trucks/day

of 20T) during the shut down of DRP-1 due to no consumption of iron ore and dolomite. No other changes in the raw materials of the integrated steel plant will be there as the additional/alternate units stated above are intermediaries and do not effect the overall output or input.

3. Fuel (Coal) - The coal consumption of DRP-1 (725 TPD) will reduce due to shut down but operation of combustor will require 250 TPD coal. Thus, decrease in coal shall be there to the tune of 725-250 = 475 TPD (~24 trucks/day of 20T).

4. Fuel (Oil) - The PGP will generate gas to replace the FO consumed in

BSM, which has already been accounted in the EC amendment dated 12.01.2012. The fuel oil consumption will be as follows:

TABLE 5

FUEL OIL CONSUMPTION Total fuel

required (TPD) for 24 hours

Remarks

As sanctioned in EC :

Blooming Mill RHF-3 (full capacity) (1X70 TPH sanctioned 2012)- already installed

20.16 @ 40% FO use (24KLD), 60% BF


Total fuel required (TPD)

for 24 hours

Remarks

Blooming Mill RHF-4 (1X70 TPH sanctioned 2017)- proposed

20.16 @ 40% FO use (24KLD), 60% BF

Subtotal 40.32 � In CTE Consent No. BO/APAE/EIC/ No. NG-3610-10/E/CC-179 dt 08.04.2011, 61 TPD FO was sanctioned.

� For EC in Ann-XXXI, question IX-C it was submitted as 200 TPD for entire plant (including blooming mill)

Amendments:

Blooming Mill RHF-3 (5 hr Turn Down during ingot RHF operation)

17.64 Worst case scenario when RHF-3 will operate for 19 hours @100% and 5 hours @40% (with FO & BF) along with ingot RHF-A & RHF-B

Blooming Mill RHF-4 20.16 No effect on RHF-4, continues with FO & BF

Ingot RHF-A 3.36 Max 24 hour consumption (4 KL)

Ingot RHF-B 3.36 Max 24 hour consumption (4 KL)

Sinter Boiler 11.26 Max 24 hour consumption

VD Boiler 4.20 Max 24 hour consumption

Coal Drier 0.84 Max 24 hour consumption (1 KL)

Total 60.82 Is equal to 61 TPD

It can be seen that approximately same amount of FO will be consumed.

a) Transportation - The overall traffic from the steel plant will reduce as explained in points 2 to 4 above. Approximately 78 trucks/day will reduce when combustor and ingot RHF will be operational.

b) Air Emissions - Air emissions are affected by (i) Stack emissions, (ii)

Fugitive emissions & (iii) Emissions due to transportation. The net emission will not increase due to following:

c) Stack emissions - The emissions from stacks are due to fossil fuel consumption or particulate matter emission from process. Since, the overall coal consumption will decrease by 475 TPD and fuel oil will decrease by 0.18 TPD, the net emissions will be lower than those sanctioned vide EC dated 02.05.2017 and previous amendment dated 12.01.2012.

d) Fugitive emissions - Since there is no increase in incoming raw

material but decline in coal, the emission due to their handling will decrease overall. There will be emissions due to material handling which will be mitigated with control measures like sprinklers, foggers, bag filters and plantation. Thus, the the overall emissions from the


plant will stay within previously sanctioned capacity as per EC dated 02.05.2017.

e) Emissions due to transportation - The overall emission due to transportation will decrease as there is decrease in incoming transportation as explained in point 5. The raw material and fuel will decrease while outgoing products and solid waste will remain same.

f) Water Consumption - There can be two scenarios for additional

water requirement :

g) When combustor is not operating then the additional water requirement will be 792 KLD

h) When combustor will be operational, the DRP-1 water requirement of

125 KLD will become zero but combustor requirement of 2 KLD will be there in addition to other units. Therefore the total additional water requirement will be 669 KLD (792-125+2 KLD).

Even though the water requirement is increasing due to additional

units, the total consumption of the entire plant i.e. 8589 KLD will remain unchanged. This is because, several water conservation measures have been implemented in last 2 years, leading to water savings to the tune of 850 KLD. These conservation measures were as follows:

i. Drift losses in cooling tower were reduced by replacing with latest

technology cooling tower (fix type/ honeycomb type replaced by optical grid type cooling towers).

ii. Paving of roads has reduced the water consumption in road sprinkling

iii. Reduction in cooling tower makeup water by doing automation of cooling tower fans on-off with respect to outlet temperature. This has also lead to energy/Power conservation.

iv. Specific water consumption has also been reduced

i) Effluent Generation - 84.2 KLD additional effluent will be generated which will be sent to the existing ETP (Capacity : 26,664 KLD), which has excess capacity to be able to accommodate this additional 0.32% effluent. The treated effluent will be used as a makeup in cooling towers, sinter plant & pig cast machine, and slag quenching.

j) Solid Waste (For Disposal) - Due to establishment of the metal slag

recovery plant, the earlier sanctioned solid waste will reduce by 3% and the balance will be managed through supply to paver block manufacturer and filling in low lying areas as per previous proposal. The additional ash generated from combustor (61 TPD) will be offset by DRP-1 shut down wherein 130 TPD Dolo char will reduce which contains nearly 60% ash content (78 TPD).


k) Energy Consumption - The additional energy consumption shall be there to the tune of 15.945 MW which shall be met from Maharashtra State Electricity Distribution Company Ltd (MSEDCL) (Ex.MSEB) .

As the overall production of the steel plant remains unchanged and the

impacts of the changes in the intermediary units during the intermediary steps of steel production will not create any additional impact, the overall impact of the entire steel plant remains same as appraised during the process of obtaining environmental clearance dated 02.05.2017. There will be no change in total production of steel.

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