Jeevaka Industries LTD (Sponge Iron Division), Nasthipur (V), Hatnoora (M), Sangareddy Dist - EXE SUM ENG
Jeevaka Industries LTD (Sponge Iron Division), Nasthipur (V), Hatnoora (M), Sangareddy Dist - EXE SUM ENG
Jeevaka Industries LTD (Sponge Iron Division), Nasthipur (V), Hatnoora (M), Sangareddy Dist - EXE SUM ENG
OF
Submitted to
Jeevaka Industries Private Limited is operating steel plant consist of DRI plant of 3 x 100 TPD to
produce 99,000 TPA of Sponge Iron, at Nasthipur, Mangapur Villages, HathnooraMandal,
Sangareddy District,Telangana. Existing plant is situated in 55 acres of land. Now it has been
proposed to go for the expansion partly in existing plant of 55 acres and the remaining in the
adjacently located additional land of 30.58 acres. Total land envisaged including existing land is
85.58 acres.
Nasthipur village 61/E1, 77/A, 77/E, 77/A, 64/A, 64/A1, 64/A1, 64/E, 66, 63/A,
63/A1, 62, 60/A, 61/A, 70/A, 73/AA1, 79/E, 73/A1, 73/A2, 73/A4,
76/E, 76/A, 76/AA, 77/AA. 73/AA4, 73/AA2, 73/AA1, 75/AA, 67/A,
61/AA, 77/AA, 77/BB, 73/AA, 74/A1, 74/A2, 74/A3, 77/AA2, 73/E,
79/A1, 79/A3, 59/1, 73/E, 73/D, 79/A4, 80/A, 65/A, 65/B
Now it has been proposed to increase the production capacity of Sponge Iron plant from 300 TPD
to 500 TPD along with Waste Heat Recovery based power plant of 10 MW capacity , establishment
of a Pellet Plant of 600 TPD capacity, Establishment of 2 x 40 T induction furnaces to produce
1000 TPD of M.S. Billets, Rolling Mill of 1000 TPD capacity, establishment of 1 x 9 MVA
Submerged electric arc furnace to produce Ferro Manganese of 100 TPD (or) Silico Manganese of
70 TPD (or) Ferro Chrome of 70 TPD (or) Ferro Silicon of 42 TPD capacity and FBC based power
plant of 10 MW capacity partly in the existing plant premises and the remaining in the adjacent
additional land .
Executive Summary
1
Jeevaka Industries Pvt. Ltd
(Expansion)
As per the Ministry of Environment, Forests & Climate Change, New Delhi notification, dated 14th
September, 2006 and its subsequent amendments, all Primary metallurgical processing industries
are classified under Category ‘A’. The Ministry of Environment, Forests & Climate Change, New
Delhi has accorded Terms of Reference (TOR) for the proposed expansion project vide letter no. IA
- J-11011 / 145 / 2006 - IA.II (I) dated 23rd July, 2018. The EIA Report has been prepared by
incorporating the TOR stipulated by the Hon’ble EAC.
Pioneer Enviro Laboratories & Consultants Private Limited, Hyderabad, which is accredited by
NABET, Quality Council of India, vide certificate No. NABET/ EIA/ 1619/ RA 026, for preparing EIA
report for Metallurgical Unit, have prepared Draft Environmental Impact Assessment (EIA) report
for the proposed expansion project by incorporating the TOR approved by Ministry of
Environment, Forests & Climate Change, New Delhi. The report contains detailed description of
the following:
Executive Summary
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Jeevaka Industries Pvt. Ltd
(Expansion)
The following are the existing & proposed products & their production capacities.
Name of the Proposed After proposed
S.No. Existing
Product expansion expansion
1. Sponge Iron 300 TPD 200 TPD 500 TPD
(99,000 TPA) (66,000 TPA) (1,65,000 TPA)
(3 x 100 TPD) (2 x 100 TPD) (5 x 100 TPD)
2. Pellet Plant --- 600 TPD 600 TPD
(1,98,000 TPA) (1,98,000 TPA)
3. M.S. Billets --- 1000 TPD 1000 TPD
(3,30,000 TPA) (3,30,000 TPA)
( 2 x 40T Induction
furnaces)
4. TMT -- 1000 TPD 1000 TPD
Bars/Structural (3,30,000 TPA) (3,30,000 TPA)
Steels
5. Ferro alloys (9 MVA furnace)
Ferro -- 100 TPD 100 TPD
Manganese (33,000 TPA) (33,000 TPA)
or
Silico -- 70 TPD 70 TPD
Manganese (23,100 TPA) (23,100 TPA)
or
-- 70 TPD 70 TPD
Ferro Chrome
(23,100 TPA) (23,100 TPA)
or
-- 42 TPD 42 TPD
Ferro silicon
(13,860 TPA) (13,860 TPA)
Power generation
6. Captive Power -- WHRB – 10 MW WHRB – 10 MW
plant & FBC – 10 MW & FBC – 10 MW
Executive Summary
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Jeevaka Industries Pvt. Ltd
(Expansion)
The following will be the raw material requirement after proposed expansion project:
Executive Summary
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Jeevaka Industries Pvt. Ltd
(Expansion)
Executive Summary
5
Jeevaka Industries Pvt. Ltd
(Expansion)
Refractory lined rotary kilns will be used for reduction of iron ore in solid state. A central
Burner located at the discharge end will be used for initial heating of the kiln.
Pellets/iron ore will be continuously fed into the kiln along with coal which has dual role of
fuel as well as reductant. Dolomite will be added to scavenge the sulphur from the coal. A
number of air tubes will be provided along the length of the kiln. The desired temperature
profile will be maintained by controlling the volume of the combustion air through these
tubes. The Carbon monoxide generated due to the combustion of coal, reduces the iron
ore and converts it into sponge iron. The rotary kiln is primarily divided into two zones viz.
the pre heating zone and the reduction zone. The preheating zone extends over 30 to 50
% of the length of the kiln and in this the moisture in the charge will be driven off and the
volatile matter in the coal will be burnt with the combustion air supplied through the air
tubes. Heat from the combustion raises the temperature of the lining and the bed surface.
As the kiln rotates, the lining transfers the heat to the charge. Charge material, pre-heated
to about 10000C enters the reduction zone. Temperature of the order of 1050 0C will be
maintained in the reduction zone, which is the appropriate temperature for solid state
reduction of iron oxide to metallic iron.
This hot material will be transferred to Heat exchanger. In Heat exchanger the material
will be cooled to 1600C. The cooler discharge material consists of sponge iron lumps,
sponge iron fines and char. Magnetic and non-magnetic material will be separated through
magnetic separators and stored in separate bins. The hot flue gases will be taken to a
Waste Heat Recovery Boilers and after heat recovery they will be treated in high efficiency
ESP and discharged into the atmosphere through stack whose height will be in accordance
with CPCB norms. 2 x100 TPD rotary kiln will be provided additionally .
Executive Summary
6
Jeevaka Industries Pvt. Ltd
(Expansion)
Iron ore fines, bentonite & coke will be used as raw materials in Rotary grate kiln to
produce 600 TPD of Pellets.
In Steel Melting Shop (SMS), Sponge Iron will be melted along with melting scrap and
fluxes to make pure liquid steel and then to mould it in required size billets. The SMS will
consist of Induction furnaces, Ladles, Cranes & Continuous Casting Machine (CCM). There
will be 2 nos. of Induction Furnaces, each of 40 T capacity and MS Billets will be produced
in Continuous Casting Machine.
In the proposed expansion project, there will 1 X 1000 TPD reheating furnaces is proposed
for the heating of billets. Furnace will be heated with Furnace oil. A bar and round mill will
be installed in the plant to produce 1000 TPD of Hot Rolled TMT Bars/ Structural steels.
1 no. of Submerged Electric Arc Furnaces of 9 MVA will be setup in the proposed expansion
project. Ferro manganese, silicon-manganese will be produced using manganese ore as
main raw material, Ferro silicon will be produced using Quartz as main raw material and
Ferro Chrome will be produced using Chrome ore as main raw material in a sub-merged arc
furnace using reducer (Coke) under high voltage.
The exhaust waste flue gases from the sponge iron kilns will pass through waste heat
recovery boilers (WHRB). The rotary kiln gases will have a temperature of 1000 0C and the
temperature of gases after heat recovery will be 1700C. These gases after heat recovery
will be treated in high efficiency. Electro Static Precipitator to bring down the particulate
matter in the exhaust gases to less than 50 mg/Nm 3. One FBC boiler will also be provided
to generate steam by using char and coal as fuel. The steam generated from WHRB & FBC
Executive Summary
7
Jeevaka Industries Pvt. Ltd
(Expansion)
Boilers will pass through steam turbine of 2 x 10 MW capacity and will be coupled to
generator to generate 20 MW electricity. This power generated will be utilized for captive
requirements of the steel plant.
The water requirement for the proposed expansion project will be 613 KLD. This includes
Make-up water for DRI Kilns, Power Plant, Pellet plant, SMS, Rolling Mill, Ferro Alloy plant
and for Domestic purpose. Air cooled condensers will be provided the power plant to
reduce the water consumption significantly. Hence the net water requirement will be
substantially reduced. Water required for the proposed expansion project will be sourced
from Ground Water. Water drawl permission for existing plant has already been obtained.
No additional permission will be required as water drawl permission has been obtained
from State Ground Water Board.
The following is the break-up of the water requirement for existing & proposed expansion
project.
WATER REQUIREMENT FOR EXISTING PLANT & EXPANSION
Quantity in KLD
S.No. Unit Existing Total after
Expansion
Plant Expansion
1. DRI Kilns (Sponge Iron) 15 10 25
2. Pellet plant -- 180 180
3. Induction Furnace -- 80 80
(MS Ingot/Billet)
4. Rolling Mill -- 80 80
Hot Rolled TMT / Structural / Cold
Rolled Bars/Wire Rod)
5. Ferro Alloy Plant -- 30 30
FeSi / FeMn / SiMn / FeCr
6. Power Plant -- 215 215
7. Domestic 2 18 20
Total 17 613 630
Executive Summary
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Jeevaka Industries Pvt. Ltd
(Expansion)
be utilized for dust suppression, ash conditioning and for greenbelt development. Sanitary
waste water will be treated in septic tank followed by sub-surface dispersion trench. The
following will be the total wastewater & it’s break-up.
Executive Summary
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Jeevaka Industries Pvt. Ltd
(Expansion)
Parameter Concentration
PM2.5 : 25.9 to 34.5 g/m3
PM10 : 42.9 to 57.2 g/m3
SO2 : 10.5 to 15.6 g/m3
NOX : 12.8 to 20.2 g/m3
CO : 435 to 630 g/m3
2 no. of samples have been collected 60 m Upstream & 60 m Downstream of Manjira River
and analyzed for various parameters. The analysis of samples shows that all the
parameters are in accordance with BIS-2296 specifications.
8 No. of ground water samples from open wells / bore wells were collected from the
nearby villages to assess ground water quality impacts and analyzed for various Physico-
Chemical parameters. The analysis of samples shows that all the parameters are in
accordance with BIS: 10500 specifications.
Noise levels were measured at 8 locations during day time & Night time. The noise levels at
the monitoring stations are ranging from 46.4 dBA to 72.0 dBA.
The likely emissions from the proposed expansion project are PM10, SO2 & NOx. The
predictions of Ground level concentrations have been carried out using Industrial Source
Complex (ISC-3) model. Meteorological data such as wind direction, wind speed, max. and
min. temperatures collected at the site have been used as input data to run the model.
Executive Summary
10
Jeevaka Industries Pvt. Ltd
(Expansion)
The predicted results show that the net resultant concentration (max. baseline conc. +
max. incremental rise in conc.) of PM10, SO2, NOx and CO will be well within the National
Ambient Air Quality Standards after commissioning of proposed expansion project. Hence
there will not be any adverse impact on air environment due to the proposed expansion
project.
The major sources of noise generation in the proposed expansion project will be STG,
boilers, compressors, DG set, etc. Acoustic enclosures will be provided to the STG. The
ambient noise levels will be within the standards prescribed by MoEF&CC i.e. the noise
levels will be less than 75 dBA during day time and less than 70 dBA during night time.
12.41 Ha. (30 Acres) of greenbelt which is inclusive of existing greenbelt will be
developed in the plant premises to further attenuate the noise levels. Hence there will not
be any adverse impact due to noise on population in surrounding areas due to the
proposed expansion project.
There will be no effluent generation in the DRI plant, Induction Furnace, Rolling mill,
Pellet plant as closed circuit cooling system will be adopted. Effluent from power plant will
be treated and after ensuring compliance with SPCB norms, it will be utilized for dust
suppression, ash conditioning and for greenbelt development. Sanitary waste water will be
Executive Summary
11
Jeevaka Industries Pvt. Ltd
(Expansion)
treated in septic tank followed by sub-surface dispersion In the existing plant, zero
discharge is being maintained and will be continued even after expansion. Hence there will
not be any adverse impact on water environment due to the proposed expansion project.
The effluent will be treated to achieve SPCB standards. Zero effluent discharge will be
adopted. All the required air pollution control systems will be provided to comply with
CPCB / SPCB norms. All solid wastes will be disposed / utilized as per CPCB / SPCB norms.
30 acres of greenbelt (inclusive of existing) will be developed as per guidelines. Hence
there will not be any adverse impact on land environment due to the proposed expansion
project.
There will be further upliftment in Socio Economic status of the people in the area. Hence
there will be further development of the area due to the proposed expansion project.
Due to this the economic conditions, the educational and medical standards of the people
living in the study area will certainly move upwards which will result in overall economic
development, improvement in general aesthetic environment and increase in business
opportunities.
In the existing plant online stack monitoring has been provided. Ambient Air Quality, Sack
monitoring & effluent analysis will be carried out regularly as per CPCB norms and the
analysis reports will be submitted to Ministry of Environment & Forest, Chennai & TSPCB
regularly. Online stack monitoring facility will be provided in the expansion project.
Executive Summary
12
Jeevaka Industries Pvt. Ltd
(Expansion)
There is no habitation in the additional land of 30.58 acres acquired for the proposed
expansion project. The expansion project will be taken up in the partly existing plant
premises and additional land acquired.
Hence no Rehabilitation & Resettlement Action Plan will be required.
With the establishment of the proposed expansion project employment potential will
increase. Land prices in the area will increase. The economic status of the people in the
area will improve due to the proposed expansion project. Periodic medical checkups will be
carried out. Top priority will be given to locals in employment.
The following are air emission control systems proposed in the proposed expansion
project:
S.No. Source Control Equipment Particulate
emission at the
outlet
1. DRI kilns with WHRBs Electro Static Precipitators (ESP) PM - 50 mg/Nm3
2. Travelling grate kiln (Pellet unit) Electro Static Precipitators (ESP) PM - 50 mg/Nm3
Induction Furnaces with CCM Fume Extraction system with bag PM - 50 mg/Nm3
3.
filters
4. Rolling mill Bag filters PM - 50 mg/Nm3
Submerged Electric arc furnace Fume Extraction system with bag PM - 50 mg/Nm3
5.
filters
CFBC Boiler Electro Static Precipitator for PM - 30 mg/Nm3
control of PM SOx - 100 mg/Nm3
6.
NOx - 100
3
mg/Nm
Note : Apart from the above Fume extraction system with bagfilters, dust suppression system,
covered conveyers etc. will also be installed
The following air pollution control systems / measures are proposed in the expansion
project:
All conveyors will be completely covered with G.I. sheets to control fugitive dust.
Executive Summary
13
Jeevaka Industries Pvt. Ltd
(Expansion)
All bins will be totally packed and covered so that there will not be any chance for dust
leakage.
All the dust prone points material handling systems will be connected with de-dusting
system with bag filters.
All discharge points and feed points, wherever the possibility of dust generation is there a
de-dusting suction point will be provided to collect the dust.
Stacks height will be in accordance with CPCB norms.
There will be no effluent generation in the Pellet plant, Ferro Alloys plant, DRI plant,
Induction Furnace & Rolling mill as closed circuit cooling system will be adopted. Effluent
from power plant will be treated and after ensuring compliance with SPCB norms, it will be
utilized for dust suppression, ash conditioning and for greenbelt development. Sanitary
waste water will be treated in septic tank followed by sub-surface dispersion.
The major sources of noise generation in the proposed expansion project will be STG,
boilers, compressors, DG set, etc. Acoustic enclosures will be provided to STG. All the
machinery will be manufactured in accordance with MoEF&CC norms on Noise levels. The
employees working near the noise generating sources will be provided with earplugs. The
extensive greenbelt development of 30 acres which is inclusive of existing greenbelt will
help in attenuating the noise levels further. Noise barriers in the form of trees are
recommended to be grown around administrative block and other utility units.
Executive Summary
14
Jeevaka Industries Pvt. Ltd
(Expansion)
The waste water generated from the proposed expansion project will be treated in the
Effluent Treatment Plant to comply with the SPCB standards and will be used for dust
suppression, ash conditioning and for greenbelt development. All the required Air emission
control systems will be installed and operated to comply with SPCB norms. Solid wastes
will be disposed off as per norms. Extensive greenbelt development of 30 acres which is
inclusive of existing greenbelt will be taken up. Desirable beautification and landscaping
practices will be followed. Hence there will not be any impact due to the proposed
expansion project.
Executive Summary
15
Jeevaka Industries Pvt. Ltd
(Expansion)
Quantity (TPA)
S.No. Waste Method of disposal
Existing Proposed Total
7. Slag from SiMn Will be utilized in road
-- 27,720 27,720 construction / given to road
contractors for road construction
8. Slag from FeMn Will be used in manufacture of
26,400 26,400
-- Silico manganese as it contains
high MnO2
9. Slag from FeCr Will be further processed in
Zigging plant for Chrome recovery
-- 27,720 27,720
and the non-chrome contents will
be sent for land filling.
10. Dust from bag Will be reused as raw material for
-- 1,320 1,320
filters manufacture of ferro alloys
11. Ash from Power Will be given to Brick
-- 50,985 50,985
Plant manufacturers
Executive Summary
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