Rashmi Mataliks

FEASIBILITY REPORT of 900000 TPA
(0.9 MTPA) Pellet Plant
at
Gokulpur, PO: Shyamraipur, PS: Kharagpur
District Paschim Medinipur, West Bengal
by
RASHMI METALIKS LIMITED

Premlata Building, 6th Floor, 39-Shakespeare Sarani
Kolkata- 700 017
OCTOBER 2014
Project Report of M/s Rashmi Metaliks Limited
CONTENTS
Chapter No Particulars Page No
Chapter-1 Executive Summary 3
Chapter-2 Introduction of the Project / Background 10
Information
Chapter-3 Project Description 18
Chapter-4 Site Analysis 37
Chapter-5 Planning in Brief 40
Chapter-6 Proposed Infrastructure 46
Chapter-7 Rehabilitation & Resettlement Plan 47
Chapter-8 Project Schedule & Cost Estimate 48
Chapter-9 Analysis of Proposed & Recommendations 49
RML_Pellet Page 2
CHAPTER-1
EXECUTIVE SUMMARY
1.1 Introduction
Rashmi Group of companies is a fast growing Group in the field of manufacturing Steel, Cement, Ferro
Alloy and Power. The company has developed core competence in minerals, steel and cement with 40
years of experience. The Group’s turnover is around Rs.3000 Crores and net worth is Rs.1000 Crores.
Rashmi Group awarded ‘Ultra Mega Project’ status by Govt. of West Bengal. The Group is also engaged
in import/export of Mineral & Mineral based products. The growth of the group during last few years has
been phenomenal and fast catching the attention of bankers, professionals and industry as a whole.
Rashmi Group, through a consortium of Steel Companies, has also obtained a coal block with a reserve of
700 million tonne of high quality coal from Govt. of India.
Rashmi Group founded in 1966 got impetus from its real promoter, a true visionary, Sri Sajjan Kumar
Patwari. The group has grown from merely a re-rolling mill to a full-fledged Cement Crushing Plant having
capacity of 2 lakh tonnes per annum at Jhargram in West Bengal. In addition to this, the Group also has a
Sponge Iron Plant with a capacity of 3.0 lakh t.p.a. at Jhargram, 25 MW Captive Power Plant and a Mini
Blast Furnace Plant of 2 lakh t.p.a.at Kharagpur in West Bengal.
M/s Rashmi Metaliks Limited has been set up a 0.9 million TPA Iron Ore Pelletization Plant at village
Gokulpur, P.O Shyamraipur, and Tehsil- Kharagpur, in Paschim Midnapur district of West Bengal
after obtaining the Necessary Consent to Establishment for 1.2MTPA Pellet Plant from West Bengal
Pollution Control Board on 12.08.2010. The commercial production was started after obtaining the
necessary consent, like Consent to Consent to Operate (CFO) 02.08.2012 from West Bengal Pollution
Control Board.
The Iron ore fines are utilized in Pellet making. The power required for the plant is made available from
WBSEDCL (West Bengal State Electric Distribution Company Limited).
The existing Pellet Plant falls under category ‘A’ project and requires Environmental Clearance from
MoEF, Govt. of India as per EIA Notification 2006 as per NGT order no. Appeal No. 05 of 2014 on
28.05.2014.
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Rashmi Metaliks Limited has been taken a decision to regularise the existing Pellet Plant of capacity 0.9
MTPA as per guide lines of MoEF letter F.No.L-11011/12/2014-IA.II(I) dated 8th September, 2014.
1.2 Project Site
The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinipur district of
West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7 and latitude 22˚21′31″N
and longitude 87˚17′21″E.The site is well connected with NH-6 which is passing beside the project site.
Nearest Railway Station is at Gokulpur just 1.5 KM away and Kharagpur Railway station is at about 5 km
by road from the project site.
1.3 Plant Layout
The Existing Plant is established in 10 acres of land over an area of 188 acre. The layout plan for proposed
project has been prepared in such a way that space is properly and purposefully utilized, process flow is
maintained and adequate circulation space is provided for operation and maintenance. The plant layout
map, which shows the layout of Iron ore Pellet plant, Administrative building, waste disposal area, raw
material storage yard, rain water harvesting pond, RWTP and green belt etc is attached.
1.4 BRIEF PROJECT DESCRIPTION
M/s Rashmi Metaliks Limited has set up anIntegrated steel Plant along with Iron Ore Pelletization
Plant at village Gokulpur, P.O Shyamraipur, Tehsil- Kharagpur in Paschim Medinipur district of
West Bengal.
The Iron ore fines are utilized in Pellet making. The power required for the plant is made available
from WBSEDCL & Captive Power. The existing capacity of the plant is given below:
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Name of the Units Units, for which Units under Units under Units, to be
permission obtained Operation Construction, implemented in
from Statutory obtaining NOC from future
Authorities WBPCB
3 3 3
1X215 M 1X215 M 1X 320 M
3
MBF 1X 320 M
2 2 2
2 X 25 M & (2X25 M ) - 1X70 M
2
Sinter Plant 1X70M
Pig Casting Machine 600 TPD 0.12 MTPA - -
10X100 TPD + 6 X 100 TPD 4 X 100 TPD -

DRI kilns 3X350 TPD 3X350 TPD
SMS 500000TPA 180000 TPA - 380000 TPA
Oxygen Plant 60 TPD - - 60 TPD
Lime Calcination Plant 1200 TPD - - 1200 TPD
Iron Ore Beneficiation 1.5 MTPA 1.5 MTPA - -
Iron Ore Pellet (EC 1.2 MTPA 0.6 MTPA 0.6 MTPA (applied for -
from MoEF) (2x0.6) MTPA CFO)
Iron ore Pellet

including grinding in
dry process 0.9 MTPA 0.3 MTPA
1.2 MTPA
3 3
Producers Gas Plant (10x 7500 NM / Hr (10x 7500 NM / - -
3
+ 1 X 6000 NM / Hr) Hr
3
+ 1 X 6000 NM /
Hr)
Ductile Iron Pipe Plant 0.20 0.14 MTPA - -
MTPA
Rolling Mill TMT Bar TMT Bar - -
(8-32 mm) & Wire Rod (5.5 (8-32 mm) & Wire
mm -12 mm) - 0.12 MTPA Rod (5.5 mm -12
mm) - 0.12 MTPA
CPP-WHRB based DRI based WHRB– DRI based WHRB DRI based WHRB – DRI based
40MW – 12 MW 18 MW CPP WHRB – 20 MW
CPP
CPP-AFBC based AFBC based - 6 MW - AFBC based -

- 6 MW
RML_Pellet Page 5
1.5 RAW MATERIALS
Table No. 1: Annual Requirement of Raw Materials for 1.2 MTPA Pellet Plant (Full Capacity in Tons/year):
Quantity of Reqd. in Sizein Source of Mode

Raw Materials TPA mm Raw o
Materials f
Iron ore fines 11,00,000 0 - 10 Orissa, Jharkhand Transport
Rail
Bentonite 20,000 0.074 Bhuj, Gujarat Rail

Coke 30,000 0-6 Australia Ship
Dolomite 21,100 0 - 50 Orissa, Chattrishgarh Rail /Truck
1.6 WATER REQUIREMENT & SOURCE
Total make up water requirement for the 0.9 MTPA Pellet Plant is 120 m3/day which is sourced at
present from the Ground Water. Water abstraction work at Kansai River bed is in progress. The
company has obtained permission from Govt. of West Bengal to draw water. A reservoir is
constructed inside plant. Estimated make up water requirement to replenish the process and
treatment losses for the facilities
Table No.2: Total Plant Raw Water Requirement
Items Total make - up water requirement

Pelletization process 100 m3/day
Domestic use & Misc. 20 m3/day

Total 120 m3/day
1.7 SOLID WASTE GENERATION AND MANAGEMENT
Table No. 3: Solid Waste Generation and Management

Sl. Process Solid waste Quantity Ton Mode of disposal
No Unit / Annum
Pellet Plant Dust from 14000 Recycled in Pellet plant.
APC devices
1.8 LAND
The Pellet plant of capacity 0.9 MTPA is installed over 10 acres area. Total project area is 188
Acres. No forest land was involved in the project site. All the land involved in the project site was
Private land. The entire land is now in the name of the plant and converted to industrial use.
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Table No.4: Details of Land use break up
MKD. DESCRIPTION SIZE IN (M.X M.) AREA IN (M.Sq.) STATUS

NO.
1. GREENARY 250914.0 EXISTING
2 TAILING YARD 87623.40 EXISTING
3. WATER RESERVOIR 20.0X15.0 300.0 EXISTING
4. WEIGH BRIDGE-4 20.0X15.0 300.0 EXISTING
8. MAIN GATE 60.0X6.0 360.0 EXISTING
9. OPEN YARD 60.0X116 6960.0 EXISTING
10. OPEN YARD 32.0X127 4064 EXISTING
11. OPEN YARD 32.0X130 4160 EXISTING
PELLET PLANT 222X182.0 40404 EXISTING
(NOC from WBPCB)
12.
PELLET PLANT 315X182.0 57330 EXISTING
(EC from MoEF)
13. OPEN YARD 315X118.5 37327 EXISTING
14. WATER RESERVOIR 147X102.5 15067 EXISTING
15. SINTER PLANT-2 152X186 28272 IN PROGRESS
16. MBF-2 250X100.0 25000 IN PROGRESS
17. SECURITY OFFICE 15.0X15.0 225.0 EXISTING
18. P&A 15.0X15.0 225.0 EXISTING
19. CANTEN EXISTING
20. STORE 140X81.0 11340 EXISTING
21. ADM. BUILDING EXISTING
22. DI PIPE PLANT 365X200 73000 EXISTING
23. ROLLING MILL 275X110 30250 EXISTING
24. SMS 187X81.0 15147 EXISTING
25. SETTLING POND 141X137 19317 EXISTING
26. SWITCH YARD 113X200 22600 EXISTING
27. SINTER PLANT-1 152X186 28272 EXISTING
28. MBF-1 120X326 39120 EXISTING
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1.8 GREEN BELT DEVELOPMENT
Trees like Sonjol, Debdaru,Sishu, palash, suitable for this regionare planted in compliance of
conditions of environmental clearance. With a view toattenuate air pollutants, to resist noise
propagation from power generation units and uptake of treated effluent to some extent, the green
belt all around the periphery of project sites and in vacant areas (33% of the total acquired land) is
being developed. Tree plantation has been undertaken in a large scale on land vacated after
cessation of construction activities. Open spaces, where tree plantation is not possible are planted
with flowering herbs and grass which act as soil binders and also helpful in preventing erosion of
topsoil.
1.9 AMENITIES/FACILITIES.
1.9.1 In-Plant Facilities
The following facilities are provided in this plant:

a. Administrative Building, Service Building
b. Construction offices and stores
c. Time and security offices
d. First Aid and fire fighting station
e. Canteen and welfare centre
f. Toilets and change rooms
g. Car parks and cycle/ scooter stands
h. Training centre
Office space has been provided as per good practice and canteens, toilets and restrooms
according to norms laid down in relevant factories act. The above facilities are adequately
furnished and equipped.
1.9.2 Employment
Establishment of small and medium scale engineering ancillaries, with cascading employment
opportunities; increased revenue to the state by way of taxes and duties; improved green cover;
Better communication and transport facilities; the proposed project has enhanced the
prospects of employment. Recruitment
for the unskilled workers for the plant is from the nearby villages. The basic
amenities viz. roads, transportation, electricity, drinking water, proper sanitation,
educational institutions, medical facilities, entertainment, etc. are developed as
far as possible.
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1.9.3 Medical Facilities/ Health care camps
Medicines are provided at the first aid centre present within the plant premises, which
cater to the needs of adjoining population. Periodic health camps like: Eye camp and Health
camps for treatment of other diseases will be conducted by the company doctors.
1.10 PROJECT COST:
The project cost is Rs. 170 Cores.
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CHAPTER-2
INTRODUCTION OF PROJECT /BACKGROUND INFORMATION
2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT
M/s Rashmi Metaliks Limited, one of the renowned Pellet manufacturing company of India,
has set up already (0.6MTPA x 2 + 0.9 MTPA) 2.1 MTPA. MoEF already issued the
Environmental Clearance for the (0.6MTPA x 2) 1.2 MTPA Iron Ore Pelletization Plant in the year
of 2012. Also Consent to Establishment NOC issued WBPCB for 1.2 MTPA Pellet Plant during
the year of 2010. A Iron Ore Pellet Plant unit of capacity 0.9MTPA is operating after obtaining the
Consent to Operate from The WBPCB on the basis of Consent to Establishment “NOC” from the
date of 02.8.2012.The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of
Paschim Midnapur district of West Bengal. The area is situated in the survey of India Topo
Sheet No. 73 N/7 and latitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected
with NH-6 which is passing beside the project site. Nearest Railway Station is at Gokulpur just
1.5 KM away and Kharagpur Railway station is at about 5km by road from the project site.
Contact Address
Address for Mr.L. B. Chourasia, V. P. – Corporate Planning
Correspondence M/s Rashmi Metaliks Limited
39, Shakespeare Sarani, Premlata Building
th
6 Floor, Kolkata - 700017
Works (Plant Site M/s Rashmi MetaliksLimited

Address) At Village- Gokulpur
P.O.Shyamraipur
P.S.: Kharagpur
District: PaschimMidnapur, West Bengal
2.1.1 COMPANY BACKGROUND
M/s Rashmi Metaliks Limited (RML) is the leading Pellet manufacturing company in India. RML
th
is incorporated under companies Act on 30 day of January 2004 which is a flag ship company
under Rashmi Group Company.
RML_Pellet Page 10
2.1.2 ABOUT THE PROJECT
M/s Rashmi Metaliks Limited set up an integrated steel plant consist of the following unit are
given below at Gokulpur village, Tehsil- Kharagpur, in paschim Midnapur district of West Bengal.
Name of the Units, for which Units under Units under Units, to be
Units permission obtained Operation Construction, implemented
from Statutory obtaining NOC
Authorities from WBPCB
3 3 3
1X215 M 1X215 M 1X 320 M
3
MBF 1X 320 M
2 2 2
2 X 25 M & (2X25 M ) - 1X70 M
2
Sinter Plant 1X70M
Pig Casting 600 TPD 0.12 MTPA - -
Machine
10X100 TPD + 6 X 100 TPD 4 X 100 TPD -
DRI kilns 3X350 TPD 3X350 TPD
SMS 500000TPA 180000TPA - 380000TPA
Oxygen Plant 60 TPD - - 60 TPD
Lime Calcination 1200 TPD - - 1200 TPD
Plant
Iron Ore 1.5 MTPA 1.5 MTPA - -
Beneficiation
Iron Ore Pellet (EC 1.2 MTPA 0.6 MTPA 0.6 MTPA -
from MoEF) (2x0.6) MTPA (applied for CFO)
Iron ore Pellet

including grinding
in dry process 0.9 MTPA 0.3 MTPA
1.2 MTPA
3
Producers Gas (10x 7500 NM / Hr (10x 7500 - -
3 3
Plant + 1 X 6000 NM / Hr) NM / Hr
+ 1 X 6000
3
NM / Hr)
Ductile Iron Pipe 0.20 0.14 MTPA - -
Plant MTPA
Rolling Mill TMT Bar TMT Bar - -
(8-32 mm) & Wire (8-32 mm) &
Rod (5.5 mm -12 mm) Wire Rod (5.5
- 0.12 MTPA mm -12 mm) -
0.12 MTPA
CPP-WHRB based DRI based WHRB– DRI based DRI based WHRB DRI based
40MW WHRB – 12 – 18 MW CPP WHRB – 20
MW MW CPP
CPP-AFBC based AFBC based - 6 MW - AFBC based -

- 6 MW
RML_Pellet Page 11
M/s Rashmi Metaliks Limited has set up a 0.9 million TPA Iron Ore Pelletization Plant at village
Gokulpur, P.O Shyamraipur, and Tehsil- Kharagpur, in Paschim Midnapur district of West
Bengal after obtaining the Necessary Consent to Establishment for 1.2MTPA Pellet Plant from
West Bengal Pollution Control Board on 12.08.2010. The commercial production was started
after obtaining the necessary consent, Consent to Operate from West Bengal Pollution Control
Board on 02.08.2012.
nd
The production from the WBPCB granted pellet plant started on 2 August 2012. The
production capacity of the pellet as envisaged is as under:
Table No. 2 : Production Capacity

Sl. Plant Facility Product Capacity Duration Remarks
No.
1. Pellet Plant Iron ore Pellet 0.6 MTPA 02.02.2012 Initially started
2. Pellet Plant Iron ore Pellet 0.9 MTPA 22.08.2014 Amendment of
Capacity
Major raw material of Iron ore are sourced from the iron ore belt of Joda-Barbil region. Coking
coal is imported from Australia. Bentonite is sourced from Kutch of Gujarat. Dolomite is be
sourced from Sundargarh, Odisha.
2.2 BACK GROUND OF THE PROJECT /BRIEF DESCRIPTION OF THE

PROJECT
The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinipur
district of West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7 and
latitude22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is
passing beside the project site. Nearest Railway Station is at Gokulpur just 1.5 KM away and
Kharagpur Railway station is at about 5km by road from the project site.
2.3 NATURE, SIZE AND MAGNITUDE OF PROJECT:
The Pellet Plant capacity 0.9 MTPA exists within the land area 10acres in the Rashmi Metaliks
Limited premises out of total area 188 Acres.
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2.4 NEED FOR THE PROJECT:

• Under existing mining scenario,Project Report
a great of M/s
amount of Rashmi Metaliks
Iron Ore Limited
Reserves comprising
of fines and lumps are available, which cannot be used directly for steel making.
• In line with Mineral Conservation & Development Rules’ 1988, and increasing
global demand, the low grade iron ores are to be upgraded Pelletization for DRI /
BF usage.
• Pelletization is a step towards mineral conservation and waste reduction. More
over these plants can act as a additional source of raw material for DRI/BF.
• Pelletization of the iron ore concentrate is considered in view of high
productivity, low energy consumption and eco-friendly process.
2.5 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/

REGION:
Iron Ore Pelletization Unit:

The project objective is to upgrade the abundant iron ore fines stored at the mine
heads through Pelletization Process and make it fit for use in DRI Kiln/ Blast
Furnace, thus preventing the loss of revenue our country is losing by selling these
low grade iron as ore reject materials. Higher percentage of Iron Ore Reserves in
the country comprises of fines and lumps. These Iron ore fines/lumps cannot be
directly used for steel making. These precious material resources (fines) are
being dumped in Export market in nominal prices. In order to preserve this
precious iron ore , Beneficiation and its onward Pelletization is most sought after
agglomeration process than sintering process in view of higher productivity,
energy consumption and eco-friendly manufacturing process.
The Ministry of Environment and Forest also encourages for establishment of Iron Ore
Pelletization plant to utilize the huge stock pile of iron ore fines.
The Pelletization of iron ore fines, which remain unutilized in most of the time or
exported at nominal prices is definitely helping the State/Nation in value addition
and also increases the resources of iron ore reserves including earning of
additional revenues from mineral for the State/Nation. Required grade of Iron Ore
and better grade Iron Ore pellet will be available to DRI plants of the region which
are at the edge of shut-down due to non-availability of required grade of iron ore
as well as quantity.
Looking at the projection of demand for Steel in the present market, it can be
realized that there is a considerable demand of Pellet in the steel making
industries. To meet the demand, new industries have to be installed. Hence, the
existing Pelletization Plant by M/s Rashmi Metaliks Limited is of great significance under
present scenario.
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Environmental
• Protect the surrounding environment during operation of the plant with appropriate
environmental safeguards to meet community expectations in terms
of environmental outcomes and cost.
• Ensure that ecological balance of the area shall not be adversely affected by
activities of proposed project.
• Protect native flora & fauna, quality of local surface & groundwater.
Socio-Economic
• To improve the living standard of local inhabitants.
• To address community concerns, if any.
• To improve indirect means of livelihood.
• To improve the socio-economic condition of local people.
2.6 Demand and Supply Gap (Market Scenario)
With reference to the National Steel Policy 2012 and as per Mineral Conservation
and Development Rules 1988, Government is facilitating for installation of Iron
Ore Pelletization Plant for Iron Ore fines which is stocked abundantly in all the
mines for pellet making. The reason behind it, is to extract all the mineral
contents of the Iron ore for utilization in steel making as a step towards mineral
conservation and simultaneously reduce the accumulated iron ore fines stored in
all the mines.
As per National Steel Policy 2012, India is having a total resource of 28 Billion
Tonnes of High grade Iron Ore taking cut-off grade of Iron Ore is having 50% Fe
and the fact that the figure can rise with greater efforts towards exploration. The
currently assessed reserved of Iron Ore seem inadequate for a long period if the
steel industry capacity expansion and production potential are to be fully realized.
Therefore, best utilization of the mineral resources (in this case ‘Iron Ore’) is
required. Whatever the mineral constituent present in the ore need to be
extracted from the ore for best utilization of the ore, Beneficiation and
Pelletization are two such processes by which the iron ore reject and low grade Iron ore can be
made ready for steel making purpose. For long term supply of iron ore to the steel
manufacturers with the increasing demand of Steel & simultaneously to reduce the demand
and supply gap of the iron ore in the present scenario following steps are being taken by the
Government;
Government is enhancing its support for intensive R & D efforts for developing
techno-economically viable technologies of Beneficiation and Agglomeration
suitable for the mineral extracted from different iron ore regions of the country.
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The Government is taking appropriate fiscal measures, whenever deemed

necessary to encourage beneficiation and agglomeration with special emphasis
on manufacture of pellets to substitute consumption of precious lump ores by
steel producers and thereby add to efforts of conservation and environmental
degradation caused by accumulation of iron ore fines. The Government bringing different
schemes to encourage investment in beneficiation depending on the ownership of the Iron Ore,
such as those coming from captive mines and those bought out from the market.
Mineral Conservation & Development Rules1988 is a step towards MineralConservation and waste
reduction. As per Mineral Conservation & Development Rules’ 1988, and increasing global
demand, the iron ores fines are to be upgraded through Pelletization for DRI / BF usage.
The targeted demand of the steel sector can be fulfilled in this way and the Iron Ore can be utilized
rather than stored as a waste.
The prevailing demand and consumption rate of mineral resources indicates that it
will come to an end in near future. So best utilization of all mineral resources need
to be done. High grade and low grade mineral fines need to be utilized for the
purpose. The Iron Ore Processing Industries and Steel making industries have
started adopting various modern technology for utilization of low grade mineral/
mineral reject for the purpose of steel making. Demand of Beneficiation and
Pelletization process is increasing each year in Indian market and also in global
market.
The pellet market consists of a small group of sellers controlling a majority of

pellet capacity worldwide. Long term contracts for supply of pellets are the norm
in the Industry. Some of the largest pellet manufacturers are from Latin
America and Sweden. The market leader in the industry is CVRD (Brazil), whose
prices are generally considered as benchmark price for pellets.
Percentage use of pellets in various blast furnaces in the world varies f rom 10% to 100%.
Considering specific consumption of iron bearing raw materials in blast
furnaces as 1.55 ton per ton of hot metal and replacement of iron ore & sinter by pellets on all India
basis was 7.5% during 2004-05, 10% during 2006-07, and 20% during 2011-12.
Existing all India capacity of Pellet production is 30-36 Million Tonne /Annum and it is likely to go up
to 50 Million Tonne in another one or two years. India is targeting pellet capacity of 80 Million Tonne
by 2015-16.
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As per the National Steel Policy 2012, the Department of Steel, Government of India
has projected production of 300 MT of Steel by the year 2025-26. On the basis of
30% replacement of Calibrated Lump Ore (i.e. CLO) by pellet on minimum side, the
requirement of pellet would be 51 MTPA against the present installed capacity of
about 30-36 MT. Besides, the sponge iron plants in the country which are in verge of
closure due to non-availability of requisite CLO both in quantity and quality will
consume more than 60% of the pellet in the mix. Presently more than 400 Sponge
Iron units are there in the country. During 2008-09, about 250 Sponge Iron plants
were operating in the country and the production was about 20 MT. Assuming only
400 units will be in operation up to 2020 (Government does not encourage the
establishment of more sponge iron units as these units are one of the major
contributor of pollution) then these 400 units can produce about 30 MT of Sponge
Iron and will require additional 20 MT and more of pellet.
So our iron ore pellet making is a supportive step to fulfil the iron ore demand of our country.
2.7 Imports Vs Indigenous Production
Iron Ore Pellet

In the earlier period, as the Iron ore CLO was available at a very nominal price, the
pellet manufacturers were exporting the pellets produced by them. In the present
circumstances, the cost of the Iron Ore /CLO has gone up unprecedentedly.
Therefore, all the production of pellet in the country, are being utilized by the steel
producers/ DRI Plants.
Iron Ore pellets are superior to other substitutes due to its High Cold Crushing
Strength resulting in minimal fines generation while multiple handling and resulting
in increased savings. With uniform composition of material, size and Guaranteed
Porosity, Swelling Index and negligible moisture due to dry process provides an
added advantage for Smooth Operation in Kiln / Furnace and improves productivity
2.8 Export Possibility

Generally, Iron ore rejects/sub grade ore are exported at nominal price. If it will be export after
required up gradation then more revenue can be obtained which will help to improve the
economy of our country.
In the export market, the present & future DRI / HBI producers in South-East Asia and the
Middle East / North African Region are the potential destinations for the Indian Pellets.
RML_Pellet Page 16
Supplies from Brazil and Sweden are meeting the present Middle East/ north Africa
DR pellet requirement. With transport cost being a competitive factor, Paradeep
proximity to South-East Asia and Middle East/ North Africa would definitely give
advantage to Indian pellet market over the suppliers from Brazil, North America &
Sweden.
Due to higher cost of quality raw materials, countries like China are looking to import Iron
Ore pellets, considering the techno-economic advantages using pellets for hot metal
production.
2.9 Domestic Market
India produces about 65 MT of Steel /year, yet with a population of 1.15 billion, its
per capita consumption is just 40 Kg / year compared to a global average of 150 Kg/year.
Government is evaluating every plan to encourage this consumption level higher, which is
making a very natural impact on demand of steel with the supports from growing middle class
and massive long term infrastructure investment plans. Invariably we may say that the
potential of processed iron ore or pellets are huge. India's Ministry of Steel is preparing a policy
document on the infrastructure that will be required by an industry capable of producing as
much as 300 MT of Steel per year - illustrating the long term goal. Considering the huge
Demand & Supply pattern, the future of the existing Pelletization plant is encouraging.
2.10 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Total Manpower engaged during operation of the 0.9MTPA Pellet Plant is 200. Apart from this,
500-600 persons are indirectly benefited by this project during the operation phase for logistic.
Table No. 3: Employment status
Sl. No Category No. of Employees

01. Managerial staff 06
02. Technical staff 22
03. Highly Skilled staff 24
04. Skilled staff 35
05. Semi-Skilled staff 35
06. Unskilled staff 70
07. Clerical staff 8
Total 200
RML_Pellet Page 17
CHAPTER-3
PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

PROJECTS
The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Medinapur
latitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is
Kharagpur Railway station is at about 5km by road from the project site. The existing Pellet Plant
is interlinking with our 0.5 MTPA Integrated steel plant.
3.2 LOCATION AND ACCESSIBILITY

The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Midnapur
district of West Bengal. The area is situated in the survey of India Topo Sheet No. 73 N/7
andlatitude 22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is
Kharagpur Railway station isat about 5km by road from the project site.
Location details of the Project Site:

Village : Gokulpur
Tehsil : Kharagpur
District : Paschim Midnapur
State : West Bengal
Latitude : 22˚21′31″N
Longitude : 87˚17′21″E
Topo sheet No. : 73 N/7
Elevation of site : Average Elevation 34m AMSL
a. Road Connectivity: The Plant site is well connected with NH-6 which is passing beside the plant.
b. Rail Connectivity: Nearest Railway Station is at Gokulpur, about 1.5km in north-eastand Khragpur
junction Railway station is around 5.0kM from the plant sitein south-East direction.
c. Airport: Nearest Air Kolkata Netaji Subash Chandra Bose International Airportwhich is about 130
km from the project site in North-East direction.
d. Port: Nearest port is at Haldia about 135 km from project site in South-East direction.
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Location Map
RML_Pellet Page 19
Plant Boundary on Mouja Map:
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3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

SELECTING THE PROPOSED SITE / SITE SUITABILITY:
Suitability of a site for a plant is decided taking in account the availability land,
Source of Raw Material Source, Source of Water, Source of Fuel, well developed
transportation infrastructure/ accessibility etc. The support of the general public
towards industrialization is also a major component before choosing a site for
installation of a Project.
Shyamraipur village of Paschim Midnapur in West Bengal District was selected for the project
considering all the factors that suits for installation of a project.
Highlights of the Considerations:
A. Availability of land which involves for handling Raw material and finished products.
B. Availability of Rail Transport for handling Raw material and Finished products.
C. Availability of good road infrastructure as very heavy equipments will be required to

betransported from the nearest state highway, railway line etc.
D. Availability of Raw Material.
E. Nearest of Market for Finished product.
Considering all above factors, site selection was carried out for implementationof the proposed
Steel project. The Company got good support from Government of WestBengalfor acquisition of
identified landand there is no habitation in the site.
3.3.1 Alternative site

The site in Gokulpur village was considered for the proposed project after evaluating a
no of socio-economic factors. The alternative sites for the proposed plant were Ray Dighi
village, Burdwan District of West Bengal. Due to none fusibility for development of private
Railway siding for Raw Materials handling, far way distance to water source and R & R
problem these sites were rejected, the Plant come in Gokulpur village in Paschim Midnapur
District of West Bengal.
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3.4 SIZE OR MAGNITUDE OF OPERATION

M/s Rashmi Metaliks Limited, one of the integrated steel along with Power generation, has set
up a 0.5 million TPA Integrated steel plant consisting Iron Ore Pelletization Plant. The company
got the permission for production of Pellet of total capacity 2.4 million TPA (1.2 MTPA EC from
MoEF and 1.2 PTPA Consent to Establishment from WBPCB), 2.1 MTPA (0.6x2 + 0.9) capacity
pellet plant commissioned and balance to be implemented 0.3 MTPA.
3.5 PROCESS DESCRIPTION-IRON ORE BENEFICIATION UNIT
3.5.1 Plant Layout

The layout has been developed keeping in view the need for unidirectional and streamlined
movement of materials. A streamlined road network has beenproposed to provide easy road
access to different plant units.
The major parameters considered to develop the layout are as given below:
i) Adequate area for locating Pellet plant.
ii) Adequate area for storage and handling of different raw materials.
iii) Adequate area for various auxiliaries and ancillary facilities.
iv) Approach road, Power Sub-station and Water supply etc.

v) Dump area for storage of waste materials.
vi) Adequate road and parking space ensuring safe and smooth movement of
man and materials within the plant premises.
vii) Raw water Reservoir and Rain water harvesting viii) Area
for Green belt.
ix) Administrative building
3.6 Iron Ore Pelletization Plant
a.Raw Materials
1) Iron ore
Requirement of iron ore fines for producing 0.9 million TPA pellet is 1.1 MTPA.
2) Bentonite
Requirement of Bentonite for producing 0.9 MTPA pellet is 20000 TPA.
3) Coke
Requirement of Coke for producing 0.9 MTPA pellet is 30000 TPA.
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4) Dolomite (Binder)
Requirement of Dolomite for producing 0.9 MPTA pellet 21000 TPA.
Table No. C3-1: Quality of Raw material
Iron ore Concentrate Bentonite Dolomite

Fe2O3 92.4% SIO2 48-55% SIO2 4-6%
CaO&MgO 1-2% AL2O3 15-21% CaO 28%
SiO2 2-3% Fe2O3 8-13% MgO 30%
Al2O3 2-3% CaO 0.7-3% LOI 38-40%
LOI 1.8-3.25% MgO 0.2-3% -- ---
Moisture 5 - 8% LOI 8-12% -- --
Coke
Fixed Carbon 65-70%
Ash 9-12%
Sulphur 0.6-1% max
Bulk Density 0.8ton /cum
Volatile matter 9-11%
Moisture 8-10%
Ash melting temperature >1350 0C
Calorific value >6000 Kcal/kg
A. Palletisation process description
Plant is sub grouped for study as explained herein,
 Concentrate unloading handling storage and reclaiming,

 Concentrate Drying , flux grinding , flux storage , blending and mixing
 Pelletizing , screening , handling
 Preheating ,
 Roasting ,
 Cooling ,
 Product handling ,
 Environment control equipment ,
 Electrical system
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CONCENTRATE UNLOADING HANDLING STORAGE AND RECLAIMING,
This division includes the unloading, handling storage blending and reclaiming of the iron ore
Concentrate, This consist of,
Stacking conveyor Belt Tipper type,

Covered shed,
Intermediate hoppers,
EOT crane with Grab Bucket,
Disc feeders,
Weigh feeders,
Belt conveyors
CONCENTRATE DRYING, FLUX GRINDING, FLUX STORAGE, BLENDING AND MIXING
This consist of energy efficient Concentrate Dryer, Flux storage, weighing system, storage bins ,
conveyor belts , mixer , additive grinding and handling .
PELLETIZING, SCREENING, AND HANDLING
The basics requirement of the system is to produce the right size round green pallets with sufficient
strength, One Disc is designed to produce 50 –75 TPH pellet.
PREHEATING
Preheating process in Palletisation comprises with equipment like Travelling Grate Heat Resistance fans,
Multi-cone cyclones, ESP, Induced Draft Fan. In This process heat recovered in cooling of the fired Pellet
is reused for drying, preheating, heating operations.
ROASTING
This is most important part of the pelletization process; Heat is transfer though conduction as well
radiation from refractory, rotary kiln furnace is used for this application. This rotary Kiln is suitably
refractory lined so that radiation losses are minimized.
The kiln is designed to operate at 1.8 rpm and the speed is adequate to meet the additional handling of
material though it.
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COOLING
Cooler is 60 sq. meter cooling area , look to be adequate capacity to cater the additional handling of the
fired pellets , Two set of cooling fans is sufficient to meet the cooling requirements. The entire fan are
equipped with VVFD, we envisage the continuous operation of all three fans to cater additional quantity of
fired pellet. Each fan is of capacity of 1,00,000 NM3/hour with static pressure of 6000 Pascal .
PRODUCT HANDLING
Product handling equipment are of adequate capacity and can handle the additional capacity envisaged.
The storage capacity further can be expanded in length if require at lateral stage, At this stage we do not
envisage any additional requirements.
POLLUTION CONTROL EQUIPMENT
Equipment involved are Electrostatic precipitator, Multicone – cyclones, Bag Filters at product discharge ,
Pneumatic handling system, etc. The Multi cyclone are in closed circuit which helps in reduction in dust
loads and clean hot air to the system and final outgoing flue gas through ESP has below 50 ppm per
normal meter cube. So the entire system with bag filter, multi cyclone in closed circuit with ESP is
sufficient enough to control and give clean environment.
ELECTROSTATIC PRECIPITATOR
S. No. Description Unit Designed
1 CUM/Hr. 500000
Gas flow rate at ESP exit
2 Deg.C 90 – 120
Operating Temperature at ESP exit
3 g/N.Cu.M 30
Dust Load (concentration) at ESP inlet
4 mg/N.Cu.M 50
Dust Load (concentration) at ESP exit
5 Mmwc 25
Pressure drop across ESP for design conditions
6 m/sec 0.8
Gas velocity at electrode zone on total area
7 Secs 16.8
Treatment time
8 Overall dust collection efficiency with all fields in % 99.833

service (guaranteed)
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INDUCED DRAFT FAN – MAIN

S. No. Description Unit Designed
1 Designed - Gas flow rate M3/Hour 4,40,000
2 Static pressure Pascal 5000

3 Operating Temperature Deg centigrade 200
4 Rated Power KW 1120

5 Type of coupling Hydraulic
INDUCED DRAFT FAN – HR FAN

Sr no Description Unit Designed
2 No of fans No 1+1
5 Rated Power of each fan KW 400
MUTLICONE CYCLONE – DRYING ZONE
The heat, recovered in the process of palletisation, is collected from heating zone of the travelling grate
and utilised for preheating and drying of the green pellet ,
Sr. no Description Unit Designed

2 No of cyclones No 1+1
4 Operating Temperature Deg centigrade 450-550
5 Pressure loss Pascal 800-1000
7 Size of the cyclone Width 4500
Length 7000
Height 11000
8 Efficiency % 85-95
MUTLICONE CYCLONE – PREHEATING ZONE
The heat , recovered in the process of palletisation, is collected from heating zone of the travelling grate
and utilised for preheating and drying of thegreen pellet ,
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Sr. no Description Unit Designed

2 No of cyclones No 1
4 Operating Temperature Deg centigrade 450-550
5 Pressure loss Pascal 800-1000
7 Size of the cyclone Width 4500
Length 7000
Height 11000
8 Efficiency % 85-95
INDUCED DRAFT FAN – HR FAN-PFREHEATING ZONE

2 No of fans No 1
5 Rated Power of each fan KW 400
FORCED DRAFT FAN – COOLING FANS

2 No of fans No 3
4 Operating Temperature Deg centigrade Ambient
5 Rated Power of each fan KW 200 each
PNEUMATIC CONVEYING SYSTEM – FOR RECYCLING OF THE DUST COLLECTED AT

MUTLICONE CYCLONES AND ESP
1 Designed - capacity TPH 4.5
ESP – 6 , Multi-cone – 3 ,
2 No of system No
Bag Filter – 3
3 Operating cycles per hour No / hour 16
4 Operating temperature Deg 60 - 100
ELECTRICAL SYSTEM
Electrical system designed is good enough to absorb the additional drives, Transformers and breakers are
of adequate capacities. Few feeders need to be inducted to provide power to the additional drives. We do
not envisage any major changes to the system.
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Pellet Making (2 x 0.6 MTPA iron ore pellets)
The pellet making process takes place in following steps:
1. Grounding of iron ore fines and additives and storage in silos.

2. Mixing of iron ore fines and additives
3. Balling unit (for making green pellets)
4. Indurations unit (for oxidizing the green pellet)
5. Gate Kiln
6. Cooler
7. Finished pellet stockpiles, stackers and declaimer system
Composition of Pellets:
Compression strength (kg/pellet) - 250
Tumbler strength- >3%
Screening index - <95%
Abrasion index - <5%
Reduction index – 70%
Alkalinity – 0 to 0.8%
Rate of expansion – 15%
Chemical composition – Total Fe- 63%, FeO – 1%
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The pellet plant shall operate on hematite iron ore fines having 8 to 9% moisture and shall be
transported from various sources to raw material storage yard at pellet plant site. Iron ore fines
from raw material storage yard shall be conveyed to iron ore silos within the pellet plant. From
there iron ore fines are dried in the rotary kiln to reduce the moisture contents below 1% before
feeding it to the ball mill to get the requisite fineness (-325 mesh, approx 80%). The additives
likes lime stone, bentonite and coke are also ground in a roller mill on time shearing bases to the
requisite fineness of 200 mesh. Than the ground iron ore fines and additives are transported
pneumatically to the respective silos in ground material storage units. Further, mixing in peddle
mixture, green pellet formation in palletizing disc, feeding green ball in furnace using double
deck roller screen and heat hardening of green pellets in indurating machine shall be carried out.
The hearth layer separation is done using naturally: the hearth being reused as hearth layer in
the furnace.
Apart from the above units all major service facilities like material handling, water supply system,
compressed air system, coal gas, ventilation and air conditioning, plant deducting, building
structure, civil works and industrial safety, electric, instrumentation and automation have been
envisaged for the proposed pellet plant.
The plant requires a multi-storeyed structural shed with footprint of 25 m x 12 m to house coal
and related process equipments. [
Material Balance
Input Materials Quantity (TPD) Output Materials Quantity (TPD)
Iron ore fines 3550 Pellet 3000

Bentonite powder 55 Dust 85
Dolomite fines 56 Moisture 321
Coke fines 81 Burnt loss 336
Total 3742 Total 2445
3.8.1 Source of Major Raw Material

a. Iron ore fines: Iron ore fines are purchased from the iron ore belt of Joda-
Barbil region.
b. Coke: The possible source of coking coal will be Australia. Indian steel
plants import coking coal largely from Australia, from the coalfields located
in New South Wales and Central Queensland regions.
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c. Dolomite: Dolomite the sourced from dolomite mines operating in
Sundargarh district of Odisha.
d. Bentonite: It procured from the mines in Bhuj, Gujarat.
3.8.2 Mode of transport of Raw Material

It has been assumed that major raw materials like iron ore and coal are
brought to the plant from outside sources by rail. Iron ore fines are
fed to pellet unit through conveyor system. The
incoming raw materials transported from the Iron Ore Mines to Plant by rail and unloaded at RML
private siding in the plant premises.
3.9 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED

IN THE PROJECT
No waste water are generated from the process. The Solid waste like ESP dust,
Broken Pellets will be reutilised in pellet making by blending with the raw material.
The plant is designed in zero discharge concept. Effluent from raw water treatment
facilities are treated in settling pond and taken to common basin. DM plant regeneration are
neutralized and taken to common basin. Soft water regeneration effluent are neutralized and
are taken to common basin for reuse. CT blow down and boiler blow down of power plant
are taken to common basin and reuse in ash handling and dust suppression. Cooling water in
Pellet plant are completely recycled in closed loop. Domestic effluent aretreated in STP and
reused for green belt.
3.10 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER

REQUIREMENT AND SOURCE
3.10.1 Source of water

Total water requirement is about 120 m3/ day, which is drawn from ground water
source through, bore well. The water abstraction work from Kansai River is work in progress.
The company already obtained the permission from the department of WRID, Govt of West
Bengal.
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3.10.2 Summary of Plant Water Requirement

Table No. C3-4: Water requirement
Items Total make - up water requirement

Pelletization process ( 100 m3/day
Grinding system, Balling
disc., cooling, etc)
Domestic use , Dust 20 m3/day

Total 120 m3/day
Supression& Misc.
3.10.3 External water system

Total water requirement will be about 120 m 3 /day, which is drawn from ground water source
through bore well/Kansai River.
3.10.4 Plant water system

The plant water system comprises of clarified water storage tank having 10 days
storage, filtration plant to meet the plant drinking water requirement, de -
mineralization plant, softening plant for meeting quality of plant make -up water
requirement apart from clarified water to be supplied as make-up to various re-
circulating water systems. In addition, clarified water will be supplied for plant
fire-fighting system.
In order to conserve water to the maximum possible extent, independent re-

circulating systems with cooling towers, heat exchangers, pump houses and
treatment units wherever required have been used for the project. Make-up water
of desired quality will be supplied to each individual re-circulating system. In
order to make the plant as a zero effluent discharge plant, necessary treatment
facilities have been considered to treat the waste generated within the plant and
treated water will be reused for slag cooling, dust suppression as well as for
meeting plant gardening.
3.10.5 Re-circulating water systems

The re-circulating water systems for Pelletizing plant comprises of pump house having cold well
and cooling tower for indirect cooling water circuit, direct cooling water circuit and other having
cold wells with heat exchangers, softening plant for soft water cooling circuits.
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a. Emergency water (EW) system: For vital equipment which require

emergency water during power failure, emergency water overhead tank along with
emergency power supply to specific circuit of tank filling pump have been considered for
preventing equipment damage.
b. Make-up water (MW) system: The total make-up water requirement for
the plant is to be about 600 cum per day has been supplied to cold wells of
re-circulating water systems to replenish the process loss and evaporation
loss.
c. Soft water (SW) system (make-up): A part of make-up water from

clarified make-up water pump house is supplied to softening plant through filtration plant
wherefrom soft water is supplied as make-up to soft water re-circulating systems.
d. DM water (as make-up) system: Part of clarified water from make-up
water pump house is supplied to DM plant through filtration plant wherefrom DM water will
be supplied to power plant.
e. Drinking and sanitation (DW) system: To meet the water requirement

for drinking and sanitation, a part of filtered water will be supplied to drinking water
overhead tank after necessary chlorination where from water will be supplied by gravity
distribution header to meet the different consumers of drinking and sanitation need.
f. Fire-fighting water system: In order to combat fire within the plant, a fire
water ring main with hydrants system conforming to TAC norms has been
provided. For this a twin compartmentalized sumps adjacent to fire water

pump house have been installed. The twin compartmentalized sumps is
filled up with water by taking tapping from make-up water distribution
header to meet the fire water requirement during fire exigencies. The fire
water pump house is provided with main fire water pumps both electric and
diesel driven, jockey pumps along with its accessories. Provided with
suitable corrosion protection coating /wrapping /tapes and at road-crossings
pipe sleeve is provided.
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3.11 Energy:
5 MW Power is sourced from WBSEDCL (West Bengal State Electrical Distribution Company
Limited) in 132kV system & Captive Power Plant. This electricity is coming through 132KV HT
power distribution line. The plant has a LT Power distribution room to provided power. The total
contract demand for the plant is 35MVA. However, there is a D.G set, which get automatically
started within15 seconds of power failure.
3.12 Environment Management
Air pollution control measures

Pellet plants operation is principally associated with air emission arising out of process gas
from induration plant (travelling grate kiln). Further fugitive dust will be generated from raw
material handling section, coal grinding, flux grinding and proportionating section and finished
product handling. So following air pollution control measures proposed to be adopted in the
pellet plant.
3.13 SOURCE OF EMISSION AND DIS CHARGE

Table No. C3-7: Source of Emission and Discharge
Sl. Process activity Pollutants released to Type of pollution

No the environmental
1. Raw materials handling, Coal dusts, iron ore dusts, Air pollution
stock house, stock piling other fugitive emission
and materials transfer from transfer points
2. Grinding and screening of Coal dust, iron ore dust Air pollution
raw materials
3. Dumping of composite Dusts from dumps, run off Air pollution, Land
solid waste comprising dumping area, erosion of pollution and
thickener mud and slag on dumps. water pollution
the ground
4. Plant sanitary waste water Waste water with Water pollution
biodegradable pollutants
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3.14 CONTROL MEASURES

Table No. C3-8: Control Measures
Sl. Location / Shop Pollution control facilities
No
1. Raw material handling area, Dust suppression system comprising of bag
materials transfer points filters, spray nozzles and piping network etc.
2. Pellet Plant a. Raw material Handling- Bag Filter in close circuit.
b. Coal grinding - Bag Filter in close circuit.
c. Flux grinding- Bag Filter in close circuit.
d. Proportionating section- Bag Filter
e. Ball Mill- Wet Scrubber
f. Travelling grate, multi cyclone in close circuit and
rotary kiln- ESP
g. Hearth Layer Separation - Wet Scrubber
h. Finished product Handling - Bag filter
All stacks are suitable with pothole and working platform so that stack monitoring can be
done as per norms of statutory authority.
3.15 WATER POLLUTION:

Total make up water requirement for the project is 120 m3/day which are sourced
from the Ground Water through bore well and water abstraction from Kansai River is work in
progress. The company has due permission from WRID,Govt. of West Bengal to draw
required water.
Since the groundwater table is at safe label in and around the plant area, the ground water
availability and the ground water regime due to the existing plant will not be affected.
The domestic effluents from the canteen and the toilets within the plant premises will be
treated in STP and treated effluents will be used in green belt. The proposed plant has
achieved a zero discharge norms with reuse /recycling of treated water from different
treatment plants. Run off from various area such as ash disposal area, solid waste dumping
area and coal stock pile area will be passed through setting tanks before discharging to
outside.
In the iron ore pellet plant; there is no effluent generation from the process.
Water is used to maintain moisture in pellets. Further water is used for equipment
cooling which is completely recycled with make-up water. Scrubbing effluent will
be treated in settling tank and will be recycled in scrubbing with make-up water
in a closed circuit.
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CHAPTER 4
SITE ANALYSIS
4.1 CONNECTIVITY
The Existing Plant is located in the village Gokulpur, P.O Shyamraipur of Paschim Midnapur
latitude22˚21′31″N and longitude 87˚17′21″E.The site is well connected with NH-6 which is
Kharagpur Railway station is at about 5km by road from the project site.
Road: NH-6 is passing beside the existing project site in south

direction.
Rail: Nearest Railway Station is Gokulpurat about 1.5km and another junction Railway
station Kharagpur is around 5.0Km apart from the project site in South - East direction.
Air Port: Nearest Airport is NetajiSubash Chandra Bose International Airport at Kolkata,
Dumdam which is about 121 km from the project site in North – East direction.
Port: Nearest port is at Haldia about 130 km from project site in South-East direction.
Township: Nearest Town & District Head Quarter is Midnapur which is 8 km from the Site
North-East direction.
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The Project set up over an area of 188 acres land. All the land involved in the project site was
private &WBIDC land. The entire land is now in the name of the plant and converted to industrial
use.
4.3 TOPOGRAPHY
The project area is mainly a plain land with an average elevation of 40 m MSL. The area is
situated in the survey of India Topo Sheet No. 73 N/7 and latitude 22˚21′31″N and longitude
87˚17′21″E. The KansaiRiver is flowing at a distance of 5.0 km from the project site in the
North direction.
There is no Reserve forest and hamlet or any habitation within the project site;
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Existing project location shown in Toposheet
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4.5 EXISTING INFRASTRUCTURE
No Infrastructure was there at the time of land acquisition. Infrastructure such as

temporary housing facility, Drinking water facility, First-aid facility, Toilet facility
are provided. Internal roads are developed inside the plant premises once all the
statutory clearances are obtained.
4.6 SOIL CLASSIFICATION
Five soil samples were collected from agriculture fields surrounding the project site. Soil samples were
collected from three different depths, 5-10 cm, 10-20 cm and 20-30 cm below the surface. The samples
were homogenized and the quantity was reduced by coning and quartering method. The samples were
packed in polyethylene bags. The soil sampling locations and analysis results are shown in Table 3.15
and Table 3.16.
4.7 CLIMATE DATA FROM SECONDARY SOURCES
The area experiences subtropical dry to wet climate. Summer starts from March and
continue up to mid-June and monsoon is from June to September. May is the hottest
month and December to January is colder months. The annual maximum
temperature varies from 28.40 C (January) to 43.60 C (May) while the annual
0 0
average minimum temperature varies from 14.4 C (December) to 29.5 C (May). On
an average 83% of rainfall is received during the monsoon season (i.e. July to
September). Wind direction and speed are most impact factors for the transportation of dusts.
Predominant wind direction is from S, SSW & NE direction.
4.8 SOCIAL INFRASTRUCTURE AVAILABLE
The project site comes under the administrative jurisdiction of Panchayat - Kalaikunda, Zilla Parishad -
Midnapur. Project area has education, drinking water facilities, transport facilities, School etc.
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CHAPTER-5
PLANNING BRIEF
5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES AND

TRANSPORTATION ETC.) TOWN AND COUNTRY PLANNING/
DEVELOPMENT AUTHORITY CLASSIFICATION
M/s Rashmi Metaliks Limited has set up a 0.9 million TPA Iron Ore Pelletization Plant out of total
Consent to Establishment obtained 1.2 MTPA at existing Plant is located in the village Gokulpur,
P.O Shyamraipur of Paschim Medinipur district of West Bengal. The area is situated in the
survey of India Topo Sheet No. 73 N/7 and latitude22˚21′31″N and longitude 87˚17′21″E.The
site is well connected with NH-6 which is passing beside the project site. Nearest Railway
Station is at Gokulpur just 1.5 KM away and Kharagpur Railway station is at about 5km by road
from the project site. The Iron ore fines are utilized in Pellet making. The power required for the
plant is made available fromWBSEDC/Captive Power.
The site is well connected with NH-6 which is passing beside the plant. Nearest Railway Station
is Gokulpur 1.5Km apart from the existing plant site and ; at about
5km by road from the project site in South-East direction. The company has own private Railway
siding taking the take-off point from NimpyraGokulpur section for transportation of raw material.
5.2 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Total Manpower engaged during operation of the Pellet Plant is 200. Apart from this,
500-600 persons are indirectly benefited by this project during the operation phase for logistic.
Sl. No Category No. of Employees

01. Managerial staff 06
02. Technical staff 22
03. Highly Skilled staff 24
04. Skilled staff 35
05. Semi-Skilled staff 35
06. Unskilled staff 70
07. Clerical staff 8
Total 200
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5.3. LAND USE
The Project is over an area of 188 acres there is no forest land was involved in the project site. All
the land involved in the project site was private &WBIDC land. The entire land is now in the name
of the plant and converted to industrial use.
5.4 GREEN BELT DEVELOPMENT
Trees like Sonjol, Debdaru, Sishu, palash, suitable for this region are planted in compliance
of conditions of environmental clearance. With a view to attenuate air pollutants, to resist noise
propagation from power generation units and uptake of treated effluent to some extent, the
green belt all around the periphery of project sites and in vacant areas (33% of the total
acquired land) is being developed. Tree plantation has been undertaken in a large scale on
land vacated after cessation of construction activities. Open spaces, where treeplantation is not
possible are planted with flowering herbs and grass which act as soil binders and also helpful in
preventing erosion of topsoil.
5.5 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)
The social infrastructure likes school and Primary Health Centre will be developed in this area.
However, the following facilities are installed within the plant site;
a. Electricity supply
b. Water supply
c. Administrative Building, Service Building
d. Construction offices and stores
e. Time and security offices
f. First Aid and fire fighting station
g. Canteen and welfare centre
h. Toilets and change rooms
i. Car parks and cycle/ scooter stands
System Design for high productivity
The productivity of the Unit and associated auxiliary objectives are achieved by adopting the
following principles;
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Use of equipment and systems of design performance and high availability which has been
fully established by a considerable record of successful operation for similar service
conditions in all plant facilities. Use of only proven design concepts and conservative designs. Strict
implementation of quality assurance norms during design, manufacture as well as installation and
commissioning stage.Strict compliance with the project company approved pre-commissioning and
commissioning roceduresas well as standard checklists forming a part of commissioning
documents for the project.
Sizing of critical equipment- margins & redundancy/standby

Adequate margins are provided while sizing all important auxiliaries and sub-systems to ensure
operation of the Unit at ultimate capacity under the worst conditions and taking into consideration
normal wear & tear.
Design for efficient operation

Centralized maintenance system is followed. All repairs of capital nature, heavy maintenance
jobs, refractory maintenance and plant civil maintenance are done by engaging specialized
external agencies.
Implementation of computer systems including local area network (LAN) with
standard user friendly software’s in the field of financial management, personnel management,
materials management, order scheduling, sales and marketing management, management
information systems (MIS), production planning and control, maintenance and spares planning,
etc. has been considered to increase work efficiency and to reduce manpower requirement.
Operation Performance Management System (OPMS)

The operation of the plant will be optimized by implementation of OPMS. This system
will clearly define the responsibilities of all key O & M personnel including the shift-in-charge. This
will also cover the system of daily reporting to the project company Corporate Office and monthly
O&M review meetings.
Operation & Maintenance Philosophy

Most of the key positions in operation and maintenance of the proposed plant at different
categories are manned by the qualified persons having experience in the similar field. However,
depending on the type of equipment /facilities along with the degree of automation contemplated,
the operation and maintenance personnel of the plant so recruited will require specific need based
training which is carried out on site by the respective equipment supplier during equipment
erection, start up and commissioning of different plant units.
RML_Pellet Page 42
O & M Organization
The major functions of the organization are briefly outlined below:

The Board of Directors formulates the policy and exercises overall control of the
organization through the Managing Director, who is the full time chief
executive. The Managing Director holds a dual office: as a member of the Board, he shares
the corporate responsibility of the other Directors; as chief executive, he is responsible to the Board
of Directors. In this capacity he is the link between the Board and the rest of the organization. He
interprets and implements the policies laid down by the Board. To enable the Managing Director
to exercise efficient control over the entire organization, the management functions are grouped
into two (2) major divisions namely (i) administration division and (ii) works division.
Functions of administration division:

The administration division is directly under the control of Director Administration
who is responsible for all administrative functions such as general administration
Personnel and human resource development, finance and accounts functions and
commercial functions. In carrying out these functions he is assisted by two General
Managers, namely General Managers Personnel and Administration, General
Managers Finance and Accounts. However, it suggested that some of the services,
such as canteen and catering services, horticulture and landscaping, security and
major fire fighting services, personnel transportation, general cleaning and sanitary
services are outsourced on contract basis but supervision of these functions is taken
care of departmentally.
Functions of works division:
The works division is under the overall control of a Director Works who is assisted by
one General Manager, one for production maintenance and services for environment division (i.e.
quality control and laboratory section headed by a Metallurgist and
environmental and safety) functions is directly under the control of Director Works.
General Manager (Production and maintenance) is in-charge of raw material handling,
Beneficiation Plant, Pellet Plant and power plant. General Manager (Environment and safety) is in-
charge of Environment division as well as quality control and safety.
Maintenance Management System
The maintenance of the plant is carried out as per the maintenance management system to be
developed by the project company. This system should aim at maximizing the availability
of the generating units while ensuring minimum maintenance cost and safety of plant &
RML_Pellet Page 43
personnel. The system should cover organizational structures, preventive maintenance

schedules, detailed work specifications covering all maintenance jobs, permit-to-work
system, long term maintenance planning, safety aspects etc.
Spare Parts Management System
The primary objective of the system will be to ensure timely availability of proper spare parts
without excessive build-up of non-moving inventory. The system is covering the following aspects:
Proper codification/identification & retrieval of all spares & consumables Proper storage & protection
Spare parts indent and procurement policy Judicious fixing of inventory levels and spare part
ordering based on experience of similar Units or other benchmarks. Development of indigenous
sources/in-house capability for imported spare parts. Development of more than one source
wherever applicable.
O & M Training
However, depending on the type of equipment/ facilities along with the degree of automation
contemplated, the operation and maintenance personnel of the plant so recruited will require
specific need based training which is proposed to be carried out on site by the respective
equipment supplier during equipment erection, start up and commissioning of different plant units.
5.5 AMENITIES/FACILITIES
5.5.1 In-Plant Facilities
The following facilities are provided in this plant:

a. Administrative Building, Service Building
b. Construction offices and stores
c. Time and security offices
d. First Aid and fire fighting station
RML_Pellet Page 44
e. Canteen and welfare centre

f. Toilets and change rooms
g. Car parks and cycle/ scooter stands
h. Training centre
Office space has been provided as per good practice and canteens, toilets and
restrooms according to norms laid down in relevant factories act. The above facilities shall
also be adequately furnished and equipped.
5.5.2 Employment Generation:
• Establishment of small and medium scale engineering ancillaries, with

cascading employment opportunities;
• Increased revenue to the state by way of taxes and duties;
• Improved green cover;
• Better communication and transport facilities;
The project has enhanced the prospects of employment. Recruitment for the unskilled
workers for the plant is from the nearby villages. The basic amenities viz. roads,
transportation, electricity, drinking water, proper sanitation, educational institutions, medical
facilities, entertainment, etc. are developed as far as possible.
5.5.3 Peripheral Developmental Activities:
M/s Rashmi Metaliks Limited has undertaken following activities already made around the
plant as a mark of their Corporate Social Responsibilities.
Sl. Scope of Activities Already Invested Amount

No. (Rs.)
1 Education 2025000
2 Water Supply including Drinking Water 775000
3 Health Care 3545000
4 Environment 1750000
5 Social Empowerment 1285000
6 Village Electricity / Solar Light 2530000
7 Sports and Culture 3968000
Infrastructure Support - construction, repair, extension
8 etc. 3339000
Grant / Donation / Financial assistance / sponsorship to
9 reputed NGOs of the society / locality doing / involve in 1200000
RML_Pellet
upliftment of standard of the society and Misc. Page 45
GRAND TOTAL:- 20417000
CHAPTER-6
PROPOSED INFRASTRUCTURE
Not applicable
RML_Pellet Page 46
CHAPTER-7
REHABILITATION & RESETTLEMENT (R & R) PLAN
Not applicable
51
RML_Pellet Page 47
CHAPTER-8
PROJECT SCHEDULE & COST ESTIMATES
Not applicable
RML_Pellet Page 48
CHAPTER-9
ANALYSIS OF PROPOSAL (FINAL ECOMMENDATIONS)
Not applicable
RML_Pellet Page 49

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FEASIBILITY REPORT of 900000 TPA

(0.9 MTPA) Pellet Plant

RASHMI METALIKS LIMITED

1.2 Project Site

1.3 Plant Layout

1.4 BRIEF PROJECT DESCRIPTION

10X100 TPD + 6 X 100 TPD 4 X 100 TPD -

Iron Ore Beneficiation 1.5 MTPA 1.5 MTPA - -

Iron ore Pellet

CPP-AFBC based AFBC based - 6 MW - AFBC based -

Quantity of Reqd. in Sizein Source of Mode

Bentonite 20,000 0.074 Bhuj, Gujarat Rail

1.6 WATER REQUIREMENT & SOURCE

Table No.2: Total Plant Raw Water Requirement

Items Total make - up water requirement

Domestic use & Misc. 20 m3/day

1.7 SOLID WASTE GENERATION AND MANAGEMENT

Table No. 3: Solid Waste Generation and Management

Table No.4: Details of Land use break up

MKD. DESCRIPTION SIZE IN (M.X M.) AREA IN (M.Sq.) STATUS

24. SMS 187X81.0 15147 EXISTING

25. SETTLING POND 141X137 19317 EXISTING

26. SWITCH YARD 113X200 22600 EXISTING

27. SINTER PLANT-1 152X186 28272 EXISTING

28. MBF-1 120X326 39120 EXISTING

1.8 GREEN BELT DEVELOPMENT

1.9.1 In-Plant Facilities

The following facilities are provided in this plant:

1.9.3 Medical Facilities/ Health care camps

1.10 PROJECT COST:

The project cost is Rs. 170 Cores.

2.1 IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

Works (Plant Site M/s Rashmi MetaliksLimited

2.1.1 COMPANY BACKGROUND

2.1.2 ABOUT THE PROJECT

Iron ore Pellet

CPP-AFBC based AFBC based - 6 MW - AFBC based -

Table No. 2 : Production Capacity

2.2 BACK GROUND OF THE PROJECT /BRIEF DESCRIPTION OF THE

2.3 NATURE, SIZE AND MAGNITUDE OF PROJECT:

2.4 NEED FOR THE PROJECT:

2.5 PROJECT OBJECTIVE AND ITS IMPORTANCE TO THE COUNTRY/

Iron Ore Pelletization Unit:

2.6 Demand and Supply Gap (Market Scenario)

The Government is taking appropriate fiscal measures, whenever deemed

The pellet market consists of a small group of sellers controlling a majority of

2.7 Imports Vs Indigenous Production

Iron Ore Pellet

2.8 Export Possibility

2.9 Domestic Market

2.10 EMPLOYMENT GENERATION (DIRECT AND INDIRECT)

Table No. 3: Employment status

Sl. No Category No. of Employees

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

3.2 LOCATION AND ACCESSIBILITY

Location details of the Project Site:

Plant Boundary on Mouja Map:

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF

Highlights of the Considerations:

C. Availability of good road infrastructure as very heavy equipments will be required to

D. Availability of Raw Material.

E. Nearest of Market for Finished product.

3.3.1 Alternative site

3.4 SIZE OR MAGNITUDE OF OPERATION