M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.

At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

For
FERRO ALLOYS MANUFACTURING – 6000 TPA

PRODUCT MIX
LOW CARBON FERRO CHROME /
LOW CARBON FERRO MANGANESE - 3600 TPA
and
FERRO MOLYBDENUM – 1200 TPA and
FERRO VANADIUM – 1200 TPA

BY
JAMSHEDPUR CHLOROCHEM PVT. LTD.

AT
Plot No. NS-88, 6TH Phase ,Adityapur Indusrtial Area,
Gamharia, District-Seraikela Kharsawan

Environment Consultant
Vardan Environet
(QCI and NABET/EIA/1619/RA 0037)
D-142, Sushant Lok-III, Sector 57
Gurgaon (Haryana)
Contact no.-9810355569
Mail ID: [email protected]
Contact No. 0124-4291036, 09899651342

Page 1
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Index

Ch. NO. TITLE PAGE NO.

CH-1 EXECUTIVE SUMMARY

CH-2 INTRODUCTION OF THE PROJECT

CH-3 PROJECT DESCRIPTION

CH-4 SITE ANALYSIS

CH-5 PLANING BRIEF

CH-6 PROPOSED STRUCTURE

CH-7 REHABILITATION & RESETTLEMENT

CH-8 PROJECT SCHEDULE & COST ESTIMATES

CH-9 ANALYSIS PROPOSAL

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER - I
EXECUTIVE SUMMARY
1.0 Introduction
India has become the world's fourth-largest producer of crude steel. The country is slated to
become the second-largest steel producer by 2020 as large public and private sector players
strengthen steel production capacity in view of the rising demand. Ferro Alloy is being used
for manufacturing of Alloy Steel, Super Steel, Tool Steel such as tensile, elongation etc. and
for manufacturing of Corrosion Resistant and Abrasion Resistant steel.
Steel consumption is expected to grow at an average rate of 6.8 per cent to reach 104 MT
by 2017 and steel production in India expected to go up to 200 MTPA by 2020 from current
70 MTPA driven by rising infrastructure development and growing demand for automotives
and so will the demand of Low Carbon Ferro Alloys for specialty steel.
Project at a Glance

1 Name of the Company M/s JAMSHEDPUR CHLOROCHEM PVT. LTD.

Registered Office NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela –
2
Factory& Admin Office Kharsawan, Jharkand
Sri Manoj Kumar Gutgutia
Sri Shiv Kumar Agarwal
3 Name of the Directors
SmtSangeeta Gutgutia
Smt Sushma Agarwal
4 Proposed Sector Ferro Alloys

5 Area of plant 0.92 acres /0.37 Ha.

6 Topo Sheet No 73 J/1

7 Latitude 220 47’ 50.17” N

8 Longitude 860 07’ 17.78” E

Proposed Units& Low Carbon Ferro Alloys& Noble Ferro Alloys –Based on
9
Total Capacity Alumino-Exothermite process: 6000 TPA
LC Ferro Chrome / LC Ferro Manganese - 3600 TPA
10 Product & capacity Ferro Molybdenum - 1200 TPA and
Ferro Vanadium - 1200 TPA
11 Cost of Project Rs.96.20 Lakhs

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

1.2 Identification of Project and Project Proponent

M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro
Alloys and Noble Ferro Alloys–Based on Alumino-Exothermite processwith total capacity -
6000 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan,
Jharkhand.
Project Promoters:
M/s Jamshedpur Chlorochem Pvt. Ltd. is promoted by,
o Sri Manoj Kumar Gutgutia
o Sri Shiv Kumar Agarwal
o Smt Sangeeta Gutgutia
o Smt Sushma Agarwal
1.3 Employment Generation - Manpower
It is estimated that the total requirement of manpower of project is around 34 persons
who/which include Supervisors, Skilled and semi-skilled work force.
1.4 Project Description
M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro
Alloys & Noble Ferro Alloys –Based on Alumino-Exothermite process with production
capacity of LC Ferro Chrome / LC Ferro Manganese - 3600 TPAand Ferro Molybdenum -
1200 TPA and Ferro Vanadium - 1200 TPA at NS-88, 6th Phase, Adityapur Industrial Area,
Dist – Saraikela – Kharsawan, Jharkand.
Dismantling of the existing unit of Hydrated Lime
There is an existing unit of Hydrated Lime – 15000TPA within the existing premises and
infrastructure. All the facilities and equipment for the existing unit will be dismantled after
obtaining Environment Clearance for the Ferro Alloys. The CTE & CTO obtained for Hydrated
Lime from JSPCB will be surrendered and New CTE & CTO shall be obtained for
manufacturing of Low Carbon Ferro Alloys – Ferro Chrome and/or Ferro Manganese – 3600
TPA and Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA.
1.5 Site Location
This project will be located at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela –
Kharsawan, Jharkand over an area of 0.92 acres / 0.37 Ha. The Latitude and Longitude of the
proposed site is220 47’ 50.17” N & 860 07’ 17.78” E respectively. No additional land will be
acquired.The availability of infrastructural facilities and logistics of operation were
considered while evaluating the possible site.

1.6 Raw Material Requirement

a) For Low Carbon Ferro Alloys
Various raw materials will be required as per the product to be manufactured. Maximum
capacity of the individual Low carbon ferro alloys or the product mix will be 3600 TPA only.
The raw material requirement at max capacity will be as below:

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

For Low Carbon Ferro Manganese – 3600 TPA (max):

Specific consumption Quantity Required
Material
T/T of Product TPA
Roasted Mn Ore 1.730 6228.00
Aluminium 0.515 1854.00
M.S. Scrap 0.118 425.00
Fluorspar 0.115 414.00
Lime 0.150 540.00
9461.00
Total 2.596

Fuel & Consumables

Wild Babool Charcoal 0.300 1080.00

Or For Low Carbon Ferro Chrome – 3600 TPA (max):

Specific consumption Quantity Required
Material
T/T of Product TPA
Chrome Ore 1.800 6480.00

Aluminium 0.632 2275.00

M.S.Scrap 0.118 425.00

Total 2.550 9180.00

Fuel & Consumables (Oxidizers)

Coal 0.400 1440.00

Barium Peroxide /Sodium
0.144 518.40
Nitrate

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

b) For Noble Ferro Alloys

Maximum capacity of the individual Noble ferro alloys will be 1200 TPA or the product mix
will be 2400 TPA only. The raw material requirement at max capacity will be as below:
Ferro Molybdenum -1200 TPA (Noble Ferro alloys)
Specific consumption Quantity Required
Material
T/T of Product TPA
Molybdic Oxide 1.020 1224.00
Aluminium Powder 0.072 86.4
Mill Scale 0.388 465.6

Iron Nails 0.163 195.6

Lime 0.041 492.00
Ferro Silicon 0.408 489.6
Total 2.092 2953.2

c) Ferro Vanadium - 1200 TPA (Noble Ferro alloys)

Specific consumption Quantity Required
Material
T/T of Product TPA
Vanadium Pentaoxide 1.030 1236.00
Mill Scale 0.010 12.00
Lime 0.070 84.00
Aluminium Powder 0.250 300.00
Aluminium Shots 0.500 600.00
M.S.Scrap 0.380 456.00
Flourspar 0.020 24.00
Total 2.260 2712.00

1.7 Water and Power Requirement

The total water requirement for the proposed project is estimated to be 17.5m3/day. Water
requirement for the proposed plant will be met through water supply by Adityapur
Industrial Area development Authority (AIADA) or Drinking water & Sanitation Department
(DW&SD) Govt. of Jharkhand. The Water Connection is already available in the Unit.
Necessary permission shall be obtained. A total of 133 KVA power will be required for the
proposed project. The Power Connection from Jamshedpur Utility and Supply Company
(JUSCO) is already available in the unit.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

1.8 Air Environment – Mitigation Measures

Source of air pollution and control measures
Source of
Section Pollutants Air pollution control Measures
Pollution

Chrome Fume extractor followed by wet

Burning of coal PM & gases
preheating scrubber

Manganese Ore Burning of Fume extractor followed by

PM & gases
roasting Babool charcoal cyclone and Bag Filters

LC Ferro Alloys Reactor vessel Fugitive Dust Fume extractor followed by bag
manufacturing area & Fumes filters

Noble Ferro Reactor vessel Fugitive Dust Fume extractor followed by

Alloys area & Fumes cyclone and Bag filter

Raw material Pulverizer for Dust and

handling & sizing grinding of raw particulate In-built dust catcher and Bag filter
section material matter

Pucca roads within the premises,

Over all Plant Fugitive dust water sprinkling in dusty areas and
Open space
area emission green belt/plantation to arrest the
fugitive dust emission.

• The pollution control equipment will regularly be operated and maintained.

• Fugitive emission will be regularly monitored and suitable action like cleaning, water
sprinkling will be taken.

1.9 Waste Generation and Management

No use of water in the manufacturing process. However water will be used for washing of
chrome ore and wet scrubber for pollution control. Water will be kept in closed circuit, but
on increase in impurities it will be treated in the designated Effluent treatment plant again
reused for washing, scrubbing and sprinkling. The storm water drains will be segregated and
channelized to water harvesting area.

Waste Water Generation and Reuse

Quantity Waste water
Process Unit Source Waste water management
KLD characteristics
Washing & Treated in ETP with facility for
Ore Washing TSS, Oil, Cr, Fe &
9.0 Scrubber chrome passivation and
& APCD Grease etc.
recycled-reused in plant

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Domestic
TSS, BOD, Oil & Will be routed through septic
use from
Domestic 0.8 Grease etc. tank & then to soak pit.
plant

Solid Waste Generation and Management

Nature of Solid Waste Quantity Management

Slag 17 TPD Used for relining of reactor vessel & sold.

Pulveriser Bag Filter &

0.6 TPD Recycle & reutilize in the manufacturing process
other APCD Dust

Hazardous waste: There is no hazardous waste from the plant except for used oil with
approx quantity of 200 Liters per annum during course of production of and is also saleable
to the registered recyclers and ETP Sludge Produced will be approx. 300 TPA and will be sold
to the refractory manufacturers.
1.10 Site Analysis
The site is within notified Industrial Area and has all the facilities for the proposed project.
Also it has good connectivity with the rail and road.
1. Road Connectivity: The site for the proposed project is well connected to Tata-
Kandra Road at a distance of 0.65 km.
2. Rail Connectivity: The nearest railway station is Gamharia Junction at 1.95 Km and
Adityapur railway station located at a distance of 4.0 km from the proposed project
site.
3. Airport: Nearest airport to the project site is Sonari, Jamshedpur at a distance of
5.22 km NE. However, nearest commercial airport is Ranchi at a distance of 95 KM
NW.

1.11 Land Use Planning

Proposed approximate use of Land after installation:
Land-use Breakup
SL Area Area
Type Of Use
No (acres) (ha)
1 Plant & Storage area 0.49 0.198

2 Administrative offices, canteen, security, etc. 0.06 0.024

3 Entrance, Roads and ETP Area 0.11 0.044

4 Green Belt & Open area 0.26 0 .105

TOTAL LAND 0.92 0.37

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

1.12 Proposed Infrastructure

a) Industrial - Plant Area
The setting up of the Main Plant Facilities, Storage, Auxiliary facilities, etc. requires0.198 ha.
land out of 0.37 ha. Company will use nearest road for materials transportation and
manpower connectivity.

b) Green Belt& Plantation

A greenbelt & plantation development plan will be prepared and implemented along with
the project. Total area for greenbelt developmentshall be 0.105 ha. The main objective of
the greenbelt is to provide a barrier between the plant and the surrounding areas.

c) Rehabilitation and Resettlements (R & R) Plan

No R & R involved.
1.13 Project Schedule and Cost Estimates

a) Project Schedule
The total project implementation schedule is 6 months from project start date. The external
agencies such as consultant, machinery suppliers, contractors of civil construction and
equipment will be selected carefully well in advance.
b) Project Cost
An indicative estimated capital cost of the proposed Plant is around Rs. 96.20 Lakh.
1.14 Analysis of Proposal
The project is technically viable as located in industrial area. Also there are existing facilities
which will be used by the project. Overall no negative impact on the socio economic
environment is anticipated.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 02
INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent

M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro
Alloys –Based on Alumino-Exothermite processfor total ferro alloys manufacturing Units of
6000 TPA with production capacity of Ferro Chrome and/or Ferro Manganese - 3600 TPA
and Noble Ferro Alloys - Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200
TPA.Project will be located at at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela
– Kharsawan, Jharkand over an area of 0.92 acres / 0.37 ha. The Latitude and Longitude of
the proposed site is 220 47’ 50.17” N & 860 07’ 17.78” E respectively. No additional land will
be acquired.
The availability of infrastructural facilities and logistics of operation were considered while
evaluating the possible site.
Dismantling of the existing unit of Hydrated Lime Unit – Equipments & Machineries only
There is an existing unit of Hydrated Lime – 15,000 TPA within the existing premises with all
the manufacturing facilities and infrastructure. All the manufacturing facilities and
equipment for the existing unit will be dismantled after obtaining Environment Clearance
for the Ferro Alloys. The CTO for Hydrated Lime from JSPCB will be surrendered and New
CTE & CTO shall de obtained for manufacturing of Low Carbon Ferro Alloys – Ferro Chrome
and/or Ferro Manganese – 3600 TPA and Ferro Molybdenum - 1200 TPA & Ferro Vanadium
- 1200 TPA.
List of plant & machineries to be dismantled enclosed as Annexure - I
Project Proponent & Promoters:
M/s Jamshedpur Chlorochem Pvt. Ltd. Has been promoted by following Directors:

1 Manoj Kumar Gutgutia

2 Shiv Kumar Agarwal The promoters have good experience in the field
of Ferro Alloys manufacturing through Alumino-
3 Sangeeta Gutgutia Exothermite process and marketing of same.

4 Sushma Agarwal

2.1.1 Project Details

M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro
Alloys –Based on Alumino-Exothermite process with production capacity of Ferro Chrome
/Ferro Manganese - 3600 TPA,Ferro Molybdenum - 1200 TPA and Ferro Vanadium - 1200
TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand.

Page 10
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Proposed Units
Considering the potential of Ferro Alloys and the experience gained by the group in this
sector, JCPL now proposes to set up the Low Carbon Ferro Alloys (LC Ferro Chrome & LC
Ferro Manganese)and Noble Ferro Alloys (Ferro Molybdenum and Ferro Vanadium) to
streamline its existing operation and to diversify to meet the industry demand. The various
facilities proposed are:

Plant Facilities Product Total Annual Capacity (TPA)

Reactor – Furnace for LC Ferro LC Ferro Chrome &/or

3600
Alloys LC Ferro Manganese
Reactor – Furnace for Noble
Ferro Molybdenum 1200
Ferro Alloys
Reactor – Furnace for Noble
Ferro Vanadium 1200
Ferro Alloys
Total Ferro Alloys capacity 6000 TPA

2.2 Brief Description of Nature of the project

Manufacturing of Ferro Alloys falls into category A under primary metallurgical unit, as per
EIA Notification 2006 and require prior environmental clearance from MoEF & CC.
Ferro Alloy is being used for manufacturing of Alloy Steel, Super Steel, Tool Steel such as
tensile, elongation etc. and for manufacturing of Corrosion Resistant and Abrasion Resistant
steel.
There are three grades of Ferro Alloys as given below:
a High Carbon
b Medium Carbon
c Low Carbon

Out of these three grades, the company intends to manufacture the low carbon Ferro
Chrome/Ferro Manganese and Noble Ferro Alloys viz., Ferro Molybdenum and Ferro
Vanadium.
2.3 Need of the Project and its Importance to the Country and/or Region
Steel Industry in India is on an upswing because of the strong global and domestic demand.
India’s rapid economic growth and soaring demand by sectors like infrastructure, real estate
and automobiles, at home and abroad, has put Indian steel industry on the global map. The
current status of iron ore and its future prospects have direct relationship mainly with steel
production in India.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Consumption of LC Ferro Chrome is expected to be 30000 – 36000 Tons per Annum. The
manufacturing capacity is only 3600 Tons per annum in our Country. The gap is being
fulfilled by Import from Russia and China.
Consumption of LC Ferro Manganese is expected to be 36000-30000 Tons per month. The
manufacturing capacity is only 6000 Tons per month in our Country. The gap is being
fulfilled by Import of Manganese Metal being the substitute from China.
Production of Noble Ferro Alloys was estimated at 31,308 tonnes as compared to 27,435
tonnes during the previous year, registering an increase of 14.12% during the year.
Production of low carbon and medium carbon ferro manganese as well as low carbon and
medium carbon silico manganese are accounted for under bulk ferro alloys production.
Steel finds wide applications in our day to day life. Various key industries like construction,
transport, communication, agriculture and energy cannot sustain without steel. The
manufacturing process from iron ore to finished product involves production of a large
number of intermediate products. All the intermediate products have a domestic as well as
a global market.
2.4 Demand – Supply Gap
In addition to steel plants, several steel casting plants have been set up in the country which
consumes Ferro Alloys. With a Proactive Make in India policy of Govt. of India and the
consumption of Indigenously manufactured Steel in the Infrastructural Projects the demand
will rise significantly and the expected projected figures may be as follows:
Projected Requirement (annual)

PRODUCT DEMAND
PRESENT 2018-19 2019-20 2020-2021 beyond
LC FERRO
36000 Tons 42000 Tons 48000 Tons 54000 Tons
CHROME
LC FERRO
30000 Tons 36000 Tons 42000 Tons 48000 Tons
MANGANESE

There is huge gap between demand and supply which is being fulfilled by Imports. This
proposed project will save Dollars by reducing Imports. The best part of this project is that
the raw material is available in our Country abundantly and hence it will be complete
replacement from Import.
2.5 Imports vs. Indigenous Production
Consumption of LC Ferro Chrome is expected to be 30000 – 36000 Tons per Annum. The
manufacturing capacity is only 3600 Tons per annum in our Country. The gap is being
fulfilled by Import from Russia and China.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Consumption of LC Ferro Manganese is expected to be 24000-30000 Tons per month. The

manufacturing capacity is only 6000 Tons per month in our Country. The gap is being
fulfilled by Import of Manganese Metal being the substitute from China.

2.6 Export Possibilityand Domestic/Export Market

The primary markets of interest for JCPL will be essentially in the state of Jharkhand and
neighboring states. Primary purpose of the project is to cater the demand of products
within the country and fill gap between demand and supply.The Eastern India is the hub of
manufacturing Steel. Moreover the items are High value and hence there is no factor of
freight in the cost and hence the entire India is the suitable market.
The entire world procures LC Ferro Chrome and Ferro Manganese from Russia and China.
Since the raw material is indigenously available, our cost of production will be cheaper and
can comfortably compete with Overseas manufacturer. The product can be Exported to
Japan, Middle East, South Korea and Europe.

2.7 Employment Generation (Direct and Indirect) Due to the Project

A wellstructured manpower is essential for uninterrupted operation and proper
maintenance of plant facilities. Employment will be generated during implementation of the
project. There will be permanent employment of 34 persons including Sr. Executives,
Managers, Administrators, Engineers, Supervisors and Skilled Technicians.
The requirement of manpower for the proposed project has been estimated keeping in view
the modern concepts of automation as described below:
Manager 2
Supervisor 2
Skilled Labour 20
Semi Skilled 10
Direct Employment 34
Indirect Employment 20
Direct employment in the plant is about 34nos. but indirectly arising employment due to
this proposed plant will be manifold involved in supply of raw material, disposal or sale of
finished goods, handling of raw material and finished goods, transportation, loading-
unloading, marketing of finished goods etc.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and
Noble Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER - 3
PROJECT DESCRIPTION
3.1 Type of Project Including Interlinked & Interdependent Projects

M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon
Ferro Alloys –Based on Alumino-Exothermite process with production capacity of LC
Ferro Chrome / LC Ferro Manganese - 3600 TPA and Ferro Molybdenum - 1200 TPA
and Ferro Vanadium - 1200 TPA at NS-88, 6th Phase, Adityapur Industrial Area, Dist –
Saraikela – Kharsawan, Jharkand. The plant will also be equipped with the most
efficient auxiliary sub- systems, material handling facilities and pollution control
equipment.
This is a Category A project as per EIA Notification and requires Environment
Clearance from MoEF & CC. Project is not interlinked and interdependent. The raw
material is primarily Ore being sold by State Government of Orissa. The other raw
material is Aluminium Powder which is manufactured by various Companies in India.
3.2 Location
Project will be located at NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela –
Kharsawan, Jharkand over an area of 0.92 acres / 0.37 Ha. The Latitude and Longitude
of the proposed site is22047’ 50.17” N&860 07’ 17.78” E respectively. No additional
land will be acquired.

Fig1: Google Image of project Site

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.2.2 Plant Layout

The layout of the plant will be developed taking into following considerations:
1. Process will be consolidated into comprehensive production units.The major utilities
and service facilities available for the existing unit will be used.
2. Sufficient space for storage of raw materials and finished products.
3. Green belt, plantation, RWH & space for pollution control facilities will be provided.
PLANT LAYOUT

Fig2: Layout Plan

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble Ferro Alloys (Ferro Molybdenum - 1200 TPA &
Ferro Vanadium - 1200 TPA)

Fig 3: Key Plan

Page 16
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.3 Site Selection

The selection of project site/location has been based on existing land in the notified
industrial area and facilities like shed, electricity connection, water, manpower etc. available
for the existing unit.
3.4 Size or Magnitude of Operation
Project envisages installation and operation of Low Carbon Ferro Alloys –Based on
Alumino-Exothermite process with production capacity of Ferro Chrome and/or Ferro
Manganese - 3600 TPA.
Project will be located on the existing plot NS-88, 6th Phase Adityapur Industrial Area,
Saraikela-Kharsawan over an area of 0.92 acres.
3.5 Project Description with Process Details
The technology for manufacturing process is proven technology of Gold Smith Alumino
Exothermite Process in which oxides of metal is reduced with proper reducers.
3.6 PROCESS DETAILS/STEPS
The manufacturing process is also known as Alumino-thermite Process. Various Inputs in
Predetermined quantity, which is calculated on the basis of the quality of raw material
and reducers is required, hence quality of raw material is of utmost importance.
a) FOR LOW CARBON FERRO MANGANESE
Roasting of Mn Ore: Mn ore received is subjected to roasting, prior to preparing the
charge mix. The ore along with Wild Babool Charcoal is arranged in alternate layers in a
vertical roasting furnace and ignited. The roasted Mn Ore is accumulated over the screen
Grid in solid block form and small amount of ash is deposited at the bottom. The gases
are passed through cyclone & bag filter to arrest the fugitive material.
Sizing of Mn Ore: The roasted Mn Ore is subjected to sizing in a jaw crusher. The crusher
enclosure will be provided with dust extraction system and passed through the same
cyclone & bag filter to arrest the fugitive material.
Grinding of Mn Ore: The sized Mn Ore is subjected to further grinding in a Pulveriser. The
Pulveriser is fitted with dedicated bag filter and grinded Mn ore is collected in powdered
form.
Mixing and Batching of Raw Material: The powdered Mn Ore and other raw materials in
desired proportion is added in the closed mixing machine and subjected to thorough
mixing by rotation for obtaining homogenous mix.
Reaction and product separation: After mixing the charge is collected in bins. Bins
containing mixed charge is placed near to refractory lined vessels. To start the reaction
initially small quantity of mixed charge is placed in the bottom of the vessel and ignite
with Magnesium Ribbon.
As this kind of chain reaction, continuous addition of mixed charge on the top of melt
enable to degassing process and separation of liquid slag. Smelting usually last for 30-35

Page 17
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

minutes in LC Ferro Manganese. After addition of complete mixed charge and reaction,
vessel is left for natural cooling for about 8-10 hours.
After cooling the material is removed from vessel where product ferro alloys and slag is
found in two separate layers which is separated product ferro alloy is found in the form
of big buttons. Broken product will be fed to hammer mill for further reduction to
granules.
Slag obtained is also crushed for reuse as reactor vessel relining or sale to outside parties.
The reaction is as follows:
LC Ferro Manganese
3MnO2 + 4Al = 3Mn + 2Al2O3
Fe2O3 + 2Al = 2Fe + Al2O3
b) FOR LOW CARBON FERRO CHROME
Washing of Chrome Ore: Chrome ore received is subjected to washing prior to preparing
the charge mix. The ore has adhered mud and gangue material which is washed off on a
platform by water jet through pipes.
The water is kept in closed circuit through a recirculation tank set-up. On increase in
impurity concentration water is treated in ETP and further recycled or reused. The
washed ore is taken for drying and preheating.

Pre-heating of Chrome Ore:The washed ore is taken for drying and preheating in a closed
system. In this coal is usedas external fuel. The system will be provided with dust
extraction system and passed through the same cyclone & bag filter to arrest the fugitive
material. Chrome fumes if any will be passed through wet scrubber.
Mixing and Batching of Raw Material: The heated Ore and other raw materials in desired
proportion is then added to the closed mixing machine and subjected to thorough mixing
by rotation for obtaining homogenous mix.
Reaction and product separation: After mixing the charge is collected in bins. Bins
containing mixed charge is placed near to refractory lined vessels. Vessel is filled with mix
charge and a heap is created, to start the reaction initially small quantity of mixed charge
is ignite with Magnesium Ribbon and the spontaneous exothermic reaction takes place
immediately.
As this kind of chain reaction, continuous addition of mixed charge on the top of melt
enable to degassing process and separation of liquid slag. Smelting usually last for 45-60
seconds in LC Ferro Chrome. After addition of complete mixed charge and reaction,
vessel is left for natural cooling for about 12-14 hours.
After cooling the material is removed from vessel where product ferro alloys and slag is
found in two separate layers which is separated product ferro alloy is found in the form

Page 18
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

of big buttons. Broken product will be fed to hammer mill for further reduction to
granules.
Slag obtained is also crushed for reuse as reactor vessel relining or sale to outside parties.
The reaction is as follows:
LC Ferro Chrome
Cr2O3 + 2Al = Al2O3 + 2Cr
Fe2O3 + 2Al = 2Fe + Al2O3

Process Flow Chart

Page 19
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

c) Manufacturing of Ferro Vanadium

Ferro Vanadium is smelted by the alumina thermite method in reactor vessel up to 2m in
diameter; Various inputs in predetermined quantity, which is calculated on the basis of
quality of raw material and reducers, are fed to a mixture machine for homogeneous
mixing. After mixing the charge is collected in bins. Bins containing mixed charge are
placed near to refractory lined vessels.
To start the reaction initially small quantity of mixed charge is placed in bottom of the
vessel and ignites with Magnesium ribbon. As this is kind of chain reaction, continuous
addition of mixed charge on the top of melt enable to degassing process and separation
of liquid slag. Smelting takes 45 – 60minutes. After addition of complete mixed charge
and reaction, vessel is left for natural cooling for 8-10 hours.The reactions of reduction of
oxides of Ferro Vanadium is presented below:

Ferro Vanadium (Noble Ferro alloy)

3V2O5 + 10 Al = 6V + 5Al2O3
2Al + Fe2O3 = 2Fe + Al2O3
The mixture is mixed in double cone blender and started the smelting by bottom priming
process of charging, which ensures a more uniform flow of the process; from 200 to 400
kg of prepared mixture are charged on to the shaft bottom and ignited by means of a
priming mixture composed of aluminium powder and electron turnings. The priming
mixture is ignited by red-hot iron rod or an electric spark.

Page 20
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

After the beginning of the alumino thermite process the remainder of mixture is charged
from special hopper equipped with a gate and a charging pipe; care is taken to ensure
that the charge is uniformly spread over the whole shaft area and the mixture is fed at a
rate so that the melt surface is constantly covered with a thin layer of it. The slow
charging rate causes the uncovering of melt surface and, consequently, increase heat
losses.
d) Manufacturing of Ferro Molybdenum
Low carbon ferromolybdenum is produced by simple and efficient off furnace silico
thermite process. The reaction of reduction of oxides in smelting of ferromolybdenum
are given below:
Ferro Molybdenum ( Noble Ferro alloy )
MoO3 + Al = Mo + Al2O3
Fe2O3 + 2Al = 2Fe + Al2O3
Smelting is done with upper ignition (top-priming). The shaft is filled with a mixture of
charge materials to a height approximately 300 mm below the upper edge, so as to
prevent splashing-out. At the end of smelting, the line of slag rises only to half the height
of shaft. Upon filling the shaft with charge materials, 2 or 3 craters are formed for
ignition mixture. Upon ignition of the mixture, it ignites quickly, and the process of
smelting occurs at a high speed.
The smelting of 5000 kg of mixture takes up 30-40 minutes. With a normal run of heat,
gases escape abundantly from the smelting shaft. With a cold run of heat (weak uneven
evolution of gases), 15-20 kg of thermite mixture with Excess reducer is given to the
charge. With a very hot run of heat and much splashing, the melt is chilled by adding
pieces of alloy scrap.
At the end of smelting, when no more gases rise from the melt, a holding time of 40 - 50
minutes is allowed to settle the beads of alloy. The melt accumulates as a block in the
spherical recess in the hearth. After the holding time, the slag hole is open to let out the
slag.

Page 21
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

PROCESS FLOW – NOBLE FERRO ALLOYS

Page 22
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.6 Raw Material Required Along With Estimated Quantity

A) For Low Carbon Ferro Manganese – 3600 TPA:
Specific
Quantity Required
Material consumption Source
TPA
T/T of Product
Roasted Mn Ore 1.730 6228.00 Odisha
Imported (UAE) & /or
Aluminium 0.515 1854.00
Ahmadabad
M.S. Scrap 0.118 425.00 Local – Jamshedpur
Fluorspar 0.115 414.00 Local - Jamshedpur
Total 2.596 8921.00
Fuel & Consumables (Oxidizers)
Wild Babool
0.300 1080.00 Kuchch Gujrat
Charcoal

Or For Low Carbon Ferro Chrome – 3600 TPA:

Specific
Quantity Required
Material consumption Source
TPA
T/T of Product
Chrome Ore 1.800 6480.00 OMC, odisha
Imported (UAE) &
Aluminium 0.632 2275.00
Ahmadabad
M.S.Scrap 0.118 425.00 Local , Jamshedpur

Fluorspar 0.115 414.00 Local, Jamshedpur

Total 2.783 9594.00

Fuel & Consumables (Oxidizers)

Coal 0.400 1440.00 Open Market

Barium
Peroxide/Sodium 0.144 518.40 Gujrat
Nitrate
Washing of Chrome Orewill be done before use to reduce the adhered impurities and
resultant slag generation. The water used for washing will be kept in closed circuit and will
be treated in ETP before reuse.

Page 23
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

B) For Noble Ferro Alloys

Maximum capacity of the individual Noble ferro alloys will be 1200 TPA or the product
mix will be 2400 TPA only. The raw material requirement at max capacity will be as
below:
Ferro Molybdenum -1200 TPA (Noble Ferro alloys)
Quantity Required
Material Source
TPA

Molybdic Oxide 1224.00 Imported

Imported (UAE) &

Aluminium Powder 86.4
Ahmadabad

Mill Scale 465.6 Local , Jamshedpur

Iron Nails 195.6 Local , Jamshedpur

Lime 492.00 Local , Jamshedpur

Ferro Silicon 489.6 Bhutan , North east

Total 2953.2

Ferro Vanadium - 1200 TPA (Noble Ferro alloys)

Quantity Required
Material Source
TPA
Vanadium Pentaoxide 1236.00 Russia

Mill Scale 12.00 Local , Jamshedpur

Lime 84.00 Local , Jamshedpur

Imported (UAE) &
Aluminium Powder 300.00
Ahmadabad
Imported (UAE) &
Aluminium Shots 600.00
Ahmadabad
M.S.Scrap 456.00 Local , Jamshedpur

Flourspar 24.00 Local Trader

Total 2712.00

Page 24
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.7 Safety Envisaged In the Project

Fire Protection Facilities: In order to combat any occurrence of fire in plant premises the
following tire protection facilities have been envisaged for the various units of the plant.
Portable Fire Extinguishers: All plant units, office buildings, stores, laboratories etc will be
provided with adequate number of portable fire extinguishers to be used as first aid fire
appliances. The distribution and selection of extinguishers will be done in accordance with
the requirement of IS: 2130-92.
Hydrant System: Internal hydrants will be provided at suitable locations and at different
levels inside the major plant units. Yard hydrants will be provided normally along the road
and in the close vicinity of the units to meet the additional requirement of water for existing
fire.

3.8 Availability of Water Its Source, Energy/Power Requirement And Source

3.8.1 Water Requirement

The total water requirement for the proposed project is estimated to be 17.5 m3/day.
Water requirement for the proposed plant will be met through water supply by Adityapur
Industrial Area development Authority (AIADA) or Drinking Water & Sanitation Department
(DW&SD) Govt. of Jharkhand.
Water Requirement
Unit Total make-up water (cum/day)

Washing & others 10.0

Water Scrubber 5.0

Domestic requirement & others 1.5

Dust suspension & greenbelt 1.0

TOTAL 17.5

3.8.2 Power Requirement

Total requirement of power for the unit is 133 KVA. The total power demand of the plant
will be met from Jamshedpur Utility and Supply Company (JUSCO).

Page 25
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.9 Quantity of Wastes to Be Generated (Liquid and Solid) and Scheme for Their
Management/Disposal

3.9.1 Air Environment – Mitigation Measures

Source of air pollution and control measures
Source of
Section Pollutants Air pollution control Measures
Pollution

Chrome Burning of Fume extractor followed bywet

PM & gases
preheating coal scrubber

Burning of
Manganese Ore Fume extractor followed by
Babool PM & gases
roasting cyclone and Bag Filters
charcoal

LC Ferro Alloys Reactor Fugitive Dust Fume extractor followed by

manufacturing furnace area & Fumes cyclone and Bag filter

Reactor vessel Fugitive Dust Fume extractor followed by

Noble Ferro Alloys
area & Fumes cyclone and Bag filter

Raw material Pulverizer for Dust and

handling & sizing grinding of particulate In-built Dust catcher and Bag filter
section raw material matter

Pucca roads within the premises,

Fugitive dust water sprinkling in dusty areas and
Over all Plant area Open space
emission green belt/plantation to arrest the
fugitive dust emission.
• The pollution control equipment will regularly be operated and maintained.
• Fugitive emission will be regularly monitored and suitable action like cleaning, water
sprinkling will be taken.

3.9.2 Waste water Generation and Management

No use of water in the manufacturing process. However water will be used for washing of
chrome ore and wet scrubber for pollution control. Water will be kept in closed circuit, but
on increase in impurities it will be treated in the designated Effluent treatment plant again
reused for washing, scrubbing and sprinkling. The storm water drains will be segregated and
channelized to water harvesting area.

Page 26
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

Waste Water Generation and Reuse

Waste
Waste water Waste water
Process Unit water qty Source
3 characteristics management
(m /day)
Treated in ETP with facility
Washing &
Ore Washing TSS, Oil, Cr, Fe & for chrome passivation
9.0 Scrubber
& APCD Grease etc. and recycled-reused in
plant
Domestic TSS, BOD, Oil & Will be routed through
Domestic 0.6 use Grease etc. septic tank & soak pit.

3.9.3 Solid Waste Generation and Management

Nature of Solid Waste Quantity Management

Slag 17 TPD Used for relining of reactor vessel & sold.

Recycle & reutilize in the manufacturing

Pluveriser Bag Filter Dust 0.5 TPD
process

Hazardous waste: There is no hazardous waste from the plant except for used oilwith
approx quantity of 200 Liters per annum ,during course of production of and is also saleable
to the registered recyclers in the market & ETP Sludge Produced will be approx 300 TPA and
will be sold to the refractory manufacturers.

3.9.4 Noise Levels

There is no major noise prone process except equipment for crushing, milling, separators,
compressors etc. The noise control will be done in three ways namely:
• By selecting low noise generating equipment, which would have below 75 dB(A) at 1m
distance. This is taken care at the equipment design stage.
• By isolating the noise unit from the working personnel’s continuous exposure by providing
acoustic aids for plant personnel.
• By administrative & safety measures, providing noise level monitoring, remedial
measures, providing noise safety appliances.

3.9.5 Green Belt Development

The Greenbelt & plantation will be developed in 0.105 ha of plant area so as to mitigate the
effects of emissions from the plant. The treated waste water from the plant will be utilized
for the greenbelt development. Roads for vehicular movement will be paved and adequate
mitigation measures will be provided to prevent fugitive emissions.

Page 27
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.9.6 Resource recovery – Mass Balance

Material Balance for Low Carbon Ferro Manganese per 1 Ton of Product
MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)
Low Carbon Ferro
Roasted Mn Ore 1.730 1.000
Manganese
Aluminium 0.515 Slag 1.503
M.S.Scrap 0.118 Off Gases 0.093
Fluorspar 0.115 Lime 0.118
Total 2.596 Total 2.596

Material Balance for Low Carbon Ferro Chrome per 1 Ton of Product
MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)
Low Carbon Ferro
Chrome Ore 1.800 1.000
Chrome
Aluminium 0.632 Slag 1.646
M.S.Scrap 0.118 Off Gases 0.137
Fluorspar 0.115 Lime 0.118
Total 2.783 Total 2.783

Material Balance for Ferro Molybdenum per 1 Ton of Product

MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)
Molybdic Oxide 1.020 Ferro Molybdenum 1.000
Aluminium Powder 0.072 Slag 0.600
Mill Scale 0.388 Off Gases 0.492
Iron Nails 0.163
Lime 0.041
Ferro Silicon 0.408
Total 2.092 2.092

Material Balance for Ferro Vanadium per 1 Ton of Product

MATERIAL QUANTITY (T) OUTPUT QUANTITY (T)
Vanadium
1.030 Ferro Vanadium 1.000
Pentaoxide
Aluminium Powder 0.250 Slag 0.900
M.S.Scrap 0.380 Off Gases 0.360
Fluorspar 0.020
Mill Scale 0.010
Aluminium shots 0.500
Lime 0.070
Total 2.260 Total 2.260

Page 28
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

3.9.7 Budget for Environmental Management

Amount in INR,
No. Particulars
Lakhs
One Time - Capital Cost
Installation of Air Pollution Control System
1 47.00
& ETP
2 Green Belt Development & RWH 2.50
Total 49.50

Recurring Cost
1 Environmental Monitoring 1.00
2 Running Cost of Pollution Control Equipments 3.80
3 Greenbelt & RWH Maintenance 1.20
Total 6.00

3.10 Schematic Representations of the Feasibility Drawing Which Give Information of EIA
Purpose.

Page 29
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER-04
SITE ANALYSIS

4.1 Connectivity
The site is within notified Industrial Area and has all the facilities for the proposed project.
Also it has good connectivity with the rail and road.
 Road Connectivity: The site for the proposed project is well connected to Tata-
Kandra Road at a distance of 0.65 km.
 Rail Connectivity: The nearest railway station is Gamharia Junction at 1.95 Km and
Adityapur railway station located at a distance of 4.0 km from the proposed project
site.
 Airport: Nearest airport to the project site is Sonari, Jamshedpur at a distance of
5.22 km NE and commercial airport Ranchi at a distance of 110 Km NW.
About 0.92acres / 0.37 Ha. of total land is in possession, with an existing unit of Hydrated
Lime – which will be dismantled on obtaining EC for the project

4.2 Land Form, Land Use and Land Ownership

Total land requirement for the proposed unit is about 0.37 ha which is already in
possession.
The present land use is industrial,also the land is located within notified industrial area.

Page 30
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

4.3 Topography
The topography of the land is generally flat and well suited for development of industrial
projects with an elevation of 261 m above MSL. The topographic of the buffer zone is
basically characterized by upland topography.
4.4 Existing Land Use Pattern
Total land requirement for the proposed unit is about 0.37 ha which is already in possession.
The present land use is industrial; also the land is located within notified industrial area.
with an existing unit of Hydrated Lime – which will be dismantled on obtaining EC for the
project. This area does not form part of any National Park, Wild Life Sanctuary and
Natural/Biosphere reserve.
4.5 Existing Infrastructure
Land
Total land requirement for the proposed unit is about 0.37 ha which is already in
possession. Land is located in notified industrial area.
Power
Total power requirement for the project is 133 KVA, which will be met from JUSCO is
available.
Water
The total water requirement for proposed plant is estimated to be 17.5 m3/day. Water will
be met from supply of AIADA or DW & SD, GoJ.
Transport
The plant site is well connected by industrial area road with Tata – Kandra Road at 0.5 Km
from the project site.
Communication
Communication facilities such as telephone, tele fax and internet are available in industrial
area near to the plant site.

Page 31
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 05
PLANNING BRIEF
5.1 Planning Concept
M/s Jamshedpur Chlorochem Pvt. Ltd. has proposed installation of a Low Carbon Ferro
Alloys –Based on Alumino-Exothermite process with production capacity of Ferro Chrome
and/or Ferro Manganese - 3600 TPA and noble ferro alloys – 2400 TPA at NS-88, 6th Phase,
Adityapur Industrial Area, Dist – Saraikela – Kharsawan, Jharkand. The plant will also be
equipped with the most efficient auxiliary sub- systems, material handling facilities and
pollution control equipment.

5.2 Employment &Population Projection

A well structured manpower is essential for uninterrupted operation and proper
maintenance of plant facilities. Employment will be generated during implementation of the
project. There will be permanent employment of 34 persons including Sr. Executives,
Managers, Administrators, Engineers, Supervisors and Skilled Technicians.
Manager 2

Supervisor 2

Skilled Labour 20

Semi Skilled 10

Direct Employment 34

Indirect Employment 20

5.3 Land Use Planning

Proposed approximate use of Land after installation:
SL Area Area
Type Of Use
No (acres) (ha)
1 Plant & Storage area 0.49 0.198

0.024
2 Administrative offices, security, etc. 0.06

3 Entrance, Roads and PCE Area 0.11 0.044

4 Green Belt & Open area 0.26 0 .105

TOTAL LAND 0.92 0.37

Page 32
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

5.4 Assessment of Infrastructure Demand (Physical & Social)

The existing infrastructure facility is adequate in the proposed project site. The social
infrastructure like school, college, temples and play ground already exist in this area. The
above infrastructure facilities need no further development for the project nor is any major
change in the infrastructure envisaged due to the project.

System Design for high Unit availability

The high availability of the Unit and associated auxiliaries objectives will be achieved by
adopting the following principles;
• 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 coal fired utility stations.
• 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 procedures as well as standard checklists forming a part of
commissioning documents for the project.
Sizing of critical equipment- margins & redundancy/standby
Adequate margins will be provided while sizing all important auxiliaries and sub-systems to
ensure operation of the Unit at full rated capacity under the worst conditions and taking
into consideration normal wear & tear.

Design for efficient operation

Centralized maintenance system will be followed. All repairs of capital nature, heavy
maintenance jobs, refractory maintenance and plant civil maintenance will be done by
engaging specialized external agencies.

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M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 06
PROPOSED INFRASTRUCTURE

6.1 Processing Area – industrial use

The processing area will comprise of various plant facilities within the premises they are –
Raw material handling & processing area, reactor area, & product handling area. Thus total
area of 0.198 ha will be developed as processing area.

6.2 Residential Area (Non-Processing Area)

There is no proposal of any residential colony as the required manpower will be sourced
from local populace. Few highly skilled posts may be filled from outsiders for whom houses
will be leased in nearby residential area. Non-processing area will comprise of facilities
within the premises such as –administrative block, road & pollution control equipment area
etc. over an area 0.068 ha Other social infrastructure like housing, schooling and medical
facilities areaalready developed in nearby area, hence, no residential colony/township is
envisaged for employees.

6.3 Green Belt

A greenbelt development plan will be prepared and implemented along with the
implementation of project. Total green belt & plantation area shall be 0.105 ha. The main
objective of the greenbelt is to provide a barrier between the plant and the surrounding
areas.
The species selection will depend upon type of soil and local species with good survival rate
will be selected.

6.4 Socio-Economic Benefits &Social Infrastructure

This is an existing notified industrial area with adequate facilities. The existing infrastructure
facility is adequate in the proposed project site. The social infrastructure like school, college,
temples and play ground already exist in this area. The above infrastructure facilities need
no further development for the project nor is any major change in the infrastructure
envisaged due to the project. Only direct and indirect employment generation is envisaged.

Page 34
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 07
REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1 Policy to Be Adopted for R & R Plan With Respect To Project-NotRequired

This is an existing notified industrial area and the land has been allotted by the Adityapur
Industrial Area Development Authority (AIADA) and already in industrial use. There is no
displacement of any houses, habitation or livestock. Thus the project does not require any R
& R plan.

Page 35
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 08
PROJECT SCHEDULE & COST ESTIMATES

8.1 Project Schedule

In this industry, any one of the following three alternate modes of project execution will be
adopted:
• Turnkey
• Semi Turnkey
• Packaged procurement mode

Statutory Clearances
The proposed project will require various statutory approvals and clearances from various
authorities of the Government. Clearances required for the proposed project are identified
and necessary action initiated to obtain the same.

Project Schedule
It is envisaged that total project will be completed within a period of 6 months from `Go-
ahead'. Land acquisition on lease is completed. The external agencies such as consultant,
machinery suppliers, contractors of civil construction and equipment will be selected
carefully well in advance. An effective project team has been formulated with Director as its
leader.

8.2 Project Cost

An indicative estimated capital cost of the proposed Plant is Rs. 96.20 Lakhs as below:

Particulars Amount (in Rs. Lakhs)

Land - 40000 sq.ft Existing
Building& Shed - 18500 sq.ft. Existing
Plant & Machinery 35.60
Laboratory Equipment 4.60
Pollution Control Equipment 49.50
Office Equipment 2.00
Furniture & Fixture 4.50
Total 96.20

Page 36
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

CHAPTER – 09
ANALYSIS OF PROPOSAL

PROMOTERS M/s Jamshedpur Chlorochem Private Limited

Project Low Carbon Ferro Alloys – Ferro Chrome & Ferro Manganese

NS-88, 6th Phase, Adityapur Industrial Area, Dist – Saraikela –

Plant location
Kharsawan, Jharkand

Markets Local & export

LC Ferro Chrome / LC Ferro Manganese – 3600 TPA

Plant capacity Ferro Molybdenum – 1200 TPA
Ferro Vanadium – 1200 TPA

Water requirement For process, domestic & others – 17.5 m3/day

Water sources Supply from AIADA or DW & SD, GoJ

Basis for assessment Per tons of finished products

Max. power demand 133 KVA from JUSCO

Main units Washing of Ore, Sizing & Mixing, Reactor

Main storages For raw materials and products – space available

Manpower 34 Nos.

Implementation period 06 months

Proposed Investment Rs. 96.20lakhs

Conclusion
Based on the performance indicators, the project is technically & financially viable, Under
both normal and contingent conditions.

Page 37
M/s JAMSHEDPUR CHLOROCHEM PVT.LTD.
At-Plot No. NS-88, 6th Phase, Adityapur Industrial Area, Saraikela-Kharsawan, Jharkhand
PFR- Proposed Low Carbon Ferro Alloys (Ferro Chrome and/or Ferro Manganese - 3600 TPA) and Noble
Ferro Alloys (Ferro Molybdenum - 1200 TPA & Ferro Vanadium - 1200 TPA)

ANNEXURE - I
DETAILS OF PLANT AND MACHINERY TO BE DISMANTLED
HYDRATED LIME PLANT

Sl.
No. Name of the Machinery Capacity

1 PULVERISER (32" CHAMBER SIZE) 2 M.T./P. Hrs

2 ROTTERY VALVE & FLOTER VALVE 5 NOS. 2 M.T./P. Hrs
3 PULVERISER (36" CHAMBER SIZE) 2.5 M.T./P. Hrs
4 HAMMER MILL (36" SIZE) 2 M.T./P. Hrs
5 HAMMER MILL (32" SIZE) 2 M.T./P. Hrs
6 BUCKET ELEVATOR 4 NOS. 2 M.T./P. Hrs
7 HYDRATOR WITH CHIMNEY 2 M.T./P. Hrs
8 SCREW CONVEYOR 3 NOS. 2 M.T./P. Hrs
9 AIR CLASSIFIER 2 M.T./P. Hrs
10 BLENDER WITH CHIMNEY 2.5 M.T./P. Hrs
11 SILO WITH CHIMNEY 12 M.T./P. Hrs
12 HOPPER 1 M.T./P. Hrs
13 BRICK KLIN 10'*20' 1 no.
14 ROASTER 2 NOS. 8'*8' 2 nos.
BASE, STAIR CASE, PLATFORM, PAINTING, FREIGHT &
15 CONSUMABLES For All Plant
16 POLLUTION CONTROL EQUIPMENT (BAG FILTERS-3 NOS.) 42 Bags Filters
17 WATER TANK 8000 Ltrs.
Welding
18 TOOLS & EQUIPMENT Machine

Page 38