PRE-FEASIBILITY REPORT

Transcription

1 /R3 PRE-FEASIBILITY REPORT FOR EXPANSION OF STEEL MANUFACTURING UNIT BY REPLACING EXISTING INDUCTION FURNACE CAPACITY Steel Billets/ Ingots- 28,800 TPA to 75,240 TPA By M/S TRISHALA ALLOYS PVT. LTD. VILLAGE- JANDIALI, BUDHEWAL ROAD, NEAR KOHARA, LUDHIANA, PUNJAB. ENVIRONMENTAL CONSULTANT Chandigarh Pollution Testing Laboratory - E I A Division (QCI/ NABET accredited) E-126, Phase- VII, Industrial Area, Mohali, Punjab Website: eia@cptl.co.in

2 INDEX 1.0 EXECUTIVE SUMMARY INTRODUCTION OF PROJECT & PROPONENT 5-6 Introduction 5 Partner background 5 Brief Description 5 Need of the project 6 Employment Generation PROJECT DESCRIPTION 7-16 Category of project 7 Location of Project 8 Alternate site selection 12 Size & magnitude of operation 12 Manufacturing Process details 12 Raw material & product details 14 Resources optimization 14 Sources of water 15 Quantity of waste generation SITE ANALYSIS DESCRIPTION OF THE ENVIRONMENT ENVIRONMENT IMPACT & MANAGEMENT PLAN PROPOSED INFRASTRUCTURE REHABILITATION AND RESETTLEMENT (R&R) PLAN PROJECT SCHEDULE & COST ESTIMATES ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) CSR ACTIVITIES 27 1

3 LIST OF FIGURES 1.0 Location of Project Location map goggle General Location Plan Layout plan Process Flow chart 13 LIST OF TABLES 1.1 Détails of area Project détails Project co-ordinates Raw material & Product Primary data Description 19 2

4 1.0 EXECUTIVE SUMMARY PRE-FEASIBILITY REPORT PRE-FEASIBILITY REPORT M/s TRISHALA ALLOYS PVT. LTD. Village Jandiali, Budhewal Road, Near Kohara, Ludhiana, Punjab. Location Co-ordinates: Latitude : 30 52'54.77"N, 30 52'56.22"N 30 52'51.38"N, 30 52'51.33"N Longitude: 75 59'25.81"E, 75 59'33.02"E 75 59'32.77"E, 75 59'25.48"E Elevation : 253 m Total project cost: - Rs 8.20 Crores (after addition of proposed machinery) - The location of the project site is given in Figure 1.0 on map of India and other area details are given in Table 1.1 1

5 Figure 1.0 Location of the Project Site PRE-FEASIBILITY REPORT LOCATION OF PUNJAB SATE AT POLITICALL MAP OF INDIA LOCATION OF DISTRICT LUDHIANA ON PUNJAB MAP LOCATION OF PROJECT SITE ON DISTRICT MAP M/S TRISHALA ALLOYS PVT. LTD...., LUDHIANA 2

6 TABLE 1.1 DETAILS OF THE AREA S. No. Particulars Details A. Location details 1. Location a Village/ Town/Plot No. b Tehsil c District d State Jandiali Ludhiana Ludhiana Punjab PRE-FEASIBILITY REPORT e Latitude 30 52'54.77"N,30 52'56.22"N 30 52'51.38"N, 30 52'51.33"N f Longitude 75 59'25.81"E,75 59'33.02"E 75 59'32.77"E, 75 59'25.48"E 2. Topo sheet No Project Area Total Area 3 Acre C. Production Capacity Existing: Steel Billets-28,800 TPA After Expansion: Steel Billets/ Ingots - 75,240 TPA D. Environmental settings 1. Nearest Village Jandiali 2. Nearest City Kohara, approx. 2.4 km in NE direction from the project site 3. National Highway/State Highway/ Express Highway NH-95 Kharar-Ludhiana is approx 1.51 km in South direction from the project site. 4. Nearest Railway Station Dhandari Kalan, approx. 8 km in SW direction from the project site 5. Nearest Airport Chandigarh Airport approx. 90 km in SW direction from the project site. 6. National Parks/ Wild Life Sanctuaries/ Nil Biosphere Reserves within 10 km radius 7. Reserved / Protected Forest within 10 km radius (Boundary to boundary distance) 8. Nearest water bodies Nilon Canal at about 12 Km 9. Source of Water Ground water Existing tube-well 10. Seismic Zone Seismic Zone IV No Reserved Forests exists within 10 km radius. 3

7 D. COST DETAILS PRE-FEASIBILITY REPORT 1. Capital Cost of the project Existing -Rs 1.20 Cr Proposed -Rs 7.0 Cr Total -Rs 8.20Cr 2. Total cost for Environmental Management Rs 70.0 Lacs Plan (EMP) 4

8 2.0 INTRODUCTION OF THE PROJECT AND PROPONENT M/s Trishala Alloys Pvt. Ltd. is already manufacturing Steel Billets at Village- Jandiali, Budhewal Road, Near Kohara, Ludhiana, and Punjab. They now want to enhance the capacity of their unit by replacing the existing 2 furnaces of capacity 4 TPH & 3.5 TPH with two no s of Induction furnaces of capacity 12 TPH & 7 TPH. The total project cost of the unit after expansion will be Rs 8.20 Crores. The projects have already 3 acres of land. No additional land is required for expansion. The capacity of the unit after expansion will be 75,240 TPA Steel Billets/ Ingots. As per G.O.I Notification dated 14/09/2006 any change in product/expansion requires Environmental Clearance. Accordingly they have to submit Form No- I along with Pre- Feasibility Report and other relevant documents for getting Environmental Clearance. Further, the project site falls within the Category A because unit falls within critically polluted area of Ludhiana, Punjab and thus the environmental clearance will be given by the MOEF & CC Delhi. This Prefeasibility report has, therefore, been prepared to assess the likely impact of the proposed expansion on various factors which may be affected with the implementation of the programme and to suggest remedial / precautionary measures, if any. I. Partner s Background: M/s Trishala Alloys Pvt. Ltd. is a Private Limited Company. The Directors of the company are as under: 1. Mr. Raj Kumar Jain 2. Mr. Sandeep Jain 3. Mr. Sanjay Jain II. Brief description of nature of the project. In view of the tremendous market potential of Iron & steel, promoters have decided to expand the capacity of the existing Steel Plant by replacing the existing 2 furnaces of capacity 4 TPH & 3.5 TPH with two no s of Induction furnaces of capacity 12 TPH & 7 TPH each. Addition 5

9 in the existing plant would improve the overall profitability of the project making it financially more viable. The production details of unit existing & proposed are as under: III. Product Name Existing Additional Total (TPA) (TPA) (TPA) Steel Billets/ Ingots: 28,800 46,440 75,240 Need for the project and its importance to the country and or region. India was the world s third-largest steel producer in The growth in the Indian steel sector has been driven by domestic availability of raw materials such as iron ore and cost-effective labour. Consequently, the steel sector has been a major contributor to India s manufacturing output. India s crude steel output grew 10.7 per cent year-on-year to million tonnes (MT) during January- March India s crude steel output during April 2017 grew by 5.4 per cent year-on-year to MT. India s finished steel exports rose per cent to 8.24 MT, while imports fell by 36.6 per cent to 7.42 MT in India s steel exports rose 142 per cent in April 2017 to 747,000 tonnes over April 2016, while imports fell by 23 per cent to 504,000 tonnes in April 2017 over April Total consumption of finished steel grew by 3.4 per cent year-on-year at MT during April 2017 (Source: Indian Brand Equity Foundation). M/s Trsihala Alloys Pvt. Ltd. has always believed in giving back something to society and has contributed significantly in developing nearby areas by building infrastructure, schools, medical facilities among its workers, creating jobs etc. The Industry will continue to serve as stimulus to national development and an economy booster to industrial development of the country. They have always been committed to bringing around a major change in the society through its quality products and by implementing global best practices, adopting efficient technologies, developing R&D and promoting CSR activities IV. Employment Generation (Direct and Indirect) due to the project. Direct employment: - for expansion additional 150 Persons will be required. Total Number of manpower after expansion will be 250 No s. 6

10 3.0 PROJECT DESCRIPTION: PRE-FEASIBILITY REPORT I. Category & type of project including interlinked and interdependent projects, if any. The project falls in Category B under schedule 3(a) Non toxic Secondary Metallurgical processing industry with capacity > 30,000 TPA in EIA Notification, Further, the project site falls within Critically Polluted Area of Ludhiana (Punjab), as such the project is to be treated as Category A and thus the environmental clearance will be given by the EAC Industry-I, Ministry of Environment Forest and Climate Change, GOI, New Delhi. Details of project is given in Table-3.1 S. TABLE-3.1 No. PARTICULARS EXISTING PROPOSED TOTAL A B EXISTING & PROPOSED CAPACITY OF FURNACES & ROLLING MILLS Induction Furnace 4 TPH & 3.5 TPH (To be Replaced) 2 no s of Induction Furnaces with capacity 12 TPH & 7 TPH PRODUCTS Steel Ingot/Billets (TPA) 28,800 46,440 75,240 C 1 2 D RAW MATERIAL MS Scrap (TPA) 31,329 50,567 81,896 Ferro-alloys(TPA) 639 1, GENERALS Project Cost (Crores) Land (Acres) 3.0 NIL 3.0 Power (KVA) Manpower (nos) Working days 24 hrs 300 working 24 hrs 330 working 24 hrs 330 working days in year days in year days in year 7

11 II. Location (map showing general location- Figure-3.1, specific location- Figure-3.2, and project boundary & project site layout- Figure-3.3) with coordinates. LOCATION: The proposed project site is located at Village Jandiali, Budhewal Road, Near Kohara, Distt. Ludhiana (Punjab). The coordinate of project site is given in Table 3.2. The general location plan of project is given Figure-3.1 & on goggle 3.2. The layout plan of the project showing different activity is given in Figure 3.3. LATITUDE LONGITUDE Table '54.77"N,30 52'56.22"N 30 52'51.38"N, 30 52'51.33"N 75 59'25.81"E,75 59'33.02"E 75 59'32.77"E, 75 59'25.48"E 8

12 Figure-3.1 Google Location map 9

13 Figure-3.2 Location map General KOHARA BUDHEWAL ROAD JANDIALI PROJECT SITE NH-95 LUDHIANA Location plan - NTS 10

14 PRE PRE-FEASIBILITY REPORT Figure-3.3 Layout Plan 11 CP

15 III. Alternate sites considered and the basis of selecting the proposed site, particularly the environmental considerations gone into should be highlighted. Addition will be done within existing premises. So, consideration of alternate site is not applicable. IV. Size or magnitude of operation. Existing plant is having 2 No s of Induction furnaces of capacity 4 TPH & 3.5 TPH. It is proposed to enhance the capacity of plant by replacing existing 2 No s of furnace with two no. of new furnaces having capacity 12 TPH & 7TPH. After expansion the production details will be as under: Product Name Existing Additional Total (TPA) (TPA) (TPA) -Steel Billets/ Ingots 28,800 46,440 75,240 V. Manufacturing Process details (a schematic diagram flow chart showing the project layout, components of the project etc. should be given) A coreless induction furnace operates on a similar principle to a transformer, i.e., the induction coil acts as primary coil, having many turns, and the charge acts as a secondary coil, with only as single turn. When an alternating current is applied to the induction (primary) coil of a furnace, a significantly larger current is induced in the metallic charge materials. The resistance to the passage of induced current within the furnace charge causes the charge to heat up until it eventually melts. Once the metal is molten, the magnetic field generated creates a stirring action in the bath, producing both homogenization of the chemical composition and assimilation of any bath additions. Electrical energy at 11 kv (3-phase) is converted to 1250 V, through a transformer. It is further subjected to a 3-phase rectifier and inverter system which converts the power to single phase, high voltage-high frequency. The frequency converter amplifies the frequency from 50 Hz to 500 Hz. This power is applied to furnace coil to generate heat. The process flow chart of manufacturing process is given Figure

16 FIGURE-3.4 FLOW CHART OF MANUFACTURING PROCESS RAW MATERIAL 253 TPD BURNING LOSSES (11.8 TPD) MELTING & REFINING PROCESS (253 TPD) SLAG (12.97 TPD) APCD DUST (0.03 TPD) CONCAST MACHINE /CAST MOLD INGOTS/BILLET (228 TPD) FINAL PRODUCT 13

17 VI. Raw material required along with estimated quantity, likely source, marketing area of final products, Mode of transport of raw Material and Finished Product. The details of product quantity and source of raw material required are given in the Table 3.3. TABLE-3.3 PRODUCTS EXISTING ADDITION TOTAL 1 Steel Billets/ Ingots 28,800 46,440 75,240 (TPA) RAW MATERIAL MS Scrap (TPA) 31,329 50,567 81,896 Ferro-alloys(TPA) 639 1, Source & Transport Local & International Markets & transport through covered Trucks. VII. Resource optimization/ recycling and reuse envisaged in the project, if any, should be briefly outlined. Water: As this project is based on Zero Discharge, 100 % recycling of water will be done in the process. Solid/ Hazardous waste: The existing quantity of slag is 3TPD and is being used for filling of low lying area. Total quantity of slag after expansion will be TPD and will be used in filling of Low lying area and in Road Making. Hazardous waste generated (0.03kl/annum) from DG sets in the form of used oil is being reused as lubricants within the industry and dust (3.1 ton/annum) recovered by bag filter is also covered under hazardous waste & sent to TSDF site for final disposal. 14

18 VIII. Availability of water its source, Energy/power requirement and source should be given. Water requirement met through existing tube well. The detail of water requirement existing & after expansion is given below:- DESCRIPTION EXISTING PROPOSED TOTAL Domestic 4.5 KLD 7.5 KLD 12.0 KLD Cooling (makeup water) 10.5 KLD 12.5 KLD 23.0 KLD Total 15.0KLD 20.0 KLD 35.0 KLD Power requirement of existing & proposed along with source is given below:- DESCRIPTION EXISTING PROPOSED TOTAL Power Requirement 4800 KVA 4800 KVA 9600 KVA Source Punjab State Power Corporation Limited, Punjab IX. Quantity of wastes to be generated (liquid and solid) and scheme for their Management/ disposal. Liquid effluents- Proposed project is based on ZERO discharge. There are no generation trade effluents from process. The waste water generated from domestic & cooling tower is being treated through septic tank and use for plantation within premises. Solid Waste - Slag is being used in filling of Low lying area and in road making. Used oil from DG sets is used as lubricants & dust from APCD sent to TSDF site for final disposal. Flue Gas Management There are no combustion related polluted gaseous emissions as no fuel is being used in the process. The air pollution will be the result of the heating and melting process in the induction furnace. The gaseous emissions coming out of the mouth of the furnace crucible need treatment before discharging it into the atmosphere. The gaseous emissions will comprise of vapors /fumes, suspended particles, and some gases. The vapors are, primarily, of metals (iron) and metal oxides (in very low quantities). Dust and 15

19 metal particles also contribute to the suspended particulates. Gaseous pollutants are, mainly, carbon di-oxide, carbon mono-oxide, and nitrogen oxides, though in very low amounts. The suspended particulate matter (SPM) concentration will be about mg/nm 3. Most of the particulates (about 75%) are expected to have size in the range of 1-5 microns. The emissions (after dilution) will have temperature of <150 C. As per the applicable statutory norms, the SPM level in the gas emission, at discharge point, shall not exceed 150 mg/nm 3. Additionally, the stack height requirements for discharge of process emissions are also to be complied with. Also, ambient air quality within the premises should not have particulate matter concentration exceeding 100µg/m 3 on 24 hour basis, and 60µg/m 3 averaged on annual basis. 16

20 4.0 SITE ANALYSIS I. Connectivity: NH-95 Kharar to Ludhiana is well connected with the project.(1.5km) Dhandari Kalan Railway Station (8.0 Km) The regional road network comprises of Kharar-Ludhiana G.T. Road (NH-95) and forms the major spine. In fact the entire road network gravitates along this major spine. The project exists in Village- Jandiali, Budhewal Road, Near Kohara, Ludhiana. II. Land Form, Land use and Land ownership: Industrial Land is registered in name of M/s Trishala Alloys Pvt Ltd. The land is already use for industrial purposes. III. Existing land use pattern (agriculture, non-agriculture, forest, water bodies (including area under CRZ), shortest distances from the periphery of the project to periphery of sanctuary, eco from the HFL industrial area, be given. It is situated in Village- Budhewal, Budhewal Road, Near Kohara, and Ludhiana. There is no sanctuary, river present within 10 km radius of the project. IV. Existing Infrastructure: The infrastructure amenities available in the area denote the economic wellbeing of the region. The project area is connected with local road and NH-95. Educational facilities up to Senior School, College, Hospital & Banking facilities are available at Kohara City about 2.4 km away from the project site. The existing building comprise of Induction Furnaces, Workshop shed & Competitive administrative block along with office quarters. V. Soil classification: The texture of soil is sandy loam. VI. Social Infrastructure available. Social infrastructure constitutes various facilities pertaining to education, health, recreational, cultural and other public amenities/ facilities available in urban areas at various levels whose availability and accessibility determines the quality of life of an urban centre. 17

21 5.0 DESCRIPTION OF THE ENVIRONMENT INTRODUCTION: The main objectives of describing the environment, which may be potentially affected, are (i) to assess present environmental quality and the environmental impacts and (ii) to identify environmentally significant factors that could preclude project development. This chapter contains information on existing environmental scenario for the following parameters. 1. Land Environment 2. Meteorology 3. Air Environment 4. Noise Environment 5. Water Environment 6. Soil Environment 7. Biological Environment 8. Socio-economic Environment ENVIRONMENTAL BASELINE DATA COLLECTION: Baseline data for the proposed plant will collected immediately after monsoon season. Primary data will be collected by monitoring & surveying of various environmental components/ parameters in the core zone during the study period, details of which are given in Table

22 TABLE-5.1 PRIMARY DATA S. PARAMETERS DESCRIPTION NO. 1 Meteorology Meteorological parameters on hourly basis at project site. Parameters: Temperature, Relative humidity, Wind Speed & Wind Direction. 2 Air Ambient air quality monitoring (24 hourly), twice a week. Parameters are PM 10, PM 2.5, SO 2, NO 2 & CO. No. of Locations: 8 locations in core and buffer zone. 3 Noise Noise level monitoring (Day & Night time), once in a season. No. of Locations: 8 locations in core and buffer zone. 4 Water Ground water sampling, once in a season. No. of Locations: 8 locations in core and buffer zone. Tested for physical and chemical parameters. 5 Soil Soil sampling, once in a season. No. of Locations: 6 locations in core and buffer zone. 6 Biological Factors Biodiversity survey, once in a season. Location: Core and buffer zone. 7 Socio-economic Environment Socio-economic survey, once in a season. Location: Core and buffer zone. 19

23 6.0 ENVIRONMENTAL IMPACT AND MANAGEMENT PLAN PARTICULARS DETAILS Impact on Air Construction/ Operational Phase Air Quality Management: Emissions Management Air emissions both gaseous and fugitive from proposed plant will be on account of process emissions from stacks of existing Induction furnace & proposed Furnace as well as DG. Sets. The mitigation measure adopted as under: The main raw material and product will be brought in and dispatched by road in covered enclosures. All the vehicle owners will have valid PUC Certificate All vehicles are loaded up-to prescribed limit during transportation. Dust suppression on haul roads will be done at regular intervals. Proper pollution control equipments like cyclone/bag filter will be provided. APCD solid waste after expansion will also be sent to TSDF site for final Disposal. A stack of adequate height equipped with Bag filter will be installed with the Induction furnace to control the particulate and gaseous emissions due to combustion of fuel. All the roads are asphalted to control the fugitive dust emissions Proper servicing & maintenance of vehicles is/will be carried out. Green Belt around the periphery and within premises will 20

24 Monitoring Management Impact on water Construction/ Operational phase Water Management be provided. Ambient air quality and stack emission will be regularly monitored to ensure that ambient air quality standards and suggested limits on stack emission loads would be met honestly at all the time. Water requirement of the plant will be meeting from existing tube well. Roof top rain water will be recharged to compensate ground water. Impact on Noise Construction/ Operational Phase Fresh water requirement of the project will be met by existing tube well. Domestic waste water generated from the plant will be treated in Septic Tank and treated water will be used in green belt development. The cooling water will be re-circulated and cooling blow down will be dispose off through septic tank. The expected noise levels of some of the proposed equipment like Pumps (82-95 db (A), Induction furnace ( db (A), DG sets ( db (A). The above noise levels worked out are without mitigation measures. With the mitigation measures the noise levels will be further restricted within very short distance from the source point. The operators/personnel working near the noise sources in the Plant will be provided with earmuffs and earplugs Green belt will be developed around the plant premises which 21

25 Noise Management will act as noise abatement measures. There will be no danger of noise pollution from plant. The green belt (plantation of dense trees across the boundary) helps in reducing noise levels in steel plant as a result of attenuation of noise generated due to plant operations and transportation. Earmuffs will be used while running the equipments of the plant. D.G sets will be provided with acoustic to control the noise level within the prescribed limit. A high standard of maintenance will be practiced for plant machinery and equipments, which helps to avert potential noise problems. Personal Protective Equipment like earplugs and earmuffs will be provided to the workers exposed to high noise level. Regular monitoring of noise level will be carried out. Solid Waste Management Management APCD dust is being sent to TSDF site and slag from process is sent to low lying area for final disposal. Green belt Management Management Green belt development in and around the plant site helps to attenuate the pollution level. Out of the total plant area approx. 5% land is already developed as green belt and it will be maintained in future also. After expansion about 30% of total project area will be developed as green belt. 22

26 Green belt has been developed as per Central Pollution Control Board (CPCB) guidelines. Native species have been planted in consultation with the local DFO. 23

27 7.0 PROPOSED INFRASTRUCTURE I. Industrial Area (Processing Area):- The site already having administrative and site control office with latest equipment like computers, walkie-talkie & computerized weighbridge, printers, fax, Xerox machine, etc. Sufficient power load exists to meet the current requirement. Water for construction and domestic purpose as well industrial purposes will be drawn from bore-well. II. Residential Area (Non Processing Area):- Labour hut / rest room, toilet, drinking water facility is already provided. III. Green Belt. The main objective of the green belt is to provide a barrier between the plant and surroundings areas. Green belt will be developed according to CPCB guidelines. IV. Social Infrastructure. There is sufficient number of educational facilities but health facilities are not up to the mark. The sports and recreational facilities are also not adequate as there is no national or state level sports complex; however an indoor / outdoor stadium of lower hierarchy is available within the town. V. Connectivity (Traffic and Rail/Metro/Water ways etc) The regional road network comprises of Kharar-Ludhiana G.T. Road (NH-95) and forms the major spine. In fact the entire road network gravitates along this major spine. 24

28 8.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN:- R & R Plan is not applicable, as it is an expansion of existing plant. 9.0 PROJECT SCHEDULE & COST ESTIMATES:- I. Likely date of start of construction and likely date of completion (Time schedule for the project to be given):- Within one year after Environmental Clearance. II. Estimated project cost along with analysis in terms of economic viability of the project:- Total proposed project cost is estimated to be around Rs Crores III. Cost toward Environment Protection: lacks 25

29 10.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) I. Financial and social benefits with special emphasis on the benefit to the local people including tribal population, if any, in the area. Financial Benefits: Benefits and advantages of expansion of existing plant: a) It will fulfill the Demand Supply Gap. b) It will improve the life style of local people by providing them jobs. Social Benefits: Greater employment for local populations Environmental benefits: a) Low emission of air pollutant (proper APCD will be installed). b) It is a Brown field project. c) Proposed project is based on ZERO discharge. Other Benefits: Revenues to the State and Central ex-chequers. Over all development of District- Ludhiana in particular and Punjab State in general. 26

30 11.0 CSR ACTIVITIES Proposed expansion will result in growth of the surrounding areas by increased direct and indirect employment opportunities in the region including ancillary development and supporting infrastructure. Special emphasis on Financial and Social benefits will be given to the local people including tribal population, if any, in the area. Development of social amenities will be in the form of medical facilities, education to underprivileged and creation of self help groups. The company will also undertake more social activities as Social Corporate Activity after expansion. These activities are as under: Sr. No. NAME OF VILLAGE ACTIVITY PROPOSED 1 Jandiali Tree Plantation, Environment awareness camp, COST (Lacs) Rs. 2.0 Construction of one classroom in the Middle School of village and its upkeep Rs. 2.0 No adverse effect on environment is envisaged as proper mitigation measures will be taken up for the same. 27