MODERNIZATION CUM EXPANSION OF INDUCTION FURNACE PRODUCTION(2,05,000 TPA TO 6,00,000 TPA) AND ROLLING MILL PRODUCTION (3, 69,000 TPA TO 6,00,000 TPA) at Sy. No. 158 (part) 159 (part), 166 170, village Chetlagoraram Mandal Toopran, District Medak, Telangana. Project Proponent: M/S. Agarwal Foundries Pvt. Ltd., Sy. No. 158 (part) 159 (part), 166 170, village Chetlagoraram, Mandal Toopran, District Medak, Telangana. Environment Consultant: Sri Sai Manasa Nature Tech Pvt. Ltd., QCI/NABET Accredited Vide S. No. 140, (Dated 05.06.2016 displayed on NABET website ) Plot No. 74/A, Flat No 102, Central Bank Building Kalyan Nagar, Hyderabad 500038 E mail: ssmntpl@gmail.com, web: www.ssmntech.com Contact no. 040 2316333, Fax No.: 040 23816222 June 2018
1.1 Introduction India is the third-largest crude steel producer in the world. In FY18, India produced 104.98 million tonnes (MT) of finished steel. Crude Steel production during 2017-18 stood at 102.34 MT. Steel consumption is expected to grow 5.7 per cent year-on-year to 92.1 MT in 2018. India s steel production is expected to increase from 102.34 MT in FY18 to 128.6 MT by 2021. The Government of India has allowed 100 per cent foreign direct investment (FDI) in the steel sector under the automatic route. Nearly 301 MoUs have been signed with various states for planned capacity of about 486.7 MT. India s per capita consumption of steel grew at a CAGR of 4.75 per cent from 45 kgs in FY09 to 65.25 kgs in FY17. The figure stood at 68 kgs during April-February 2017-18. National Steel Policy 2017 seeks to increase per capita steel consumption to the level of 160 kgs. M/s. Agarawal Foundries (P) Ltd. has a steel Plant located at Sy. No. 158 (part) 159 (part), 166-170, village- Chetlagoraram, Mandal- Toopran, District- Medak, Telangana. The company has obtained Environmental Clearance for the existing units vide order No. SEIAA/TS/MDK-05/2015 dated 06.02.2016 for Induction Furnace with production capacity 205000 TPA and rolling mill Production 369000 TPA at located at at Sy. No. 158 (part) 159 (part), 166-170, village- Chetlagoraram, Mandal- Toopran, District- Medak, Telangana. Now, company is proposing to remove the existing old furnaces with 6 x 30 TPH Induction furnaces. After expansion total induction furnace production capacity will be 600000 TPA and rolling mill production capacity will be 600000 TPA. The company already acquired 32.0 acres of land and proposed expansion will be done within existing plat premises. The salient features of the project are given Table 1. Table 1-Salient Features of the Project Project Name Total Area M/s. Agarwal Foundries (P) Ltd. 32 Acres Sy. No. 158 (part) 159 (part), 166-170, village- Location of Project Chetlagoraram, Mandal- Toopran, District- Medak, Telangana 1
Existing Production Capacity Induction furnace - 2,05,000 TPA Rolling Mill 3,69,000 TPA Proposed Production Capacity Production Capacity Induction furnace - 2,05,000 TPA Rolling Mill 3,69,000 TPA Total Capacity after Expansion Induction furnace - 6,00,000 TPA Rolling Mill 6,00,000 TPA Raw Material Sponge Iron (60%), Pig iron (15 %) and Scrap (25%) Source Ground water Total Water Quantity 395 KLD Water demand Existing 125 KLD Proposed 270 KLD Sources of water Man power Electricity Consumption Nearest railway station Nearest airport Proposed Expansion Project Cost Ground water Existing 250 Nos. Proposed- 100 Nos. Existing 25000 kva Proposed 31500 kva Source: Telangana State Electricity Board Tupran Railway Station 9.0Km, NNW Hyderabad Airport 58Km, S Rs. 40 Crores 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 2.1 Identification of Project and Project Proponent MS Agarwal Foundries Pvt. Ltd., established in 2005, is a leading steel company manufacturing Sponge Iron, MS Billets, Structural Steel and TMT Steel Bars. We are ISO 9001:2008 certified company and the products what we are manufacturing are also BIS registered. With a progressive vision and focus on customer s interests, the company expanded its business operations in retail sector by adding MS Life Brand with Fe 500 & Fe 550 grades. 2
The Manufacturing Process using raw materials, right from Iron ore, coal and dolomite in our DRI unit to the final product, Steel rebars are in-house manufactured in our integrated steel plant, gives us that Extra edge required to serve all our clients with the best quality product at extremely competitive prices. Empowered with the most qualified and experienced personnel, M/S. Agarwal Foundries Pvt. Ltd comes up with the best possible deal for our customers and deliver products that meet their categorical requirements without compromising on quality. Coupled with prompt service back up, our products and services have earned M/S Agarwal Foundries Pvt. Ltd, a reputation of being a reliable and favored company in the construction field arena. 2.2 Brief Information about the Project The company is proposing to expand the induction furnace and rolling mill production at Sy. No. 158 (part) 159 (part), 166-170, village- Chetlagoraram, Mandal- Toopran, District- Medak, Telangana. 2.3 Need for the Project and Its Importance to the Country or Region The demands of steel are increasing day by day in India due to rapid Industrialization, Booming in construction sector and other infrastructure project. Considering the said scenario, M/s. Agarwal foundries Pvt. Ltd. is proposing to increase in Exesting steel plant capacity. 2.4 Employment Generation This plant will keep the skilled manpower hence the local village people are exposed to the skilled jobs and get feeding to their livelihood. The estimated manpower requirement for expansion is 100. Employment will be provided for the surrounding village s people those who are educated also. The status of socio economic will improve in these rural areas. 3.0 PROJECT DESCRIPTION 3.1 Type of Project Including Interlinked and Interdependent Projects, If Any. No interlinked projects were associated with this project. 3.2 Location M/s Oswal Smelters (P) Ltd. is located at Sy. No. 158 (part) 159 (part), 166-170, village- Chetlagoraram, Mandal- Toopran, District- Medak, Telangana and falls between the latitude 17 o 45 25.23 N and longitude 78 o 30 24.97 E. The industry is situated at around 45 km from Hyderabad city. Location of the Project is shown in Figure 1 and study area map is given in Figure -2. 3
Project Site FIGURE 1: LOCATION MAP 4
FIGURE 2: 10-KM TOPOGRAPHICAL MAP 5
3.3 Details of Alternate Sites No alternate site was considered. As this is an expansion project, the land adjacent to the existing land has been selected. 3.4 Size or Magnitude of Operation Existing Production Capacity Induction furnace Rolling Mill Induction furnace Rolling Mill 2,05,000 TPA 3,69,000 TPA Proposed Production Capacity 3,95,000 TPA 2,31,000 TPA Total Production Capacity after Expansion Induction furnace Rolling Mill 6,00,000 TPA 6,00,000 TPA 3.5 Project Description with Process Details 3.5.1 Induction furnace The induction arc furnace operates as a batch melting process producing batches of molten steel known heats. The furnace operating cycle is called the tap-to-tap cycle and is made up of the following operations: Furnace charging Melting Refining De-slagging Tapping Furnace turn-around The process flow diagram is given below: 6
3.5.2 TMT Bar Hot Billet received from Steel Melt Shop are inspected and cut to length as per the size of TMT to be rolled. These hot billets are directly sent to rolling mill via hot charging conveyor without any preheating. The hot Billets are passed through roughing stands and then goes to Continuous Stands. These stands are with A.C. motor for Variable speeds. After that the bar passes through TMT Box where it goes under Thermo Mechanical Treatment to improve upon Corrosion Resistance and Mechanical properties like Yields tress, Elongation, Bending, Tensile strength, etc. After passing through TMT box, the bar is cut into lengths to accommodate on cooling bed. After the bar is cooled it is cut into fix lengths as per requirement of market through Shearing Machine. At an interval of 1 hour a sample is drawn for checking weight per meter and mechanical properties. The TMT process is given below: 7
3.6 Raw Material Required Along With Estimated Quantity, Likely Source, Marketing Area of Final Product/S, Mode of Transport of Raw Material and Finished Product The raw materials required for the production induction furnace and TMT Bar is given below: Mode of Sr. No. Particular Quantity (TPA) Source Transportation 1 Sponge Iron 421200 Sister Industry/Open Market By road 2 Scrap 168480 Open Market By road 3 Pig iron 105300 Open Market By road Material Balance for Billets Input TPA Out Put TPA Sponge Iron 421200 Billets 600000 Scrap 168480 Slag 77330 Pig Iron 105300 Burning Losses 9858 Additives 7020 Others Losses 14812 Total 702000 702000 Rolling Mill Input TPA Out Put TPA Billets 600000 TMT bar 582000 Waste fines (3%) 18000 Total 600000 600000 8
3.7 Resource Optimization/ Recycling and Reuse Water will use for cooling system, Scrubbers, Domestic and greenbelt purposes. Cooling water will be recirculating in system. Slag will be sold to bricks and construction industry. 3.8 Availability of Water Its Source, Energy/ Power Requirement and Source 3.8.1 Water Requirement The manufacturing process does not require water in process. The water requirement in the Project will be for cooling purpose, domestic consumption and green belt development. The details of water requirement for different purposes are presented below: Water Requirement Item Water Requirement in KLD (Existing) Water Requirement in KLD (Proposed) Total Water Requirement (KLD) Cooling Purpose 60 220 280 Scrubber 25 40 65 Domestic Purpose 10 10 20 Dust Suppression Greenbelt 30-30 Total 125 270 395 3.9 Quantity Of Wastes to be Generated (Liquid And Solid) And Scheme For Their Management/ Disposal 3.9.1 Solid Waste Generation& its Disposal Slag will be sold to construction industry and mill waste will be sold to cement industry. The details of solid waste are given in below table: Slag Mill Waste Particular Quantity (TPD) 215 TPD 50 TPD 9
3.9.2 Liquid Effluent No liquid effluent will be generated at the plant site. The domestic wastewater generated will be treated in STP and treated water will be reuse for green belt development. 4.0 SITE ANALYSIS 4.1 Connectivity 4.1.1 Nearest Railway Station Devarapalli - 2Km from the plant site. 4.1.2 Nearest Airport Hyedrabad airport is 45 km from the plant site. 4.2 Land form, Landuse and Land Ownership The Land use conversion already done. 4.3 Topography The topography of the region is mostly plain dry industrial land and the climatic conditions are semi-arid. The average annual rainfall is 700 mm, and the maximum and minimum temperatures are 45 o C & 16 o C respectively. There are no Ecological and Sensitive areas like Religious and Historic places, Archeological Monuments, Scenic Areas, Hill Resorts, Biosphere reserves, National Parks and Sanctuaries, Seismic Zones and Defense installations within the circular area of 10 km radius from plant site. 5.0 PLANNING BRIEF 5.1 Planning Concept The proposed project involves additional in Induction Furnace and rolling mill production. 5.2 Population projection The man power of plants includes manager, Engineer, skilled and unskilled Labours and medical officers etc. As for the socio-economic is concerned from the plant activity nearby villagers shall get in direct employment for about 350 persons. The proposed plant activities also shall bring the positive change in the villages as the mine shall provide direct employment to more than 100 people indirectly. 5.3 Land use planning The project is located in 32 Acres land. There will not be change in land use as the land already has converted in Industrial Area. 10
Sr. No. Existing Area (Acres) Proposed Area (Acres) Total Area (Acres) Plant Area 11.0 6.0 17.0 Road Area 3.0-3.0 Open Area and 7.44-1.44 Future Expansion Area Greenbelt Area 10.56-10.56 Total 32.0 32.0 5.4 Assessment of Infrastructure Demand (Physical & Social) On the basis of the preliminary site visit, the infrastructure demand in the villages was assessed on the basis of need and priority. The assessment will be made in the socio economic survey &will be submitted at the time of final presentation regarding Environment Clearance. 5.5 Amenities/Facilities Rest shed, first-aid centre, ambulance service, drinking water facilities, will be provided. 6.0 PROPOSED INFRASTRUCTURE 6.1 Plant Area (Processing Area) The main plant area comprises of Induction furnace area and rolling mill area, raw material handling area, storage area and greenbelt area etc. 6.2 Residential Area (Non Processing Area) As the local persons will be given employment, no residential area/ housing is proposed within the mining lease area. 6.3 Green Belt More than 1/3 rd (10.56 acres) of total land availability is reserved for plantation i.e. greenery. Greenbelt development plan Local DFO will be consulted in developing the green belt. Greenbelt of 33% of the area will be developed in the plant premises as per CPCB guidelines. The tree species to be selected for the plantation are pollutant tolerant, fast growing, and wind firm, deep rooted. A three tier plantation is proposed comprising of an outer most 11
belt of taller trees which will act as barrier, middle core acting as air cleaner and the innermost core which may be termed as absorptive layer consisting of trees which are known to be particularly tolerant to pollutants. 6.4 Water Management About 395 KLD will be required for steel project. This water will be supplied from ground water. 6.5 Sewerage System The domestic wastewater generated will be sent to septic tanks followed by soak pits. 6.6 Industrial Waste Management No industrial waste will be generated at the plant site. The domestic wastewater generated will Treated in STP. 6.7 Solid Waste management Slag will be sold to construction industry and mill waste will be sold to cement industry. 7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN There will be no displacement of houses. Hence rehabilitation and resettlement is not envisaged. 8.0 PROJECT COST ESTIMATES The total cost for expansion project will be around Rs. 40 Crores. 9.0 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) 9.1 Financial and Social Benefits with Special Emphasis on the Benefit to the Local People Including Tribal Population, If Any, In the Area. The proposed Expansion plant will provide employment to about 100 local people and helping them earn livelihood. The infrastructure facilities also will be improved in the surrounding area. *********** 12
Annexure 1: Plant Layout 13