PRE-FEASIBILITY REPORT FOR OM SAIRAM STEEL AND ALLOYS PVT LTD PLOT No. F-1,2,3,8,9,10, ADDL. MIDC, PHASE II, AND GUT NO. 46 & 63, VILLAGE DAREGAON, TEHSIL: JALNA DIST: JALNA, MAHARASHTRA 2014-15
1. Executive Summary This is a proposal to establish industry on an industrial land in the governmental industrial estate, Jalna. This industry is involved in manufacturing one standard product mild steel billet/ingot. This industry propose to involve in manufacturing sponge iron, power generation, M S billet/ingot and M S bar, angle & channels a manufacturing unit at entry 3(a) a, 1(d) b, 3(a) b, and 8(a) b with category of the schedule in EIA notification promulgated in 2006 which is in good demand for growing development status in India and region. This will not disturb the present land use because our area occupied will be only small % of influence zone 10 km and is already industrial. No prime agriculture land will be put to this industrial use. The surrounding land is already under industrial use. Trees will be maintained and not razed down. No rehabilitation is involved. There will be no problematic waste materials as all will be reused in brick manufacturing. Water, power, raw material, and market is assured and found available with ease. Full precautions will be taken for pollution control, resource conservation and environmental protection. 2. Introduction & Background 2.1 Project & Project Proponents This is a proposal to establish an metallurgical industry of large size in an industrial land in the Government industrial estate, namely Maharashtra Industrial Development Corporation (MIDC). This is an integrated project mainly for standard product of MS billet/ingot and MS structural TMT bars, angle & channels. The Proponents are M/s Kapila Metals Pvt. Ltd. (KMPL) at Plot No. B-102 To 105, Addl. MIDC, Phase III, Tehsil: Jalna, Dist: Jalna, Maharashtra. 2.2 Nature of the Project This project will be with an aim to produce mild steel billets and mild steel structural TMT bars. The required water, power and workforce are available. The total cost of the project is Rs. 540 Cr. and the village panchayat desires that such industry should come up here. We have purchased land in the already existing MIDC and hence infrastructure is available. This unit will have a capacity to produce 1. Sponge (500x2 DRIPalnt ) 1000TPD 2. Power Generation 50MW 3. Billet/Ingot 1000TPD 4. TMT Bar, Angle & Channels 1000TPD 5. Building Construction (Shade & Office) 35000 m 2 Thus Project falls under Entry 3(A); Category A.
2.3 Market for this Project: While designing this project and already involved in the same line since last 20 years we have considered the aspects like demand-supply gap (locally and regionally). There is a large scale development in this region for building construction, government irrigation and road development projects and industrial fabrication. All of them need steel. At the same time all of them have waste scrap ends which is otherwise a burden to them needing an outlet. Our conveniently placed venture will be useful to them and for us market is assured, needing no unnecessary storage. Thus this product has a good market and it is assured by our best quality supply done earlier. Our product has market with Jalna, Aurangabad, Pune & Mumbai Manufacturers and all major cities for repairs 2.4 Employment Generation: Employment Potential Skilled, Semi-Skilled And Unskilled The industry and its supporting activity need many types of people right from manual to managerial strength, in a pyramid. The raw material handling may need unskilled workers with people on vehicles and vehicle repairers as skilled ones. So in manufacturing activity all three types i.e. skilled, semi skilled and unskilled people are required. The overall potential including the garages, loadingunloading actions, eateries, small shop owners is moderate though not substantial. The local people can get a good share out of this. In the factory, science and technology prevails and there some outsiders will have to be engaged at least for the time being. If the second generation local people acquire that skill, they too will be able to fill the gap and accrue benefit of higher jobs. If the activity becomes stable by that time, perhaps expansion may become possible further and then employment availability may further enhance. It can be stated that by this activity employment potential is certainly increasing in all walks of life skilled, semi-skilled and unskilled, though in a moderate way. The manpower required for administration and production purposes will be recruited locally without any difficulty. The unit will have 400 work-force and 40 staff members 2.6 Location The government has a desire to improve status of this district and has encouraged MIDC industrial estate at Jalna. In order to have a sustainable development, the pollution generation from this industry is finally made insignificant having taken all the precautions from raw material selection up to low or no waste generation and conversion. This site area is of medium dimension, has a connecting road and has approachability. This site is connected with Maharashtra state electricity board power. When various sites were seen, this site appeared to be environmentally best as also from the business angle and therefore this option was finally adopted. This site is in the MIDC means safe transportation, less need of utilities, less constructing buildings and roads, less fuel and less water. This site has a good connecting road and has approachability. This site has power supply from MSEDCL. MIDC supplies water to the industries. There is no sensitive establishment in the vicinity such as health resorts, hospitals, archaeological monuments, sanctuaries, etc. Google image of surrounding area of 10 km radius is as under
Figure No. 1: 10 Km Radius Google Image Of Kapila Metals Pvt. Ltd. 3. Project Description 3.1 Introduction This proposed project is for production of sponge iron 1000 TPD, power generation 50MW and 1000 TPD of billet/ ingot and/or ms structural bar, angle & channel 1000 TPD. 3.2 Product: # Product Capacity (TPD) 1 Sponge Iron 1000 2 Power Generation 50MW 24MW From WHRBC 26MW From CFBC 3 M.S. Billets 1000 4 Ms Bars, Angle & Channels 1000 3.3 Justification of plant capacity: We have proposed a plant capacity of 1000 TPD. This is an optimum size for us because it is manageable both from production, pollution control and quality assurance point of view. All necessary infra-structure for this capacity can be conveniently arrange for this level of production such as transformer foundation, control panel room, water complex etc. This adds to the flexibility and ease of spares storage. Ladles, tundish, moulds, spray chamber, gas battery, O & M tools kit, will all serve the purpose well. On all side in the vicinity we have industries in the MIDC estate. For proposed expansion we will install three nos. of electric furnace having capacity 40T each. 3.4 Raw Materials: There is only one basic raw material requirement for our product is iron ore pellet, coal and ms scrap. As a supporting raw material we need Raw Material / Ton
Name Quantity in Ton For Sponge Iron Iron Ore Pellet 1450MT Coal B Grade 1200MT Dolomite 30MT For Power Plant (Fbc Boiler 24MW & WHR 26MW) Dolochar 48MT Coal 75MT Flue Gas From Dri Kiln 104 MT Billets Sponge Iron 920MT Scrap 100MT Pig Iron 100MT Rolling Mills Ingot/ Billets 1015MT 3.5 Project Details: This unit is in the field of fabrication job work, now the existing scenario and proposed project details are as follows, # Particular Details 1. Production Capacity TPD Sponge Iron 1000 Power Generation 50MW Ms Billets 1000 Ms Structural Bar, Angle & Channels 1000 2. Area m 2 116000 3. Built-Up Area m 2 35000 4. Furnace 40 T 3nos. 5 Furnace Temperature 0 c 1600 6 Stack 40mt Height, 1.3m Dia & 80mt Height 2.0m Dia 7 Fuel For Furnace Coal & Electricity 8 Power MW 35 9 D. G. Set Kva 2 No. 10 Water Requirement m 3 /d 1150 11 Man Power 440 12 Waste Water Treatment ETP 13 Investment Cr. 540
3.6 Process Coal Dolomite POWER Waste Flue Gas DRI Spong e Iron Induction Furnace Billet CCM Unit Heated Billet Rolling Mill Iron Ore Finished Stock Yard for TMT Bars *QST Quenching and Self Tempering Fig No. 2 Process Chart The site layout includes area for production as well as pollution control activity. In the production side, main factory shed transformer foundation, control panel room, laboratory, concast shed, caster and utilities. The final layout is based on the technical considerations and flow pattern of the material. 3.7 Gaseous Emissions: Emissions are form coal fired boiler, kiln, furnace and laddle, fume extraction system with cyclone for collecting particulate matter followed by boiler ESP, and wet scrubber for dolomite crushing unit with proper Stack will be provided after the control equipment. Attached To Height In Meters Furnace Boiler 40m, 1.3m dia & 80m,2m dia
3.8 Hazardous & Solid Waste: # Particulars Quantity Disposal A Non Hazardous Waste 1 Slag 170 TPD 2 Process Dolochar 48 TPD Refractory 12 TPM -- 3 Ash 118 TPD 4. Proposed Infrastructure Sale To Brick Manufacturer And Will Be Used For Filling Of Low Line Area Will Be Used Fbc Boiler As Fuel Sale To The Brick Manufacturer The all Infrastructure like administrative block, roads, storage area, product storage, transformer, fuel Oil storage, etc needs to be constructed and will be around 35000 m 2 5. Project Schedule & Cost Estimate The project is scheduled to be completed in 6-8 months after receipt of prior environmental clearance. The proponents have already initiated the process for various other permits and some of these have been obtained: IEM from govt. Of India, ministry of industry, New Delhi Building plan (planning phase) NOC from local body /MIDC in pipeline It is anticipated that all the permissions will be in hand within 3-4 months The implementation schedule can be given as # Activity/Event Period 1 Plot Procurement Already in possession 2 Main Shed, Water Tanks, Foundations, Control -- Room, Office Building 3 Plant & Machinery Erection, Material Handling Equipments 20-24 Months ----------------------------------- X O X---