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PRE-FEASIBILITY REPORTOF
Total Production Capacity and augmentation of
integrating melting and rolling facilityPROPOSED BY
M/s KUNDLAS LOH UDYOG
LOCATED AT-BALIANA, TEHSIL-BADDI, DIST.-SOLAN,
STATE-HIMACHAL-PRADESH
PREPARED BY
SHIVALIK SOLID WASTE MANAGEMENT LIMITEDQCI/NABET EIA CONSULTANT ORGANIZATIONS
Registered Office:
Village Majra, Post Office Dabhota, Tehsil Nalagarh
Distt. Solan, Himachal Pradesh - 174101
CorporateOffice:
SCO 20-21, 2nd Floor, Near Hotel Dolphin, Baltana,
Zirakpur Punjab- 140 604
Phone/Telefax: 01762 – 509496
PROPOSED TOR
3(a): STANDARD TERMS OF REFERENCE FOR CONDUCTING ENVIRONMENT IMPACT ASSESSMENT STUDY FOR METALLURGICAL INDUSTRIES (FERROUS & NON FERROUS) PROJECTS AND INFORMATION TO BE INCLUDED IN EIA/EMP REPORT
A. STANDARD TERMS OF REFERENCE (TOR)
1) Executive Summary
2 ) Int roduct ion
i. Details of the EIA Consultant including NABET accreditation
ii. Information about the project proponent
iii. Importance and benefits of the project
3) Project Description
i. Cost of project and time of completion.
ii. Products with capacities for the proposed project.
iii. If expansion project, details of existing products with capacities and whether
adequate land is available for expansion, reference of earlier EC if any.
iv. List of raw materials required and their source along with mode of transportation.
v. Other chemicals and materials required with quantities and storage capacities
vi. Details of Emission, effluents, hazardous waste generation and their management.
vii. Requirement of water, power, with source of supply, status of approval, water
balance diagram, man-power requirement (regular and contract)
viii. Process description along with major equipments and machineries, process flow
sheet (quantative) from raw material to products to be provided
ix. Hazard identification and details of proposed safety systems.
x. Expansion/modernization proposals:
a. Copy of all the Environmental Clearance(s) including Amendments thereto
obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A
certified copy of the latest Monitoring Report of the Regional Office of the Ministry
of Environment and Forests as per circular dated 30th May, 2012 on the status of
compliance of conditions stipulated in all the existing environmental clearances
including Amendments shall be provided. In addition, status of compliance of
Consent to Operate for the ongoing Iexisting operation of the project from SPCB
shall be attached with the EIA-EMP report.
b. In case the existing project has not obtained environmental clearance, reasons
for not taking EC under the provisions of the EIA Notification 1994 and/or EIA
Notification 2006 shall be provided. Copies of Consent to Establish/No
Objection Certificate and Consent to Operate (in case of units operating prior to
EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB
shall be submitted. Further, compliance report to the conditions of consents
from the SPCB shall be submitted.
4) Site Details
i. Location of the project site covering village, Taluka/Tehsil, District and State, Justification for selecting the site, whether other sites were considered.
ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000
scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally
sensitive places)
iii. Details w.r.t. option analysis for selection of site
iv. Co-ordinates (lat-long) of all four corners of the site.
v. Google map-Earth downloaded of the project site.
vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial
area/Estate/Complex, layout of Industrial Area indicating location of unit within
the Industrial area/Estate.
vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show photographs of plantation/greenbelt, in particular.
viii. Landuse break-up of total land of the project site (identified and acquired),
government/ private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (not required for industrial area)
ix. A list of major industries with name and type within study area (10km radius) shall be incorporated. Land use details of the study area
x. Geological features and Geo-hydrological status of the study area shall be included.
xi. Details of Drainage of the project upto 5km radius of study area. If the site is
within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the project site and maximum Flood Level of the river
shall also be provided. (mega green field projects)
xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition
process and expected time of complete possession of the land.
xiii. R&R details in respect of land in line with state Government policy
5) Forest and wildlife related issues (if applicable):
i. Permission and approval for the use of forest land (forestry clearance), if any, and
recommendations of the State Forest Department. (if applicable)
ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed
site delineating the forestland (in case of projects involving forest land more than
40 ha)
iii. Status of Application submitted for obtaining the stage I forestry clearance along
with latest status shall be submitted.
iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere
Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit
the map duly authenticated by Chief Wildlife Warden showing these features vis-à-
vis the project location and the recommendations or comments of the Chief Wildlife
Warden-thereon
v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the
State Government for conservation of Schedule I fauna, if any exists in the study
area
vi. Copy of application submitted for clearance under the Wildlife (Protection) Act,
1972, to the Standing Committee of the National Board for Wildlife
6) Environmental Status
i. Determination of atmospheric inversion level at the project site and site-specific
micro-meteorological data using temperature, relative humidity, hourly wind
speed and direction and rainfall.
ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and
other parameters relevant to the project shall be collected. The monitoring stations
shall be based CPCB guidelines and take into account the pre-dominant wind
direction, population zone and sensitive receptors including reserved forests.
iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency
given in the NAQQM Notification of Nov. 2009 along with - min., max., average
and 98% values for each of the AAQ parameters from data of all AAQ stations
should be provided as an annexure to the EIA Report.
iv. Surface water quality of nearby River (100m upstream and downstream of
discharge point) and other surface drains at eight locations as per
CPCB/MoEF&CC guidelines.
v. Whether the site falls near to polluted stretch of river identified by the
CPCB/MoEF&CC, if yes give details.
vi. Ground water monitoring at minimum at 8 locations shall be included.
vii. Noise levels monitoring at 8 locations within the study area.
viii. Soil Characteristic as per CPCB guidelines.
ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation
of materials, additional traffic due to proposed project, parking arrangement etc.
x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the
study area shall be given with special reference to rare, endemic and endangered
species. If Schedule-I fauna are found within the study area, a Wildlife
Conservation Plan shall be prepared and furnished.
xi. Socio-economic status of the study area.
7) Impact and Environment Management Plan
i. Assessment of ground level concentration of pollutants from the stack emission
based on site-specific meteorological features. In case the project is located on a
hilly terrain, the AQIP Modelling shall be done using inputs of the specific terrain
characteristics for determining the potential impacts of the project on the AAQ.
Cumulative impact of all sources of emissions (including transportation) on the
AAQ of the area shall be assessed. Details of the model used and the input data
used for modelling shall also be provided. The air quality contours shall be plotted
on a location map showing the location of project site, habitation nearby, sensitive
receptors, if any.
ii. Water Quality modelling - in case of discharge in water body
iii. Impact of the transport of the raw materials and end products on the surrounding
environment shall be assessed and provided. In this regard, options for transport of
raw materials and finished products and wastes (large quantities) by rail or rail-cum
road transport or conveyor-cum-rail transport shall be examined.
iv. A note on treatment of wastewater from different plant operations, extent recycled
and reused for different purposes shall be included. Complete scheme of effluent
treatment. Characteristics of untreated and treated effluent to meet the prescribed
standards of discharge under E(P) Rules.
v. Details of stack emission and action plan for control of emissions to meet standards.
vi. Measures for fugitive emission control
vii. Details of hazardous waste generation and their storage, utilization and
management. Copies of MOU regarding utilization of solid and hazardous waste in
cement plant shall also be included. EMP shall include the concept of waste-
minimization, recycle/reuse/recover techniques, Energy conservation, and natural
resource conservation.
viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A
detailed plan of action shall be provided.
ix. Action plan for the green belt development plan in 33 % area i.e. land with not less
than 1,500 trees per ha. Giving details of species, width of plantation, planning
schedule etc. shall be included. The green belt shall be around the project
boundary and a scheme for greening of the roads used for the project shall also be
incorporated.
x. Action plan for rainwater harvesting measures at plant site shall be submitted to
harvest rainwater from the roof tops and storm water drains to recharge the
ground water and also to use for the various activities at the project site to
conserve fresh water and reduce the water requirement from other sources.
xi. Total capital cost and recurring cost/annum for environmental pollution control
measures shall be included.
xii. Action plan for post-project environmental monitoring shall be submitted.
xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency
Management Plan including Risk Assessment and damage control. Disaster
management plan should be linked with District Disaster Management Plan.
8) Occupational health
i. Plan and fund allocation to ensure the occupational health & safety of all contract
and casual workers
ii. Details of exposure specific health status evaluation of worker. If the workers'
health is being evaluated by pre designed format, chest x rays, Audiometry,
Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular
defect) ECG, during pre placement and periodical examinations give the details of
the same. Details regarding last month analyzed data of above mentioned
parameters as per age, sex, duration of exposure and department wise.
iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of
hazards and whether they are within Permissible Exposure level (PEL). If these are
not within PEL, what measures the company has adopted to keep them within PEL so
that health of the workers can be preserved,
iv. Annual report of heath status of workers with special reference to Occupational
Health and Safety.
9) Corporate Environment Policy
i. Does the company have a well laid down Environment Policy approved by its
Board of Directors? If so, it may be detailed in the EIA report.
ii. Does the Environment Policy prescribe for standard operating process /
procedures to bring into focus any infringement / deviation / violation of the
environmental or forest norms / conditions? If so, it may be detailed in the EIA.
iii. What is the hierarchical system or Administrative order of the company to deal
with the environmental issues and for ensuring compliance with the
environmental clearance conditions? Details of this system may be given.
iv. Does the company have system of reporting of non compliances / violations of
environmental norms to the Board of Directors of the company and / or
shareholders or stakeholders at large? This reporting mechanism shall be detailed
in the EIA report
10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.
11) Enterprise Social Commitment (ESC)
i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item-wise details along with timebound action plan shall be included. Socio-economic development activities need to be elaborated upon.
12) Any litigation pending against the project and/or any direction/order passed by any
Court of Law against the project, if so, details thereof shall also be included. Has the unit
received any notice under the Section 5 of Environment (Protection) Act, 1986 or relevant
Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s)
and present status of the case.
13) A tabular chart with index for point wise compliance of above TOR.
Pre-feasibility Report
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 1
Table of Contents1 EXECUTIVE SUMMARY ............................................................................................................ 4
1.1 Introduction .................................................................................................................................................................... 4
1.2 Synopsis of the Report............................................................................................................................................... 5
2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION ............................ 6
2.1 Identification of the Project and Project Proponent .................................................................................. 6
2.2 Brief Description of Nature of the Project....................................................................................................... 7
2.3 Need for the Project and Its Importance to the Country and or Region.......................................... 7
2.4 Demand –Supply Gap ................................................................................................................................................. 8
2.5 Employment Generation (Direct and Indirect) Due to Project............................................................. 9
3 PROJECT DESCRIPTION ........................................................................................................10
3.1 Type of Project.............................................................................................................................................................10
3.2 Location...........................................................................................................................................................................11
3.3 Details of Alternate Sites ........................................................................................................................................14
3.4 Size and Magnitude of operation........................................................................................................................14
3.5 Project Description with Process Details.......................................................................................................15
3.6 Source of Pollution and it’s Control ..................................................................................................................17
3.7 Selection Criteria of plant species for Green Development Plant .....................................................17
3.8 Resource optimization/Recycling and Reuse..............................................................................................18
3.9 Availability of water its source, Energy/Power requirement and source....................................18
3.10 Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal ............................................................................................................................................................19
4 SITE ANALYSIS.........................................................................................................................20
4.1 Connectivity ..................................................................................................................................................................20
4.2 Land Form, Land use and Land ownership...................................................................................................22
4.3 Topography ...................................................................................................................................................................22
4.4 Existing Land Use pattern......................................................................................................................................23
4.5 Existing Infrastructure ............................................................................................................................................23
4.6 Soil Classification........................................................................................................................................................23
4.7 Social Infrastructure available ............................................................................................................................23
5 PLANNING BRIEF ....................................................................................................................24
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 2
5.1 Planning concept (type of industries, facilities, transportation etc.) Town and country,
planning/ development authority classification.......................................................................................................24
5.2 Population Projection ..............................................................................................................................................24
5.3 Land use planning (breakup along with green belt etc.) .......................................................................24
5.4 Assessment of infrastructure demand (physical and the social) ......................................................24
5.5 Amenities/Facilities..................................................................................................................................................24
6 PROPOSED INFRASTRUCTURE ...........................................................................................25
6.1 Industrial area (processing area) ......................................................................................................................25
6.2 Residential Area (non- Processing area)........................................................................................................25
6.3 Green Belt.......................................................................................................................................................................25
6.4 Social Infrastructure .................................................................................................................................................25
6.5 Connectivity ..................................................................................................................................................................25
6.6 Water Management (Source and Supply of Water)..................................................................................25
6.7 Sewerage System........................................................................................................................................................26
6.8 Industrial Waste Management ............................................................................................................................26
6.9 Solid Waste Management.......................................................................................................................................26
6.10 Power Requirement & Supply/source ............................................................................................................26
7 REHABILITATION AND RESETTLEMENT (R & R) PLAN ...............................................27
8 PROJECT SCHEDULE & COST ESTIMATES ........................................................................28
8.1 Total Project Cost .......................................................................................................................................................28
9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) .............................................29
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 3
List of Table
Table 2-1: Project Details................................................................................................................................... 6
Table 2-2: Employment Details ....................................................................................................................... 9
Table 3-1: Salient Features of the Project ................................................................................................ 10
Table 3-2: Coordinate....................................................................................................................................... 11
Table 3-3: List of Existing Machinery along with Capacity................................................................ 14
Table 8-1: Total Project Cost ......................................................................................................................... 28
List of Figure
Figure 3-1: Process flow sheet ...................................................................................................................... 11
Figure 3-2: Location Map of the Project Site ........................................................................................... 12
Figure 3-3: 10 km Radius Buffer Location Map ..................................................................................... 13
Figure 3-4: Water Balance Chart.................................................................................................................. 19
Figure 4-1: Map Showing 10 km Radius of Environment Sensitivity Map around Project
Location ................................................................................................................................................................. 21
List of Annexure
Annexure-I: Consent to Operate
Annexure-II: Copy of Tatima
Annexure-III: Partnership Deed
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 4
1 EXECUTIVE SUMMARY
1.1 Introduction
M/s Kundlas Loh Udyog is an existing secondary steel based industrial unit located at Kh
No. 414, 415, 416, 418 and 133 of mauza Baliana, Vill. Baliana, Tehsil- Baddi, Distt.- Solan,
State-Himachal Pradesh. The existing industrial unit has installed production capacity of
~54000 MT/Annum (~165 MT/day) of rolled steel sections using MS scrap/ingot as basic
raw material.
M/s Kundlas Loh Udyog is planning for capacity expansion and augmentation. In the
process the industrial unit will increase its molten metal generation capacity, addition of
continuous casting machine (CCM), and enhancing re-rolling mill capacity. After proposed
expansion, installed production capacity of the industrial unit will increase to ~92500
MT/Annum (~280 MT/day) along with increased quantity of raw material from 109.1
MT/Day to 310 MT/day. The existing coal based furnace would be used as standby and
same would comes in the production process during failure of induction furnaces having
total consumption of fuel i.e. Coal around 19000 kg and FO around 9216 kg for the
production of ~280 MT/day.
The industrial unit has valid “Consents to operate” for the existing setup and the renewal of
the same has applied on Date 13.03.2015 (Attached as Annexure I). The proposed
expansion will be done in the existing plant premises only.
The proposed project planning needs “Environmental Clearance” from the MoEF as
per the EIA Notification, 2006. The project is classified under Category A due to
“General Conditions” (interstate boundary) as Metallurgical Industries (primary
metallurgical processing), listed as Item 3(a) of the schedule of the EIA Notification.
Water for construction and domestic purpose will be drawn from borewell. Approximately 65
KLD water will be used for industrial and domestic purposes. Total Power load will increase
to around 11000 KVA to run the additional plant & machinery during. The electrical power
will be sourced from Himachal Pradesh State Electricity Board (HPSEB).
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
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Total land area available with the industrial unit, presently, is around 0.778941 Ha. There
shall not be any change in the land area in the proposed project planning.
1.2 Synopsis of the Report
The pre-feasibility report includes a brief introduction of the company, need and
justification of the project, process description, required and available resources, proposed
Environment Management Systems, land-use and proposed infrastructure, project
schedule and cost estimate and proposed Terms of reference for conducting the EIA
studies. M/s Kundlas Loh Udyog has engaged M/s Shivalik Solid waste management limited
as their Environmental Consultant to conduct the EIA studies for obtaining Environmental
Clearance (EC) for the proposed Project.
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 6
2 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION
2.1 Identification of the Project and Project Proponent
M/s Kundlas Loh Udyog located at Kh No. 414, 415, 416, 418 and 133 of mauza Baliana,
Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh. The proponent plans to
enhance the production capacity of the plant due to huge demand of the same.
The existing plant has ~54000 MT/Annum (165 MT/Day) and it has planned to increase
up to ~92500 MT/Annum (280 MT/Day) (rolled sections) by increased quantity of raw
material from 109.1 MT/Day to 310 MT/day by using two induction furnaces each having
12 MT/heat capacity with increased raw material consumption around 310 MT/day.
The details of the project is given in Table below-
Table 2-1: Project Details
S. No Parameters Description
1 Identification of
project
Project falls under Metallurgical Industries Item 3(a) of
the schedule of EIA notification of Sept 14, 2006 issued by
MOEF & CC.
2 Project Proponent M/s Kundlas Loh Udyog
3 Brief description of
nature of the project
The proposed project is for the expansion of the
production capacity from ~54000 MT/Annum (165
MT/Day) to ~92500 MT/Annum (280 MT/Day) (rolled
sections) by increased quantity of raw material from 109.1
MT/Day to 310 MT/day by using two induction furnaces
each having 12 MT/heat capacity within already
established premises only.
There is a provision for the replacement of induction
furnace having 6 MT/hr to 12 MT/hr and additionally one
12 MT/hr and CCM with 20 MT/hr with re-rolling mill
with 14 MT/hr.
4 Salient Features of the Project
4.1 Proposed plant
capacity
~92500 MT/Annum (280 MT/Day) (rolled sections) by
using two induction furnaces each having 12 MT/heat
capacity and CCM with 20 MT/hr and re-rolling mill with
14 MT/hr.
4.2 Total Plot Area Total Plot Area –0.778941 Ha.
4.3 Location Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal
Pradesh
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S. No Parameters Description
4.4 Water requirement Water for construction and domestic purpose will be drawn
from Borewell.
Approximately 65 KLD water will be used during
operational phase.
4.5 Source of water Borewell
4.6 Wastewater 9 KLD generated domestic waste water will be used for
the irrigation purposes.
Most of water quantity shall be used for cooling purpose in
proposed project activity and same shall be reused within
the plant premises after neutralization and addition of
makeup water.
4.7 Man Power Around 321 person
4.8 Electricity/Power
requirement
Total Power load around 11000 KVA to run the additional
plant & machinery during Construction and Operational
Phase.
Source: Himachal Pradesh State Electricity Board
(HPSEB)
In case of Power failure DG sets of 2X125 KVA Capacity
would be provided.
4.9 Alternative site The proposed addition will be established in the existing
plant premises only.
4.10 Land form, Land use
and land ownership
Private land, owned by M/s. Kundlas Loh Udyog
5.0 Project cost The estimated cost of the proposed Project is
approximately Rs. 1019.75 Lacs.
2.2 Brief Description of Nature of the Project
M/s Kundlas Loh Udyog is an existing industrial unit which plans to enhance the
production capacity up to 280 MT/day (rolled sections) by using two induction furnaces
each having 12 MT/heat capacity and rerolling mill (including reheating furnace) having
production capacity of ~14 MT/hr (while operating in single shift of 8 hours) at Vill.-
Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh.
2.3 Need for the Project and Its Importance to the Country and or Region
India is the world’s third-largest producer of crude steel (up from eighth in 2003) and is
expected to become the second-largest producer by 2016. The growth in the Indian steel
sector has been driven by domestic availability of raw materials such as iron ore and cost-
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
Shivalik Solid Waste Management Ltd. Page 8
effective labor. Consequently, the steel sector has been a major contributor to India’s
manufacturing output.
The Indian steel industry is very modern with state-of-the-art steel mills. It has always
strived for continuous modernization and up-gradation of older plants and higher energy
efficiency levels. While plant closures and privatization are rare in India, the private sector
is considered to be the engine of growth in the steel industry and technological changes
and modernization are taking place in both the public and the private sector integrated
steel plants in India.
2.4 Demand –Supply Gap
Steel production of India accounted for 14.33 million tons in 1990-91, which gradually
increased to 36.12 million tons in 2003-04. Rapid rise in production has resulted in India
becoming the 3rd largest producer of crude steel in 2015 and the country continues to be
the largest producer of sponge iron or DRI in the world. As per the report of the Working
Group on Steel for the 12th Five Year Plan, there are many factors exists which carry the
potential of raising the per capita steel consumption in the country. These include among
others, an estimated infrastructure investment of nearly a trillion dollars, a projected
growth of manufacturing from current 8% to 11-12%, increase in urban population to 700
million by 2030 from the current level of 400 million, emergence of the rural market for
steel currently consuming around 10 kg per annum. At the time of its release, the National
Steel Policy 2005 had envisaged steel production to reach 110 Million Metric Tonnes
(MMT) by 2019-20. However, based on the assessment of the current ongoing projects,
both in greenfield and brownfield, the Working Group on Steel for the 12th Five Year Plan
has projected that domestic crude steel capacity in the county is likely to be 140 MT by
2016-17 and has the potential to reach 149 MT if all requirements are adequately met. The
National Steel Policy 2005 is currently being reviewed keeping in mind the rapid
developments in the domestic steel industry (both on the supply and demand sides) as well
as the stable growth of the Indian economy since the release of the Policy in 2005. India is
expected to become the world's second largest producer of crude steel in the next 10 years,
moving up from the third position, as its capacity is projected to increase to about 300 MT
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
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by 2025. Huge scope for growth is offered by India’s comparatively low per capita steel
consumption and the expected rise in consumption due to increased infrastructure
construction and the thriving automobile and railways sectors.
2.5 Employment Generation (Direct and Indirect) Due to Project
Total manpower of the proposed project would be around 321. The detail is given below-
Table 2-2: Employment Details
S. No. Type of Employment Total
1. Managerial/Office Staff 07
2. Skilled/Supervisory 74
3. Un-skilled/Workers 240
Total Employment 321
During Construction phase the labors and workers will be hired from nearby areas.
Pre-feasibility Report of Expansion of Total Production Capacity and augmentationof integrating melting and rolling facility of M/s Kundlas Loh Udyog
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3 PROJECT DESCRIPTION3.1 Type of Project
M/s Kundlas Loh Udyog is an existing industrial unit. The existing setup included induction
furnace and re-rolling mill (including reheating furnace) having production capacity of ~
14 MT/hr (while operating in single shift of 8 hours). After expansion, the proposed
capacity of the plant would be around ~280 MT/Day (rolled sections) by using two
induction furnaces each having 12 MT/heat capacity within the existing plant premises.
The proposed project belongs to expansion of production capacity and augmentation of the
existing unit. During failure of induction furnace, existing coal based furnace would be
utilized with total coal (fuel) consumption around 19000 kg and FO around 9216 kg for the
production of 280 MT/Day (rolled sections). The existing coal based furnace used as
standby along with the induction furnaces. Salient feature of the plant is given in Table
below-
Table 3-1: Salient Features of the Project
S. No. Particulars Existing Proposed expansion Total
1. Coal based Furnace 6 MT/heat - 6 MT/heat
2. Induction Furnace - 2X12 MT/heat 24 MT/heat
3. Installed
production capacity
~165 MT/day ~115 MT/day ~280 MT/day
4. Fixed capital
investment
719.24 Lacs 300.51 Lacs 1019.75 Lacs
5. Fuel consumption Pulverized Coal-
19000 kg
Furnace Oil-9216 kg
- Pulverized Coal-
19000 kg
Furnace Oil-9216 kg
6. Electrical power
requirement
4210.53 KVA 6789.47 KVA 11000 KVA
7. Raw material
requirement
109.1 MT/Day 200.9 MT/Day 310 MT/Day
8. Land area 0.778941 Ha. 0 0.778941 Ha.
9. Manpower
requirement
54 267 321
10. Gross water
requirement
0.5 KLD (Domestic) 64.5 (Domestic +
Industrial)
65 KLD (Domestic +
Industrial)
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S. No. Particulars Existing Proposed expansion Total
11. Solid waste
generation
Slag
Mill scale
20 MT
3 MT
12. Hazardous waste
APCD dust
Spent lubricant
600-800 kg/day
400 kg/year
Source: Project Report
* Existing induction furnaces with 6 MT/hr would be replaced with 12 MT/hr and
provision for additional induction furnaces with aggregate capacity of around ~24 MT/hour.
Figure 3-1: Process flow sheet
3.2 Location
The proposed project site is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-
Himachal Pradesh. The coordinate is given in Table below-
Table 3-2: Coordinate
Latitude 30°54'59.27"N
Longitude 76°50'01.02"E
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Figure 3-2: Location Map of the Project Site
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Figure 3-3: 10 km Radius Buffer Location Map
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3.3 Details of Alternate Sites
No alternate site is examined the details of land is as follows-
Land requirement and availability:
Land is already available in plant premises at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan,
State-Himachal Pradesh.
Land ownership Details:
Land is already belongs to M/s Kundlas Loh Udyog at Vill.- Baliana, Tehsil- Baddi,
Distt.- Solan, State-Himachal Pradesh.
Tatima is attached as Annexure II.
3.4 Size and Magnitude of operation
M/s Kundlas Loh Udyog is an existing industrial unit at Village Baliana. The proposed
project is for expansion of production capacity and augmentation of the existing plant. The
plant is running with ~165 MT/Day of production capacity and rerolling mill (including
reheating furnace) and it has proposed to enhance the capacity up to ~280 MT/Day by
increased quantity of raw material from 109.1 MT/Day to 310 MT/day by using two
induction furnaces each having 12 MT/heat capacity with increased raw material
consumption around 310 MT/day within the plant premises.
The list of existing machinery is given in Table below-
Table 3-3: List of Existing Machinery along with Capacity
S.No.
Machinery Capacity
1. Induction Furnace(with 2 Pots) 6 M.T
2. Reheating Furnace Thermocouple 14 Ton /Hour
3. Roughing Mill 370 MM (3i)
4. Intermediate Mill 370 MM (2i)
5. Finishing Mill 360 MM (2i)
6. Reduction Gear 5.5:1
7. Pinion Gear 1:1
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S.No.
Machinery Capacity
8. Electric Motor 1250
9. Electric Motor 500
10. Electric Transformer 1500 KVA
11. E.O.T Crane 5 M.T
12. Mobile Crane 15 M.T
13. Cooling Bed 13.71x6.09 Mt.
14. Shearing/ Cutting Machine 10 Ton/ Hour
15. Striating Machine 12 Ton/ Hour
16. Lathe Machine 8 Ft
17. Lathe Machine 12 Ft
18. Lathe Machine 14 Ft
19. Lathe Machine 16 Ft
20. Shaper Machine 24 Inches
21.Roller of equal Angles & Channel of size 35, 40, 50,
65, 75 & 100, 75
22. Drill Machine 50 MM
23. Grinder 2800 RPM
24. Welding Machine 4 KW
25. Electric Generator 125 KW
26. Weight Bridge 50 Ton
3.5 Project Description with Process Details
The industrial unit is planning for capacity expansion/augmentation integrating melting
and rolling facility and also increasing overall production capacity. Firstly the preparation
of stored scrap would be carried out with sized, classified and accordingly stocked sent to
the induction furnace shell via overhead with the help of traveling crane equipped with
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hydraulic grab having capacity of 2m3. Induction melting system has two shells and
operated with same electrical line. During operation of one shell, another one is fed with
scrap to decrease the process time. The induction furnaces are driven by transformer.
The melted scrap is tilted from hydraulically operated induction furnaces into liquid steel
ladle having capacity 35 ton. The liquid steel is transferred to ladle furnace to adjust the
final analysis and temperature, suitable for billets with the help of installed sliding gate
mechanism on bottom of each ladle and the liquid steel is stirred with a inert gas such as N2
or Ar.
After reaching the desired analysis and temperature, it will take on to the casting platform
by casting machine with the help of casting carne, capable to cast square billets from 100 to
165 mm. the melt shop also includes one (2) strands continuous machine where the casting
of the billets would be done.
In caster the sliding gate is opened and liquid steel starts to flow into 2 strand tundish
located on tundish car through the tundish nozzles into caster moulds where liquid steel
start to solidify by re-circulating water. The steel billet is completely solidified by water jets
through the strand. After the straightening and withdrawal mechanism produced billets
are cut into desired length. A flat type cooling bed is used to cool down the hot billets.
At the end of cooling bed, the billets would be transferred by forklifts or by crane to make it
stacking.
A laboratory, equipped with a sample preparation equipment spectrometer analyzer is
incorporate to check the conformity of products with the chemical and quality standards
required.
Water is treated in the water treatment facilities and used as the makeup water. The
industrial cooling water is cleaned, cooled and re-used in the water facilities. A de-dusting
plant, equipped with high temperature filters is provided to the dust content of furnace exit
gas.
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3.6 Source of Pollution and it’s Control
A) Flue Gas management
The flue gases generated during melting of scrap are the major source of air pollution.
Quality and quantity of flue gases mainly depends upon type of Scrap used in Furnace, i.e.
degree of contamination in the Scrap. These flue gases need proper treatment for removal
of dust particles before being discharged into the atmosphere. Major pollutants generated
in the process will be Carbon Dioxide, Carbon Monoxide, Suspended dust (PM10, PM2.5,
Heavy metals like As, Cr, Pb, Cd, Zn & Mn), Sulpher Dioxide (traces), Oxides of Nitrogen (in
low concentration, depending on the temp of the process) and emissions from DG sets.
Currently the Air Pollution Control Device (APCD) unit with cyclone & bag filters is
installed at the facility & its capacity will be increased in accordance with the proposed
expansion to control the emissions within permissible limit will be let-out through stack.
B) Hazardous Waste Management
Around 20 MT Slag would be generated. The disposable waste would be around 18 MT out
of 20 MT which would be stored along with generated Slag dust from cyclones and Bag
filters around 600-800 kg and transported to TSDF. The rest 2 MT would be reusable for
recovery of metal and same would be recycled for the production process.
C) Green Belt
Green belt will be developed as per CPCB guidelines. Plants of the various species will be
planted in the plant and peripheral areas of the project site.
3.7 Selection Criteria of plant species for Green Development Plant
The selection of plant species for the development depends on various factors such as
climate, elevation and soil. Area falls under the tropical region and thus the plants that area
adapted to this condition should be selected. The plant should exhibit following
characteristics in order to be selected for plantation.
1. The species should be fast growing and providing optimum penetrability.
2. The species should be wind firm and deep rooted
3. The species should form a dense canopy.
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4. As far as possible, the species will be locally available
5. Species tolerances to air pollutants like PM, SO2, and NOx should be preferred.
6. The species should be permeable to help create air turbulence and mixing within
the belt.
7. There should be no large gaps for the air to spill through.
8. Tree with high foliage density, leaves with larger leaf area and hairy on both the
surface.
9. Ability to withstand conditions like inundation and drought.
10.Soil improving plants (Nitrogen fixing, rapidly decomposable leaf litter).
11.Attractive appearance with good flowering and fruit bearing.
12.Bird and insect attracting tree spacing.
3.8 Resource optimization/Recycling and Reuse
Various steps shall be taken for recycle/ reuse in the proposed project is as mentioned
below:
Waste water generated shall be mainly from cooling and same shall be reused
within the plant premises by neutralizing.
Slag from furnaces, Dust from cyclones & Bag filters are hazardous materials
generated on site, will be stored and transported to TSDF site.
3.9 Availability of water its source, Energy/Power requirement and source
Water for construction and domestic purpose will be drawn from borewell. Approximately 65
KLD water will be used for industrial and domestic purposes. Water balance is given in Figure
below-
Total Power load of 11000 KVA will be used to run the additional plant & machinery during
construction and operational phase.
Source: Himachal Pradesh State Electricity Board (HPSEB). In case of power failure two DG
sets of 125 KVA provided.
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Figure 3-4: Water Balance Chart
3.10 Quantity of wastes to be generated (liquid and solid) and scheme for their
Management/disposal
Around 20 MT Slag would be generated. The disposable waste would be around 18 MT out
of 20 MT which would be stored along with generated Slag dust from cyclones and Bag
filters around 600-800 kg and transported to TSDF. The rest 2 MT would be reusable for
recovery of metal and same would be recycled for the production process.
Solid waste management will be done as per MSW 2000 rule & amended thereof. Water
shall be for cooling purpose in proposed project activity. Waste water generated shall be
mainly from cooling shall be reused within the plant premises. Generated domestic waste
water will be sent to septic tank.
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4 SITE ANALYSIS4.1 Connectivity
The Plant site is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal
Pradesh. The Plant is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal
Pradesh. Project location is about 2.3 km away from National Highway-105. The project
site is around 447 m above MSL.
The site is well connected by road and railways and the neighboring city and town is
Chandigarh and Baddi around 31.5 km and 10.8 km away from project site respectively.
The nearest railway station is Chandigarh Railway station about 34.8 km, S. Chandigarh
Airport is around 42.6 km, S away from the project site.
The study area map is given in Figure below-
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Figure 4-1: Map Showing 10 km Radius of Environment Sensitivity Map around Project Location
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4.2 Land Form, Land use and Land ownership
Land is already available with M/s Kundlas Loh Udyog located at Vill.- Baliana, Tehsil-
Baddi, Distt.- Solan, State-Himachal Pradesh. The land is hilly terrain, utilized for the
cultivation, forest and industrial purposes.
4.3 Topography
The topography of the district is mountainous with elevation ranging from 300 meters to
3000 meters from above sea level. The mountain ranges of the district lie on the outer
Himalayas and are a part of Shivalik ranges. Doon valley is the most fertile tract in Nalagarh
tehsil. The Saproon valley in Solan tehsil and Kunihar valley in Arki though small in size,
are also fertile. The district by and large is also climatically suitable for growth of
temperate fruits.
Climate:
The climate of the district is sub-tropical in the valley and tends to be temperate on the
hilltops. There are four major seasons. The winter season commences from November to
February and ends in March; summer season extends from March to June, followed by the
monsoon period extending from July to September. Maximum precipitation occurs during
July to September. Average annual rainfall in the district is about 1140.86 mm, out of which
85% rainfall occurs during June to September. In the winter season, precipitation as
snowfall also occurs in the higher reaches up to 1000 m elevation and as rainfall in low hills
and valleys of the district. Mean maximum and minimum temperature ranges between
32.2°C (May) and 0.6°C (January).
Geology:
The state of Himachal Pradesh is covered by the rocks ranging in age from Precambrian to
Recent. The normal order of super-position of the rocks in the Lesser Himalaya has been
affected by later events of thrusting. Owing to its complex tectonism and geological
evolution, establishing an unanimously-accepted geology and stratigraphy of Himalaya
remained mired with debate and controversy- posing a natural deterrent.
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4.4 Existing Land Use pattern
The land is hilly terrain, utilized for the cultivation, forest and industrial purposes. The
existing land is used as industrial purposes. The land of the area is flat plain having slight
slope and well developed industrial area.
4.5 Existing Infrastructure
The infrastructure amenities available in the area denote the economic wellbeing of the
region. The project area is connected with NH-105 and SH-9. Educational facilities up to
Senior School, College, Hospital & Banking facilities are available at Baddi about 10.8 km
away from the project area. The existing building comprise of rolling mill shed, Workshop
shed & Competitive administrative block along with office quarters at the existing
premises.
4.6 Soil Classification
Soils of the area have been classified under three Orders i.e. Alfisols, Entisols and
Inceptisols and all the thirty two Soil Series identified in the area have been further
classified into four Suborders; five Great Groups; six Subgroups and fourteen Families.
Soil testing will be done and will be submitted at EIA (Baseline study) stage.
4.7 Social Infrastructure available
Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers etc.
are all available on nearby area.
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5 PLANNING BRIEF
5.1 Planning concept (type of industries, facilities, transportation etc.) Town
and country, planning/ development authority classification
The industrial area and the related facilities are already developed hence no planning is
envisaged. The nearby towns have the modern facilities.
5.2 Population Projection
There would not be any significant development/increase in the population of surrounding
area. Workers for the proposed project will come from the local residents in the
surrounding villages. There won’t be any influx of people in the area due to proposed
project.
5.3 Land use planning (breakup along with green belt etc.)
The open space inside the plant area will suitably landscape and covered with the
vegetation of indigenous variety. Green Belt area will be developed as per the CPCB
guidelines.
The proposed expansion and augmentation of the unit will be done within existing plant
premises having total area around 0.778941 Ha, already acquired by the project
proponent.
5.4 Assessment of infrastructure demand (physical and the social)
The proposed expansion and augmentation of proposed project within well developed
industrial unit and falls in industrial area therefore all facilities/amenities like medical,
educational, housing, transportation, communication, shopping etc are available nearby
places. Local workers will be employed for the construction during proposed expansion; no
long term infrastructure will be required.
5.5 Amenities/Facilities
Major basic facilities are available for the proposed project. Road, electricity, water,
transportation facility etc are well developed in the surrounding area. All the amenities
related to project on the site will be installed.
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6 PROPOSED INFRASTRUCTURE
6.1 Industrial area (processing area)
Site Infrastructure:
The site already having administrative and site control office with latest equipment
like computers, walkie‐talkie & computerized weigh‐bridge, 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 borewell.
6.2 Residential Area (non- Processing area)
The employee quarters are provided within the plant premises. During construction
period, the manpower would be hired from nearby areas.
6.3 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.
6.4 Social Infrastructure
Schools, colleges, hospitals & healthcare centers, shops & bazaars, community centers, etc.
are all available in nearby area.
6.5 Connectivity
The Plant is located at Vill.- Baliana, Tehsil- Baddi, Distt.- Solan, State-Himachal Pradesh.
Project location is about 2.3 km away from National Highway-105. The site is well
connected by road and railways and the neighboring city and town is Chandigarh and
Baddi around 31.5 km and 10.8 km away from project site respectively. The nearest
railway station is Chandigarh Railway station about 34.8 km, S. Chandigarh Airport is
around 42.6 km, S away from the project site.
6.6 Water Management (Source and Supply of Water)
Water consumption for the unit will be as small as the requirement for the cooling system
where water will be re-circulated in the closed circuit. About 65 KL water will be required
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on daily basis out of which 10 KL is used for the domestic and same would be drawn from
borewell.
6.7 Sewerage System
Around 9 KLD domestic waste water would be generated and same would be disposed off
through soak pit.
6.8 Industrial Waste Management
Around 20 MT Slag would be generated. The disposable waste would be around 18 MT out
of 20 MT which would be stored along with the dust around 600-800 kg and transported to
TSDF. The rest 2 MT would be reusable for recovery of metal and same would be recycled
for the production process.
6.9 Solid Waste Management
Generation of solid waste will be minimum. Generated waste shall be sold to recycler. Solid
waste management will be done as per MSW 2000 rule & amended thereof.
6.10 Power Requirement & Supply/source
Total power load around 11000 KVA would be required, met from HPSEB. In case of Power
failure two DG sets of 125 KVA capacity will be provided.
Source: Himachal Pradesh State Electricity Board (HPSEB).
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7 REHABILITATION AND RESETTLEMENT (R & R) PLAN
No, Rehabilitation and Resettlement (R & R) Plan required.
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8 PROJECT SCHEDULE & COST ESTIMATES
The Project is envisaged to be undertaken immediately after getting statutory approvals.
8.1 Total Project Cost
Total estimated Project cost is approximately Rs. 1019.75 Lacs. The details of the breakup
is given in Table below-
Table 8-1: Total Project Cost
Existing (Lacs) Proposed (Lacs) Total (Lacs)
719.24 300.51 1019.75
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9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
This project is for expansion of production capacity and augmentation of existing plant for
the production of steel related products. Due to huge demand, it has proposed to enhance
the capacity of the plant up to 280 MT/Day with the implementation of the proposed
project, the socio-economic status of the local people will improve substantially. The land
rates in the area will improve in the nearby areas due to the proposed activity. This will
help in upliftment of the social status of the people in the area. The proposed project will
also help to increase the natural beauty of the area by developing and planting new plants
along with road as well plant premises.
Annexure
Annexure-I
Annexure-II
Annexure-III
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