M/s Padmavati Steels Limited Shivalik Solid Waste Management Ltd PRE-FEASIBILITY REPORT 1.0 EXECUTIVE SUMMARY: 1.1 Project & Project Proponent M/s Padmavati Steels Limited located at Trilokpur Road, Kala Amb, Village Johron, Tehsil Nahan and Dist. Sirmaur, Himachal Pradesh, this plant manufactures MS Bars, G I Pipes, ERW Pipes and M.S. Scaffoloding. M/s Padmavati Steels Limited. is an existing composite Rolling Mills unit which plans to install three Induction furnaces each with capacity of 15 MT in addition to one Rolling Mill with production capacity of 36000 MTPA at Trilokpur Road, Kala Amb, Village Johran, Tehsil Nahan and Dist Sirmaur, H.P. making the total capacity 67500 MTPA of MS billets along with 45000 MT capacities of rolled products. Project falls under Category A due to interstate boundary of Haryana within 10 Km as Metallurgical Industries (secondary metallurgical processing) Item 3(a) of the schedule of EIA notification of Sept 14, 2006 issued by MOEF & CC. Water for construction and domestic purpose will be drawn from Department of Industries and Commerce (DIC). Approximately 14 KLD water will be used for during operational phase. Existing Power load is 5,000 KW & additional of 4,800 KW will be required plant & machinery during Construction and Operation Phase. Expected source is Himachal Pradesh State Electricity Board (HPSEB). Total Plot Area: 4.77Ha 1
33
Embed
M/s Padmavati Steels Limited - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/...M/s Padmavati Steels Limited Located at Village Johran, Trilokpur Road,
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
PRE-FEASIBILITY REPORT
1.0 EXECUTIVE SUMMARY:
1.1 Project & Project Proponent
M/s Padmavati Steels Limited located at Trilokpur Road, Kala Amb, Village
Johron, Tehsil Nahan and Dist. Sirmaur, Himachal Pradesh, this plant
manufactures MS Bars, G I Pipes, ERW Pipes and M.S. Scaffoloding.
M/s Padmavati Steels Limited. is an existing composite Rolling Mills unit
which plans to install three Induction furnaces each with capacity of 15 MT in
addition to one Rolling Mill with production capacity of 36000 MTPA at
Trilokpur Road, Kala Amb, Village Johran, Tehsil Nahan and Dist Sirmaur,
H.P. making the total capacity 67500 MTPA of MS billets along with 45000 MT
capacities of rolled products.
Project falls under Category A due to interstate boundary of Haryana
within 10 Km as Metallurgical Industries (secondary metallurgical
processing) Item 3(a) of the schedule of EIA notification of Sept 14, 2006
issued by MOEF & CC.
Water for construction and domestic purpose will be drawn from Department
of Industries and Commerce (DIC). Approximately 14 KLD water will be used
for during operational phase. Existing Power load is 5,000 KW & additional of
4,800 KW will be required plant & machinery during Construction and
Operation Phase. Expected source is Himachal Pradesh State Electricity Board
(HPSEB). Total Plot Area: 4.77Ha
1
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
1.2 Salient Features of the Project
SALIENT FEATURES OF THE PROJECT
PROJECT PROFILE The steel plant will be expanded for
the projected production of 67,500 MT
/annum from the current production
of 36000 MTPA of Rolled products
after the expansion of current from
2.25 Hectares to 4.77Hectares.
LOCATION LATITUDE: 30O 31’ 05.84” E
LONGITUDE: 77 O 12’ 04.07” N
EXISTING CAPACITY: 36000 MTPA of Rolled Product
PROPOSED CAPACITY: 67,500 MTPA of Billets
PROPOSED ROLLING MILL SECTION MATERIAL REQUIRED
REQUIRED ROLLING MATERIAL 45000 MTPA
LESS WASTAGE @4% 1800.00
HOT ROLLED STRIPS/BARS 43200.00
BILLETS/INGOTS REQUIRED 45000.00
LESS
BILLETS/INGOTSINDEGENOUS
45000.00
PIPE MILL SECTION MATERIAL REQUIRED
HOT ROLLED STRIPS/BARS 43200.00
LESS WASTAGE @2% 900.00
PIPE MANUFACTURED 43200.00
GALVANISING SECTION MATERIAL REQUIRED
AVAIABLE ERW PIPES 42300.00
ADD. INC. IN WT. IN THE
PROCESS@3%
12600
G. I. PIPE 43500.00
2
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
ANNUAL RAW MATERIAL REQUIRMENT AT 100% CAPACITY
SCRAP REQUIRED 70875.00
BILLETS/INGOTS REQUIRED 0.00
SILICO MANGANESE 1063.125
ALUMINIUM SHOTS 708.750
ZINC 8.700
LAND AREA 4.77Hectares (56-14Bighas )
SCREENING CATEGORY 3(a) Category A as per EIA Notification
14th Sep, 2006 and amended thereof.
COST OF THE PROJECT Rs. 37.36 Crores
RESOURCE REQUIREMENT
SOURCE & QUANTITY OF
WATER
Source: DIC (Industries Department, and
Govt. of Himachal Pradesh).
Quantity : Currently Approximately 10
KLD is being utilized for domestic and
industrial purpose & Approximately 14
KLD water will be used after the proposed
expansion
POWER Existing Power load is 5,000 KW &
additional of 4,800 KW will be required for
plant & machinery during Construction
and Operation Phase
Total Power Load: 9800KW
Source: Himachal Pradesh State
Electricity Board (HPSEB)
MAN POWER Present Employees: 302
Proposed Employees after expansion: 635
ENVIRONMENTAL MANAGEMENT SYSTEM
WASTE WATER Domestic waste water generated will be
send to septic tank/ soak pit, hence no
generation of sewage sludge at site. Water
shall be used in boilers and also for
3
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
cooling purpose in proposed project
activity. The same shall be reused within
the plant premises after neutralization
FLUE GAS EMISSION Stack attached to induction furnace, boiler
and DG sets will lead to emission. Exhaust
emissions from the DG sets and stacks of
suitable height are provided as per
SPCB/CPCB guidelines.
Particulate matter, Sulphur Dioxide and
Nitrogen Oxides will be the major
pollutants.
HAZARDOUS WASTE Sludge, Used oil, Discarded containers /
liners.
Environmental control measures
Air pollution Bag filters for emissions from
Induction Furnaces
Wet scrubbers for emissions from
Re-heating Furnace
Provision of stack of 30 m height for
discharge of emissions as per CPCB
guidelines
Water pollution Quantitative recycle of effluents to
maintain “Zero effluent discharge”
Domestic wastewater treated in
septic tanks with soak pit disposal.
Noise: Acoustic enclosures for DG set and
other noise generating machines
Hazardous wastes Slag from induction furnaces, dust
collected in bag filters and sludge
from wet scrubber will be collected,
stored and sent to authorized TSDF
site
Green belt Available vacant land shall be
utilized for plantation and
development of lawns.
4
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
2.0 INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION:
Ferro-alloys are among the essential inputs required for steelmaking. It
improves the quality of steel, by controlling the harmful impurities and at the
same time improves the mechanical properties of steel through alloying.
Growth in Global as well as domestic steel industry directly drives the demand
of Ferro-alloys. Since Indian steel industry is under massive expansion, there
is a tremendous potential for investment in Ferro-alloy production.
Steel being a basic commodity for all industrial activities, quantum of its
consumption is considered an index of industrial prosperity. Since
independence, there has been a substantial growth in the steel sector in India
from 1.5 Million Tons in 1950-51 to about 31 Million Tons at present.
Additional steelmaking capacity of about 8 to 10 Million Tons /year exists in
the secondary steel sector. Despitethe above growth in the steel sector, the
per capita steel consumption continues to remain at a level of about 27 kg
only, compared to about 350 to 450 kg in the developed countries and 40 to
100 kg in some of the developing countries. Further, with nearly 20% of the
world population, India’s contribution is only of the order of 3.4% of world
steel production. Hence, short-term and long-term strategies are necessary in
planning the development of the steel industry in the country to improve the
level of per capita steel consumption. It is expected that with the measures
taken by Govt. of India for promotion consumption of iron and steel and
expected growth of Indian economy the requirement of steel will significantly
increase and accordingly the domestic manufacturing capacity needs to be
increase.
The details of the project proponent are given below: Land Revenue record is
attached as Annexure IV.
5
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
M/s Padmavati Steels Limited Located at Village Johran, Trilokpur Road, Kala
Amb, Tehsil Nahan and Dist. Sirmaur, Himachal Pradesh
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT
M/s Padmavati Steels Limited is an existing composite Rolling Mills unit
which plans to install three Induction furnaces each with capacity of 15 MT in
addition to one Rolling Mill with production capacity of 36000 MTPA at Village
Johran Trilokpur Road, Kala Amb, Tehsil Nahan and Dist Sirmaur, H.P.
making the total capacity 67500 MTPA of Billet.
2.3 NEED OF THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY
AND/ OR REGION
The Indian steel industry has entered into a new development stage from
2007-08, riding high on the resurgent economy and rising demand for steel.
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. 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 3 rd
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 exist many factors
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 600 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
6
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Steel Policy 2005 had envisaged steel production to reach 110 million tonnes
(mt) 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.
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 3 rd 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 exist many factors 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 600 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 tonnes (mt) by 2019-20. However, based
on the assessment of the current ongoing projects, both in green field and
brown field, 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
7
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
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 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 THE
PROJECT
The project is currently providing direct employment to 302 persons which will
be increased to 635 after the proposed expansion . Local workers will be hired
from the nearby villages.
3.0 PROJECT DESCRIPTION
3.1 Type of Project
This project is for expansion of existing steel plant for proposed capacity of
67,500 MTPA from existing capacity of 36000 MTPA of Rolled Product The
Metallurgical Industries (secondary metallurgical processing) is listed at serial
no. 3(a) of the Schedule of EIA Notification 2006 and falls under Category A
due to existence of interstate boundary with Haryana at a distance of 1 Kms.
The project is not interlinked with any other project.
3.2 Location:
The proposed location of the project is situated at village Johran, Trilokpur
road Tehsil Nahan, District Sirmaur, Himachal Pradesh.
The location details are mentioned below:-
Latitude : 30O 31’ 05.84” E
Longitude : 77 O 12’ 04.07” N
8
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
The vicinity map is given below:
Fig: 3.1 Vicinity Map of the Project Site
Project Site
9
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Fig 3.2 Project Site
PROJECT SITE
10
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Fig 3.3 10 Km Buffer map
11
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Fig 3.4 Lay Out Plan
12
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
3.3 Details of Alternate Sites
No alternative site has been considered for the project, & the project will be
expanded in the land adjoining the current project site
Site Selection Criteria
Major techno-economic feasibility considerations
Land requirement and availability:
Private land owned by M/s. Padmavati Steels Limited 4.77 Hectares (56-14
Bighas
Land ownership Details:
Land is already available with M/s Padmavati Steels Limited at village
Johran, Trilok pur road Tehsil Nahan, District Sirmaur, Himachal Pradesh.
3.4 Size or magnitude of operation
The proposed project is to expand the capacity of currently existing steel
plant to 67,500 MTPA from 36000 MTPA of Rolled Product. At present there
are about 16 member units. The plant will consist of treatment units
comprising physical, chemical and biological treatment including dewatering
of sludge and other required infrastructure. The project outlay is estimated to
be around Rs. 37.36 Crores
3.5 Project description with process details
3.5.1 Manufacturing process of M.S. /S.S. Billets
(a) The Preparation of Charge
In general, induction furnaces use pig iron, sponge iron and/or iron scrap
as raw material for making steel. However, in the present case, only scrap
iron will be use as raw material. for steel making in the induction furnace.
Selected scrap of consistent quality is to be used. This is because
elimination of some elements from the molten metal is difficult in an
induction furnace and in the case where these are present in high
13
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
quantities; a secondary metallurgical unit is required to refine the metal up
to the desired extent. As soon as the furnace is charged, the switches
admitting power current to the induction coil are closed.
(b) Melting the Charge in Induction furnace
Working of Induction Furnace After the furnace is switched on; current
starts flowing at a high rate and a comparatively low voltage through the
induction coil of the furnace, producing an induced magnetic field inside
the central space of the coils where the crucible is located. The induced
magnetic fluxes thus generated cut through the packed charge in the
crucible. As the magnetic fluxes cut through the scraps and complete
the circuit, they generate an induced current in the scrap. This
induced current, as it flows through the highly resistive path of the
scrap mix, generates tremendous amounts of heat and melting of scrap
starts. As soon as the charge has melted clearly, any objectionable slag
is skimmed off, and the necessary alloying elements are added. When
these additives have melted completely, the power input may be increased
to bring the temperature of metal up to the point most desirable for
pouring. The current is then turned off and the furnace is tilted for pouring
into a ladle. As soon as pouring has ceased the crucible is cleaned
completely from any slag or metal droplets adhering to the wall of the
crucible and the furnace is now ready for charging again.
(c) Continuous Casting of Billets/Blooms
One (1) No. 4-strand continuous casting machine for casting of billets will
be used. The main operations involved in the whole process of turning out
billets/blooms are:
Checking the individual major components of the casting machine
and their synchronized operation.
Insertion of a dummy bar to close the bottom end of the mould;
14
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Accurate centering of the tundish over the mould;
Transferring the ladle to the casting aisle and placing it on the ladle
stand of the casting machine;
Pouring of liquid steel from the ladle through a slide gate
mechanism into the lined tundish;
Pouring of liquid steel into the water cooled mould through tundish;
Passage of liquid steel through water cooled mould tubes initiated
by withdrawing dummy bar;
Oscillation of the mould
Maintaining a constant level of liquid steel in the mould and introducing
lubricants into the mould throughout the casting process;
Controlling the intensity of cooling of the emerging billets in the primary
and secondary cooling areas;
Straightening and cutting of billets.
(d) Billet Cutting
The automatic gas cutting torches are provided for cutting billets to a
desired length. The equipment comprises a water cooled structure for
trolley support, Auto cutter trolley with drive mechanism, a gas and
pneumatic panels suitable for both the strands. The trolley moves on
the rails above the hot strand in the direction of discharge. During cutting,
torch swings like a pendulum across the hot strand at a
predetermined cutting speed. In the forward direction trolley moves
at casting speed swing to the clamping of the hot strand whereas
retracting the trolley to the home position is carried out by motorized drive.
15
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
(e) Billet Processing
The billets from a particular cast are lifted from the cooling bank
and stored separately. When cooled, they are inspected on each face
for defects; surface defects are normally removed by a swing frame
grinder, etc
16
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
17
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
3.5.2 Details of Expansion Capacity
A. Proposed Melting Section
Number of Furnace 3
Capacity of Each Furnace 15 MT
Number of Heats per day 5
Number of working Hours 15 Hrs
Number of working Days 300
Capacity of Ingots 3x5x15 225 Tonnes /Day
Annual Capacity/
Production
225 × 300 Appx 67500MT/Annum
Source: Project Report
B. Rolling Mill Section
ROLLING MILL SECTION EXISTING
TONS/ DAY
PROPOESED TOTAL
TONS /ANNUM
Required Rolling Material 150 45000
Less : Wastage@ 4% 6 1800
Hot Rolled Strips/ Bars 144 43200
Billets / Ingots Required 150 45000
Less : Billets / Ingots In
House
150 45000
Balance Purchases From
Open Market
0
18
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
C. Pipe Mill Section
PIPE MILL SECTION EXISTING
TONS/ DAY
PROPOESED TOTAL
TONS /ANNUM
Hot Rolled Strips/ Bars 144 43200
Less : Wastage@ 2% 3 900
Pipe Manufactured 141 42300
D. Galvanising Section
GALVANISING SECTION EXISTING
TONS/ DAY
PROPOESED
TOTAL
TONS /ANNUM Available ERW Pipes 141 42300
Add. Inc. in Wt. in the process
@3%
4.20 1260.00
G. I. Pipe 145 43500
3.5.3 Annual Raw Material Requirement
Annual Raw material requirement at 100 % capacity is as follows
Discipline Quantity in MT
Scrap Required 70875.00
Billets/Ingots Required 0.00
Silico Manganese 1063.125
Aluminum Shots 708.750
G I Moulds 2126.250
Zinc 8.700
19
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
Raw Material Consumption at Different Capacity Levels:
Year of
Operation
Capacity
Utilization
1st Year 60%
2nd Year 70%
3rd Year 80%
Source: Project Report
3.5.3 Pollution : Source and Control Management
Flue Gas management
The flue gases generated during melting of scrap are the major source of air
pollution. Quality and Characteristics of flue gas shall be required during
dispersion modeling. Flue gas from Re-heating furnace in the Re-heating
Furnace should also be taken into account. 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 (PM 10, PM
2.5), Sulphur Dioxide (traces), Oxides of Nitrogen (in low concentration) and
Emissions from DG sets. Currently the air Pollution Control Device (APCD)
unit i.e. bag filters is installed after the induction furnace at the facility &
its capacity will be increased in accordance with the proposed
modernization to control the emissions within permissible limit will be let-
out through stack.
Hazardous Waste Management
Slag from furnace, dust from Bag house are hazardous materials generated
on site which will be stored and transported to authorized TSDF site
located at Nalagarh Himachal Pradesh at a distance of 81 Kms from
20
M/s Padmavati Steels Limited
Shivalik Solid Waste Management Ltd
project site .
Green Belt
Green belt will be developed according to CPCB guidelines. Plants of the
various species will be developed in the plant and peripheral areas.
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.
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.
4. As far as possible, the species will be locally available
5. Species tolerance 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.