Project Proponent: M/S. Metarolls Ispat Pvt. Ltd.

Project Proponent: M/S. Metarolls Ispat Pvt. Ltd.

Gut No. 48, Daregaon, Adjacent to MIDC Phase II, Taluka-Jalna, District – Jalna, Maharashtra.

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: [email protected] , web: www.ssmntech.com Contact no. 040-2316333, Fax No.: 040-23816222

September, 2018

MODERNIZATION CUM EXPANSION OF MS BILLETS /Alloys billets PRODUCTION (1,58,400 TPA TO 7,28,400 TPA) AND

TMT BAR PRODUCTION (1,58,400 TPA TO 7,28,400 TPA) AND ADDITIONAL UNIT OF PRODUCTION OF FERRO MANGANESE

21500 TPA /SILICO MANGANESE 18000 TPA at


http://www.ssmntech.com/

M/s Metarolls Ispat Pvt Ltd. Pre-Feasibility Report

1.0 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. Metarolls IspatPvt Ltd.(MIPL)has a steel Plant located at Gut No. 48, Daregaon, Adjacent

to MIDC Phase II, Taluka-Jalna, District – Jalna, Maharashtra.

The company has obtained Environmental Clearance for the existing units vide order No. SEAC

2011/CR-683/TC2 dated 30th Sep. 2014 for TMT bars with production capacity 1,50,000TPA at


Now, company is proposing to expend MS Billets/Alloy billets and TMT Bars production

1,58,400 to 7,20,000TPA. MIPL will replace the old furnaces with new furnaces.

The company already acquired 19.05 acres of land and proposed expansion will be done within

existing plant premises.

The salient features of the project are given Table 1.

Table 1-Salient Features of the Project

Project Name M/s. Metarolls Ispat Pvt Ltd. (MIPL)

Total Area 19.05 Acres

Location of Project Gut No. 48, Daregaon, Adjacent to MIDC Phase II, Taluka-

Jalna, District – Jalna, Maharashtra

Production Capacity

Existing Production Capacity

MS Billets - 1,58,400 TPA

TMT Bars– 1,58,400TPA

Proposed Production Capacity

MS Billets - 5,70,000 TPA

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TMT Bars – 5,70,000 TPA

Total Capacity after Expansion

MS/Alloy Billets - 7,28,400 TPA

TMT Bars – 7,28,400 TPA

Additional Ferro Alloys Furnace (9 MVA) Unit

Ferro Manganese - 21,500 TPA

Raw Material

Billets

Sponge Iron (40%) Scrap (58%) and Other Minerals (2%)

TMT Bars

Billets

Ferro Alloys

Manganese Ore,Dolomite and Quartz

Water demand

Source – Own Reservoir

Total Water Quantity– 415 KLD

Existing – 215 KLD

Proposed – 200 KLD

Sources of water Own water reservoir

Man Power Existing – 450 Nos.

Proposed- 400Nos.

Electricity Consumption

Existing – 29.0 MW

Proposed – 26.0 MW

Total –55 MW

Source: Maharashtra State Electricity Distribution.

Nearest railway station Jalna Railway Station –9.0Km, ESE

Nearest airport Aurangabad – 48 Km, SW

Proposed Expansion Project Cost

Existing – INR 74.0 Crores

Proposed – INR 200 Crores

Total –INR:- 274.0Crores

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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of Project and Project Proponent

Metarolls Ispat Pvt. Ltd.(MIPL) (Formerly-Meta Rolls & Commodities Pvt. Ltd) is the flagship

company of the Steel conglomerate, "Rajuri Group". Metarolls Ispat Pvt. Ltd. (MIPL) is

established, in the year 2004, incorporated under companies act, 1956, which intends to

manufacture Iron and Steel products. MIPL has started its commercial operation in 2005 to

manufacture M.S. Billets through Concast technology with capacity of 728400 MTPA & now

operating with capacity on 1,58,400 MTPA.

At present MIPL manufacturing TMT bars introducing forward integration to set up rolling mill

by adopting edge over new technology of Hot Billet Rolling Technology in Maharashtra state

and produce high strength steel bars for the Construction sector in India with production

capacity of 158400 MTPA by employing stringent quality standards and contemporary

technology like, the ‘Quenching and Tempering (TMT) Technology’ by the world renowned

‘THERMEX’, HSE, Germany.

Our company produces its own high quality BILLETS, and its Hot Billet Rolling Mill is operated

through ultra-modern computerized machinery with a fully equipped Quality Control Lab that

ensures quality as per BIS & Thermex parameters. Having established a quality management

system functioning at all levels, the company strives for continual improvement and ensuring

customer delight at all times.

2.2 Brief Information about the Project

The company is proposing to expand the induction furnace and rolling mill production along with

adding new 9 MVA Electric Arc Furnace at Gut No. 48, Daregaon, Adjacent to MIDC Phase II,

Taluka-Jalna, District – Jalna, Maharashtra.

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.

Metarolls Ispat Pvt. Ltd. is proposing to increase in existing 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 400nos. 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.

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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/sMetarolls Ispat Pvt. Ltd. is located at Gut No. 48, Daregaon, Adjacent to MIDC Phase II,

Taluka-Jalna, District – Jalna, Maharashtra. The industry is situated at around 50 km from

Aurangabad city.

Location of the Project is shown in Figure – 1 and study area map is given in Figure -2.

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FIGURE – 1: LOCATION MAP

Project Site

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FIGURE – 2: 10-KM TOPOGRAPHICAL MAP

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 (MS Billets) 1,58,400 TPA

Rolling Mill(TMT Bars) 1,58,400 TPA

Proposed Production Capacity

Induction furnace (MS Billets/Alloys Billets) 5,70,000 TPA


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Total Production Capacity after Expansion

Induction furnace (MS Billets/Alloys Billets) 7,28,400 TPA


Addition of New unit

Ferro Alloys

Ferro Manganese – 21500 TPA or

Silica Manganese – 18000 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

moltensteel 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:

Procurement of Raw Materials

Melting of Raw material in induction Furnace

Casting of M S Billet in continue Casting Machine

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3.5.2 TMT Bar

Hot Billet received from Steel Melt Shop are inspected and cut to length as per the sizeof TMT

to be rolled. These hot billets are directly sent to rolling mill via hot chargingconveyor without

any preheating.

The hot Billets are passed through roughing stands and then go toContinuous Stands. These

stands are with A.C. motor forVariable speeds.After that the bar passes through TMT Box

where it goes under Thermo MechanicalTreatment 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 coolingbed.

After the bar is cooled it is cut into fix lengths as per requirement of marketthrough Shearing

Machine.At an interval of 1 hour a sample is drawn for checking weight per meter

andmechemical properties.

3.5.2 Ferro Alloys

Ferro-alloys are produced by reducing metals from their oxides contained in ores by using a

suitable reduction under conditions created to ensure a high recovery of the valuable elements

from the starting materials. Such reduction reactions are characterized by stability of an oxide

at high temperatures. The stability of all oxides will become more stable with increasing

temperature. An element which forms a stronger oxide can under appropriate conditions be

used as reductant for a less strong oxide. The reaction will proceed successfully if the difference

of oxygen involved with a small difference, favorable conditions should be formed to make the

reaction proceed.

The presence of iron or iron oxides can facilitate some reduction processes. Iron dissolves the

reduced element, forms a compound with it, and thus lowers the melting point of an iron

element alloy is lower than that of the pure element, e.g. in Ferro-manganese production, and

therefore the reaction of reduction of the element can proceed at a lowertemperature.

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Figure: 2.3 Process Flow Chart of Ferro Alloy Project

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:

Billets Raw Material

Sr. No. Particular Quantity (TPA) Source Mode of

Transportation

1 Scrap 438480 Sister Industry/Open

Market By road

2 Sponge Iron 310800 Open Market By road

3 Other

Minerals 15120 Open Market By road

Total 764400

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TMT bar Raw Materials

Sr. No. Particular Quantity (TPA) Source

1 Billets 728400 In-house

Ferro Alloys Raw Material

Ferro Manganese

S. No. Raw Materials Quantity (MT)

1 Manganese Ore (with Average Mn 44%)

2.1 – 2.4 2 Coke (with average Fixed Carbon 80%)

0.30

3 Coal (with average Fixed Carbon 60%)

0.3 4 Dolomite

0.2

Silico Manganese

S. No. Raw Materials Quantity (MT) 1 Manganese Ore (with Average Mn 44%)

2.5 – 2.8

2 Coke (with average Fixed Carbon 80%)

0.40 3 Coal (with average Fixed Carbon 60%)

0.40

4 Dolomite

0.2 Material Balance for Billets

Input TPA Out Put TPA Sponge Iron 438480 Billets 728400 Scrap 310800 Slag 22680 Additives 15120 Burning Losses 13320 Total 764400 764400

Rolling Mill

Input TPA Out Put TPA Billets 728400 TMT bar 728400 Total 7,28,400 7,28,400

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.

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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 Existing Water Requirement

(KLD)

Proposed Water Requirement

(KLD)

Total Water Requirement

(KLD)

Cooling Purpose 185 180 365 Domestic Purpose

20 20 40

Dust Suppression 10 - 15 Total 215 200 415

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:

Particular Quantity (TPA) Slag from Induction Furnace 22680 Slag from SEAF 14850

3.9.2 Liquid Effluent

No liquid effluent will be generated at the plant site. The domestic wastewater (32 KLD)

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 NearestRailway Station

Jalna Railway Station –5.0 Km, ESE

4.1.2 Nearest Airport

Aurangabad airport is 48 km from the plant site.

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4.2 Landform, 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 oC& 16oC 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 ,rolling mill production and

addition of EAF.

5.2 Population projection

The man power of plants includes manager, Engineer, skilled and unskilled labors and medical

officers etc. As for the socio-economic is concerned from the plant activity nearby villagers shall

get in direct employment for about 300 persons. The proposed plant activities also shall bring

the positive change in the villages as the mine shall provide direct employment to more than

500 people indirectly.

5.3 Land use planning

The project is located in 19.05 Acres land. There will not bechange in land use as the land

already has converted in Industrial Area.

Area Existing Area (Acres) Proposed Area (Acres)

Total Area (Acres)

Plant Area 6.0 4.6 10.6 Road Area and open Area

2.2 - 2.2

Area for Future Expansion Area

4.6 - -

Greenbelt Area 6.25 - 6.25 Total 19.05 19.25

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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 1/3rd (6.25 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

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 415 KLD will be required for steel project.This water will be supplied from own water

reservoir.

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.

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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. 200.00 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 400 local people and helping

them earn livelihood. The infrastructure facilities also will be improved in the surrounding area.

***********

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Annexure 1: Plant Layout

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Project Proponent: M/S. Metarolls Ispat Pvt. Ltd.

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