M/s. MAULI METALLICS PRIVATE · PDF fileMaharashtra M/s. MAULI METALLICS ... 6 Present landuse Non-agricultural Barren Land ... domestic crude steel capacity in the county is likely

Pre-Feasibility Report: M/s Mauli Metallics Pvt. Ltd.

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PRE-FEASIBILITY REPORT

FOR

NEW UNIT

OF

MANUFACTURING OF 30,000 TPM M.S. BILLETS

AND 30,000 TPM TMT BARS

At Gut No. 58, Daregaon, Tahsil & District Jalna,

Maharashtra

M/s. MAULI METALLICS PRIVATE LIMITED

EIA Consultant: Pollution and Ecology Control Services

(PECS), Nagpur (MS).


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1.0 INTRODUCTION

1.1 PREAMBLE:

The Indian steel industry has recorded remarkable performance in recent years. India's

iron and steel industries are one of the important backbone in the wealth of the country.

In 2014-2015, India was the third largest producer of raw steel and is the largest producer

of sponge iron in the world. The industry produced 91.46 metric tonnes of total finished

steel and 9.7 metric tonnes of pig iron. Most iron and steel in India is produced from iron

ore. The industry is now capable of producing high quality materials to stringent

international specification for high-end applications. 21st century is widely perceived to

be the century of Asia and India is looked upon as one of the economies with most

promising prospects. This possesses a formidable challenge as well as an opportunity to

the Indian corporate sector. The national steel policy has set a target of 100 million

tonnes of steel by 2018. The major steel producers in India are planning to expand their

capacities in the tune with the national steel policy formulation. M/s. Mauli Metallics

Pvt. Ltd. is not exception to that and therefore intends to establish a new unit to meet

the ever increasing demand of steel in national and international market. The total cost of

the Project is Rs. 70 Cr.

1.2 PROJECT DISCRIPTION:

The production details of the proposed project are given below

Sr.No.

Name Proposed Production

1. M.S. Billets 30,000 TPM

2. TMT Bars 30,000 TPM


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Raw Material

The key raw material required is Sponge Iron and Scrap, which can be locally procured

from the vendors directly. Processing of sponge iron and scrap material is economically

viable, because of high value of raw materials and the relatively low cost of processing.

SITE DESCRIPTION:

The plant of M/s. Mauli Metallics Private Limited is established to manufacture and

process M.S. Billets and TMT Bars. The factory is located at Gut No. 58, Daregaon,

Tahsil & District Jalna, Maharashtra.

SITE LOCATION & ITS ADVANTAGES:

• The proposed unit will be located at Daregaon, Jalna. The site is near Industrial

Unit Jalna. The place is very well connected by road to neighboring cities. This

will be of immense use for transportation of produce and will accordingly help to

reduce the total cost.

• Further due to ever growing population and Construction industry the unit is very

much viable.

• Due to the roadside location of the unit there is easy availability of other

infrastructure facilities like Power, Water, Labour, etc.


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75°50' 75°55'

19°45'

19°50'

19°55'

N

PREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES

10 KM. TOPOGRAPHY MAP

Gut No. 58, Daregaon, Tahsil & District Jalna, Maharashtra

TOPO SHEET NO.47 M/13

SCALE 1: 50,000

RESEVED FORESTR.FR.F

Nidhana

Ghanewadi

Fanduiwadi kurdGavliwada

Gundewadi

Jamwadi

Kanhaiyyanagar

Kharpudi

Gaulwadi

Rohaeadi

LondewadiBethlam

Samangaon

Antarwala

KajlaPankheda

Kumbephal

Devpimapalgaon

Siraswadi

Dargaon

Javasgaon

Bhilpuri Budruk

Haldula

Matrewadi

Selgaon Davalwadi

Dinegaon

Nagewadi

Chandan Jhira

Rajewadi

Khadgaon

Najik PangriMandwa

Tatewadi

Panshendra

Juna

Indewadi

Dal Nala

Kundalika

N

Kundalika

River

Talav

Mukt

a

SO

UTH

CE

NTR

AL

RA

ILWA

YM

ainLin

e

Moti

Talav

Talav

Industrial Area

Daregaon

Shravan

Ghanewadi

Talav

Nadi

Jamwadi

Pirsawangi

19°55'

19°45'

50'19°

75°55'75°50'

JALNA

Devmurti

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

PROJECT SITE

FOREST BOUNDARY

RAILWAY

INDEX

MukateshwarLake

Figure 1: Study Area

SOURCE & AVAILABILITY OF WATER:

Water will be sourced from Ground Water and the total water requirement for the

proposed project will be about 80 KLD.

POLLUTION CONTROL MEASURES:

The pollutants in the form of solids, liquids and gases are generated from various

technological units and, if let out as such, will have hazardous effects on the

environment. Pollution of the environment, not only adversely affects the flora and fauna,


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but also shortens the life of plant and equipment. This vital aspect, therefore, has been

taken into account while planning the plant and equipment and adequate measures have

been proposed to limit the emission pollutants within the stipulations of statutory norms.

• Dust suction system which will control fugitive emission due to material handling.

• Dust suppression system will be provided in the form of water sprinklers.

• All vibrating screens and weigh feeders below the hopper; day bins etc are covered to

prevent leakages of dust.

• Conveyors are covered to prevent dust pollution.

• All discharge and feed points wherever the possibility of dust generation is there is

provided with dust suppression system.

• Bag Filters will be provided for the extraction of dust particles.

• During construction only domestic waste generated will be treated in packaged type

STP.

• Dust will be generated during transportation, storing of raw material and construction

activities. The dust emission shall be mitigated by water spraying on the roads within

the plant premises.

• Domestic / sewage effluent shall be treated in packaged type STP.

2.1 INTODUCTION OF THE PROJECT AND BACKGROUND OF PROJECT

PROPONENT

M/s. Mauli Metallics Private Limitedwill carry out their production processes at Village

Daregaon, Tehsil Jalna, District – Jalna, (M.S). The incorporation of latest technology

and machines enables them to meet the upcoming production requirements and growing

market needs. The location map is shown in Fig. 2 and the details of the project are

presented in Table 1.


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Source: mapsofindia.com

Figure 2: Location of Project Site

Table 1: Environmental Setting of the Proposed Project Site

SrNo

Particulars Details

1 Project Site Gut No. 58, Daregaon, Tahsil & District Jalna,

Maharashtra

2 Latitude 19°50'31.96"N3 Longitude 75°50'42.89"E

4 Elevation above MSL 529 m

5 Toposheet 47 M/13

6 Present landuse Non-agricultural Barren Land

7 Climatic conditions(Based on nearest IMD station dataAurangabad)

Annual Average Maximum Temperature : 400C

Annual Average Minimum Temperature :120C

Annual Average Humidity : 19-24 %Annual Average Rainfall : 600-700mm

8 Nearest Highway

State HighwayNearest State Highway is Aurangabad- Jalna-

Nagpur Highway 2 kms NE

9 Nearest Airport Aurangabad : 60 kms W.


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10 Nearest Railway Station Railway Station: Jalna is at a distance of 5 Kms SE

11 Nearest Town Jalna 4.0 kms E.

12 Forest Reserved Forest : 5.5 km NE

Reserved Forest : 6.0 km NE

13 Sanctuaries / National Parks /

Biosphere etc

Nil

14 Hills/ Valleys Nil

15 Streams / Rivers Kundalika River : 3.5 km ENE

Mukta River : 9.0 km NNE

Moti Talav : 1.5 km E

Ghanewadi Talav : 7.0 km N

Daregaon Talav : 2.5 km SW

Shravan Talav : 8.0 km SSW

Mukateshwar Talav : 2.5 km E

16 Defense Installations Nil

17 Historical Places Nil

CRITERIA FOR LAND IDENTIFIED

• Rehabilitation/Resettlement not required.

• No National Park, Biosphere Reserve and Wildlife Sanctuary including

• No archaeological monument, interstate boundary and defense installation.

• No notified critically polluted area.

• No nallah/water body, public roads, forests within the project site.

• Availability of Raw Material.

• Availability of Water.

• Assured Power Supply.

• Market available for finished products.

• Availability of man power.

• Availability of industrial infrastructure.


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2.2 JUSTIFICATION:

The demand for steel in the country is currently growing at the rate of over 8% and it is

expected that the demand would grow over by 10% in the next five years. However, the

steel intensity in the country remains well below the world levels. Our per capita

consumption of steel is around 110 pounds as compared to 330 Pounds for the global

average. This indicates that there is a lot of potential for increasing the steel consumption

in India. To meet the increasing demand and to stimulate economic growth the proponent

has proposed the project.

As per the report of the Working Group on Steel for the 12 th 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

buoyed by projects like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv

Gandhi Awaas Yojana among others. 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 greenfield and

brownfield, the Working Group on Steel for the 12 th 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.

Source: http://steel.gov.in/overview.htm. Ministry of Steel, Government of India.

2.3 EMPLOYMENT GENERATION (DIRECT & INDIRECT):

The total manpower required after the proposed project will be 250.


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3.0 PROJECT AT GLANCE

1. Name of the proposed unit : M/s Mauli Metallics Private Limited

2. Location of the proposed unit : Gut No. 58, Daregaon

Tehsil : Jalna

District : Jalna

3. Products to be manufactured:

Sr.No.

Name Proposed Production

1. M.S. Billets 30,000 TPM

2. TMT Bars 30,000 TPM

4. Raw Material Requirement :

Name of the Raw

Material

Total Requirement (TPM)

For M.S. BILLETS

MS Scrap 24960

Sponge Iron 6240

For TMT BARS

MS Billets 30,000 (in Molten Stage)

5. POWER REQUIREMENT:

The power required will be supplied by State Electricity Board. The power requirement

for the proposed project will be 10,000KVA.


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3.1 PROCESS DETAILS

Manufacturing Process of M.S. BILLETS & TMT BARS

Induction Furnace

The induction furnace is used to melt many different sorts of metals, from common steel

to more exotic alloys or precious metals. The greatest advantage of the induction furnace

is its low capital cost, its easier installation, simpler operation, no noise generation and

there is very little heat loss due to radiation from the furnace. The raw material (Sponge

Iron, MS scrap, Ferro Manganese and Ferro Silicon) is charged into the induction

furnace. As soon as the furnace is charged, the switches admitting power current to the

induction coil are closed.

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. As the magnetic

fluxes cut through the scraps and complete the circuit, they generate an induced current in

the scrap which is known as eddy current, this eddy current flows through the highly

resistive path of the scrap mix, generates tremendous amounts of heat and melting of

scrap starts. Soon a pool of molten metal forms in the bottom causing the charge to sink.

The induced current which is generated in the charge mixed and heated more

homogenously. 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

upto the point most desirable for pouring. The current is then turned off and the furnace

is tilted for pouring into a crucible. 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. The temperature of the furnace will be 16500C.

When the total scrap as per the capacity of the crucible is molten, the sample is taken

from liquid steel and tested for the composition of steel and the carbon contents.

Therefore some additives of ferro-alloys like Silico-managanese, silicon, aluminum shots

and are added to the liquid steel to maintain the composition and quality. The billets in

the molten stage are transferred to rolling line for the production of TMT Bars bypassing


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the reheating furnace. The cooled TMT Bars are then inspected and dispatched. The

process flow chart is presented in the Figure 3.

Figure 3: Process flow Chart for Hot Billet Rolling Process

Advantages of Hot Billet Rolling Process

Energy saving is the main benefit as it consists in avoiding the normal cooling of the

billet down to room temperature and the reheating for initiating the rolling. Thus the

process is of less energy and more environmentally friendly.

Billets in molten condition will be directly fed to Hot Billet Rolling machine thus

saving of fuel & electricity.


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No additional increment in GLC for PM & SO2.

No need of storing fuel required in Gasifier for conventional Re-heating Furnace in

rolling mill

No generation of Fly Ash.

No space will be required for storage of Billets and fly ash.

Easy handling of Process.

Low operational cost of rolled steel depending on unit costs

Reduced civil works and infrastructure costs

Reduced energy consumption

Less man power required.


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4.0 SELECTION OF SITE & LOCATION OF PLANT

Selection of the site for any project is the most important aspect for it’s successful

operation & better economic viability. Proximity to Raw material source, assured supply

of fuel and other infrastructural support are required to be essentially examined while

selecting the site of the plant. The following basic requirements are necessarily required

to be fulfilled.

i. Availability of water from continuous source.

iii. Power supply/ evacuation arrangement.

iv. Nearer access through road.

Site Selection Criteria

• No Rehabilitation/Resettlement required.

• No National Park, Biosphere Reserve and Wildlife Sanctuary including

• No archaeological monument, interstate boundary and defense installation.

• No notified critically polluted area.

• No nallah/water body, public roads, forests within the project site.

• Availability of Raw Material.

• Availability of Water.

• Assured Power Supply.

• Market available for finished products.

• Availability of man power.

• Availability of industrial infrastructure.

4.1 LOCATION:

The proposed project is situated in Gut No. 58, Daregaon, Tahsil & District Jalna,

Maharashtra.


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4.2 TYPE OF THE PROJECT:

The proposed project involves manufacturing of M.S. Billets & TMT Bars.

4.3 SITE ANALYSIS

LAND USE

The existing land is non-agricultural barren land.

TOPOGRAPHY

The topography of the land is plain.

EXISTING LAND USE PATTERN

The existing land is non-agricultural barren land.

GREEN BELT

33% of total land will be developed as Green belt in and around the project site.

SOCIAL INFRASTRUCTURE

Social infrastructure will be developed as per need based in the Villages

4.4 Availability of Utilities

For successful running of any unit most important factor is the availability of Raw

Materials, as well as Utilities & Power, Water Connectivity which are required to

efficiently run the Equipment.


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5.0 Water System & Plant Utilities:

5.1 Source of Water

Water required for the plant will be drawn from Ground Water.

5.2 Water Consumption

Water will be sourced from Ground Water and the total water requirement for the

proposed project will be 80 KLD.

5.3 Fire Protection System

The fire fighting system will be designed in conformity with the recommendations of the

Tariff Advisory Committee (TAC) of Insurance Association of India. While designing

the fire protection systems for proposed facilities its extreme ambient conditions need

special attention. Codes and Standards of National Fire Protection Association (NFPA)

will be followed, as applicable.


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6.0 ENVIRONEMENTAL MANAGEMENT PLAN

6.1 Sources of Pollution

The major sources of pollution from proposed units can be classified under the following

heads:

• Pollutants in the waste gases namely, suspended particulate matter (SPM), sulphur

dioxide, NOX and Carbon monoxide, etc.

• Fugitive dust generated during vehicular movement

• Noise pollution

• Waste water and sewage

• Solid Waste Generation

The various measures proposed to mitigate the impact of these pollution sources on the

environment are discussed below:

6.2 Pollution Control Measures

6.2.1 Air Pollution

Proper care will be taken by installing Bag filters followed by Stack to control source

emission. Hence there will not be any major deposition of pollutants into air, land and

water.

To control fugitive dust emissions due to vehicular movement water sprinkling and

spraying system will be installed. Internal roads will be asphalted.

6.2.2 Water Pollution

It is estimated that total effluent generation from the proposed project will be from

cooling process. This wastewater will be treated in settling tank and will be reused in the

process. The domestic effluent will be treated through packaged type STP.

Zero discharge condition from the proposed plant will be maintained.


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6.2.3 Noise Pollution

There will no such high noise generate due to operation of proposed units, however Noise

generation may occur due to handling of raw materials and finished products. For that

Ear plugs/ ear muff will be provided to the workers working in noisy area.

6.2.4 Solid Waste Management

Following are the solid waste generation due to operation of proposed units:

a. Slag (1200 TPM) from Induction Furnace

b. Tail Cuttings (900 TPM) from Rolling Mill

Disposal of Slag from Ferro Alloys:

Slag generated from Induction Furnace will be used for hardening of working area,

internal road, brick manufacturers, concreting.

Tail cuttings generated from the Rolling Mill will be recycled in Induction Furnace.

6.2.6 Plantation

33% of total land will be developed as Green belt in and around the project site.

During plantation landscaping pattern will be considered. The plantation scheme covers

the plantation of ornamentals plants and some local fruit bearing species.

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 should be indigenous and locally available

5. Species tolerance to air pollutants like SPM, 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.

Documents

M/s. MAULI METALLICS PRIVATE · PDF fileMaharashtra M/s. MAULI METALLICS ... 6 Present landuse Non-agricultural Barren Land ... domestic crude steel capacity in the county is likely