PRE-FEASIBILITY REPORT & EMP...PRE-FEASIBILITY REPORT & EMP PROPOSED EXPANSION OF THE EXISTING UNIT TO PRODUCE MILD STEEL BILLETS/INGOTS AND ... with the business of manufacturing

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REGISTERED OFFICE : WORKS:

D – 6, Vivek Vihar, Phase – 1,

New Delhi – 110095

Narain Nagar Industrial Estate,

Bazpur Road, Kashipur, District

Udham Singh Nagar, Uttarakhand

PRE-FEASIBILITY REPORT & EMP

PROPOSED EXPANSION OF THE EXISTING UNIT TO

PRODUCE MILD STEEL BILLETS/INGOTS AND

BARS/ SECTIONS THROUGH AUGMENTATION IN

THE EXISTING INDUCTION FURNACES CAPACITY.

Project or Activity 3(a) due to Metallurgical industries (ferrous & non

ferrous) and Category-A (a. Secondary metallurgical industry,

b. Project site is located within 05 km from the interstate boundary)

Products (Mild Steel) Capacity (MTPA)

Existing Proposed Total

Mild Steel Billets/Ingots 57,600 1,42,400 2,00,000

Mild Steel Bars/Sections 88,200 1,11,800 2,00,000

Project Proponent:

M/s Kashi Vishwanath Steels Private Limited

Proposed Expansion of the existing Unit to produce Mild Steel Billets/Ingots and MS

Bars/Sections (Capacity - 2,00,000 MTPA each) through augmentation in the existing

Induction Furnaces capacity by M/s Kashi Vishwanath Steels Private Limited.

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1.0 EXECUTIVE SUMMARY

1.1 Preamble

M/s Kashi Vishwanath Steels Private Limited (KVS) is an existing industry involved

for production of M S Billet/Rolled products (TMT Bars) through Induction Furnace

– CCM – Rolling Mill route for production of 2,00,000 TPA MS Billets/Ingots & Rolled

product respectively.

To make end product economically viable in present fluctuating market, M/s

KVS have decided to go for expansion by replacement of the existing 5 Tons (02

Nos.) and 4 Tons (02 Nos.) Induction Furnaces with 6 Tons (03 Nos. - replacement

of existing IFs) and 10 Tons (01 no. replacement & 02 nos. new) capacity

Induction Furnaces and modernize Continuous Casting Machine (CCM) &

increasing the output (speed) of existing Rolling Mill through modernization to

enhance the annual production capacity from existing MS Ingots 57,600 TPA

and Steel Bars 88,200 to 2,00,000 TPA respectively.

Capacity expansion by replacing the existing Induction Furnaces will essentially

meet the increasing steel demand. Expansion shall take place within the existing

plant area of 14.78 Acres (59817.0 Sqm). No additional land shall be required for

the project. The company has sound financial background and good market

base which they will use to replace existing Induction Furnace with higher

capacity to become economic steel producer of the region.

M/s Kashi Vishwanath Steels Private Limited is a thirty three years old company

based at Kashipur, Uttarakhand. Sh. Mithlesh Kumar Agarwal starts his career

with the business of manufacturing Katha in 1954. Later, he installed a Rice Mill in

1969 and then a Sugar Industry in 1973. Afterwards, his sons carried on the good

word and set up industries like Solvent Extraction Plant, Vegetable Oil Refinery,

Steel Industry, and Spinning Mill under his guidance and supervision. He is socially

very active, a Chartered Member of Lions Club, Ex-President of Vyapaar

Mandal, Ex-Vice Chairman of Nagar Palika, Ram Nagar and associated with

many other social organizations.

Shri Devendra Kumar Agrawal, the principal promoter of the group is S/o Sh

Mithlesh Kumar Agrawal, aged about 59 years and a Chemical Engineer by

qualification. He has a rich experience spanning thirty five years in the various

industries such as Solvent Extraction Plant, Vegetable Oil Refining and Steel

manufacturing. He was the first entrepreneur to set up Solvent Extraction Plant in




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Uttar Pradesh to extract oil from Sunflower Seeds. He is an active Rotarian and

was as served as District governor during the year 2014 – 15. He is actively

engaged in social activities such as promoting awareness about environmental

issues, encouraging sports persons and achievers in academics.

Shri Arpan Jindal aged about thirty four years, a management graduate by

qualification and having about ten years’ experience in running industrial units.

Apart from being the brain behind the modernization and expansion activities of

the flagship company during the last few years, he was instrumental in setting up

the casting manufacturing facility and lining up the supply of automobile

castings to automobile majors such as TATA Motors and Bajaj Auto Ltd. at Pant

nagar. He was also instrumental in setting up the Food processing plant in

Kashipur to serve the Uttarakhand with highly hygienic food product like Potato

Chips, Extruded Snacks & Indian Ethnic Namkeen, Sticks, Multigrain Chips, Puff

Rings, Sun Chips, Coated Peanuts Masala, & various Indian Ethnic Namkeen.

At that time, there was no steel manufacturing facility in Kumaon region

and KVS foresaw the opportunity and tapped the huge potential that the

situation offered. The company was set up in the year 1985 with a small and

manual rolling mill. During the journey of more than three decades, the

company has not only expanded but also has gone in for backward integration

by setting up its own Steel Melting Shop by installing Induction furnaces.

Recently, the company adopted the technology whereby steel billets produced

from induction furnace are directly rolled in the rolling mill, thereby bypassing

altogether the requirement of any fuel. This led to cleaner environment as there

is no fuel consumption and therefore no emission and at the same time, this

enabled the company to cut cost of manufacturing to remain a cost effective

option for its consumers.

After having gone in for various expansions and modernizations, the company,

having four induction furnaces, a continuous casting machine and two rolling

mills, manufactures totally ISI marked products like TMT Bars, Mild Steel Angles,

Flats, Squares, Rounds and Channels of various sizes totaling about sixty five

product combinations under IS specification No. 1786, 2062,15911,2830 and

2831, which is a unique feature in the region.

In the ever changing steel making technology and market dynamics, KVS has

always been at the forefront to recognize the change and adapt to the fast

changing environment. It is only due to a highly motivated team of executives




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that the company has been able to achieve consistent growth inspite of

cyclical recessionary trends in the steel industry and specially the downturn in

the recent years.

It has a very wide dealer network across the States of Uttarakhand, Uttar

Pradesh and National Capital Region. Ethical business conduct, close and

regular communication by marketing team and excellent product quality have

ensured that in spite of a very wide choice, the dealers have been very loyal to

the company and have been associated for a very long period.

The company’s products are ISI certified and enjoy premium over its peers

specialty in the Uttarakhand market. The Quality Management System,

Environment Management System and OHSAS of the company are certified to

conform to ISO:9001, ISO:14001 and OHSAS:18001 respectively.

The Company as well as its promoters was given following awards for their

contributions towards the society and Nation.

1- “PARYAVARAN PURUSKAR” by the Government of Uttarakhand

2- “UDYOG RATAN AWARD” by the Government of Uttarakhand

3- “UDYOG PATRA AWARD” by the Union Minister, Govt. of India

4- “JEWELS OF UP & UTTARAKHAND” by the Government of Uttarakhand

5- “ISPAT UDYOG RATAN AWARD” by the Union Minister, Govt. of India

6- “AMAR UJALA EXELLENCE AWARD” by the Union Minister, Govt. of India






the recent years.

The company was set up in the year 1985 initially and obtain NOC from Uttar

Pradesh Pollution Control Board on Dated 12.12.1985 for setting up of small Steel

industry for the production of 30.0 MTPD Steel plates, Angles & Channels at

Narain Nagar Industrial Estate, Bazpur Road, Kashipur. Further NOC expansion

was taken on dated 24.06.1992 with an expanded capacity of 100 MTPD. Again

NOC expansion was taken by the company on dated 21.12.2005 for the

production of MS Ingots – 160 MTPD by installing additional 05 MT capacity

Induction Furnace. On 26.04.2006 further the existing unit was expand by




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obtaining prior NOC from UPPCB to produce MS Bars, Angles & Channels – 245

MTPD. M/s KVS has a valid CCA issued by UEPPCB for the Period 01.04.2017 to

31.03.2018 & now applied for further renewal.

M/s Kashi Vishwanath Steels Private Limited is having the existing production

capacity of MS Ingots 57,600 TPA and Steel Bars 88,200. Now Company is

proposed for expansion of the existing Unit by increase in the Production

capacity of MS Ingots - 1,42,400 MTPA and Steel Bars - 1,11,800 through

augmentation in the existing Induction Furnace capacity & required Utilities.

After proposed expansion production capacity of MS Ingots and Steel Bars will

become @200000 MTPA each.

The project activity is listed at S.No. 3(a), Secondary Metallurgical Industry, under

Category ‘B’, as per the EIA Notification, 2006. However, as the project site is

located within 05 km from the interstate boundary (Uttar Pradesh and

Uttarakhand Boarder), the General Condition of the notification is applicable

and hence the project falls under Category ‘A’ and will be appraised by the

Expert Appraisal Committee (Industry-1).

1.2 Salient Features of the Project

Table: 01.01

Sr. No. Parameters Description

1. Plant Capacity Existing (MTPA)

MS Ingots - 57,600, Steel Bars – 88,200

Proposed (MTPA)

MS Ingots - 1,42,400, Steel Bars – 1,11,800

Total: 2,00,000 MTPA each

2. Category of Project as per

EIA Notification &

Amendments

Activity 3 (a) “A”

(Category “B” To be treated “A” as it is

falling within 05 KM radius of inter State

boundary)

3. Proposed Project Proposed expansion of the existing Unit

to produce Mild Steel Billets/Ingots and

Bars/Sections through augmentation in

the existing Induction Furnaces capacity

(replacement of existing IF’s) in the

existing complex.

4. Total area of the Plant 14.78 Acres, (59,812 Sqm)




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5. Capital Cost Rs. 10.0 Crores

6. Location Narain Nagar Industrial Estate, Bazpur

Road, Kashipur, District Udham Singh

Nagar, Uttarakhand.

7. Coordinates of the Site Latitude: 29°11'21.16" N

Longitude: 79°00'09.86" E

8. Products Mild Steel Billets/Ingots/Bars/Sections

9. Water Requirement/Source

water Requirement Total Water – 136.0 KLD

Fresh Water – 54.5 KLD

Recycled Water – 81.5 KLD

Source of water Ground Water i.e. Bore well

10. Water Break-up

(Fresh Water)

Industrial Cooling : 7.0 KLD

Scrubbers : 1.0 KLD

Dust suppression : 2.0 KLD

Domestic : 22.5 KLD

Green-belt : 22.0 KLD

Total : 54.5 KLD

11. Waste Water

Management

Waste water generation

Mode of Disposal

Proposed Sewage Treatment Plant

(Capacity – 25.0 KLD)

18.0 KLD

Reused in Green belt

12. Employment generation Existing – 400 Nos.

Proposed – 100 Nos.

Total – 500 Nos.

13. Power Supply/ Start up

Power

Existing – 16.5 MW

Proposed – 5.0 MW

Total – 26.5 MW (Sources from UPCL)

14. DG Set Existing – 63 KVA (to be replaced)

Proposed – 685 KVA (125, 160 & 400 KVA

on standby basis)

15. Furnaces

(Induction)

Existing: 5 Tons (02 Nos.) & 4 Tons (02 No)

Proposed: 6 Tons (03 Nos. - replacement

of existing IFs)& 10 Tons (01 no.

replacement & 02 nos. new)

Total: 6 Tons (03 Nos.) & 10 Tons (03 Nos.)




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16. Furnaces for Reheating

(Coal Fired)

Existing: 02 Nos.

Table: - 01.02 Products Details





Note: W.r.t the above products, industry will manufacture MS Billets/Ingots for

existing rolling products facility or sold it directly. Steel Bars/sections will be

manufactured either using existing Billets/Ingots or through purchased Ingots

from other industries on campaign basis so that the maximum production

capacity will not exceed 2,00,000 MT/Annum each.

Table: 01.03 Summary of water, wastewater, air & solid waste details

S.

No.

Particulars Details

A. Water, waste water details

1. Water supply

sources

Ground Water i.e. existing Bore well

2. Total water

requirement

Initially total water demand is 136.0 KLD and recycled

water is 81.5 KLD. Fresh Water required for Production of

Mild Steel Billets/Ingots/Bars/Sections will be 54.5 KLD

after proposed expansion.

3. Total waste

water

generated

No waste water generation from industrial process

except CT Bleed & DM (Softener) Plant reject which shall

be reused in the green belt development & Dust

Suppression respectively.

4. Treatment/Dis

posal details

Treated sewage (18.0 KLD) will be reused in green belt

for irrigation purpose. No effluent will be discharged

outside the premises.

B. Air pollution details

1. Sources of air

pollution

Induction & coal fired Furnace’s, DG set.




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2. Air pollution

control units

proposed

Existing: 5 Tons (02 Nos.) and 4 Tons (02 Nos.) & Furnaces

for Reheating (Coal Fired – 02 Nos.)

Proposed: 6 Tons (03 Nos. - replacement of existing IFs)

and 10 Tons (01 no. replacement & 02 nos. new)

Stack attached to existing Furnaces are lead to

emission. Hoods shall be provided to cater the emission

generation from Induction Furnaces which shall be leads

to stack. Particulate matter, Sulphur dioxide and

Nitrogen oxides will be the major pollutants. Cyclone

separator, Bag Filter and wet scrubber are installed to

mitigate the emissions. However electricity will be used

for melting in the existing/proposed furnaces.

Existing DG Set: 63 KVA (to be replaced). Green

insulated DG Set of 685 KVA (125, 160 & 400 KVA on

stand by basis) is proposed (Proposed DG Set to be

operated during emergency in case of power failure

only). Stack height shall be 5.0 M ARL of the D.G. house

to regulate the emission within the permissible norms.

C. Solid/Hazardous wastes

1. Source of

solid waste

Domestic sources and Manufacturing process

2 Total quantity

of solid waste

generated

Domestic solid waste –100 kg/day

Hazardous solid waste

Sl.

No. Source

Quantity of hazardous

waste generated

Lit/month Lit/annum

1. Spent oil from DG set 50.0 L 600.0 L

3. Treatment/Dis

posal of solid

wastes

The domestic wastes (100 kg/d) will be segregated at

source and collected in bins. The organic portion of the

solid wastes will be treated in compost pits and

recyclable portion will be disposed to the recycler for

scientific recycling.

Hazardous waste will be transported to TSDF as per

Hazardous and Other Wastes (Management and

Transboundary Movement) Rules, 2016.




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1.3 Water requirement and wastewater treatment and discharge details.

i). Quantity of Water required and Wastewater generated

In order to conserve fresh water, water economy has been an underlying

criterion for selection of plant and equipment. Water recirculation systems have

been planned to cater extensive recycling and reuse of return water from plant

processes. Industrial quality water will be used in the secondary side of plate

heat exchangers for cooling of process water in the primary side and also for

direct cooling circuits. For the primary side, soft water will be re-circulated in

closed circuits.

Evaporative cooling towers will be provided for cooling industrial water in open

circuit recirculation systems. Process water losses in various circuits will be

compensated by adding make-up water of required quantity. Estimated make-

up water for operation of the proposed Project including requirement of water

for domestic uses is given in below Table.

Initially total water demand is 136.0 KLD and recycled water is 81.5 KLD. Fresh

Water required for Production of Mild Steel Billets/Ingots/Bars/Sections will be

54.5 KLD after proposed expansion, which will be met from existing Bore well.

01 No. bore well is proposed to be drilled & which will work as stand by during

maintenance. Approval for additional abstraction of water to be taken from

CGWA.

The water requirement of the unit will be fulfilled from ground water source i.e.

bore wells. Quality water from DM (softener) plant will be utilized in the industrial

cooling and IF’s cell, contact clamp & electrode cooling. While raw water shall

be utilized scrubber, green belt & domestic purpose.

Sewage Treatment Plant (Capacity – 25.0 KLD) will be installed to treat the

Domestic sewage. Cooling Tower & Softener Plant Bleed shall be reused in the

green belt development & Dust Suppression respectively. Treated sewage will

be reused in green belt for irrigation purpose. No effluent will be discharged

outside the premises.

The changes will be localized and no change in the physical environment will

be envisaged as the treated waste water shall be reused.

The break-up of the consumption of water is as presented in table below:




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Sr.

No.

Particulars Existing

Water

requirement

(KLD)

After proposed

Expansion Total

water requirement

(KLD)

Additional water

requirement

(KLD)

1. Industrial Cooling 60.0 70.0 10.0

Scrubbers 1.0 1.0 --

2. Miscellaneous i.e.

Dust suppression

2.5 2.5 --

3. Domestic Purpose 18.0 22.5 4.5

4. Green Belt 24.0 40.0 16.0

Total 105.5 136.0 30.5

WATER BALANCE:

Total water requirement: 136.0 KLD

Fresh water requirement: 54.5 KLD

Recycle/reuse water: 81.5 KLD

Table: 01.04 Water consumption and discharge (KLD)

Sr.

No.

Requirement

for

Water

Consumption

Process

Losses

Waste water

generation

ETP /STP

losses

Recycled/

Reuse

A. Industrial Process

Industrial

Cooling

70.0 5.5 00 64.5

Scrubbers 1.0 1.0 00 00

Miscellaneous

i.e. Dust

suppression

2.5 2.5 00 00

Total

(Industrial)

73.5 9.0 00 64.5

B. Domestic 22.5 4.5 18.0 00

C. Green belt 40.0 40.0 00 00

Total input water to STP 18.0 1.0 17.0




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Total (KL/Day) 136.0

54.5 (Fresh)

+ 81.5

(Recycle)

53.5 18.0 1.0 81.5

Note:

18.0 KLD of waste water will be generated from the Domestic uses after

proposed Expansion. All the generated sewage will be treated in the

proposed STP (Capacity - 25.0 KLD) & reuse in green belt for irrigation

purpose.

No waste water generation from industrial process except CT & Softener

Plant Bleed which shall be reused in the green belt development & Dust

Suppression respectively.

Zero discharge will be achieved.




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Fig: 01.01 Water Balance Diagram

Proposed Expansion of the existing Unit to produce mild steel Billets/Ingots/Bars/

Sections (Capacity-2,00,000 MTPA) through augmentation in the existing Induction

Furnaces capacity by M/s Kashi Vishwanath Steels Private Limited.

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ii) Waste water treatment and disposal details

The treatment methods and the final disposal of each type of wastewater

generated are appended in the table 01.06 below:-

Table:- 01.05 Sewage/wastewater treatment and discharge

Source Quantity, KLD Treatment Re-use of treated

wastewater

Cooling Tower

bleed off, DM

(Softener)

Plant reject

CT bleed – 1.0 KLD

Softener Bleed – 0.5

KLD

Sedimentation

followed by

Neutralization

takes place.

Treated waste water

shall be reused in the

green belt

development & Dust

Suppression

respectively.

Domestic

activities

Sewage – 18.0 KLD Domestic

sewage will be

treated in

proposed STP.

Treated sewage shall

be reused in the

green belt

development for

irrigation purpose.

1.4 Raw Material Storage & Handling

The raw materials required for the expansion of existing Unit to produce Mild

Steel Billets/Ingots and MS Bars/Sections (Capacity – 2,00,000 MTPA each)

through augmentation in the existing Induction Furnaces capacity are The Major

raw materials are required for proposed project are Sponge iron, Pig Iron and

alloys. It will be mainly transported by road. Raw materials will be procured as

per the production requirement. Raw material shall be brought to the yard in

trucks are unloaded and stacked in different piles by pay loaders. Large area is

covered by well‐designed warehouse, which shall be containing store office,

raw material store, finished product store, etc. The personnel protective

equipment’s like hand gloves, safety shoes, goggles, helmet, clothing, etc. will

be provided to the workers as per requirement. All the motors and electrical

connections will be flame proof.

The basic raw materials required for producing liquid steel are Sponge Iron, Iron

scrap, Ferro-Alloys etc. The main raw materials and their annual requirement




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along with the source of the raw materials for the proposed expansion Project

are given below:

Table 01.06 Annual Requirement of Raw Material with source of supply

Table 01.06.01: For making of MS Billets/Ingots (Melting Division)

S.

No.

Raw Materials Ratio Quantity (Tons/annum) Source of

Supply Existing Additional Total

1. Sponge Iron 77.0 47935.64 118507.56 166443.20 Koenjhar,

Orissa

2. Iron Scrap/ Pig Iron 22.50 14007.17 34628.83 48636.00 Delhi & UP

4. Ferro-Alloys 0.50 311.27 769.53 1080.80 Raipur & UP

Total 100 62254.08 153905.92 216160.0

Table 01.06.02: For making of MS Bars/Section (Rolling Division)

S.

No.

Raw Materials Quantity (Tons/annum) Source of


1. MS Billets/Ingots 89543.0 113502.54 203045.68 Open Market

1.5 Mass Balance

Table 01.07: Mass Balance of MS Billets/Ingots

Inputs Outputs

Raw Material MT Product & Waste MT

Sponge Iron 77.0 MS Billets/Ingots 91.8

Iron Scrap/ Pig Iron 22.50 Slag 6.2

Ferro-Alloys 0.50 Burning losses 2.0

Total 100 Total 100

Table 01.08: Mass Balance of MS Bars/Section

Inputs Outputs


MS Billets/Ingots 91.8 MS Bars/Section 90.42

Mill Scale 0.5

End cutting 0.5

Burning losses 0.38

Total 91.8 Total 91.8




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1.6 Air Pollution Details

The major air pollution sources from the industry are DG set and Furnace process

sections. These sources are provided with stacks of adequate height (30-32 mtr)

so as to disperse the emanating flue gases containing SPM, oxides of sulfur and

nitrogen without affecting the ground level concentrations as per the regulatory

requirements.

The sources of air pollution, type of fuel used, fuel consumption and chimney

heights for each of the air pollution sources the proposed project are indicated

in the following table:-

Table: 01.09 Air pollution sources, fuel consumption and chimney height details

SI.

no.

Stack

attached to

Fuel

used

Fuel

consump

tion

No. of

stacks

Stack

height

Air

pollution

control

Unit

Predicted

emissions

1. Induction

Furnace

Elect

ricity

-- Existing –

04

Proposed

-02

30 m

AGL

for

each

Cyclone

separator,

Bag Filter

and wet

scrubber

with each

Induction

Furnace)

Particulate

matter,

SO2 and

NOx

2. Coal Based

Furnace 02

Nos.

(Reheating)

Coal 20.0

MTPD

Existing -

02 Nos.

32 m

AGL

for

each

Cyclone

separator,

Bag Filter

and wet

scrubber

Particulate

matter,

SO2 and

NOx

3. Green

insulated DG

set Existing 63

KVA (to be

replaced)Pro

posed 685

KVA (125, 160

& 400 KVA on

stand by

basis)

HSD 112 L/hr

Approx.

03 5 m

ARL

for

each

DG

set

Stack SO2, NOx,

SPM




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1.7 Noise Pollution Details

The major source of noise pollution in the industry is the DG set for which

acoustic enclosure is proposed. Also ambient noise levels will be ensured within

the ambient standards by inbuilt design of mechanical equipment and building

apart from vegetation (tree plantations) along the periphery and at various

locations within the industry premises. All noise generating machines will be

spread at different places within the cover sheds & noise curtails will be

provided at noise generating process areas.

1.8 Solid Waste Details

The quantity of solid waste generated from the proposed industry is detailed in

the following table.

Table: 01.10 Solid waste generation during the operation phase

Total No. of Employees 500

Assuming per capita solid waste generation rate as 0.2 kg/capita/day

Quantity of solid waste generated 100 kg/day

Organic solid waste : 60 % of the total waste 60 kg/day

Inorganic solid waste : 40 % of the total waste 40 kg/day

Disposal of domestic solid waste Domestic wastes are

segregated at source,

collected in bins and

composted.

1.9 Hazardous waste generation and its management during the manufacturing

process

Hazardous Wastes (spent oil) generated during Operation phase dealt as per

Hazardous and Other Wastes (Management and Transboundary Movement)

Rules, 2016.

Table:- 01.11 Summary of the total quantity of hazardous & E-Waste:

Sl.

No.

Source Quantity of hazardous

waste

generated

Category

according to

Schedule I of

hazardous

Treatment/ Disposal

Lit/month Lit/annum




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waste

1. Waste oil

from DG set

50 L 600 L 5.1 Handed over to

authorized recyclers

/re-processors

2. E-Waste As & when

generated

As & when

generated

Handed over to


/re-processors

1.10 Green Belt

Total 59817.00 Sq m land area is available at site; out of this 19740.00 Sq m (i.e.

33.0 % of total area) shall be developed as greenbelt and other forms of

greenery by planted the native species. Approx. 20% of the area is already

developed as Green Belt and being maintained. Additionally 13% of the area is

also proposed to develop Green Belt. This green area also enhances the

aesthetic beauty of the area.

1.11 Power & Fuel Requirements

After proposed expansion, the Unit at full capacity will demand 26.5 MW of

power, which shall be supplied through Grid (UPCL). Existing power demand is

16.5 MW. Existing DG Set is 63 KVA capacity (to be replaced). Green insulated

DG Set of 685 KVA (125, 160 & 400 KVA on standby basis) is proposed (Proposed

DG Set to be operated during emergency in case of power failure only).

20.0 mt/day approx. coal is being used as a fuel in the existing furnace at Rolling

plant (02 Nos., Coal fired).

1.12 Environmental Impacts and Management Plan

1.12.1 Environmental Management Plan during Construction Phase




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Activity Environmental

attributes

Cause Impact characteristics

Nature Duration Reversibility Significance,

Mitigative measures

Dismantling of

Existing

Induction

Furnace

Air Pollution

(Dust)

Excavation of

the area, Gas

cutting etc.

Direct

Negative

Short

Term

Reversible Significant. Personnel

Protective Equipment

(PPE) shall be used.

Noise Pollution Noise

generation

from

hammering/

dismantling

activities

Direct

Negative

Short

Term




Land use Storing of

scrap, waste

refractory

bricks

Direct

Negative

Short

Term

Reversible Insignificant, as

storage is temporary

Water Pollution Potential for

seepage from

the waste

storage area.

Direct

Negative

Short

Term

Reversible Significant, Proper

care of the Storage

area shall be taken.

Temporary check

dam along temporary

storage area shall be

made, if required.

Transportation

of scrap /

spares /

waste

material /

construction

material

Air Pollution

(Dust & Gases)

Transportation

of scrap /

waste material

by trucks

Direct

Negative

Short

Term

Reversible Medium, Regular

emission checks shall

be performed.


generated

from loading /

Direct

Negative

Short

Term

Reversible Insignificant, Regular

vehicle maintenance

shall be done. PPE




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unloading and

movement of

vehicles

shall be provided.

Construction

activities

Air Pollution

(Dust & Gases)

Operation of

construction

machinery,

welding &

others

Direct

Negative

Short

Term

Reversible Insignificant. PPE shall

be provided to

workers

Noise Pollution Generation

from

construction

activities

Direct

Negative

Short

Term

Reversible Significant. PPE shall

be provided to

workers

Land Use Storage of

spares,

Refractory

Direct

Negative

Short

Term

Reversible Insignificant. Storage

is temporary and

during construction

period only

Disposal of

scrap / waste

material

(including

refractory)

Air Pollution

(Dust & Gases)

Due to

movement of

Vehicles

Direct

Negative

Short

Term


be provided

to workers

Noise Pollution Due to loading

/unloading

Direct

Negative

Short

Term

Reversible Insignificant. Regular

vehicle maintenance

shall be done. PUC

vehicles are allowed

for transportation. PPE

shall be provided

to workers

1.12.2 Environmental Management Plan during Operation Phase




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attributes


Nature Duration Reversibility Significance, Mitigative measures

Transportation

of the Sponge

Iron, Pig Iron &

Alloys to the

site

Air Pollution

(Dust & Gases)

Haul road

dust emission.

Gaseous

emissions due

to Vehicle

exhaust

Direct

Negative

Short

Term

Reversible Water sprinkling shall be done

where material will be unloaded

in bins.

Regular vehicle maintenance

and pollution check shall be

done.

Besides, the management will

ensure proper usage of the PPE’s

by the workers to avoid any

exposure to dust.


pollution due

to unloading

of raw

material and

vehicle

movement

Direct

Negative

Short

Term

Reversible Low, the unloading will be done

in covered area from low height.

• PPE shall be provided to the

workers working in the area.

Operation of

Induction

Furnace

Air Pollution,

Thermal

Pollution

In induction

furnace the

melting of

scrap, pig

iron and

alloys will

take place.

During

melting there

Direct

Negative

Long

Term

Reversible Cyclone separator, Bag Filter

and wet scrubber with each

Induction Furnace) to reduce

particulate matter emissions from

stack to keep the level below 50

mg/Nm3 and fugitive emissions in

the surrounding areas.




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may be some

fugitive

emission.

Water Pollution Backwash

water from

DM Plant &

CT bleed

Direct

Negative

Long

Term

Reversible Significant. Neutralization Pit shall

be installed to treat the waste

water and shall be used for dust

suppression & green belt.

Noise Pollution Due to

furnace

operations

Direct

Negative

Long

Term

Reversible Management will ensure proper

usage of the PPE’s by the workers

to avoid any exposure to dust.

Solid waste

generation

During liquid

steel making

process slag

will be

generated

Direct

Negative

Long

Term

Irreversible Slag generated during the

process shall be used for

road/area and land

development.

Billet Caster

Casting of

Billets

Consumption

of water

Cooling of

mould and

billets

Direct

Negative

Short

Term

Reversible Insignificant. Water recycled

back after cooling in Cooling

Towers. Only make-up water is

required

Solid waste

generation

Generation

of Scales

Direct

long

Term

Reversible Scale shall be recovered in

Settling

Tank and recycled in IF

Generation

of scrap (end

cuts)

Direct

long

Term

Reversible Reused in IF’s

Noise pollution Caster rollers

(rolling

Direct

short Reversible Ear plug/muff shall be provided

to the employees working in that




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noise) Term area

Rolling Mill

Rolling of

Billets

Water Pollution

Cooling of

rollers and

flushing of

scales

Direct

Negative

Short

Term

Reversible Water for cooling of rollers and

mill scales shall be taken in

Settling cum Oil & Grease trap

where oil and mill scale shall be

separated out and treated water

shall be recycled.

Hazardous

Waste

Generation

Used Oil

Direct

Negative

long

Term

Irreversible Spent oil from DG set and from

Oil & Grease trap shall be sold to

the registered recycler only

Solid Waste

Generation

Cobbles, end

cuts (Scrap)

and Mill scale

Direct

Negative

long

Term

Reversible Mill scale shall be removed from

the Settling pit and Shall be used

in IF’s.

DG Set

Operation of

The DG Set

Air Pollution,

HW generation

Flue gas

emission,

used oil

generation

Direct

Negative

Short

Term

Reversible The DG will be operated in case

of power failure only. Green DG

sets shall be installed. Spent Oil

will be dealt as per Hazardous

and Other Wastes (Management

and Transboundary Movement)

Rules, 2016.


of noise

during DG Set

operation

Direct

Negative

Short

Term

Reversible The DG Sets will have acoustic

enclosure to minimize the noise.

Domestic Waste




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Operation

and

of Domestic

utilities

Water Pollution Operation of

Washroom,

toilets –

Waste water

generation

Direct

Negative

long

Term

Reversible The sewage will be treated

through proposed STP & reused in

green belt.

Solid Waste

Generation

Inorganic &

Organic

waste of

Domestic

activities

Direct

Negative

long

Term

Reversible The domestic wastes are

segregated at source, collected

in bins and composted.

Green Belt Development

Development

and

maintenance

of Green Belt

Reduction in

Air Pollution

and Noise

Pollution

Plantation of

trees With in

Premises to

cover 33% of

the area

Direct

Positive

long

term

Reversible Positive Impact due to

development of a proper green

belt along the periphery of the

premises. This will act as barrier

for air emission and noise

Socio-economic Development

Employment

Generation

Direct

Positive

Positive Impact due to direct

employment of persons from the

nearby area.

Substantial benefits in the form of

contracts to local agencies for

different services.

Employment generation in

transport sector for transportation

of raw material and finished

goods.

Proposed expansion & modernization of the existing Unit to produce MS Billets/Ingots and

MS Bars/Sections (Capacity - 2,00,000 MTPA each) through augmentation in the existing


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2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

M/s Kashi Vishwanath Steels Private Limited (KVS) is an existing plant for

production of M S Billet/Rolled products (TMT Bars) through Induction Furnace –

CCM – Rolling Mill route for production of 1,45,800 TPA MS Billets/Rolled product.



Nos.) and 4 Tons (02 Nos.) Induction Furnaces with 6 Tons (03 Nos. - replacement

of existing IFs) and 10 Tons (01 no. replacement & 02 nos. new) capacity

Induction Furnaces and modernize Continuous Casting Machine (CCM) &

increasing the output (speed) of existing Rolling Mill through modernization to

enhance the annual production capacity from existing MS Ingots 57,600 TPA

and Steel Bars 88,200 to 2,00,000 TPA respectively.






capacity to become economic steel producer of the region.

The company was set up in the year 1985 initially and obtain NOC from Uttar

Pradesh Pollution Control Board on Dated 12.12.1985 for setting up of small Steel

industry for the production of 30.0 MTPD Steel plates, Angles & Channels at

Narain Nagar Industrial Estate, Bazpur Road, Kashipur. Further NOC expansion

was taken on dated 24.06.1992 with an expanded capacity of 100 MTPD. Again

NOC expansion was taken by the company on dated 21.12.2005 for the

production of MS Ingots – 160 MTPD by installing additional 05 MT capacity

Induction Furnace. On 26.04.2006 further the existing unit was expand by

obtaining prior NOC from UPPCB to produce MS Bars, Angles & Channels – 245

MTPD. M/s KVS has a valid CCA issued by UEPPCB for the Period 01.04.2017 to

31.03.2018 & now applied for further renewal.









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become @200000 MTPA each..

2.1 PLANNING CONCEPT

Land use is Industrial (Non agriculture). Being the approved Industrial Area

as Narain Nagar Industrial Estate, Bazpur Road, Kashipur, District Udham

Singh Nagar, Uttarakhand.

The existing infrastructure is Road, Power and Water.

Adequate Infrastructure has been planned.

The finished Products will be marketed in Domestic Market for fulfillment of

growing Market Demand.

2.2 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

M/s Kashi Vishwanath Steels Private Limited is a thirty three years old company

based at Kashipur, Uttarakhand. Sh. Mithlesh Kumar Agarwal starts his career

with the business of manufacturing Katha in 1954. Later, he installed a Rice Mill in

1969 and then a Sugar Industry in 1973. Afterwards, his sons carried on the good

word and set up industries like Solvent Extraction Plant, Vegetable Oil Refinery,

Steel Industry, and Spinning Mill under his guidance and supervision. He is socially

very active, a Chartered Member of Lions Club, Ex-President of Vyapaar

Mandal, Ex-Vice Chairman of Nagar Palika, Ram Nagar and associated with

many other social organizations.

Shri Devendra Kumar Agrawal, the principal promoter of the group is S/o Sh

Mithlesh Kumar Agrawal, aged about 59 years and a Chemical Engineer by

qualification. He has a rich experience spanning thirty five years in the various

industries such as Solvent Extraction Plant, Vegetable Oil Refining and Steel

manufacturing. He was the first entrepreneur to set up Solvent Extraction Plant in

Uttar Pradesh to extract oil from Sunflower Seeds. He is an active Rotarian and

was as served as District governor during the year 2014 – 15. He is actively

engaged in social activities such as promoting awareness about environmental

issues, encouraging sports persons and achievers in academics.

Shri Arpan Jindal aged about thirty four years, a management graduate by

qualification and having about ten years’ experience in running industrial units.

Apart from being the brain behind the modernization and expansion activities of

the flagship company during the last few years, he was instrumental in setting up




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the casting manufacturing facility and lining up the supply of automobile

castings to automobile majors such as TATA Motors and Bajaj Auto Ltd. at Pant

nagar. He was also instrumental in setting up the Food processing plant in

Kashipur to serve the Uttarakhand with highly hygienic food product like Potato

Chips, Extruded Snacks & Indian Ethnic Namkeen, Sticks, Multigrain Chips, Puff

Rings, Sun Chips, Coated Peanuts Masala, & various Indian Ethnic Namkeen.

and KVS foresaw the opportunity and tapped the huge potential that the

situation offered. The company was set up in the year 1985 with a small and

manual rolling mill. During the journey of more than three decades, the

company has not only expanded but also has gone in for backward integration

by setting up its own Steel Melting Shop by installing Induction furnaces.

Recently, the company adopted the technology whereby steel billets produced

from induction furnace are directly rolled in the rolling mill, thereby bypassing

altogether the requirement of any fuel. This led to cleaner environment as there

is no fuel consumption and therefore no emission and at the same time, this

enabled the company to cut cost of manufacturing to remain a cost effective

option for its consumers.

After having gone in for various expansions and modernizations, the company,

having four induction furnaces, a continuous casting machine and two rolling

mills, manufactures totally ISI marked products like TMT Bars, Mild Steel Angles,

Flats, Squares, Rounds and Channels of various sizes totaling about sixty five

product combinations under IS specification No. 1786, 2062,15911,2830 and

2831, which is a unique feature in the region.






the recent years.

It has a very wide dealer network across the States of Uttarakhand, Uttar

Pradesh and National Capital Region. Ethical business conduct, close and

regular communication by marketing team and excellent product quality have

ensured that in spite of a very wide choice, the dealers have been very loyal to

the company and have been associated for a very long period.




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The company’s products are ISI certified and enjoy premium over its peers

specialty in the Uttarakhand market. The Quality Management System,

Environment Management System and OHSAS of the company are certified to

conform to ISO:9001, ISO:14001 and OHSAS:18001 respectively.

The Company as well as its promoters was given following awards for their

contributions towards the society and Nation.

1- “PARYAVARAN PURUSKAR” by the Government of Uttarakhand

2- “UDYOG RATAN AWARD” by the Government of Uttarakhand

3- “UDYOG PATRA AWARD” by the Union Minister, Govt. of India

4- “JEWELS OF UP & UTTARAKHAND” by the Government of Uttarakhand

5- “ISPAT UDYOG RATAN AWARD” by the Union Minister, Govt. of India

6- “AMAR UJALA EXELLENCE AWARD” by the Union Minister, Govt. of India






the recent years.

2.3 BRIEF DESCRIPTION OF NATURE OF THE PROJECT

The project activity is listed at S.No. 3(a), Secondary Metallurgical Industry, under

Category ‘B’, as per the EIA Notification, 2006. However, as the project site is

located within 05 km from the interstate boundary (Uttar Pradesh and

Uttarakhand Boarder), the General Condition of the notification is applicable

and hence the project falls under Category ‘A’ and will be appraised by the

Expert Appraisal Committee (Industry-1).

M/s Kashi Vishwanath Steels Private Limited has an existing steel plant for

production of M S Billet/Rolled products (TMT Bars) through Induction Furnace –

CCM – Rolling Mill route. M/s KVS is incorporated on 05 September 1985 &

having the existing production capacity of Mild Steel Billets/Ingots/ Bars/Steel

Sections @145800 MTPA. Now Company is proposed for expansion of the existing

Unit by increase in the Production capacity @54200 MTPA through

augmentation in the existing Induction Furnace capacity & required Utilities. No

additional facility will be installed.




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Table 02.01: Detail of the existing and proposed capacities

Plant

Facilities

Existing Proposed Total (after proposed

expansion)

Unit Capacity Unit Capacity Unit Capacity

Induction

Furnace

5 Tons

(02

Nos.)

4 Tons

(02 No)

57,600 6 Tons (03 Nos.

- replacement

of existing IFs)&

10 Tons (01 no.

replacement &

02 nos. new)

1,42,400 6 Tons (03

Nos.)

10 Tons

(03 Nos.)

2,00,000

Continuous

Casting

M/c

(CCM)

2

Strand,

4/7 m

radius

57,600 Modernization 1,42,400 2 Strand,

4/7 m

radius

Rolling Mill 1 88200 Modernization 1,11,800 -- 2,00,000

Downstream facilities like Continuous Casting Machine, Rolling Mill require

modernization to meet the proposed production capacity. In Rolling Mill motors

with the Rollers shall be replaced with high speed motors to meet the annual

production of 2,00,000 Tons of Ingots or rolled product.

2.4 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGION

The main need of the proposed expansion is to meet the demands of MS Billets

in the domestic market for the production of Steel re-rolled products. Mild steel

Ingots are the basic raw material for the manufacture of various types of re-

rolled products, for e.g. rounds, flats, channels equal and upequal angles etc. A

major part of this re-rolled products in the form of cold-twisted deformed bars

are used in building construction as reinforcement.

Over the last few years, there has been a great change in the Indian Economic

Scenario due to Global slowdown which affected the whole world including

India. The major sector which took the toll was Steel & Power Sector.

M/s KVS is presently operating Induction Furnace (04 Nos.) of capacity 5 Tons (2

Nos.) & 4 Tons (02 No.) capacity with annual production of 57,600 & 88,200 TPA

of MS Billets/Ingots and Rolled products. 02 Nos. of coal fired Furnaces are also

available for reheating purpose at Rolling Plant & operating as per requirement.




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KVS have decided to go for expansion by replacement of the existing Induction

Furnaces to 6 Tons (03 Nos. - replacement of existing IFs) & 10 Tons (01 no.

replacement & 02 nos. new) capacity to enhance the annual production

capacity to 2,00,000 TPA MS Billets/Ingots and Rolled product (TMT Bar/sections),

to make its end product more economically viable to withstand the present

market situations. Capacity expansion by replacement of existing Induction

Furnaces will essentially meet the increasing steel demand in India.

The Directors of KVS Premier Group of companies are experienced Industrialist,

dynamic, practical, hardworking & self-made entrepreneur. The management

team consists of experienced and matured professionals. The team is quite

capable of managing the business. Therefore, no financial problem is

envisaged.

Steel is one of the most important products of the modern world and is of

strategic importance for any industrial nation. Historically, all nations during their

industrialization phase have been supported by a strong steel industry of their

own. From construction, industrial machinery to consumer products, steel finds a

wide variety of applications. It is also an industry with diverse technologies based

on the nature and extent of use of raw materials. India is the 4th largest

producer of steel in the world accounting for production of 81.54 million tons of

crude steel in 2013-14. It also holds the third position in consumption of steel. Thus

there is great potential in steel industry in India.

GOI has envisage the growth of steel sector to attain a production capacity of

300 Million Tonnes by 2020 hence in order to achieve this capacity it is essential

to create the facilities based on local resources to produce steel.

2.5 DEMAND-SUPPLY GAP

Domestic Demand

Generally, a developing economy undertakes large number of infrastructure

projects, which are necessary for building of the nation and ensuring economic

growth. China is a leading example of the economic growth through

phenomenal development of infrastructure.

Strong economic growth rate 8.7% p.a. and present low per capita

consumption in India is expected to drive demand for steel, which is likely to




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grow @ 7.5% per annum as per Ministry of Steel, Government of India

projections, as detailed in the National Steel Policy 2005. As per Government

estimates, the demand is likely to cross 300 MTPA by 2019-2020.

However, it is considered widely that the above projections are on a

conservative side and the demand is likely to grow at CAGR of about 10% per

annum. As per the estimates of Confederation of Indian Industries (CII), the steel

demand in

India is likely to grow to 80-85 MTPA by 2015 itself, thereby registering a growth

rate of about 12.00% per annum.

Domestic Scenario

Rapid rise in production has resulted in India becoming the 4 the largest

producer of crude steel and the largest producer of sponge iron or DRI in the

world.

Since 2016 the demand for steel industry has been growing contentiously.

Introduction of New Steel Policy 2017 and introduction of GST has opened a

new demand situation for secondary steel sector.

As per the report of the Working Group on Steel for the 12th Plan, there exist

many factors which carry the potential of raising the per capita steel

consumption in the country, currently at 59.2 kg. 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.

As per NSP 2017, It is expected that at the current rate of GDP growth, the steel

demand will grow threefold in next 15 years to reach a demand of 230 MT by

2030-31. However, even with this demand of finished steel by 2030-31, India’s per

capita consumption would reach only to 158 Kgs, lower than the current global

average of 208 kg.

Export demand

Though India started steel production in 1911, steel exports from India began

only in 1964. Exports in the first five years were mainly due to recession in the

domestic Iron and Steel market. Once domestic demand revived, exports




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declined. India again started exporting steel only in 1975 touching a figure of 1

Mt of pig iron and 1.4 Mt of steel in 1976-77. Thereafter, exports again declined

to pick up only in 1991-92 to 0.39 Mt. In 1995-96, exports of semi-finished and

finished steel products were 1.77 Mt while in 2003-04 exports reached 5.2 Mt.

During 2004-05, exports of these products have declined to 4.4 Mt. The exports

have increased by 8.9 per cent in 2006-07 over 2005-06 to touch 4.9 Mt. Exports

have declined in the year 2007-08 by 6.1 per cent to 4.6 Mt – from 8.9 per cent in

2006-07.

Imports of semi-finished and finished steel products mainly HR plates, HR

coils/sheets and CR coils/sheets by India have been in the range of 1.1 Mt and 2

Mt, during the last ten years.

In view of the above and anticipated higher emphasis on export of steel

products in future as per National Steel Policy-2005 (26 Mt exports of steel

products by 2020), export demand in the range of 10% to 15% of apparent

consumption of various products and 150% for GP/GC sheets has been

considered.

The country now has a vision to achieve annual steel production, consumption

and export of 110 Mt, 90 Mt and 26 Mt respectively by the year 2019-20. To cater

to the recent and anticipated surge in domestic demand, export and

enhancement in the economy of scale, various existing steel producers and

new entrepreneurs have drawn expansion plans/Greenfield steel

projects/acquisitions & mergers.

2.6 IMPORTS VS. INDIGENOUS PRODUCTION

The Indian infrastructure sector is likely see a massive growth due to increasing

economic status thus in order to keep the supply ready to match the demand

of construction steel the additional capacity of TMT steel Bars is most immediate

requirement of time.

After Proposed expansion, plant will produce 2,00,000 MTPA quality Mild Steel

Billets/Ingots/Bars/Sections via Induction Furnace – CCM – Rolling Mill route to

meet the Indigenous demand of quality steel and reduce the import

requirement of steel.

2.7 EXPORT POSSIBILITY & DOMESTIC / EXPORT MARKETS




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There is export potential to other countries, for which detailed market study is to

be conducted. However KVS intends to manufacture the products for good

domestic markets.

2.8 EMPLOYMENT GENERATION DUE TO THE PROJECT

After proposed expansion, the total direct employment potential of the existing

industry would be about 500 people. However, apart from this there will be

significant non estimated employment generation at the supplier firms and

service industry providing services to the company. Company shall be giving

preference to people from economically weaker sections for employment in

various semiskilled/ unskilled jobs thereby contributing to their upliftment.

Table:-02.02

Sl.

No.

Category No. of

Employees

Functional Area

01. Key Managerial

Staff

20 Finance, Marketing, Production,

Quality control, R&D, Logistics etc.

02. Administration 30 Office

03. Plant Staff 100 Production Process, Maintenance,

stores, Safety & Un skilled workers 04. Skilled &

semiskilled

200 Production Process

05. Contract

Workers

150 Plant activities

Total 500

3.0 PROJECT DESCRIPTION

3.1 Type of Project

M/s M/s Kashi Vishwanath Steels Private Limited propose for expansion of the

existing Unit to produce Mild Steel Billets/Ingots and MS Bars/Sections (Capacity

– 2,00,000 MTPA each) through augmentation in the existing Induction Furnaces

capacity at Narain Nagar Industrial Estate, Bazpur Road, Kashipur, District

Udham Singh Nagar, Uttarakhand by using existing manufacturing and

infrastructure facilities. Various utilities viz. new Induction Furnace, cooling tower,

& DG set, etc. will be proposed to install to meet the requirements.




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Total capital investment in the proposed expansion project activities will be Rs.

10.0 Crore. It includes construction, plant machineries and installation,

environment protection measures cost, etc.

3.1.1 Infrastructure

Land: The Company has acquired 14.78 Acres i.e. 59,817.00 Sq mt land in

Government approved industrial area as Narain Nagar Industrial Estate, Bazpur

Road, Kashipur, District Udham Singh Nagar, Uttarakhand. Vacant land 10896.0

Sqm) shall be used for proposed expansion activities.

Power: After proposed expansion, the Unit at full capacity will demand 26.5 MW

of power, which shall be supplied through Grid (UPCL). Existing power demand is

16.5 MW.

Existing DG Set is 63 KVA capacity, which shall be replaced. Green insulated DG

Set of 685 KVA (125, 160 & 400 KVA on standby basis) is proposed. Proposed DG

Set will be operated during emergency in case of power failure only.

Water: Water is required for production process, domestic utility and Green belt.






CGWA. Necessary provision for storage of water and water supply has been

made in project cost.

Storage: Company has sufficient provision for storage of raw material & finished

goods.

Transportation: Adequate resources / infrastructure for transportation of raw

Material and finished goods are available in Kashipur area.

Connectivity: The Project site is connected by 20 meter wide connecting road to

the Highway.

All the other infrastructural facilities are expected to be adequately available to

the Unit.




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3.1.2 Technical Know-How

The Production unit will have technical staffs that are qualified as per the

provision of the Rules, separately for manufacturing and quality assessment. The

technical staff shall be assisted by the supporting staff.

Further, necessary assistance from plant and machinery suppliers would also be

taken by the promoters, for successful implementation of the plant.

3.1.3 Construction Activities

In proposed project activity, dismantling of existing Induction Furnace would be

done along with the required utilities. All Construction and commissioning

activities of proposed project shall be carried out after getting amendment in

Environmental Clearance from MoEF, New Delhi and obtain Consent to Establish

(CTE) from Uttarakhand Environment Protection & Pollution Control Board

(UEPPCB), Dehradun. Erection of various machineries shall start simultaneously.

Construction materials like brick, steel, sand aggregates, tiles etc. will be

procured locally in the desired quantity as and when required. All construction

materials will be transported via road only. Temporary storage yard will be

provided for the storage of construction material. Storage yard will be covered

from all the sides.

Construction work after EC for proposed expansion of existing Unit would be

done as given below:-

Table:- 03.01- Construction Details

S. No. Construction Area (Sq.mt)

1. Buildings/ shed 7487.00

2. IF’S, Cooling Tower, Utilities, DG set 3209.00

3. STP/RWH 200.00

Total Land 10896.00

3.2 Location of the Project




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Proposed expansion of Existing Unit to Produce Mild Steel Billets/Ingots and MS

Bars/Sections (Capacity – 2,00,000 MTPA each) through augmentation in the

existing Induction Furnaces capacity in the existing complex by M/s Kashi

Vishwanath Steels Private Limited at Narain Nagar Industrial Estate, Bazpur Road,

Kashipur, District Udham Singh Nagar, Uttarakhand.

No alternate site was considered –

The basis of selection of this site is that the State of Uttarakhand is providing

suitable Industrial environment with proper infrastructure support.

The availability of Raw Material, Power and other infrastructure. Our Finished

Products buyers are also located in Uttarakhand State.

Name of the

Company


Registered

Office

D – 6, Vivek Vihar, Phase – 1, New Delhi – 110095

Address for

Correspondence


Narain Nagar Industrial Estate, Bazpur Road, Kashipur,

District Udham Singh Nagar, Uttarakhand

The project site is located Latitude: 29°11'21.16" N, Longitude: 79°00'09.86" E

(central) and Altitude: 235.0 Meters (MSL). Corner coordinates of the existing site

is as below:

Sr. No. Point/Direction Latitude Longitude

1. A - SE 29˚11’16.07’’ N 79˚ 00’10.54’’ E

2. B - E 29˚11’19.35’’ N 79˚ 00’13.16’’ E

3. C - E 29˚11’21.16’’ N 79˚ 00’09.86’’ E

4. D - NE 29˚11’25.10’’ N 79˚00’11.46’’ E

5. E - NW 29˚11’25.10’’ N 79˚ 00’04.68’’ E

6. F - SW 29˚11’20.41’’ N 77˚ 00’01.29’’ E




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Fig: 03.01 – Location of the Project




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3.3 Site Description

The proposed expansion project to produce Mild Steel Billets/Ingots and MS


existing Induction Furnaces capacity by M/s Kashi Vishwanath Steels Private

Limited is situated at Narain Nagar Industrial Estate, Bazpur Road, Kashipur,

District Udham Singh Nagar, Uttarakhand. The area is situated in the survey of

India Topo Sheet No. 55O4 and Coordinates Latitude: 29°11'21.16" N, Longitude:

79°00'09.86" E. The nearest National Highway NH – 74: 0.30 km S (aerial) away

from the site. The nearest Railway station Kashipur is 4.5 Km NW away from the

site. Pant Nagar Airport is 48.71 Km SE (aerial) from the site.

3.3.1 Site Selection

At the existing site adequate transportation facilities are available for

transportation of product to Uttarakhand and other region of country. Hence

the proposed project will be beneficial and techno-economically feasible.

Hence, no alternative site is analyzed.

The main features of the site including environmental considerations that make

it suitable for proposed expansion of existing Unit are given below:

Availability of sufficient stretch of land with flat terrain in industrial Estate

(Narain Nagar Industrial Estate, Bazpur Road, Kashipur, District Udham Singh

Nagar, Uttarakhand)

No habitation in the plant site, hence no direct R&R issues

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.

No declared biodiversity parks/sanctuaries are there in the surroundings of

the site as Jim Corbett National Park is 24.05 km N away from the site

Nearness to source of main raw materials

Location of consumer centre

Convenient Rail & Road links

Uttarakhand is providing suitable Industrial environment with proper

infrastructure support.

Adequate availability of raw material, power and other infrastructure.




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Financial and social benefits with special emphasis on environmental

consideration and benefit to the local people will be kept as top priority for the

proposed project.

3.4 Size or Magnitude of Operation

The industry “M/s Kashi Vishwanath Steels Private Limited (KVS)” is a large scale

industrial unit with a total capital investment of Ten Crores only for the proposed

expansion. Annual Production of Mild Steel Billets/Ingots and Bars/Sections

products will be 2,00,000 MTPA each after proposed expansion through

augmentation in the existing Induction Furnaces capacity.

3.5 Project Description with Process Details (A Schematic Diagram/Flow Chart

Showing the Project Layout, Components of the Project etc.).








M/s KVS have proposed for replacement of the existing 5 Tons (02 Nos.) & 4 Tons

(02 No) Induction Furnaces with 6 Tons (03 Nos. - replacement of existing IFs) &

10 Tons (01 no. replacement & 02 nos. new) capacity Induction Furnaces and

modernize Continuous Casting (CCM) & increasing the output (speed) of

existing Rolling Mill through modernization to enhance the annual production

capacity from existing MS Ingots 57,600 TPA and Steel Bars 88,200 to Production

capacity of MS Ingots - 1,42,400 MTPA and Steel Bars - 1,11,800 so that

production could achieve 2,00,000 TPA Mild Steel Billets/Ingots and

Bars/Sections.

The finished products will be transported through the existing road network. Total

land acquired by the existing industry is 59817 Sq. m. Proposed production

facility along with the required utilities will be set up in part vacant land of the

existing premises. After proposed expansion total fresh water requirement will be

about 54.5 KLD. Water requirement for the project will be sourced from ground

water. The unit at full capacity will demand 26.5 MW of power, which shall be

supplied by UPCL. Existing DG Set is 63 KVA capacity, which to be replaced).




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Green insulated DG Set of 685 KVA (125, 160 & 400 KVA on standby basis) is

proposed (Proposed DG Set to be operated during emergency in case of

power failure only).

Table: - 03.02 Products Details





Note: W.r.t the above products, industry will manufacture MS Billets/Ingots for

existing rolling products facility or sold it directly. Steel Bars/sections will be

manufactured either using existing Billets/Ingots or through purchased Ingots

from other industries on campaign basis so that the maximum production

capacity will not exceed 2,00,000 MT/Annum each.

Plant

Facilities

Existing Proposed Total (after proposed

expansion)

Unit Capacity Unit Capacity Unit Capacity

Induction

Furnace

5 Tons

(02

Nos.)

4 Tons

(02 No)

57,600 6 Tons (03 Nos.

- replacement

of existing IFs)&

10 Tons (01 no.

replacement &

02 nos. new)

1,42,400 6 Tons (03

Nos.)

10 Tons

(03 Nos.)

2,00,000

Continuous

Casting

M/c

(CCM)

2

Strand,

4/7 m

radius

57,600 Modernization 1,42,400 2 Strand,

4/7 m

radius

Rolling Mill 1 88200 Modernization 1,11,800 -- 2,00,000

3.5.1 Process Description

The manufacturing process identified for the existing unit is one which is well

established and proven and presently being followed by majority of similar

manufacturing units mostly in small or medium scale sector.

Steel Melting Shop

Steel Melting Shop is having complete facilities right from Receiving and

Processing Yard for Raw Material, Charging Bays, Furnace Transformer, cooling




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towers, water softening plant, EOT Cranes, Storage Yards, Conveyor Systems for

feeding, Bin weighing system, Ladle heater, compressor, pumps, Electrical Power

and Control System, etc.

No additional facility in the Steel Melting Shop shall be required, except the

transformers to meet maximum power demand of the new Induction Furnaces

& desired modernization of existing CCM & Rolling mill. To achieve the proposed

production shop shall also adopt IFCC route as per the existing facility. The

production plan of the steel melt shop shall be based on production of 2,00,000

tons of cast Billet.

a) Induction Furnace

Induction furnace is basically furnaces meant for use of Sponge Iron as major

raw material to produce mild steel. These furnaces work on the principal of

electromagnetic induction. After the furnace is switched on, current start

flowing at a high rate and 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 field thus

generated cut through the packed charge in the crucible. As the magnetic flux

cut through the scrap and complete the circuit, they generate an induced

current in the scrap. The induced current as it flows the highly resistive path of

scrap mix, generate tremendous amount of heat and melting the scrap. 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 the 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.

The slagging & pouring usually takes 15 – 20 minutes and one cycle/heat is

completed in about 2 hrs. During charging of sponge iron, Ferro alloys & Scrap

and also during pouring, some hot gases and small amount of smoke (resulting

from burning of carbon & gangue materials in the charge) comes out from the

mouth(top opening) of the furnace. These gases & smoke are taken care of. For

10 ton furnace where up to 10heats can be obtained by using 70% sponge iron

and 30% melting grade pig iron/ ferro alloys/ scrap. The installed capacity and

number of heats can be calculated as below for 70:30 (sponge/ pig iron)

charge:




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1. Melting

2. Ceramic Crucible

3. Thermal Insulation

4. Lining with Sensor

5. Cable

5a. Current Spool

6. Cooling Coil

6a. Furnace Head

6b. Snout

7. Tee Snout

8. Yoke

9. Vibration Dampers

10. Antenna for

Ground Fault

Monitoring

Figure 03.02: Induction Furnace

Table 03.03: Induction Furnace Capacity (Existing & Proposed)

Parameters Existing After Expansion

Furnace capacity 5 Tons (02 Nos.) and

4 Tons (02 No)/heat = 18

Tons / heat

6 Tons (03 Nos. - replacement

of existing IFs) & 10 Tons (01

no. replacement & 02 nos.

new)/heat = 48 Tons / heat

Tap-to-tap cycle

time/min

120 120

Number of heat/day 11-12 12

No. of operating days 330 360

Equivalent liquid steel 1,45,800 2,00,000

Production of Cast

billet/ Ingots or Bars/

Sections tons/year

1,45,800 2,00,000

It may be seen from Table above that tap to tap time has been aimed at

approx. 120 minutes enabling production of 12 heats per day from each

Induction Furnace. The Induction Furnace lining will require repair/replacement




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after about 15-16 heats. Lining repair will be done in-situ. In order to ensure

uninterrupted operations a second crucible, lined and ready should be

available.

Thus, each furnace station will consist of two crucibles complete with all fitting

and auxiliaries installed adjacent to each other.

Molten metal in an induction furnace is caused to circulate automatically by

electromagnetic action. When alloy additions are made to molten metal, the

stirring action results in creating a homogenous product at a minimum time. For

making medium carbon steel in electric induction furnace, the foremost

consideration is the optimum utilization of the furnace with emphasis on

elimination of delays so as to save power i.e. the most effective cost.

However, time between tap and charge, charging time, power delays etc. are

items of utmost importance for meeting the objective of maximum output with

lower operational cost. First of all the crucible/furnace is brought to a vertical

position and after checking all safety conditions, power is switched on

immediately; a molten heel is formed at the bottom of the crucible. Now

sponge iron is charged in buckets by the crane and pig iron is charged either by

electromagnet or buckets by overhead crane. The charging usually takes

15minutes. Thereafter, the furnace lid is closed and melting continues for about

an hour. Alloy additions and de-oxidants are added as from the top into the

molten metal.

Once the furnace contains the full capacity of molten steel (1600 – 1650 °C);

slag is manually skimmed off from the top. The slag is skimmed into a slag pot

kept near the mouth of the furnace on the furnace platform. Next the hydraulic

tilting device is actuated and liquid metal from the ladle is discharged in there

factory lined central pouring trumpet, which then flows through the bottom

plate runners and comes up through bottom hole of the ingot moulds. Arranged

properly molten metal is poured through the tundish. Two sets of pencil ingot

moulds are usually kept, where one cools the other is prepared etc. for the next

pouring.

The most advantageous aspect of Induction Furnace is that they are relatively

low in capital cost as compared to other types of melting units. Its installation is

comparatively easier and its operation is also simpler. Among other advantages,

there is very little heat loss due to radiation from the furnace as the bath is

constantly covered and there is practically no noise in attending their operation.




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However, time between tap and charge, charging time, power delays etc. are

items of utmost importance for meeting the objective of maximum output with

lower operational cost. At the ladle treatment station, liquid steel is ringed with

nitrogen to homogenize its temperature and composition.

High Tension power supply is transferred to the converter through step down

transformers where power is converted from AC to DC. 605 KVA (132, 33, 440

KVA) Furnace Transformer has been provided with each furnace and 220 KVA

Auxiliary Transformer.

The three phases Oil Immersed Transformer is rugged designed to meet the

requirement of ladle refining operation. It will be of continuous duty. The

selection of secondary voltage is effected by means of triple pole remote

operated on load, tap changer. The transformer is designed for forced cooling

and the oil is circulated in the heat exchanger (mounted on tank) by means of

an oil pump, and is cooled by water. In the water circuit, a flow meter with

electrical contacts is provided which gives an alarm in case the cooling water

rate falls below the set value. The primary terminals of the transformer are

terminated on top of the tank into HV bushings and the secondary terminals in

heavy sectional copper bars.

DM Plant: Apart from the above, the electrical control panel of Induction

furnace needs to be cooled by De-mineralized water primarily to avoid any

electrical conduction through cooling water. To achieve this, 2 nos. of DM Plant

of capacity 10,000 LPD, each have been provided.

Cranes: 2x25/10 MT and 2x10/5 MT EOT cranes to handle the raw material and

finished product have been provided. All cranes will comply IS 3177 – Code of

practice for electric overhead travelling cranes and IS-807 – Code of practice

for electric overhead traveling cranes, which is meant for EOT cranes in steel

plants.

Cooling Water System: The system will take care of cooling water requirement of

Induction Coil, magnetic yokes, and water cooled cables. 2 nos. of Cooling

Towers of capacity 210 Cubic meters have been provided. While 2 nos. of

Cooling Towers of capacity 240 Cubic meters are proposed.

Ventilation Plant: Ventilation system for Air cooling of the electrical room and the

electrical equipment comprising of blower fan and exhaust fan, fan motor and




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filters are housed in the same building. Air from the blower leads to the electrical

room through ducts.

b) Continuous Casting Machine: The ladle containing liquid steel is placed on

the turret and brought over the tundish. The tundish act as a buffer and enable

the liquid steel to move homogeneously down through the nozzles, provided at

the bottom of the tundish into moulds. The automatic mould level controller

controls the steel level in the mould. The subsequent primary and secondary

cooling transform the liquid steel into billets of the required dimensions and is

drawn out with the help of a withdrawal and straightener unit and cut into

required length by the shear provided in each strand. Once a ladle is emptied

another ladle is brought into the casting position and the casting continues. The

billets are gradually shifted to the rolling mill through conveyer or stacked orderly

at the dispatch end for outside dispatch or for rolling plant. The details about the

cast number and quality of billets are marked on the billet stack.

CCM is used to produce billets of cross sections 100mm x 100mm to 125mm x

125mm directly from molten metal by passing the same through mould tubes

designed to produce specific sections. Molten metal passes through the mould

tubes by gravity where solidification of outer layer of the metal occurs due to

Mould tube cooling by cooling water. As the metal moves out of the tube &

progresses along a curve from vertical to horizontal direction, water through

nozzles is sprayed over the metal shell which results in thickening of the shell. This

thickness continuously increases with cooling as the metal (section produced

after passing through mould tube) progresses & the section finally becomes

solid. As the section becomes horizontal, it is passed through straightening &

withdrawal unit where it is straightened. The section (billet) is then cut online into

pieces of desired length.

c) Plant Water System: Water required in Cooling Tower as make up. Raw water

requirement for CT, DM plant, area cleaning system etc. shall be met through

bore-wells. Water tank of adequate capacity (depending upon equipment

requirement & workforce) has been constructed within the premises.

d) Compressed Air System: Compresses air is required primarily at three locations

in the plant viz. in Induction Furnace, in CCM & in Dust Extraction System (bag

filter).




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e) Fire Protection System: Adequate fire-fighting equipment has been provided

for each production unit. Following systems of fire protection has been provided

in the steel plant:

• Water hydrants network around all the shops.

• Smoke detectors in critical areas such as control rooms

• CO2 type portable fire extinguishers for electrical rooms flooding system and

• Foam type fire extinguishers near lubrication, hydraulic and fuel oil installation.

Adequate number of portable fire extinguishers will be provided at various

locations in the plant shed, LT panel room & DG set room.

f) Plant Electrical System: Plant Electrical System will have a 132/33/440/220 kV

outdoor type sub-station. The power supply through furnace transformers will be

supplied to furnace whereas power supply through auxiliary transformer which

will be used for EOT crane operations, CCM operations, furnace auxiliaries,

pumps for cooling water, lighting etc.

g) Emergency Back-up Power: 1 no. of 63 KVA silent type DG set has been

provided already which to be replaced & 685 KVA (125, 160 & 400 KVA on

standby basis) DG Set is proposed for power to the auxiliaries of plant when

UPCL power is not available. This will also be useful for emergency power to take

care of safe shut down of important auxiliaries of plant. During total power

failure, above DG set will also support for Emergency lighting for personnel

movement in some main location of steel plant.

h) Storage Yard: Raw material shall be brought to the yard by trucks are

unloaded and stacked in different piles by pay loaders.

i) Emission control System i.e. a compartment type bag house having 8 to 10

compartments with polyester felt filter bags is installed to comply with the

emission norm from the Induction Furnace. The flue gases from furnace is being

drawn through an interconnecting ductwork by induced draft fan & exhaust to

the chimney. The system will meet the emission standards during operation of

the plant and ensure clean plant operation. The fume exhaust hood with duct

provided around the furnace circumference to capture the fumes generated

during tapping operation. Cyclone separator & wet scrubber are also provide to

control the emission. Emission level at the outlet for Induction Furnace is ensured

less than 50 mg/ Nm3.




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Reheating Furnace

Reheating furnace is used for heating of billets before hot rolling in Rolling Mill.

Coal based furnace is used as fuel in reheating furnace. The billets

manufactured as described above are cut into required sizes and then fed into

a reheating furnace where it is reheated to temperatures up to of 1050°C; the

rate at which heat is absorbed by the billet has to be controlled to avoid partial

rolling.

At present Billets are directly fed from CCM to the Rolling Mill bypassing the

Reheating Furnace. Reheating Furnace is used only when there is no feed from

CCM.

Rolling Mill

The billets produced in CCM (Size-100x100 to 125x125 mm) will be fed directly to

Rolling Mill of the steel plant. There will be One Hi speed rolling mill for of

capacity 1x20 TPH for production of TMT bars varying from 12mm to 28mm in

size.

Proposed expansion may leeds a feasibility to produce Mild Steel Billets/Ingots

thru existing/proposed facility & it may either used for making Bars/Sections by

itself or sold to the market as such. Meanwhile it may purchase the Billets/Ingots

from respective industries/local market for making Bars/Sections as per

eventually changes in the market.




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Fig - 03.03: Schematic of process flow




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3.6 RAW MATERIALS

3.6.1 Quantity requirement

The basic raw materials required for producing liquid steel are Sponge Iron, Iron

Scrap, Ferro-Alloys etc. The main raw materials and their annual requirement

along with the source of the raw materials for the proposed Project are given

below:

Table 03.04: Annual Requirement of Raw Material with source of supply

Table 03.04.01: For making of MS Billets/Ingots (Melting Division)

S.

No.

Raw Materials Ratio Quantity (Tons/annum) Source of


1. Sponge Iron 77.0 47935.64 118507.56 166443.20 Koenjhar,

Orissa

2. Iron Scrap/ Pig Iron 22.50 14007.17 34628.83 48636.00 Delhi & UP

4. Ferro-Alloys 0.50 311.27 769.53 1080.80 Raipur & UP

Total 100 62254.08 153905.92 216160.0

Table 03.04.02: For making of MS Bars/Section (Rolling Division)

S.

No.

Raw Materials Quantity (Tons/annum) Source of


1. MS Billets/Ingots 89543.0 113502.54 203045.68 Open Market

3.7 Mass Balance

Table 03.05: Mass Balance of MS Billets/Ingots

Inputs Outputs


Sponge Iron 77.0 MS Billets/Ingots 91.8

Iron Scrap/ Pig Iron 22.50 Slag 6.2

Ferro-Alloys 0.50 Burning losses 2.0

Total 100 Total 100

Table 03.06: Mass Balance of MS Bars/Section

Inputs Outputs


MS Billets/Ingots 91.8 MS Bars/Section 90.42

Mill Scale 0.5

End cutting 0.5

Burning losses 0.38

Total 91.8 Total 91.8




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3.6.3 Storage facility for raw materials and products

Existing storage facilities is adequate for the raw materials, products etc.

Table 03.07:- Details of Storage Facilities

Sl. No. Storage Facility for Facility

1. Raw Materials Warehouse.

2. Products Finished good store.

3. Industrial Effluent No waste water generation from industrial

process except CT Bleed & DM (Softener)

Plant reject which shall be reused in the

green belt development & Dust Suppression

respectively.

Treated sewage (18.0 KLD) will be reused in

green belt for irrigation purpose. No effluent

will be discharged outside the premises.

4. Hazardous Waste TSDF/Authorized recyclers

3.6.4 Machinery & Equipment Details

The detailed list of machinery & equipment’s in the industry are appended in the

Tables below:-

Table 03.08: List of the machinery & equipment’s

Sr.

No.

Facilities Existing (Nos.) Proposed

(Nos.)

Total (Nos.)

1. 3200 kW / Induction

Furnace

5 Tons (02 Nos.)

4 Tons (02 No)

6 Tons (03 Nos. -

replacement of

existing IFs)& 10

Tons (01 no.

replacement &

02 nos. new)

6 Tons (03 Nos.)

10 Tons (03 Nos.)

2. CCM (2 Strand,

4/7 m radius)

01 No. 01 No. 2 Nos.

3. Coal based Furnace 2 Nos.

(Reheating at

Rolling Plant)

-- 2 Nos.

4. 3200 kW Furnace

Transformer

2 Nos. 2 Nos. 4 Nos.

5. 1000 kVA Auxiliary

Transformer

2 Nos. 1 Nos. 3 Nos.




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6. E.O.T Crane 4 Nos. 4 Nos. 8 Nos.

7. Cooling Tower 3 Nos. 2 Nos. 5 Nos.

8. Water Softener Plant 1 Nos. 1 Nos. 2 Nos.

9. Air compressor 3 Nos. 3 Nos. 6 Nos.

10. Mono Block pumps &

Bore well

Lot One No. Bore

well

Two No. Bore

well

11. H.T Sub-station with

breaker, Control

Panel, Control Cable

Lot Lot Lot

12. L.T Panel, M.C.C

Panel, VCB, DBS,

FDBS, LT Cables, Light

lifting, Man Cooler

Fan, Switch Gear

etc.

Lot Lot Lot

13. Weigh Bridge 60/100

Ton Capacity

2 No. 1 No. (60 Ton) 3 Nos.

14. Mould Stand,

Charging Box,

Tundas, Teramer

Table, Span etc.

Lot Lot Lot

3.7 RESOURCE OPTIMIZATION/RECYCLING AND RE-USE ENVISAGED IN THE PROJECT

100% of waste water will be recycled and Zero discharge condition will be

maintained.

Metal recovery from furnace slag will be taken & reused for road

development.

The liquid steel produced will be used in a manner to produce hot billet

suitable for rerolling, thus online hot rerolling practice is being adopted.

Waste water generated from water softener system will be used for dust

suppression purpose after neutralization.

Treated Sewage will be reused in the Green belt for irrigation purpose.

Mill scale generated in the rolling mill will be sold to Ferro Alloys Plant or

other authorized persons.

Iron bearing dust will be reused in the IF’s itself.

The ash which will be generated from coal Furnace in the form of fly ash

and bottom ash sold to brick Kiln.

3.7.1 DOMESTIC SOLID WASTE RE-USE




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The total quantity of domestic wastes generated is about 100.0 kg/day which

will be segregated at source, collected in bins and composted. The composted

waste will be used as manure for landscape development.

3.8 WATER, ENERGY/POWER REQUIREMENT & SOURCE

3.8.1 Water

The water demand will be met from ground water source i.e. Borewell. The

requirement of water for the unit is for domestic, industrial purposes. Details are

appended in section 3.9.1 later in the report.

3.8.2 Power

After proposed expansion, the Unit at full capacity will demand 26.5 MW of

power, which shall be supplied through Grid (UPCL). Existing power demand is

16.5 MW.

Existing DG Set is 63 KVA capacity, which to be replaced. Now company

proposes to install D.G. set of 685 KVA (125, 160 & 400 KVA on standby basis)

each to serve as an alternative source of power supply (for essential services) to

this unit during emergency in case of power failure.

3.9 WASTES GENERATED & SCHEME FOR THEIR MANAGEMENT/DISPOSAL

3.9.1 Water demand and wastewater/effluent discharge

Source of water supply: Ground water i.e. Bore wells

Total number of employees: 500 Nos.

Per capita water demand: 45 LPCD, therefore water demand for human

consumption is 22.5 KLD.

Water requirement, waste water generation & mode of Disposal:

Sr.

No.

Particulars Existing

Water

requirement

(KLD)

After proposed

Expansion Total

water requirement

(KLD)

Additional

water

requirement

(KLD)

1. Industrial Cooling 60.0 70.0 10.0

Scrubbers 1.0 1.0 --

2. Miscellaneous i.e. Dust 2.5 2.5 --




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suppression

3. Domestic Purpose 18.0 22.5 4.5

4. Green Belt 24.0 40.0 16.0

Total 105.5 136.0 30.5

Total water requirement: 136.0 KLD

Fresh water requirement: 54.5 KLD

Recycle/reuse water: 81.5 KLD

Sr.

No.

Requirement

for

Water

Consumption

Process

Losses

Waste

water

generation

ETP /STP

losses

Recycled/

Reuse

A. Industrial Process

Industrial

Cooling

70.0 5.5 00 64.5

Scrubbers 1.0 1.0 00 00

Miscellaneous

i.e. Dust

suppression

2.5 2.5 00 00

Total

(Industrial)

73.5 9.0 00 64.5

B. Domestic 22.5 4.5 18.0 00

C. Green belt 40.0 40.0 00 00

Total input water to STP 18.0 1.0 17.0

Total (KL/Day) 136.0

54.5 (Fresh) +

81.5

(Recycle)

53.5 18.0 1.0 81.5

Note:

18.0 KLD of waste water will be generated from the Domestic uses after

proposed Expansion. All the generated sewage will be treated in the

proposed STP & reuse in green belt.

Zero discharge will be achieved.




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Fig: Water Balance




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3.9.2 TREATMENT SCHEME FOR WASTE WATER

Brief Description of proposed STP

The generated sewage will be treated up to tertiary level in Sewage Treatment

Plant (STP). The entire (100%) treated sewage from STP of 25.0 KLD capacity will

be reused in the Green Belt.

The installed capacity of STP will be 25.0 KLD, Various treatment units which will

engaged in sewage treatment and listed below.

1. Bar Screen cum O&G Trap

2. Equalization Tank

3. Anaerobic Tank

4. Aerobic Tank

5. Tube Settler

6. Multi-grade Sand Filter

7. Activated Carbon filter

8. Cartridge Filter

9. Ultrafiltration Unit

10. UV Unit

Anticipated Characteristics of sewage:

COD : 300 – 500 mg/l

BOD : 200 – 400 mg/l

pH : 7.0 – 8.0

TSS : 400 – 500 mg/l

O & G : <10mg/l

Fecal Coliform : Not specified

Anticipated Characteristics of treated sewage:

COD : < 50 mg/l

BOD : < 10 mg/l

pH : 6.5 – 9.0

TSS : < 10 mg/l

O & G : Nil

Fecal Coliform : < 100 MPN / 100 ml

Turbidity : < 2 NTU




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Treatment Scheme:

The sewage will be treated through screening cum O&G trap, equalization cum

preconditioning tank, Anaerobic digestion, Aerobic digestion, Tube settler, Multi-

grade sand filter, Activated Carbon Filter, Cartridge Filter, Ultrafiltration followed

by UV unit.

Stage 1: Preliminary Treatment: Septic Tank, Screening cum Oil & Grease Trap,

Raw sewage cum collection sump (Equalization Tank).

Stage 2: Primary Treatment: Anaerobic Digester

Stage 3: Secondary Treatment: Aeration Tank, Clarifier

Stage 4: Tertiary Treatment: Supernatant Tank, Multi-grade Sand Filter, Activated

Carbon Filter, Cartridge Filter, Ultrafiltration Unit, Ultra Violet Unit and Filter Press.




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3.9.3 Rainwater Harvesting & Groundwater Recharging

Rainwater harvesting in the present scenario holds vast potential in controlling

runoff and resulting water logging problems besides assuring an alternative

source of water and a supplement to existing natural resources in a wide variety

of circumstances.

A rainwater harvesting system comprises components of various stages namely-

Transporting rainwater through pipes or drains, Filtration, Storage in tanks for

reuse or recharge.

\

Fig: 03.04 – Design of Typical Recharge Pit

Two major systems that are ideal for industrial developed areas of are artificial

ground water recharge, and roof top rainwater harvesting (The mode NBC-

2005). The mode of harvesting are basically site specific and depends the

amount of precipitation, availability of total number of rainy days, nature of

storage structures, nature of aquifers etc.

In general CGWB norm suggest not to artificially recharging if water table is less

than 5.0 m. Also recharging is not recommended for aquifers with TDS levels

higher than 4000 mg/L or high levels of chemical composition like Nitrate,

Fluoride, and Arsenic etc.




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In this project it has been planned to provide 02 Nos. rainwater harvesting

recharge pit (Trench) and 02 No. rain water harvesting tank. Rainwater

collected from the rooftop would be diverted by drain pipes to a settlement /

filtration tank, from which it would flow into the recharge pit. Water filters would

be provided prior to the chamber to arrest and separate any suspended matter

present in the rain water. The recharge pits are designed with three concentric

circular chambers in which the outer chamber is filled with sand, the middle one

with coarse aggregate and the inner most layer with pebbles.

Fig : 03.05 Cross section of Recharge Trench

Any surplus runoff which overflows the recharge pits would be collected in the

unpaved areas and allowed to get absorbed. Also there would be proper storm

water drainage network to collect the excess storm water runoff.

Rain Water Harvesting (RWH) System Calculation

Based on the area statement, the total roof/surface area receiving the rainfall is

as follows:

Total plot Area: 59817.0 m2

Proposed ground coverage area of the unit receiving: 11437.0 m2




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As per data available, the annual rainfall in Kashipur: 1296.85 mm

Total rainy days in a year: 80 days

Average rainfall per day: 1296.85 /80 = 16.21 mm/day

The intensity of rainfall considered is 16.21 mm/hr, (Heavy rain fall) which

generally occurs in one hour (for the purpose of calculations, the higher value of

rainfall intensity is being considered in view of unpredictable nature of rainfall for

arriving at total storage volume)

Therefore, intensity of rainfall: 16.21 mm/hr

RUN-OFF (Discharge)

Q = 10*C*I*A

Where:

Q: run off in cubic meters/hr

C: Co-efficient/Impermeability factor of the surface

I: Intensity of rainfall (11.56 mm/hr)

A: Total drainage area in hectare

Co-efficient of Run off/Impermeability Factor [C]

S. No. Description of Surface Value of run off

coefficient factor of the

surface (C)

1. Terraces, Hard paved surfaces 0.9-0.95

2. Paved Surfaces, roads 0.85-0.90

3. Gravel path, loosely paved walk, rocky

surface

0.70-0.85

4. Brick paved, Compact ground 0.50-0.70

5. General Ground 0.50-0.60

6. Natural Ground, sloping ground 0.20-0.50




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Run Off Calculation:

(i) Run off from ground coverage area of the existing unit

Q1 = 10*0.8*16.21*11437.0 /10000 (since 1 hectare = 10000 m2)

= 148.32 m3/hr

(ii) Run off from Landscape of the existing unit

Q2 = 10*0.6*16.21*11963.0 /10000

= 116.35 m3/hr

Total run off discharge (Q): Q1 + Q2 = 148.32 + 116.35 = 264.67 m3/hr

Considering the first flush of rainwater after a dry period shall be allowed to run

to waste as it will be contaminated with dust, bird droppings etc.

Total run off = 0.9 * 264.67 = 238.20 m3/hr

Considering retention storage of rain water harvesting is 30 min

Total capacity of RWH storage: 238.20 *30/60 = 119.10 m3

The total no. of RWH proposed: 02

Capacity of each RWH: 59.55 m3 (approx. 60 m3)




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Fig. 03.06 SCHEMATIC FOR RAIN WATER HARVESTING

Sedimentation Tank

Filtration Tank

Recharge pit

well

Coarse Sand

Charcoal

Pebbles

Gravels

Manhole

Vent




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3.9.4 Air pollution Sources

The major air pollution sources from the industry are DG set and Furnace

sections. These sources are provided with stacks of adequate height so as to

disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen

without affecting the ground level concentrations. Cyclone separator, Bag Filter

and wet scrubber are installed to mitigate the emissions. However electricity will

be used for melting in the proposed furnaces.

The sources of air pollution, type of fuel used, fuel consumption and chimney

heights for each of the air pollution sources of the proposed project are

indicated in the following table:-

Table: 03.09 Air pollution sources, fuel consumption and chimney height details

SI.

no.

Stack attached

to

Fuel

used

Fuel

cons

umpti

on

No. of

stacks

Stack

height

Air pollution

control

Unit

Predicted

emissions

1. Induction

Furnace

Electri

city

-- Existing

– 04

Propos

ed -02

30 m

AGL for

each

Cyclone

separator, Bag

Filter and wet

scrubber with

each IF’s)

Particulate

matter, SO2

and NOx

2. Coal Based

Furnace 02 Nos.

(Reheating)

Coal 20.0

MTPD

Existing

- 02

Nos.

32 m

AGL for

each

Cyclone

separator, Bag

Filter and wet

scrubber

Particulate

matter, SO2

and NOx

3. Green insulated

DG set Existing 63

KVA (to be

replaced)Propos

ed 685 KVA (125,

160 & 400 KVA on

stand by basis)

HSD 112

L/hr

Appr

ox.

03 5 m ARL

for each

DG set

Stack SO2, NOx,

SPM

3.9.5 Noise Pollution Details

The major source of noise pollution in the industry is the DG set for which

acoustic enclosure is proposed. Also ambient noise levels will be ensured within

the ambient standards by inbuilt design of mechanical equipment and building

apart from vegetation (tree plantations) along the periphery and at various

locations within the industry premises. All noise generating machines will be

spread at different places within the cover sheds.




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3.9.6 Solid Waste Details

The quantity of solid waste generated from the proposed industry is detailed in

the following table.

Table: 03.10 Solid waste generation during the operation phase

Total No. of Employees 500

Assuming per capita solid waste generation rate as 0.2 kg/capita/day

Quantity of solid waste generated 100 kg/day

Organic solid waste : 60 % of the total waste 60 kg/day

Inorganic solid waste : 40 % of the total waste 40 kg/day

Disposal of domestic solid waste Domestic wastes are

segregated at source,

collected in bins and

composted.

3.9.7 Hazardous waste generation and its management during the

manufacturing process

Hazardous Wastes (spent oil) generated during Operation phase dealt as per

Hazardous and Other Wastes (Management and Transboundary Movement)

Rules, 2016.

Table:- 03.11 Summary of the total quantity of hazardous & E-Waste:

Sl.

No.

Source Quantity of hazardous

waste

generated

Category

according to

Schedule I of

hazardous

waste

Treatment/ Disposal

Lit/month Lit/annum

1. Waste oil

from DG set

50 L 600 L 5.1 Handed over to


/re-processors

2. E-Waste As & when

generated

As & when

generated

Handed over to


/re-processors

3.9.8 Environmental Impacts and Management Plan

3.9.8.1 Environmental management plan during construction phase (Table: -

03.12




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attributes


Nature Duration Reversibility Significance,

Mitigative measures

Dismantling of

Existing

Induction

Furnace

Air Pollution

(Dust)

Excavation of

the area, Gas

cutting etc.

Direct

Negative

Short

Term





generation

from

hammering/

dismantling

activities

Direct

Negative

Short

Term




Land use Storing of

scrap, waste

refractory

bricks

Direct

Negative

Short

Term

Reversible Insignificant, as

storage is temporary

Water Pollution Potential for

seepage from

the waste

storage area.

Direct

Negative

Short

Term

Reversible Significant, Proper

care of the Storage

area shall be taken.

Temporary check

dam along temporary

storage area shall be

made, if required.

Transportation

of scrap /

spares /

waste

material /

construction

Air Pollution

(Dust & Gases)

Transportation

of scrap /

waste material

by trucks

Direct

Negative

Short

Term

Reversible Medium, Regular

emission checks shall

be performed.


generated

Direct

Negative

Short Reversible Insignificant, Regular

vehicle maintenance




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material from loading /

unloading and

movement of

vehicles

Term shall be done. PPE

shall be provided.

Construction

activities

Air Pollution

(Dust & Gases)

Operation of

construction

machinery,

welding &

others

Direct

Negative

Short

Term

Reversible Insignificant. PPE shall

be provided to

workers


from

construction

activities

Direct

Negative

Short

Term


be provided to

workers

Land Use Storage of

spares,

Refractory

Direct

Negative

Short

Term

Reversible Insignificant. Storage

is temporary and

during construction

period only

Disposal of

scrap / waste

material

(including

refractory)

Air Pollution

(Dust & Gases)

Due to

movement of

Vehicles

Direct

Negative

Short

Term


be provided

to workers

Noise Pollution Due to loading

/unloading

Direct

Negative

Short

Term

Reversible Insignificant. Regular

vehicle maintenance

shall be done. PUC

vehicles are allowed

for transportation. PPE

shall be provided

to workers

3.9.8.2 Environmental Management Plan during Operation Phase




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attributes


Nature Duration Reversibility Significance, Mitigative

measures

Transportation

of the Sponge

Iron, Pig Iron &

Alloys to the

site

Air Pollution

(Dust & Gases)

Haul road dust

emission.

Gaseous

emissions due

to Vehicle

exhaust

Direct

Negative

Short

Term

Reversible Water sprinkling shall

be done where

material will be

unloaded in bins.

Regular vehicle

maintenance and

pollution check shall

be done.

Besides, the

management will

ensure proper usage

of the PPE’s by the

workers to avoid any

exposure to dust.

Noise Pollution Noise pollution

due to

unloading of

raw material

and vehicle

movement

Direct

Negative

Short

Term

Reversible Low, the unloading will

be done in covered

area from low height.

• PPE shall be provided

to the workers working

in the area.

Operation of

Induction

Furnace

Air Pollution,

Thermal

Pollution

In induction

furnace the

melting of

scrap, pig iron

and alloys will

take place.

Direct

Negative

Long

Term

Reversible Cyclone separator,

Bag Filter and wet

scrubber with each

Induction Furnace) to

reduce particulate

matter emissions from




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During melting

there may be

some fugitive

emission.

stack to keep the level

below 50 mg/Nm3 and

fugitive emissions in the

surrounding areas.

Water

Pollution

Backwash

water from DM

Plant & CT

bleed

Direct

Negative

Long

Term

Reversible Significant.

Neutralization Pit shall

be installed to treat the

waste water and shall

be used for dust

suppression & green

belt.

Noise Pollution Due to furnace

operations

Direct

Negative

Long

Term

Reversible Management will

ensure proper usage of

the PPE’s by the

workers to avoid any

exposure to dust.

Solid waste

generation

During liquid

steel making

process slag

will be

generated

Direct

Negative

Long

Term

Irreversible Slag generated during

the process shall be

used for road /area

and land

development.

Billet Caster

Casting of

Billets

Consumption

of

water

Cooling of

mould and

billets

Direct

Negative

Short

Term

Reversible Insignificant. Water

recycled back after

cooling in Cooling

Towers. Only make-up

water is required

Solid waste

Generation

Generation of

Scales

Direct

long Reversible Scale shall be

recovered in Settling




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Term Tank and recycled in IF

Generation of

scrap (end

cuts)

Direct

long

Term

Reversible Reused in IF’s

Noise pollution Caster rollers

(rolling

noise)

Direct

short

Term

Reversible Ear plug/muff shall be

provided to the

employees working in

that area

Rolling Mill

Rolling of

Billets

Water

Pollution

Cooling of

rollers and

flushing of

scales

Direct

Negative

Short

Term

Reversible Water for cooling of

rollers and mill scales

shall be taken in

Settling cum Oil &

Grease trap where oil

and mill scale shall be

separated out and

treated water shall be

recycled.

Hazardous

Waste

Generation

Used Oil

Direct

Negative

long

Term

Irreversible Spent oil from DG set

and from Oil & Grease

trap shall be sold to the

registered recycler only

Solid Waste

Generation

Cobbles, end

cuts (Scrap)

and Mill scale

Direct

Negative

long

Term

Reversible Mill scale shall be

removed from the

Settling pit and Shall be

used in IF’s.

DG Set




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Operation of

The DG Set

Air Pollution,

HW

generation

Flue gas

emission,

used oil

generation

Direct

Negative

Short

Term

Reversible The DG will be

operated in case of

power failure only.

Green DG sets shall be

installed. Spent Oil will

be dealt as per

Hazardous and Other

Wastes (Management

and Transboundary

Movement) Rules,

2016.

Noise Pollution Generation of

noise during

DG Set

operation

Direct

Negative

Short

Term

Reversible The DG Sets will have

acoustic enclosure to

minimize the noise.

Domestic Waste

Operation

and

of Domestic

utilities

Water

Pollution

Operation of

Washroom,

toilets –

Waste water

generation

Direct

Negative

long

Term

Reversible The sewage will be

treated through

proposed STP & reused

in green belt.

Solid Waste

Generation

Inorganic &

Organic waste

of Domestic

activities

Direct

Negative

long

Term

Reversible The domestic wastes

are segregated at

source, collected in

bins and composted.

Green Belt Development

Development

and

maintenance

Reduction in

Air Pollution

and Noise

Plantation of

trees With in

Premises to

Direct

Positive

long

term

Reversible Positive Impact due to

development of a

proper green belt




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of Green Belt Pollution cover 33% of

the area

along the periphery of

the premises. This will

act as barrier for air

emission and noise

Socio-economic Development

Employment

Generation

Direct

Positive

Positive Impact due to

direct employment of

persons from the

nearby area.

Substantial benefits in

the form of contracts

to local agencies for

different services.

Employment

generation in transport

sector for

transportation of raw

material and finished

goods




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3.9.8.3 Environment Management Cell

An Environment Management Cell has been constituted to review, assess and

monitor the progress of Environmental Management Plan implementation. Plant

in- charge is the head of cell. If necessary, the cell invites experts from the plant

or outside.

Considering the importance of the pollution control and environmental

protection, a set of personnel will be identified from different units of the plant

such as infrastructure, construction, technical, operations, maintenance,

industrial safety, waste management, human resource and contract and

material management wings of the project, who shall also work full time for

implementation of various components of Environment Monitoring Program such

as the maintenance and operation of pollution control systems, monitoring of

pollutants including development of green cover.

The group has meets periodically and monitors the progress made with respect

to Environment management plan implementation and initiates the measures as

and when required.

3.9.8.4 Environment Monitoring Program

Monitoring of environmental factors will enable us to identify the changes in the

environmental impacts at various locations. To ensure the effective

implementation of the EMP, monitoring of ambient air quality, stack emissions,

analysis & monitoring of water environment and noise level will be carried out as

required / specified by statutory authority.

Table: - 03.13 Environmental Monitoring at Work Zone

Sr.

No.

Place of monitoring Parameters of

pollution

Frequency of

monitoring

1. Stack emission Temperature, Velocity,

Gas discharge, PM,

NOx and SO2

Carried out

Quarterly

2. Ambient air quality at

plant boundary and

nearby habitation

PM2.5, PM10, NOx, SO2,

O3, Pb, CO, NH3, C6H6,

As, Ni, BaP

Quarterly at 2

locations

3. Monitoring of surface and As per IS:10500 and Carried out once




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ground water quality

surrounding areas of

product storage site

CPCB norms in 3 months

(seasonal)

4. Noise monitoring near

fans, product house, raw

material yard and plant

boundary

Leq dB(A) Work zone noise

levels once in a

month, Ambient

noise levels once

in 3 months

5. Effluent generated within

the plant

pH, SS, TDS, COD, BOD.

temperature, oil and

grease

Daily

Note: The monitoring will be carried out as per Consent conditions and in

consultation with UEPPCB. In future the EC compliance condition will also be

included.

Capital and recurring cost earmarked for environmental protection measures:

Cost for Proposed project activity is Rs.10.0 Crores. Cost of EMS is 0.50 Crores

(Proposed Scenario).

Expenditure earmarked towards the local area development, Social Welfare

programme and Ecological conservation (ESC): 2.5 % of the project cost i.e.

0.25 Crores.

3.9.8.5 Risk Reduction Measurement & Recommendation in view of Safety

Consideration

There will be a full-fledged safety section forming part of the plant. This is

catering the needs of safety supervision of all units coming under the operating

plant. The main responsibilities of this cell are as follows:

All construction work places will be inspected for any unsafe conditions and

unsafe practices. Any unsafe condition or unsafe practices will brought to the

notice of project management enabling remedial actions to be taken.

Storage site should be confined & identified properly.

Wind indicator should be provided at the highest level of the plant to know

the wind direction.




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Provision of flameproof electrical fittings / equipment’s.

Proper maintenance of earth pits.

Strict compliance of security procedures like issue of identity badges for

outsiders, gate passes system for vehicles, checking of spark arrestors fitted to

the tank lorries etc.

Strict enforcement of no smoking.

Periodic training and refresher courses to train the staff in safety firefighting.

Employee training and education will be carried out.

Structural fireproofing in the process area could be considered as a safety

measure in the light of probable spill and fires in the area.

Emergency drills should be carried out periodically to ensure preparedness

must continue.

SOPs to be documented & must be kept updated on priority.

Good housekeeping, use of PPE, Engineering controls, Enclosure processes,

scrubber system, display of safety boards, SOP of loading / unloading, safety

shower etc. are important safety measures have taken to keep these

chemicals within TLV.

Appropriate personal protective equipment will be provided & ensure the

usage of them.

Water storage of adequate capacity to meet the requirements of water for

firefighting purposes.

Fire hydrants and automatic sprinkler system. Diesel driven pumps and

headers to supply water to fire hydrant network.

Equipment required for personal safety like blankets, gloves, apron, gum

boots, face mask helmets, safety belts, first aid boxes etc. will be provided.

The steel manufacturing industry is labor intensive and uses large scale and

potentially hazardous manufacturing processes. The industry experiences

accident rates that are high compared with some other manufacturing

industries. Some examples of such hazards likely to occur in Induction Furnace,

Continuous casting machine (CCM), Billet Caster and Rolling Mill, at M/s KVS are

given below:

These mainly impact on those working within the industry, although health

hazards can also impact on local communities.

1. Fire at Lubrication and Hydraulic oil installations

2. Physical Hazards due conveyor system, material handling




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3. Fugitive Dust of Raw Material Handling at charging bay, storage yard

4. Collapse of Structures/Fall of Material, stacking failure

5. Loading/ Unloading failures

6. Electrocution/ Electrical Hazards

7. Accidental Spillage of hot molten metal

Physical Hazards onsite

1. Dust Exposure at coal crushing area (reheating furnace at Rolling Plant)

2. Fall of Sling rope of EOT Crane during material handling

3. Accident due to Conveyor feeding system

4. Slip/Trip/ Fall due to improper stacking of material

5. Contact with Hot molten Mild steel

Loading/Unloading operation/ Storage

1. Approach of heavy good vehicles for unloading material

2. Excessive Dust during Loading/unloading operation

3. Conveyor moving parts

4. Cleaning of overflows

5. Unauthorized passages, travelling over transportation system

6. Motor overloading

7. Unclean platforms causing staggering and falls

Hazards in Induction Furnace

1. Heat Radiation

2. Exposure to molten metal Fumes

3. Electrical hazards.




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Table 3.14: General Risk Assessment

S. No. Hazards &

Details

Persons &

risk

Control Measures Action Plan in case of

Emergency

1. Induction

Furnace- Fire

hazard caused

by

fuels/ignitable

substances

Persons

working in

the Furnace

area

Emergency alarm to be put on to

signal the emergency.

Emergency Kit is kept ready near the

plant.

Fire -fighting equipment/ Foam type

extinguishers on vehicles and

mounted on walls are kept readily

available.

Water hose is provided.

No smoking zone is declared.

Plant workers are trained to fight fire.

Switch off the system

Fire extinguishers are to be

used immediately.

Water hose will be operated to

set out the fire depending on

the situation.

Outside fire brigade is to be

called if the fire cannot be

extinguished immediately.

Inform the occupier /manager

and activate the onsite

emergency plan.

Immediate first aid to the

victims and sent to the hospital

for treatment.

2. In case of

Furnace crack,

molten metal

may leak

causing splash

of hot metal.

Persons

Working in

the tapping

area.

Continuous monitoring of Furnace

shell is done to maintain and observe

proper temperature.

Movement of staff and labour is not

permitted near the furnace.

Heat zone is displayed near the

furnace.

Immediately drain out the

Furnace by pouring or tapping

out. Molten splashed metal is

allowed to cool down before

removing.

Further process is stopped till

repairs are conducted.




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Safety shoes, safety goggles, hand

gloves, apron and safety helmet

provided to the workers.

In case of Fire, Fire-fighting

equipment is used to set out

the fire.

3. Molten hot

metal may fall

on Human

body.

Persons

working in

the

tapping

area.

Whole process is done under super

vision of qualified/trained persons.

Only trained labours are allowed with

proper heat proof dress/gum boots/

aprons.

Entry of other workers/persons is

strictly prohibited.

No entry zone should be

declared.

First aid should be given to the

victim and sent to the hospital

for further treatment.

4. Hoist rope

breakage in

E.O.T Crane.

Persons

standing

below the

crane, bay

and nearby

areas.

No movement of strange people in

crane bay and nearby areas.

Frequent checking of rope and other

load bearing material before process

is started.

Cranes are not allowed to operate

without line clear signal.

Weak rope is immediately replaced.

Crane movement is carried out

only after getting the signal of

line clearance.

5. Electrical

Transformers –

Electrical shock

and Fire.

Persons

near the

transformer

Shock proof insulated PCC platform. Cut off power supply.

Treat the injured for electrical

shock.

If fire is caused, immediately

fight fire with available

resources, summoning outside

help if necessary.




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6. Charging of

scrap and other

material in

furnace and

moving parts

like fly wheel,

roller stand and

other

accessories.

Cut/burn and

fire hazards

may be

possible.

Persons

working in

the raw

material

handling

yard and

in the

furnace

floor.

Workers are provided with gloves and

proper equipment to handle and

feed the scrap.

Workers charging the materials in the

furnace are equipped with fire proof

dress and proper equipment to

handle the scrap and material.

Fire proof system made available and

firefighting equipment like

extinguisher and water with sufficient

number of points easily available.

Only trained and qualified people will

operate the furnace.

Immediate first aid should be

given to the victim by trained

person and refer to the

doctor/hospital for further

treatment.

7. Control Rooms-

Electrical

Shocks

Persons

working in

the control

room

Earth leakage circuit breaker

installed.

Main supply will be

immediately shut off.




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4.0 SITE ANALYSIS

4.1 Connectivity:

Proposed Expansion & modernization of the existing Unit to produce Mild Steel

Billets/Ingots and Bars/Sections (Capacity - 2, 00,000 MTPA each) through

augmentation in the existing Induction Furnaces capacity is located at Narain

Nagar Industrial Estate, Bazpur Road, Kashipur, District Udham Singh Nagar,

Uttarakhand. The nearest National Highway N NH – 74 is 0.30 km S away from the

site. The nearest Railway station Kashipur is 4.5 Km NW away from the site. Pant

Nagar Airport is 48.71 Km SE (aerial) from the site.

4.2 Land Use:

M/s Kashi Vishwanath Steels Private Limited (KVS) has acquired 14.78 Acres

(59,817.0 Sq. m) land in notified industrial estate (Notified by Govt. of

Uttarakhand vide letter no. 1052/ID/07-Industry/2004-05, dated 15 January 2005)

at Narain Nagar Industrial Estate, Bazpur Road, Kashipur, District Udham Singh

Nagar, Uttarakhand.

4.2.1 Site Selection:

At the existing site adequate transportation facilities are available for

transportation of product to Uttarakhand and other region of country. Hence

the proposed expansion/modernization project will be beneficial and techno-

economically feasible. Hence, no alternative site is analyzed.

The main features of the site including environmental considerations that make

it suitable for proposed Expansion & Modernization of Existing Herbal Extraction

Unit are given below:

Availability of sufficient stretch of land with flat terrain in industrial Estate

(Nagar Industrial Estate, notified by Govt. of Uttarakhand)

No habitation in the plant site, hence no direct R&R issues

Suitable topography and geography for construction of facilities

Suitable seismic zone

The plant site is not falling within the vicinity of any monument or in an

archeologically sensitive area.




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No declared biodiversity parks/sanctuaries are there in the surroundings

of the site as Jim Corbett National Park is 24.05 km N away from the site

Location of consumer centre

Convenient Rail & Road links

Uttarakhand is providing suitable Industrial environment with proper

infrastructure support.

Adequate availability of raw material, power and other infrastructure.

Financial and social benefits with special emphasis on environmental

consideration and benefit to the local people will be kept as top priority for the

proposed project.

4.3 Topography:

Proposed Expansion & Modernization will be carried out in the existing Unit to

Produce Mild Steel Billets/Ingots/Bars/Sections & situated at Narain Nagar

Industrial Estate, Bazpur Road, Kashipur, District Udham Singh Nagar,

Uttarakhand.

The area is located in the survey of India Topo Sheet No. 55O4 and Coordinates

Latitude: 29°11'21.16" N, Longitude: 79°00'09.86" E.

The site lies in seismic zone IV as per Seismic zonation & intensity Map of

Uttarakhand and has the low seismic potential.

There is no Capable Fault within the study area. The seismic zone map of

Uttarakhand is shown in the Fig. – 04.01.




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Fig – 04.01: Seismicity Map of Uttarakhand State

4.4 Existing Land Use Pattern:

The existing industrial land is in Narain Nagar Industrial Estate, Bazpur Road,

Kashipur, District Udham Singh Nagar, Uttarakhand. The land break-up details

are shown in Table – 04.01

Table – 04.01: Land break-up details

S. No. Construction Area (Sq m.) Area (%)

1. Built up area for Plant &

Facilities (ground coverage)

28114.00 47.00

2. Roads and Drains 4785.00 8.00

3. Greenbelt 19740.00 33.00

4. Common Plot Area 7178.00 12.00

Total Land 59817.00 100.00




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Fig: 04.02 Pie chart of Land use

4.5 Existing Infrastructures:

It is a proposal of expansion & modernization of existing unit so infrastructure

such as Drinking water facility, First-aid facility, Toilet facility are adequately

available and shall be provided during construction and operation phase.

Proposed Plant facilities will be developed inside the plant premises once all the

statutory clearances are obtained.

Land: The Company has acquired 14.78 Acres i.e. 59,817.00 Sq mt land in

Government approved industrial area as Narain Nagar Industrial Estate, Bazpur

Road, Kashipur, District Udham Singh Nagar, Uttarakhand. Vacant land 10896.0

Sqm) shall be used for proposed expansion activities.

Power: After proposed expansion, the Unit at full capacity will demand 26.5 MW

of power, which shall be supplied through Grid (UPCL). Existing power demand is

16.5 MW.

Existing DG Set is 63 KVA capacity, which shall be replaced. Green insulated DG

Set of 685 KVA (125, 160 & 400 KVA on standby basis) is proposed. Proposed DG

Set will be operated during emergency in case of power failure only.

Water: Water is required for production process, domestic utility and Green belt.


47%

8%

33%

12%

Pie Chart Showing the Land break-up details of M/s KVS

Built up area for

Plant & Facilities

(ground coverage)

Roads and Drains

Greenbelt

Common Plot Area




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CGWA. Necessary provision for storage of water and water supply has been

made in project cost.

Storage: Company has sufficient provision for storage of raw material & finished

goods.

Transportation: Adequate resources / infrastructure for transportation of raw

Material and finished goods are available in Kashipur area.

Connectivity: The Project site is connected by 20 meter wide connecting road to

the Highway.

All the other infrastructural facilities are expected to be adequately available to

the Unit.

4.6 Soil Classification:

Udham Singh Nagar district may be broadly divided into two physiographic units

from north to south viz., Bhabar and Tarai respectively. Since the area is located

in the Himalayan foothills, a very thick column of alluvium is deposited, which

further is classified into two distinct divisions:

(A) The piedmont fan deposits known as Bhabar

(B) The Tarai Alluvium

These zones spread in northeast – southwest direction all along the foothills of

the Siwalik formation having a maximum width of less than 30 km. The general

gradient towards south varies from 9 to 17 m/km. The slope gradually decreases

towards south in the Tarai region and becomes almost flat close to the

boundary between Tarai and Central Ganga plains, which exists few km south

of the southern boundary of the study area. The geomorphology of an area

plays a very significant role in the groundwater movement and occurrence.




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The soil types are controlled by the topography and rock types. Based on the

National bureau of soil Survy and Land Use Planning (ICAR) Nagpur, the soils of

the district Udham Singh Nagar can be classified into Udifluventic Ustochrepts,

Typic Ustipsamments, Udic Ustochrepts, Udic Haplusstolls, Typic Ustochrepts as

determined by their diagnostic properties. The Bhabar soils lay at the northern

extremity of Khatima and Bazpur blocks, part of the alluvial fan deposits. Soils are

shallow with sandy to loamy texture, poorly sorted, comprising mainly of gravel,

sand, silt, clay with pebbles etc.

The Tarai soils run all along the northern extremity of the district, form continuous

fringe with the Bhabar Zone. Bhabar formation is found in extreme northern parts

of the Khatima and Bazpur blocks, boundary demarcated by the contact of

Tarai and Bhabar. The Tarai belt is 8–25 km in width, and the general slope is <1%

towards south. Soil is calcareous, moderately productive and suitable for

extensive cultivation of high yielding variety of crops like rice and sugar cane.

Soils typify marshy and swampy environment.

4.7 Climatic Data:

The climate varies from Sub-tropical and sub-humid with three distinct seasons

i.e. summer, monsoon (rainy season) and winter. The rainy season starts from the

month of middle June to September end, and followed by the winter season,

which starts from the end of October and goes up to February. The winter rains

are generally experienced in late December or early January, which brings

down the temperature and that’s how December and January are the coldest

months in the district. The summer season starts from March and it goes up to

June. The hottest months of the year are May and June. The maximum

temperature in the district goes up to 42˚C during the summers and the

minimum temperature is between 1 and 4˚C, further north of the district, the

temperature comes down to 0.4˚C in winter season. Rainfall, spatially, is highly

variable depending upon the altitude. The intensity of the rainfall increases from

south to north and the amount of rainfall decreases in generally from west to

east. About 90% of the rainfall received during the monsoon period, and the

remaining 10% of the rainfall in non-monsoon period. The average annual rainfall

is 1296.85 mm (Year; 2004).

4.8 Social Infrastructure:




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Infrastructure is the basic physical and organizational structures needed for the

operation of a society or enterprise or the services and facilities necessary for an

economy to function.

The term typically refers to the technical structures that support a society, such

as roads, water supply, sewers, electrical grids, telecommunications and so forth

and can be defined as "the physical components of interrelated systems

providing commodities and services essential to enable, sustain, or enhance

societal living conditions.

Viewed functionally, infrastructure facilitates the production of goods and

services, and also the distribution of finished products to markets, as well as basic

social services such as schools and hospitals; for example, roads enable the

transport of raw materials to a factory.

Kashipur is a major transport hub in Uttarakhand, acting as a gateway for the

cities of Ranikhet, Pauri and Gairsain. The city is served by the National Highways

NH 309 and NH 734. The NH 734 (formerly NH 74) connects to Najibabad via

Jaspur and Nagina, while the NH 309 connects Kashipur to Rudrapur in the east,

and the cities of Ramnagar and Srinagar to the north.

Major tourist attractions in the city include:

Drona Sagar Lake

Shree Moteshwar Mahadev Mandir

Maa Balsundari Mandir

Chaiti Mela

Gurudwara Shri Nankana Sahib

Tumaria Dam

Giri Sarovar

Arya Samaj Mandir

Kashipur is home to four colleges affiliated to the Kumaun University, Nainital:

Radhey Hari Government P.G. College, Chandrawati Tewari Girls P. G. College,

Sriram Institute of Management and Technology and Kashipur college of

Education. The city also hosts the campus of an Indian Institute of Management.

The Indian Institute of Management Kashipur, also known as IIM Kashipur, is a

public business school located in the Escorts Farm area of the city. It is one of the




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thirteen Indian Institutes of Managements the government has set up during the

Eleventh Five-year Plan.

5.0 PLANNING BRIEF

5.1 Planning Concept (Type of Industries, Facilities and Transportation etc.)

Town and Country Planning/ Development Authority Classification:








5.2 Population Projection

Existing employment is 400 persons. After proposed expansion, the total direct

employment potential of the existing industry would be about 500 people.

However, apart from this there will be significant non estimated employment

generation at the supplier firms and service industry providing services to the

company. Company shall be giving preference to people from economically

weaker sections for employment in various semiskilled/ unskilled jobs thereby

contributing to their upliftment.

Table:-05.01 Employees Details

Sl.

No.

Category No. of

Employees

Functional Area

01. Key Managerial

Staff

20 Finance, Marketing, Production,

Quality control, R&D, Logistics etc.

02. Administration 30 Office

03. Plant Staff 100 Production Process, Maintenance,

stores, Safety & Un skilled workers

04. Skilled & semiskilled 200 Production Process

05. Contract Workers 150 Plant activities

Total 500




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5.3 Green Belt Development

Local native species suitable for this region will be planted in compliance of

conditions of environmental clearance. With a view to attenuate air pollutants,

to resist noise propagation from proposed DG set and uptake of treated effluent

to some extent, the green belt all around the periphery of project sites and in

vacant areas (33% of the total acquired land) will be developed. Tree

plantation will be undertaken in a large scale on land vacated after cessation

of construction activities. Open spaces, where tree plantation is not possible will

be planted with flowering herbs and grass which act as soil binders and also

helpful in preventing erosion of topsoil. Proposed green belt will be being

strengthened regularly.

Total 59817.00 Sq m land area is available at site; out of this 19740.00 Sq m (i.e.

33.0 % of total area) shall be developed as greenbelt and other forms of

greenery by planted the native species. Approx. 20% of the area is already

developed as Green Belt and being maintained. Additionally 13% of the area is

also proposed to develop Green Belt. This green area also enhances the

aesthetic beauty of the area.

Locally available Tree Species and other Aromatic Plants are sown in linear

parallel fashion all along the periphery at 2.5 M c/c spacing. Green belt also

developed along with the roads as well as the fence and all the open land

available at premises. Different Plant Species belong with a number of relevant

characteristic features viz. tolerance or towards air pollution, habit growth rate,

flowering phenology, canopy shape and approximate surface area etc.

Plants are grown in such a way to function as Pollutants sinks as well as it

improve the aesthetics of the area and provide possible habitats for Birds, thus

increasing hospitable nature also.

As per the concern of proposed Project new trees will be planted to strengthen

the existing Green belt.




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GREEN BELT PHOTOGRAPHS




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5.4 Assessment of Infrastructure Demand (Physical & Social):

M/s Kashi Vishwanath Steels Private Limited, is proposing for expansion &

modernization of existing Unit to produce Mild Steel Billets/Ingots and MS


existing Induction Furnaces capacity at Narain Nagar Industrial Estate, Bazpur

Road, Kashipur, District Udham Singh Nagar, Uttarakhand.

Planning Concept

Land use Industrial (Non agriculture). Being the notified Industrial estate as

Narain Nagar Industrial Estate, Bazpur Road, Kashipur, District Udham Singh

Nagar, Uttarakhand.

The existing infrastructure i.e. Road and other utilities like electricity; water are

adequately available. The stable power distribution network for the industrial

complex where this project is coming up.

The adequate Infrastructure has been planned.

The site is well connected with roads for movement of raw material and

finished products and other material.

5.4.1 System Design for High Productivity:

The productivity of the Unit and associated auxiliary objectives are achieved by

adopting the following principles:-

Use of equipment and systems of design, performance and high availability

which shall be fully established by a considerable record of successful operation

for similar service conditions in all plant facilities. Use of only proven design

concepts, conservative designs, strict implementation of quality assurance

norms during design, manufacture as well as installation and commissioning

stage. Strict compliance with the project, company approved pre-

commissioning and commissioning procedures as well as standard checklists

forming will be a part of commissioning documents for the project.

5.4.2 Sizing of Critical Equipment- Margins & Redundancy/Standby:




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Adequate margins will be provided while sizing all important auxiliaries and sub-

systems to ensure operation of the Unit at ultimate capacity under the worst

conditions and taking into consideration normal wear & tear.

5.4.3 Design for Efficient Operation:

Centralized maintenance system is being followed. All repairs of capital nature,

heavy maintenance jobs and plant civil maintenance will be done by engaging

specialized external agencies.

Implementation of computer systems including local area network (LAN)

with standard user friendly software’s in the field of financial management,

personnel management, materials management, order scheduling, sales and

marketing management, management information systems (MIS), production

planning and control, maintenance and spares planning, etc. shall be

considered to increase work efficiency and to reduce manpower requirement.

5.4.4 Operation Performance Management System (OPMS):

The operation of the plant will be optimized by implementation of OPMS. This

system will clearly define the responsibilities of all key O & M personnel including

the shift-in-charge. This will also cover the system of daily reporting to the project

company Corporate Office and monthly O&M review meetings.

5.4.5 Operation & Maintenance Philosophy:

Most of the key positions in operation and maintenance of the existing plant at

different categories are being manned by the qualified persons having

experience in the similar field. However, depending on the type of equipment

/facilities along with the degree of automation contemplated, the operation

and maintenance personnel of the plant so recruited will require specific need

based training which is carried out on site by the respective equipment supplier

during equipment erection, start up and commissioning of different plant units.

5.5 Amenities/Facilities:

5.5.1 In-Plant Facilities:

The following facilities are provided in this plant:

a. Administrative Building, Service Building

b. Construction offices and stores




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c. Time and security offices

d. First Aid and firefighting station

e. Canteen

f. Toilets

g. Car parks and cycle/ scooter stands

h. Training Centre

Office space are provided as per good practice and canteens, toilets and

restrooms according to norms laid down in relevant factories act. The above

facilities are also be adequately furnished and equipped.

5.5.2 Employment Generation:

The total direct employment potential w.r.t. the proposed modernization &

expansion is about 100 people. However, apart from this there will be significant

non estimated employment generation at the supplier firms and service industry

providing services to the company. Company is giving preference to people

from economically weaker sections for employment in various semiskilled/

unskilled jobs thereby contributing to their upliftment. The total employment

potential of the existing industry after the proposed modernization & expansion

would be 500 people.

The project has enhanced the prospects of employment. Recruitment for the

unskilled workers for the plant is from the nearby villages. The basic amenities viz.

roads, transportation, electricity, drinking water, proper sanitation, educational

facilities, medical facilities, entertainment, etc. shall be developed as far as

possible.

5.5.3 Peripheral Developmental Activities:

M/s Kashi Vishwanath Steels Private Limited will undertake various activities

around the project site as a mark of their Corporate Social Responsibilities viz.

Education, Water Supply, including Drinking Water, Health Care, Environment,

Social Empowerment, Sports and Culture.

Generous Contribution for Better Tomorrow

KVS Premier has substantial exposure in the field of corporate social

responsibilities as mentioned below:




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KVS Premier established charitable trust in the name of Galwalia Seva Shiksha

Sansthan undertaking progressive initiative in education and other social issues.

KVS Premier has set up Pyare Lal Nand kishore Galwalia Rajkiya Mahavidyala

Ramnagar. It has also built the fully furnished Computer Education block and

renovation of school building at Mahadev Nagar near Bheem Nagar, Kashipur.

Established Library at Gomti Pooran Prasad Garg Inter College, Ramnagar for the

benefit of the readers at large.

KVS Premier has also extended assistance by creating and maintaining the infra-

structure of Girls Govt. Inter College, Kashipur.

KVS Premier has Constructed "Jindal Auditorium" at Kumaon Garhwal Chamber

of Commerce & Industry, Kashipur to facilitate various social and corporate

activities for the entire business community.

KVS Premier has encouraged search for local talents in sports and athletics in

the region. Stress has been laid in fitness and healthcare as well.

KVS Premier has sponsored a Blood Donation Camp in a large scale associate

with L.D. Bhatt Govt. Hospital, Kashipur at KVS Premier Campus.

Last but not least, the group provides scholarships to meritorious students of the

region and some of those have excelled in their lives and have now a

respectable identity of their own in the society.

6.0 REHABILITATION & RESETTLEMENT (R & R) PLAN:

Not Applicable

7.0 PROJECT COST ESTIMATES:

Initiated Project cost is estimated as under:

Table – 05.02: Cost of Project

Details : Rs. in Lacs

Land : 00

Civil & Structural Cost : 400

Plant & Machinery : 600

Total : 1000

Means of Finance:

Details : Rs. in Lacs

Internal Accrual/Finance : 1000

Total : 1000




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The proposed expansion & modernization project will become beneficial to the

surrounding area or community in terms of infrastructural development, social

development, employment and other benefits. The proposed project has a

potential for employment of skilled, semiskilled and unskilled employees during

construction phase as well as operation phase. Additionally 100 nos. of person is

likely to get employment due to the project. The project will spend 2.5 % of

project cost for socio-economic development & for nearby educational

institutes.

8.0 ANALYSIS OF PROPOSAL:



Nos.) & 4 Tons (02 No) Induction Furnaces with 6 Tons (03 Nos. - replacement of

existing IFs)& 10 Tons (01 no. replacement & 02 nos. new) capacity Induction

Furnaces and modernize Continuous Casting Machine (CCM) & increasing the

output (speed) of existing Rolling Mill through modernization to enhance the

annual production capacity from existing MS Ingots 57,600 TPA and Steel Bars

88,200 to 2,00,000 TPA respectively.






capacity to become economic steel producer of the region. In Rolling Mill

motors with the Rollers shall be replaced with high speed motors to meet the

annual production of 2,00,000 Tons of rolled product. The steel industries in

general are on priority list as they contribute in overall development of the

country and in particular will produce steel and steel products at economic cost

and also have export potential to earn/save foreign exchange.

Proposed expansion may leeds a feasibility to produce Mild Steel Billets/Ingots

thru existing/proposed facility & it may either used for making Bars/Sections by

itself or sold to the market as such. Meanwhile it may purchase the Billets/Ingots

from respective industries/local market for making Bars/Sections as per

eventually changes in the market.




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Project will create direct & indirect employment opportunities within the

surrounding region. Unit will use good faith efforts to employ local people from

the nearby villages depending upon the availability of skilled & un-skilled man-

power surrounding the project site.

In operation phase, the proposed project would require significant workforce of

non-technical and technical persons. Migration of highly education and skilled

experience will result in increase of skill in the surrounding villages. In addition,

the proposed project shall enhance the prospects of employment.

It can be concluded from the matrices that the resultant impact is beneficial in

the interest of common man, the society, the state and as the country as a

whole. The benefits can be summarized as below:

The proposed project will provide quality steel product to the users. This

project is essential in-view of production of high value downstream products.

KVS Premiere group is endeavoring in manufacturing Construction Steel &

Structural Sections as per BIS Specifications 2830:2012, 2831:2012, 1786:2008,

2062:2011, 15911:2010.

There should be positive impact on the socio-economic condition of the area

in terms of direct and indirect employment due to the proposed expansion

project.

Numbers of local trained persons are likely to find jobs.

This is cost effective & energy efficient proposal and aims at sustainable

development.

These products also have export potential. Hence, possibility of earning

foreign exchange.

The project will spend 2.5 % of project cost for Social Welfare programme and

Ecological conservation.

Documents

PRE-FEASIBILITY REPORT & EMP...PRE-FEASIBILITY REPORT & EMP PROPOSED EXPANSION OF THE EXISTING UNIT TO PRODUCE MILD STEEL BILLETS/INGOTS AND ... with the business of manufacturing