Pre feasibility Report For ASR Steels & Power Pvt. Ltdenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...PREFEASIBILITY REPORT ASR STEELS & POWER PRIVATE LIMITED DETOX CORPORATION

Pre feasibility Report

For

ASR Steels & Power Pvt. Ltd

New Project

Sponge Iron, Ingots/Billets, Rolled products, Power Plant

At

Village: Morghar - Desalpar,

Taluka: Bhachau, Dist:Kutch,

Gujarat

Prepared by

M/s Detox Corporation Private Limited

Surat, Gujarat

NABET Accreditation vide minutes of 15th Accreditation committee meeting for Surveillance assessment

PREFEASIBILITY REPORT ASR STEELS & POWER PRIVATE LIMITED

DETOX CORPORATION PRIVATE LIMITED 1 2015

1 Executive summary ..................................................................................... 5

2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION ....................... 5

2.1 Identification of project and project proponent ................................................. 5

2.1.1 Project Proponent ........................................................................................ 5

2.1.2 Identification of Project ................................................................................ 6

2.2 Brief description of nature of project ............................................................... 6

2.3 Need of project and its importance to the country and or region ......................... 6

2.4 Demand Supply gap ..................................................................................... 6

2.5 Imports vs. indigenous production ................................................................. 9

2.6 Export Possibility ......................................................................................... 9

2.7 Domestic/ export markets ............................................................................. 9

2.8 Employment Generation (Direct and Indirect) due to the project Employment ...... 9

3 Project Description ....................................................................................... 9

3.1 Interdependent project ................................................................................. 9

3.2 Location (map showing general location, specific location, and project boundary &

project site layout) with coordinates .......................................................................... 10

3.3 Details of alternate sites considered and the basis of selecting the proposed site,

particularly the environment considerations gone into should be highlighted .................... 14

3.4 Size or magnitude of operation .................................................................... 15

3.5 Project description with process ................................................................... 15

3.6 Raw material details ................................................................................... 20

3.7 Equipment Details...................................................................................... 21

3.8 Resource optimization/ recycling and reuse envisaged in the project ................. 22

3.9 Availability & Source of water, Availability & Source of Electricity ...................... 22

3.9.1 Source of water and its availability ............................................................... 22

3.9.2 Source of electricity and its availability ......................................................... 23

3.10 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/ disposal ............................................................................................. 23



3.10.1 Waste Water generation & Management plan ................................................. 23

3.10.2 Solid waste generation & Management plan ................................................... 23

3.10.3 Hazardous Waste Generation & Management Plan .......................................... 24

3.10.4 Stack details and Air Pollution Control Measures ............................................. 24

4 Schematic representation of the feasibility drawing which give information of EIA

purpose…. .............................................................................................................. 24

5 SITE ANALYSIS ......................................................................................... 26

5.1 Connectivity .............................................................................................. 26

5.2 Land Form, Land use and Land ownership ..................................................... 26

5.3 Topography (along with map) ...................................................................... 26

5.4 Existing land use pattern (agriculture, non agriculture, forest, water bodies –

including CRZ), shortest distances from the periphery of the project to periphery of the

forests, national park, wild life, sanctuary, eco sensitive areas, water bodies (distance from

HFL of the river), CRZ. In case of notified industrial area, a copy of Gazette notification

should be given. ..................................................................................................... 26

5.5 Existing infrastructure ................................................................................ 27

5.6 Soil classification ....................................................................................... 27

5.7 Climatic data from secondary sources ........................................................... 27

5.8 Social Infrastructure available ..................................................................... 27

6 Planning Brief ............................................................................................ 27

6.1 Planning Concept (type of industries, facilities, transportation etc) Town and

country planning/ Development authority classification ................................................. 27

6.2 Population Projection .................................................................................. 27

6.3 Land use planning (break up along with green belt etc) ................................... 28

6.4 Assessment of infrastructure demand (Physical and social) .............................. 28

6.5 Amenities/ Facilities ................................................................................... 28

7 PROPOSED INFRASTRUCTURE ..................................................................... 28

7.1 Industrial area (Processing area) ................................................................. 28

7.2 Residential area (Non processing area) ......................................................... 28



7.3 Green belt ................................................................................................ 28

7.4 Social infrastructure ................................................................................... 29

7.5 The existing infrastructure is sufficient to cater the additional load due to the

proposed expansion project. Connectivity (Traffic and transportation, Road/ Rail/ Metro/

Water ways etc) ...................................................................................................... 29

7.6 Drinking water Management (Source & Supply of water) ................................. 29

7.7 Sewerage system ...................................................................................... 29

7.8 Industrial waste management ..................................................................... 29

7.9 Solid waste management ............................................................................ 29

7.10 Power requirement & supply/ source ............................................................ 29

8 Rehabilitation and Resettlement (R & R) Plan ................................................. 29

8.1 Policy to be adopted (Central/ state) in respect of the project affected persons

including home oustees, land oustees and landless laborers .......................................... 29

9 PROJECT SCHEDULE & COST ESTIMATES ...................................................... 29

9.1 Likely date of start of construction and likely date of completion ....................... 29

9.2 Estimated project cost along with analysis in terms of economic viability of the

project….. .............................................................................................................. 30

10 Analysis of proposal (Final Recommendations) ............................................... 30

10.1 Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area .................................................... 30

10.2 Budgetary allocation for social welfare in the area .......................................... 30



List of Tables

Table 1: Product Profile ............................................................................................. 6

Table 2: Demand of Pig Iron, Sponge Iron& Finished Steel. ............................................ 6

Table 3: Supply & Demand Gap ................................................................................. 7

Table 4: Category wise demand of Long & Flat Products ................................................ 7

Table 5: Present & Future Installed Capacity ................................................................ 8

Table 6: Import & Export Statistics ............................................................................. 9

Table 7: Employment generation due to proposed expansion.......................................... 9

Table 8: Site location .............................................................................................. 13

Table 9: Product Profile ........................................................................................... 15

Table 10: Raw material Details ................................................................................ 21

Table 11: List of Equipments ................................................................................... 21

Table 12: Water Consumption .................................................................................. 22

Table 13: Electricity allocation ................................................................................. 23

Table 14: Waste Water generation ........................................................................... 23

Table 15: Solid Waste Details .................................................................................. 23

Table 16: Details of Stack details and APC measures of proposed activity ....................... 24

Table 17: Connectivity ............................................................................................ 26

Table 18: Meteorology data ..................................................................................... 27

List of Figures

Figure 1: Satellite image showing project location with surrounding features .................. 11

Figure 2: Satellite image showing previous (AS per ToR granted) and Present Project

Location ............................................................................................................... 12

Figure 3: Site map of 10 Km radius .......................................................................... 14

Figure 4: Sponge Iron Manufacturing Flow Diagram .................................................... 17

Figure 5: Flow Diagram of Steal based Turbo Generator Set ......................................... 20



1 Executive summary

ASR Steels & Power Pvt. Ltd. proposes to install a new project of integrated steel plant,

rolling mill products and captive power plant at Survey no. 469/P-3,471,472,473,474/P-1, 474/P-2,474/P-3 & 155/P-1(Old) Village Morghar-Desalpar, Taluka: Bhachau, District:

Kutch, Gujarat.

There is no national park, sanctuary or forest land in surrounding 10 Km radius. The project

doesn’t fall under CRZ boundaries.

The water consumption for the proposed project is 1000 KL/day mainly for cooling, boiler

and drinking. Waste water generated will be mainly in form of cooling and boiler blow down.

The company proposes to install rotary kiln, induction furnace, reheating furnace, AFBC

boiler and WHRB as a part of proposed project.

Slag, coal char and ash will be mainly generated as solid waste whereas used oil will be

used as hazardous waste. Used oil will be mainly generated as hazardous waste which shall

be reused for lubrication purpose.

2 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of project and project proponent

2.1.1 Project Proponent

ASR Steels & Power Private Limited is a state-of-the-art Manufacturing unit of high strength

deformed steel Re-bars and Structural Steel Sections. ASR is fully equipped to ensure

quality at every stage of production, so as to deliver perfect product. Modern and apt

machinery, testing and quality checks along with qualified operators make the task easy for

the company to deliver the best every time.

The Group has a very strong presence in the various market of the country domestically and

a number of destinations abroad including Asia, Middle East, Europe and Africa. The

domestic market is also well aware of the brand “ASR” which will give a further pushup to

the marketing concern.

In order to meet the market demands, the company now propose to install a new integrated

steel plant and power plant at Village: Morghar-Desalpar, District: Bhachau, Kutch, Gujarat.



2.1.2 Identification of Project

ASR Steels & Power Pvt. Ltd. Proposes to install a new project of integrated steel plant,

rolling mill products and captive power plant at Survey no. 469/P-3,471,472,473,474/P-1,

474/P-2,474/P-3 & 155/P-1(Old) Village Morghar-Desalpar, Taluka: Bhachau, District:

Kutch, Gujarat. The proposed products with its production capacity is as mentioned below

Table 1: Product Profile

PRODUCTS PRODUCTION CAPACITY

Sponge Iron 18000 MT/month

Billets/Ingots 24000 MT/month

Rolled Products 24000 MT/month

Power Plant

• AFBC

• WHRB

25 MW

• 12 MW

• 13 MW

2.2 Brief description of nature of project

The project fall under category A, section 3 (a) of EIA notification September 2006 and

amendment thereof vide notification no. S.O 3067 (E) dated 1st December 2009.

2.3 Need of project and its importance to the country and or region

In order to meet the increasing demand of steel product in domestic as well as international

market the company proposes for an integrated steel plant.

2.4 Demand Supply gap

The demand of Pig Iron, Sponge Iron, & finished Steel for last five years is given in Table

below:

Table 2: Demand of Pig Iron, Sponge Iron& Finished Steel.

CATEGORY 2007-08 2008-09 2009-10 2010-11 2011-12*

Pig Iron 5.28 6.21 5.88 5.68 5.78 Sponge Iron 20.37 21.09 24.33 25.08 20.37 Total Finished Steel (alloy + 56.07 57.16 60.62 68.62 73.42



non alloy)

Source: Joint Plant Committee; *provisional Supply & Demand Gap for year 2012-13 to 2019-20is presented in the following table

Table 3: Supply & Demand Gap

CATEGORY 2012 -13

GREEN FIELD EXPANSION (2012 -13 TO 2019 -20)

2019-20 REMARKS

S-I S-II S-I S-II Finished Steel demand 74 171 166 Projected Capacity (Crude Steel)

110 120 100 230 210 Main producers with Sy. Producers

Projected Availability (Crude Steel)

105 84 70 180 172 95 % Capacity utilization

Projected Availability (Finished Steel)

95 162 155 95 % Capacity utilization

Gas (-) / Surplus (+) (+) 21 (-) 9 (-) 11** * 70 % actualization of the incremental capacity, 95% capacity& 90 % conversion ratio

* As against 133 MT assumed by other sources

** Gap may go upto more than 30 MT subject to lower capacity installation than indicated

above.

Category wise demand of Long & Flat Products is given in Table below

Table 4: Category wise demand of Long & Flat Products

CATEGORY WISE DEMAND PROJECTION (LONG PRODUCT)

Category Explanatory variable (CAGR during 2005 -06 to 2010- 11)

Growth Rate assumed for 12th Plan (%)

Project based on assumed growth rate (2016-17) MT

Bars & Rods Construction (8.3%) 11.0 44.1

Structural Construction (8.3%) 9.5 9.4

Rly. Material Construction (8.3%) 5.0 1.4

Total Non-flat - 10.50 54.90

Category wise demand projection (Flat Product)

Category Explanatory variable (CAGR during 2005 -06 to 2010- 11)

Growth Rate assumed for 12th Plan (%)

Project based on assumed growth rate (2016-17) MT



Plates Consumption of Oil & Gas (8.9 %) GDCF in plant & machinery (8.9%)

7.5 7.3

HR Coils / Sheet IIP in manufacturing (9.7%)

9.0 23.80

CR Coils / Sheets IIP in transport equipment (12.30%) consumption of petrol (4.3)

11.0 11.8

Coated Sheet - 10.8 8.8

Electrical Sheet Installed capacity in power (6.6%)

8.0 0.8

Tin plates GDCF in plant & machinery (8.9%)

8.0 0.6

Pipes GDCF in plant & machinery (8.9%)

12.0 2.9

Total Flat 11 56.0

Source: Conference on development and growth scenario for Steel industry in India

The present & future installed capacity is given in table below

Table 5: Present & Future Installed Capacity

2011-12 2016-17

SAIL 13.4 21.4

RINL 2.82 7

TAT STEEL 6.8 14

JSW 9.93 13.9

JSW ISPAT 3.3 4.5

ESSAR 6.3 10

JSPL 3 8

BHUSHAN STEEL 2.3 5.2

BHUSHAN POWER 1.8 2.5

OTHERS 39.35 62.50

TOTAL 89 149

Source: Report of Working Group on Steel Industry, 12th FY plan



2.5 Imports vs. indigenous production

Refer Table 6

2.6 Export Possibility

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

conducted.

2.7 Domestic/ export markets

Refer Table 6

The Import & Export Statistics for Past five Years is given in Table below

Table 6: Import & Export Statistics

Year Total Finished

Steel

Import Export Real Consumption of Total Finished

Steel

2007-2008 56.075 7.029 5.45 52.125

2008-2009 57.164 5.841 5.183 52.351 (0.4%)

2009-2010 60.624 7.381 3.876 59.339 (13.3%)

2010-2011 68.621 6.664 3.987 66.423 (11.9%)

2011-2012 (Prov) 73.416 6.825 4.246 70.915 (6.8%)

(All the above are mentioned in million tons)

Source : JPC; figures in brackets indicate the percent increase over the previous year

2.8 Employment Generation (Direct and Indirect) due to the project Employment

The total employment generation due to the proposed project is given below:

Table 7: Employment generation due to proposed expansion

Skilled Unskilled

Manpower 150 350

3 Project Description

3.1 Interdependent project

There is no interlinked or interdependent project with the proposed project.



3.2 Location (map showing general location, specific location, and project

boundary & project site layout) with coordinates

The location of site with type of land and boundary coordinates is as below



Figure 1: Satellite image showing project location with surrounding features

Nearest Highway NH 8A 1.98 Km

Nearest village 2.85 Km



Figure 2: Satellite image showing previous (AS per ToR granted) and Present Project Location



Table 8: Site location

Feature Description

Survey No. Survey no. 469/P-3,471,472,473,474/P-1, 474/P-2,474/P-3 &

155/P-1(Old)

Village: Morghar-Desalpar, Taluka: Bhachau,

Distt:Kutch, Gujarat

Latitude and Longitudes of the

project site

Lat-23.314258 N

Long-70.210830 E

Type of Land Barren land

Nearest Village Morghar (~ 2.85 Km)

Bhudarmora (~ 3.20 Km)

Nearest railway station Bhachau Railway Station (~ 14.30Km)

National Highway NH 15 (~ 13 Km)

NH 8A (~1.98 Km)

Nearest port Kandla (~ 33.63 km)



Figure 3: Site map of 10 Km radius

3.3 Details of alternate sites considered and the basis of selecting the proposed

site, particularly the environment considerations gone into should be

highlighted

The suitability of a site was determined by the following major considerations.

Availability of adequate land

No forest land, National Park, Sanctuary, Historical Monuments etc present within 10

Km radius of project site.

Suitability of the land from topographical and geological considerations

Road/ Rail connectivity to the project site for transportation of raw materials,

products and employees

Proximity to human settlement

Availability of water for domestic and industrial purpose

Power from Captive power plant and GEB grid



3.4 Size or magnitude of operation

The proposed products with its production capacity is as mentioned below

Table 9: Product Profile

PRODUCTS PRODUCTION CAPACITY

Sponge Iron 18000 MT/month

Billets/Ingots 24000 MT/month

Rolled Products 24000 MT/month

Power Plant

• AFBC

• WHRB

25 MW

• 12 MW

• 13 MW

3.5 Project description with process

The following furnaces, kilns, boilers shall be installed in the proposed project

Equipment Details

Equipment Total nos. to be installed

Rotary Kiln : 1 no. * 250 TPD

1 no. * 350 TPD

Induction furnace : 2 nos. * 30 T

Rolling Mill : 2 nos.

AFBC Boiler : 1 no.

WHRB Boiler : 2 no.

Sponge Iron Plant

The production process of sponge iron involves four steps namely:

i. Raw material preparation plant: The raw material preparation plant consists of

crushers and screens through which the seized material required for process is

prepared. Normally, jaw crushers are used for iron ore crushing and roll or impact



crushers for coal. The feeding for the crushers are done through the conveyors and

vibrating feeders.

ii. Stock house: The stock house consists of the raw material storage bins; which store

material up to 24 hours plant requirement. There are four bins one each for iron ore,

feed coal, dolomite and injection coal. The raw materials are fed into a rotary kiln

through the volumetric/weigh feeders at a predetermined rate.

iii. Reduction kiln: The processing of the materials consists mainly of kiln and cooler

system. The iron ore is pre-heated and reduced in a rotary kiln and passes to the

rotary cooler; where it gets cooled. The cooled material is then passes to the belt

conveyor; where the cooler discharge is fed to the product house conveyor. The

material is then led to the product separation circuit. An intermediate bin is provided

to take care of any eventualities occurring due to breakdown of the product

separation circuit.

iv. Product separation plant: In the product separation section, the sponge iron and the

coal-char (un-burnt coal) are separated. The cooler discharge material is screened to

different sizes, and fed into magnetic separator. The sponge iron is magnetic and

hence, it gets attracted to the magnet present in the magnetic separator and is

discharged to separate bins the dust in the hot gases settles and gets cleaned.

Operation of Rotary Kiln and Cooler:

Rotary Kiln: Rotary kiln is 3.0 m in diameter and 42 m long; and it is positioned inclined at

an angle of 1.432o approximately. It is rotated by AC variable speed motor at a stem less

variable speed ranging from 0.2 to 1.0 RPM. Due to the inclination and the rotary motion in

kiln; the material moves from the feed end of the kiln to the discharge end in approximately

4.5 hours. The fine coal is blown from the discharge end to maintain the required

temperature profile. The material and the hot gases move in the counter current direction.

As a result, the iron ore gets preheated and gradually reduces by the time it reaches

discharge end. The reduced material is then transferred to the rotary cooler via transfer

chute.

Rotary Cooler: The rotary cooler is 2.3 in diameter and 22 m in length. It is also inclined at

1.432o approximately. It rotates at 1.2 RPM. It is driven by AC motor. The water is sprayed

on top of shell; which cools the material inside the cooler indirectly. The material reaches 80 oC temperatures approximately; and discharged by the double pendulum valve to the

conveyor. The double pendulum valve actually acts as a seal for prevention of atmospheric



air entering the rotary cooler. The material discharged on conveyor is then sent for product

separation system. Here, the material is segregated in different sizes and also magnetic

sponge iron is separated from non-magnetic char.

The gases flowing into counter current direction gets to the dust-settling chamber and

heavier particles settles down. These particles are continuously removed by the wet

scrubbing system. The gases then pass to the Forced Draft (FD) Cooler; where the gases

are cooled. The gases leaving the kiln are very hot and have a lot of heat energy. The gases

are then passed through Electrostatic Precipitator (ESP) for dust concentration to reduce

below the acceptable norms and discharged to the atmosphere through stack of adequate

height.

Figure 4: Sponge Iron Manufacturing Flow Diagram

Waste Heat Recovery Boiler System

The waste heat recovery boilers are designed to operate only with the thermal energy in the

waste gases from the rotary kilns and these boilers do not need any supplementary or

auxiliary firing. There is no fuel usage in the waste heat recovery boilers. The waste gases

from After Burning Chamber (ABC) of Sponge Iron Kilns will be conveyed to the waste heat



boilers through gas ducts. Proper refractory lining shall be given for the ducting as the

gases will be coming at high temperature in the range of 950–975oC

Alloy Steel Product

Induction arc Furnace

The induction arc furnace is the principle furnace type for the production of the Alloy Steels.

The primary application of the furnace is for the re-melting of the steel scrap or sponge iron.

Furnace Operations:

The induction arc furnace operates as a batch melting process producing batches of molten

steel known “heats”. The furnace operating cycle is called the tap-to-tap cycle and is made

up of the following operations:

• Furnace charging

• Melting

• Refining

• De-slagging

• Tapping

• Furnace turn-around

Charging:

The charging material consisting of steel scrap & additives is loaded into the furnace in such

a way that large and high melting pieces stand parallel close to crucible while low melting

Components in the middle of the crucible.

Melting:

At the beginning of melting the furnace works for 5 to 10 minutes on low power until the

surge of current fed from the generator disappear. The furnace power is then brought up to

a maximum. The charge melts with the crucible held closed. When the charge approaches

the fluid stages than the solid pieces are pressed back with a crow bar. The furnace is then

loaded to its capacity by adding small size of scrap as soon as the charge melted. The slag

is formed to protect the metal from oxidation and to avoid reduce the melting loss. Excess

slag is skimmed off periodically. At the last, Ferro Manganese, Silicon Manganese & Ferro

Silicon is added to deoxidize the metal.

Ladle Refining Furnace:

Ladle refining furnace (LRFs) are used to desulfurize steels, remove other impurities and

hold the molten steel for casting operations. Without LRFs, higher tap temperatures are

normally required from steel making furnaces due to heat losses during refining during



conventional ladles. Costs of extended furnace time, refractory wear and power or fuel

consumption can all be reduced using LRFs to perform holding and refining. The ladle

refining furnace also acts as a buffer between the steel making furnace and continuous

caster, reducing casting costs and allowing greater flexibility in steel making operations.

Ladle Refining Process:

Large ladles are used in most metal melting operations to transfer molten metal from

melting furnaces to refining or pouring stations. Ladle refining furnaces are basically ladles

with a heating source and lid. LRFs are used to reheat or maintain steel tapped from a steel

making furnace to a precise temperature and or refine it to exact chemical specifications.

Refining is performed by adding chemicals to remove impurities, adding ingredients which

enhance strength, and homogenizing the molten steel to achieve uniform characteristics.

LRFs provide an ideal reining station with precise temperature control, stirring action for

homogeneity, and ports for alloy addition and slag removal. Reheating steel in a ladle

refining furnace is typically accomplished by electric arc heating.

AFBC Power Plant

The design, manufacture, inspection, testing and installation of all equipment and system of

the proposed captive power plant shall confirm to the latest editions of Indian and

International codes and standards. Best Engineering Practices shall be followed wherever

the relevant standards are not available.

Process and mechanism

Steam Turbine Generators (STG) are the main assembly in the power Plant. Imported coal

shall be used as main fuel in the STG. The steam generator(s) shall be Bubbling type

Atmospheric Fluidized bed Combustion (AFBC) having single drum and outdoor type.

The boiler shall be receiving the water from specialized water Treatment System, which

shall convert raw water to soft water suitable for the boiler application. The steam

generated at boiler will be passed through the turbine attached to it. In turbine Generator,

the steam will be used to rotate the coil in magnetic field to produce electricity. This

electrical energy will be supplied to step-up transformer, from where, it is transmitted

Process and Control Mechanism

Steam Turbine Generator (STG) is the main assembly in the Power Plant. Coal char,

imported coal and waste heat shall be used as main fuel in the STG. The steam generator



shall be Atmospheric Fluidized Bed Combustion (AFBC) and Waste heat recovery boiler

semi-outdoor type.

The boiler shall receive the water from specialized Water Treatment System; which shall

convert raw water to soft water suitable for the boiler application. The steam generated at

Boiler will be passed through the Turbine attached to it. In turbine Generator, the steam will

be used to rotate the coil in magnetic field to produce electricity. The simplified process flow

diagram of the proposed CPP is attached herewith as Figure 5

Figure 5: Flow Diagram of Steal based Turbo Generator Set

Part of the steam shall be used to regenerate the feed water temperature and thereby

improve the thermodynamic cycle efficiency. The steam after doing work in STG shall pass

through an Air Cooled condenser. This condensate so formed shall be pumped back vide

pumps to the generator and then to the boiler.

The coal/coal-char combustion will emit exhaust gasses, which shall be passed through an

Electrostatic Precipitator, which will reduce the emission levels before passing out through

the chimney. The ash generated from the boiler shall be sent through a high-pressure

pneumatic system to transfer ash to a silo.

There will be other auxiliary systems which shall be used to like Compressed air system, air-

conditioning system, etc; detailed description of the same is given in subsequent sections.

3.6 Raw material details

The source of raw materials and its mode of transportation are as follows:



Table 10: Raw material Details

Sr. No. Materials Consumption Source Mode of

Transportation

1 Sponge

Iron/HBI

18000-10000

MT/Month

Own Production/Purchases

(Domestic/Imported)

Road / Sea

2 Scrap 12000-20000

MT/Month

Purchases

(Domestic/Imported)

Road / Sea

3. Steel Billets /

Ingots

24500 MT/Month Own Production/Purchases

(Domestic/Imported)

Road / Sea

4. Iron Ore/Pellets 28800MT/Month Purchases

(Domestic/Imported)

Road / Sea

5. Coal for Sponge 21600 MT/Month Purchases

(Domestic/Imported)

Road / Sea

6. Lime Stone 720 MT/Month Purchases

(Domestic/Imported)

Road / Sea

Raw Material Details for power plant

7. Coal for CPP 13500 MT/ Month Purchases

(Domestic/Imported)

Road / Sea

3.7 Equipment Details

The list of equipment to be installed is mentioned in Table 11.

Table 11: List of Equipments

Sr. No. Equipment Capacity

1 Rotary kiln 1x250MT

1x350MT

2 Induction furnace 2x 30MT

3 AFBC Boiler 12 MW

4 WHRB 13 MW



Marketing area of finished products & Mode of transportation of finished products:

The marketing area for the proposed product will be Indian Market and the same shall be

transported via truck

3.8 Resource optimization/ recycling and reuse envisaged in the project

Various steps undertaken for recycle/ reuse in the proposed project is as mentioned below:

• The waste water generated due to proposed project shall be neutralised and reused

for gardening purpose and partly recycle back in system.

• Used oil and spent oil shall be reused for lubrication purpose.

• Slag shall be reused for land filling and road construction purpose or sold to recycler

• Coal char will be used as fuel for power plant

3.9 Availability & Source of water, Availability & Source of Electricity

3.9.1 Source of water and its availability

Source of water: Gujarat Water Infrastructure Limited (GWIL)

Total water consumption: 1000 m3/day

No ground water will utilised for the proposed project activity. The total water consumption

for the proposed project is as mentioned below

Table 12: Water Consumption

Purpose Water Consumption

Cooling 90

Boiler 300

Drinking 50

Kiln cooling 400

Green belt 60

other 100

Total water consumption 1000 KL/day



3.9.2 Source of electricity and its availability

Electricity shall be obtained from captive power generation and Gujarat Electricity Board.

The total power requirement for the plant for proposed project is given in Table 13.

Table 13: Electricity allocation

Source Proposed requirement

SEB/ Grid 5 MW

Captive power plant 25 MW

Stand by silent DG set 1000 KVA each

3.10 Quantity of wastes to be generated (liquid and solid) and scheme for their

management/ disposal

3.10.1 Waste Water generation & Management plan

Table 14: Waste Water generation

Purpose Waste Water generation Disposal plan

Cooling tower blow down 20 KL/day After neutralization, Shall be recycle

back in the system and partly reused

for gardening purpose Boiler blow down 80 KL/day

Domestic reject 20 KL/day Shall be send to septic tank/ soak pit

Total waste water 120 KL/day

3.10.2 Solid waste generation & Management plan

Solid wastes generated from the project activity are as mentioned below

Table 15: Solid Waste Details

Sr. No. Type of waste Quantity Disposal Method

1 Fly Ash 200 MT/Day Shall be sold to cement plant/ Brick

manufacturers for reused



2. Coal Char 90 MT / Day Shall be reused in power plant as fuel with coal

3. Slag 140 MT/ Day Shall be reused in land filling and road

construction

3.10.3 Hazardous Waste Generation & Management Plan

Waste Generated Quantity Disposal Plan

Used oil 70 KL/Annum

Will be reused within plant

premises as lubrication oil/

sent to TSDF site.

3.10.4 Stack details and Air Pollution Control Measures

Stack details and Air Pollution Control Measures (A.P.C) is shown below

Table 16: Details of Stack details and APC measures of proposed activity

Stack Attach to Height Air Pollution Control Measures

AFBC Boiler 1 * 50.00 m ESP

WHRB Boiler 2 * 50.00 m Bag filter for circuits and Electro

Static precipitator is combined

with WHRB

Induction furnace 2 * 30.00 m Fume Extraction System

D G Sets 18.00 m ---

4 Schematic representation of the feasibility drawing which give information of

EIA purpose

The proposed project of integrated steel plant and captive power plant falls under category

A, section 3 (a) of EIA notification September 2006 and amendment there of vide

notification no. S.O 3067 (E) dated 1st December 2009,which require prior Environmental

Clearance before starting construction, production or any other allied activities related to



the project. For getting the Environmental Clearance; it is required to carry out the

Environmental Impact Assessment (EIA) study report.

Definition of EIA

Environmental Impact Assessment (EIA) is a formal process used to predict how industrial

development or construction project will affect natural resources such as water, air, land,

socioeconomic and bio ecological environment.

An EIA usually involves a sequence of steps:

(1) Screening to decide if a project requires assessment and to what level of detail.

(2) Preliminary assessment to identify key impacts, their magnitude, significance, and

importance.

(3) Scoping to ensure the EIA focuses on key issues and to determine, where more detailed

information is needed.

(4) Implementing the main EIA study, which involves detailed investigations to predict

impacts, assess their consequences, or both.

Methodology

Environmental Impact Assessment (EIA) studies include identification, assessment,

quantitative evaluation and prediction of possible impacts. To minimize the impact of the

project on various environmental attributes, mitigation measures are suggested for

implementation along with the project.

The methodology of this study can be schematized as detailed below:

To gather information on present environmental conditions and relevant national

environmental guidelines and EIA procedures.

Scoping of impacts.

Assessment of significant impacts.

Description of residual impacts.

Development of monitoring plans.

To inform all relevant and involved authorities regarding the impact of the project on

the environment and the proposed mitigation measures.



5 SITE ANALYSIS

5.1 Connectivity

The project site is well connected to NH 15 and NH 8 A. The site is well connected by road

and rail to rest of country. The details of highway and rail network are as mentioned below:

Table 17: Connectivity

Description Distance

Transportation

NH 15 (~ 13 Km)

NH 8A (~1.98 Km)

Bhachau Railway Station (~ 14.30Km)

Nearest Town/City Gandhidham (~ 26.58 km )

Nearest Village

Morghar (~ 2.85 Km)

Bhudarmora (~ 3.20 Km)

Sukhpar (3.84 Km)

5.2 Land Form, Land use and Land ownership

The proposed project is new project located at barren land. The company has acquired the

new land.

5.3 Topography (along with map)

The topography map of the area will be submitted at the time of presentation.

5.4 Existing land use pattern (agriculture, non agriculture, forest, water bodies –

including CRZ), shortest distances from the periphery of the project to

periphery of the forests, national park, wild life, sanctuary, eco sensitive

areas, water bodies (distance from HFL of the river), CRZ. In case of notified

industrial area, a copy of Gazette notification should be given.

There is no forest, national park, wild life sanctuary, eco sensitive areas in surrounding 10

Km of the plant boundary

CRZ is not applicable to the project. The project falls outside the notified industrial area.



5.5 Existing infrastructure

The company has installed machinery and related utility at the project location pertaining to

existing products.

5.6 Soil classification

Detail soil testing will be done and will be submitted at later stage.

5.7 Climatic data from secondary sources

The climatic data for the March to May 2012 in the study are as below

Table 18: Meteorology data

Average Wind speed 4.40 m/s

Wind direction SW to NE

Temperature 17oC to 41oC

5.8 Social Infrastructure available

The project site is located approximately 2.0 km from the human settlement. Basic

amenities of life are easily available in the area. Primary health centre, school, drinking

water, electricity, communication, road network, transportation facility is available in the

vicinity.

The existing infrastructure is sufficient to cater the additional load due to the proposed

expansion project.

6 Planning Brief

6.1 Planning Concept (type of industries, facilities, transportation etc) Town and

country planning/ Development authority classification

The industrial area and the related facilities are already developed hence no planning is

envisaged. The nearby towns have the modern facilities.

6.2 Population Projection

There would not be any significant increase in the population of surrounding area as the

almost workers for the proposed project will come from the local residents in the



surrounding villages. There won’t be any influx of people in the area due to proposed

project

6.3 Land use planning (break up along with green belt etc)

The total land acquired by the project proponent is 45 acres

6.4 Assessment of infrastructure demand (Physical and social)

New industrial shed will be constructed with the required amenities.

6.5 Amenities/ Facilities

Major basic facilities are available for the proposed project. Road, electricity, water,

transportation facility etc are well developed in the surrounding area.

All the amenities related to project on the site will be installed

7 PROPOSED INFRASTRUCTURE

7.1 Industrial area (Processing area)

The total industrial area acquired by the company is 45 acres.

7.2 Residential area (Non processing area)

No labour colony is envisaged in the existing as well as proposed project. Only

administrative building will be constructed.

7.3 Green belt

33 % of the area shall be developed as green belt

The existing green belt area within the premises consists of the following plant species.

Jatropha curcas

Peltophorum pterocarpum

Albizia lebbeck

Ficus benghalensis

Salvadora persica

Salvadora oleoides



7.4 Social infrastructure

Basic amenities of life are easily available in the area. Primary health centre, school,

drinking water, electricity, communication, road network, transportation facility is available

in the vicinity.

7.5 The existing infrastructure is sufficient to cater the additional load due to the

proposed expansion project. Connectivity (Traffic and transportation, Road/

Rail/ Metro/ Water ways etc)

The connectivity to the project site is discussed in Table 17, page no. 26

7.6 Drinking water Management (Source & Supply of water)

GWIL water will be used for all the activities including drinking purpose

7.7 Sewerage system

Soak pit/ septic tank will be used for domestic waste water disposal

7.8 Industrial waste management

The industrial waste generated will be mainly in form of hazardous waste and solid waste.

Slag, coal char and ash will be major solid waste generated and used oil will be used as

hazardous waste

7.9 Solid waste management

As per section 3.9.2

7.10 Power requirement & supply/ source

The company shall use captive power plant as well and power from Gujarat Electricity

Board. The detail bifurcation is as mentioned in section 3.8.2

8 Rehabilitation and Resettlement (R & R) Plan

8.1 Policy to be adopted (Central/ state) in respect of the project affected

persons including home oustees, land oustees and landless laborers

Not applicable

9 PROJECT SCHEDULE & COST ESTIMATES

9.1 Likely date of start of construction and likely date of completion

Likely date of start of construction: Within two months after obtaining EC



Likely date of completion of construction: May 2018

9.2 Estimated project cost along with analysis in terms of economic viability of

the project

Total project cost: 250 crores

10 Analysis of proposal (Final Recommendations)

10.1 Financial and social benefits with special emphasis on the benefit to the local

people including tribal population, if any, in the area

The following activities will be done for social welfare -

Plantation on Road side.

Contribution in development of infrastructure for public use such as Bus Stop,

sheds, Public Toilet etc.

Contribution in towards health awareness Programmes.

Contribution in Books distribution to children in nearby village.

Contribution in providing better medical infrastructure in nearby area of kutch

district.

10.2 Budgetary allocation for social welfare in the area

Rs. 50 lakhs will be spent on Social Welfare Activity.

Documents

Pre feasibility Report For ASR Steels & Power Pvt. Ltdenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...PREFEASIBILITY REPORT ASR STEELS & POWER PRIVATE LIMITED DETOX CORPORATION