PRE – FEASIBILITY REPORT - Welcome to...

PROJECT NAME : EXPANSION IN MANUFACTURING OF SPONGE IRON, TMT BARS, M.S. BILLET/ S.S.

BILLETS , MS RLLED BARAND CAPTIVE POWER PLANT & WHRB

PRE - FEASIBILTY REPORT

APPLICANT : GALLANTT METAL LIMITED

DOCUMENT NO.:

ENVISIONENVIRO TECHNOLOGIES PVT. LTD.

NOVEMBER’ 2017 34

PRE – FEASIBILITY REPORT





DOCUMENT NO.:


NOVEMBER’ 2017 35

INDEX1.1 EXECUTIVE SUMMARY.........................................................................................................................38

1.2 SALIENT FEATURES OF THE PROJECT............................................................................................38

1.3 PROPOSED PLANNING .........................................................................................................................40

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION ....................................41

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ...................................................41

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT..................................................................42

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION.42

2.4 DEMAND - SUPPLY GAP .......................................................................................................................43

2.5 IMPORTS VS. INDIGENOUS PRODUCTION.....................................................................................43

2.6 EXPORT POSSIBILITY...........................................................................................................................43

2.7 DOMESTIC/ EXPORT MARKETS........................................................................................................43

2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT..............432.8.1 DIRECT EMPLOYMENT .......................................................................................................................................432.8.2 INDIRECT EMPLOYMENT .................................................................................................................................433.0 PROJECT DESCRIPTION .......................................................................................................................44

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT PROJECTS, IF

ANY. ............................................................................................................................................................44

3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND PROJECT

BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES. ........................................44

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING THE

PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL CONSIDERATIONS GIVEN

INTOSHOULDBE HIGHLIGHTED. ......................................................................................................44

3.4 SIZE OR MAGNITUDE OF OPERATION ............................................................................................45

3.5 RAW MATERIAL (Quantity and Source), PRODUCT AND MODE OF TRANSPORT ...........45

3.6 PRODUCT..................................................................................................................................................47

3.7 SOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT...........48

3.8 AVAILABILITY OF WATER, ENERGY/ POWER REQUIREMENT AND SOURCE. ...................483.8.1 WATER DEMAND ....................................................................................................................................................483.8.2 POWER DEMAND ....................................................................................................................................................493.8.3 MANUFACTURING PROCESS ............................................................................................................................ 493.8.3.1 Process Description of Sponge Iron Manufacturing Unit......................................................................493.8.3.2 Process Description of Captive Power Plant .............................................................................................. 53





DOCUMENT NO.:


NOVEMBER’ 2017 36

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR

THEIR MANAGEMENT/ DISPOSAL...................................................................................................613.9.1 SOLID ..........................................................................................................................................................................613.9.2 Hazardous Waste.....................................................................................................................................................613.9.3 WASTE WATER........................................................................................................................................................ 613.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE......................................................................................................62

4.0 SITE ANALYSIS........................................................................................................................................63

4.1 CONNECTIVITY .......................................................................................................................................63

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP .......................................................................634.2.1 LANDFORM .............................................................................................................................................................. 634.2.2 LAND USE..................................................................................................................................................................634.2.3 LAND OWNERSHIP ...............................................................................................................................................634.3 TOPOGRAPHY (ALONG WITH MAP)..............................................................................................................634.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST, WATER

BODIES (INCLUDING AREA UNDER 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

THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED INDUSTRIAL AREA, A COPY OF

THE GAZETTE NOTIFICATION SHOULD BE GIVEN.....................................................................63

4.5 EXISTING INFRASTRUCTURE ............................................................................................................64

4.5.1 BASIC AMENITIES................................................................................................................................................645.6 SOIL CLASSIFICATION ..........................................................................................................................64

4.7 CLIMATE ...................................................................................................................................................65

4.8 SOCIAL INFRASTRUCTURE AVAILABLE.........................................................................................65

5.0 PLANNING BRIEF ...................................................................................................................................65

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND

TRANSPORTATIONETC.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT

AUTHORITY CLASSIFICATION...........................................................................................................65

5.2 POPULATION PROJECTION ................................................................................................................66

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.)....................................66

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)..........................67

5.5 AMENITIES/ FACILITIES......................................................................................................................67

6.0 PROPOSED INFRASTRUCTURE .........................................................................................................68

6.1 INDUSTRIAL AREA (PROCESSING AREA) ......................................................................................68





DOCUMENT NO.:


NOVEMBER’ 2017 37

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)...................................................................................... 686.3 GREEN BELT ............................................................................................................................................68

6.4 SOCIAL INFRASTRUCTURE.................................................................................................................68

6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/ METRO/WATER

WAYS ETC.) ..............................................................................................................................................68

6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER) ............................68

6.7 SEWERAGE SYSTEM..............................................................................................................................68

6.8 INDUSTRIAL WASTE MANAGEMENT ..............................................................................................69

6.9 SOLID WASTE MANAGEMENT ...........................................................................................................69

6.10 POWER REQUIREMENT AND SUPPLY/ SOURCE .........................................................................69

7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN) ...........................................................69

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT AFFECTED

PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND LANDLESS LABOUR (A

BRIEF OUTLINE TO BE GIVEN)..........................................................................................................69

8.0 PROJECT SCHEDULE AND COST ESTIMATES................................................................................69

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF COMPLETION

(TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN). ...........................................................69

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT. .............................................................................................................69

9.0 ANALYSIS OF PROPOSAL.....................................................................................................................70

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BENEFITS TO

THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA. ..............70

10.0 CONCLUSION............................................................................................................................................72

**********************





DOCUMENT NO.:


NOVEMBER’ 2017 38

1.0 EXECUTIVE SUMMARY

1.1 EXECUTIVE SUMMARYGallantt Metal Limited (GML) is a large scale existing industrial unit which is situated atSurvey No. 175/1, Village - Samkhaiyali, Tehsil- Bhachau, District - Kutch, Gujarat.

The proposed expansion in capacity is due to increase in market demand. The proposedexpansion is coming up within existing plant area 116Acres (4, 73,325Sq.m). No additionalland is required for the proposed expansion. The expected capital investment for theproposed expansion will be Rs. 216 Crore and the total project cost will be 536Crore.The proposed expansion is categorized under 3 (a) of Gazette Notification dated 14thSeptember, 2006 and its subsequent amendment. Thus, the project is “A” category project.1.2 SALIENT FEATURES OF THE PROJECT

Particulars DetailsLatitude N ELatitude 23°19’4.47” N Latitude 23°19’2.33” NLongitude 70°29’10.21” E Longitude 70°29’10.21” ES WLatitude 23°18’33.97” N Latitude 23°18’32.58” NLongitude 70°29’28.95” E Longitude 70°29’41.87” E

Longitude

Toposheet No. 41I/7,8,11 & 12Production Capacity S.No.

Product Existing (TPA) Proposed (TPA)1 Sponge Iron 2,25,000 373500

S.No.

Product Existing(TPA)

Proposed (TPA)1 Sponge Iron 2,25,000 3735002 M.S. Billets 3,36,000 4284003 TMT Bars 3,30,000 4224004 MS rolled Bar 5346 68435 Runner &Raiser 891 891(No change in capacity)Power Generation6 Power Plant(AFBC) 25 MW 35 MW7 Power Plant(WHRB) 8MW 16MW





DOCUMENT NO.:


NOVEMBER’ 2017 39

2 M.S. Billets 3,36,000 4284003 TMT Bars 3,30,000 4224004 MS rolled Bar 5346 68435 Runner &Raiser 891 891Power Generation6 Power Plant(AFBC) 25 MW 35 MW7 Power Plant(WHRB) 8MW 16MW

Estimated project cost Project Cost Amount (In Rs.)Existing 380Proposed 216Total 596Man Power Existing - 960; Proposed - 290; Total – 1250(Approx.)Elevation Highest – 42 MSL; Lowest – 39 MSL.Land use Industrial LandNearest Habitation/Town Samkhiyali - 1.04 Km, SE

Nearest Airport Bhuj - 83.31 Km, WNearest Highway S. No. Particulars Distance (Km) Direction

(From Project Boundary)1. NH-8A 750 m S2. NH-15 2.90 E3. SH-42 13.62 WSource: All distances are taken with respect to Google Earth.Nearest railway trackfrom project boundary Samkhaiyali- 1.04 Km, SE

Power supply Phase Demand (MW) Expected SourceOperational 33 MWH (Existing)18 MWH (Proposed)51 MWH (Total) Existing & proposed CPP andremaining will be met from State gridas and when required.Nearest Telephone Samkhaiyali- 1.04 Km, SENearest Dispensary andGovt. Hospital Dispensary and Govt. Hospital and education facility are present in nearest habitationSamkhaiyali- 1.04 Km, SE.Educational facilityWater demand andsupply S.No.

Particulars Water Demand (KLD)Existing Proposed Total1. IndustrialCooling 485 133 618Boiler 428 233 661





DOCUMENT NO.:


NOVEMBER’ 2017 40

Process 145 96 2332. Domestic 215 61 2763. Plantation 45 14 59Total 1318 537 1855

Source: - Water from GWIL water supply system.Nearest tourist places None within the study area.Defense installations None within the study area.Archeological Features None within the study area.Ecological sensitivezones None within the study area.Nearest Forests S. No. Particulars Distance (Km) Direction

(From Project Boundary)1. R.F. Near Gamdau Village 11.50 NNE(Source: All distances are taken with respect to Google Earth.Nearest streams/rivers/ water bodies(from project boundary)

S. No. Particulars Distance (Km) Direction

(From Project Boundary)

Water Bodies1. Kara Vokra 7.60 WSW2. Gupt Nadi 4.50 SW3. Amliyara Nadi 8.15 S4. Vango Nadi 10.45 SE5. Khari River 9.82 E6. Pipla Talav 6.06 E7. Babudi Nadi 13.50 E8. Adhoi Nadi 2.80 N9. Gorasar Talav 4.50 SSE(Source: All distances are taken with respect to Google Earth.Seismic zone As per the 2002 Bureau of Indian Standards (BIS) seismic zone map of India, categorized as“Severe” Zone-IV.

1.3 PROPOSED PLANNINGCompany : Gallantt Metal LimitedProject Cost : Existing – 380; Proposed-216; Total-536CroreProduction : As given below:-S.

No.

Product Proposed

(TPA)1 Sponge Iron 3735002 M.S. Billets 428400





DOCUMENT NO.:


NOVEMBER’ 2017 41

3 TMT Bars 4224004 MS rolled Bar 68435 Runner & Raiser 891(No change in capacity)Power Generation6 Power Plant (AFBC) 35 MW7 Power Plant (WHRB) 16MW

Table 1: Land Use of Project Site

S.

No.

Land Use Area (Acre) Percentage

(%)Existing Proposed Total1. Plant Area Office Area,Residential Colony (Allcovered area).40.60 - 40.60 50.60%

2. Paved Area (Road, Corridor,Parking and Drainage). 2.10 2.10 2.155%3. Green Belt Area 28.08 28.08 33%4. Future for expansion 45.22

14.245%Plant Area - 18.10 18.10Paved area - 0.40 0.40Greenbelt - 10.20 10.205. Open area - 16.52 16.52Total 116.00 116.00 116 100

2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENTGallantt Metal Limited is company incorporated by two patron companies; namely M/s.Govind Mills Limited based at Gorakhpur (Uttar Pradesh; India) and M/s. Ganesh LaxmiProcessors Pvt. Ltd. based at Surat (Gujarat; India). At present, M/s. Govind Mills Limited isinvolved in running Flour Mills, Induction Furnaces and Re-rolling Mills in and aroundGorakhpur.Gallantt Metal Ltd has set up an integrated steel plant near to Bhachau in Gujarat formanufacture of Sponge iron, Steel billets, M.S Bars, Runner riser, MS Rolled Bars and captivepower plantGallantt Metal Limited (GML) is a large scale industrial unit which is located at Survey No.175/1, Village- Samkhaiyali, Tehsil-. Bhachau, District- Kutch (Gujarat). The company





DOCUMENT NO.:


NOVEMBER’ 2017 42

manufactures sponge iron, TMT Bars, M.S. Billets/S.S. Billets and having Captive powerplants now GML has decided to expand its sponge iron, TMT Bars, M.S. Billet/ S.S. Billets andcaptive power plant capacity within existing premises of industries.Name and address ofthe Applicant Gallantt Metal Limited (GML)Dinesh Agarwal (Director)Address: Gallantt Metal LimitedPlot No 123, Ground Floor, Ward 10 BC, Opp. IFFCO ColonyGandhidham, Kutch-370201 Gujarat, India.Telephone No. No. –02837-283555Email:- [email protected], [email protected]

2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECTThe proposed expansion is for manufacturing Sponge Iron - 3,73,500TPA; M.S Billets -4,29,000TPA; MT Bars -4,22,400 TPA, MS Rolled Bar - 6,843 TPA. No change in runner &Riser Capacity, it is remains same as 891 TPA; Captive power plant of AFBC -35MW; WHRBbased power plant -16MW, respectively due to increase in market demand.2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR

REGIONThe need for the expansion unit for Sponge Iron, TMT Bars, M.S. Billet/S.S. Billet andCaptive power plant and WHRB. This is due to the rising infrastructural demand from theexisting unit and to keep its continuous supply, owing to the growth in the region. CaptivePower plant will be installed to meet the demand of electricity.India is world's largest sponge iron producer with an annual production of about 26-28MnT against installed capacity of 46-47 MnT. There are over 400 sponge iron units in India.Indian sponge iron industry is highly fragmented. Top 20 producers contribute about 60-65% of total production where as rest contribute 35-40% of the production. Sponge ironcontributes 25% of India's total crude steel production of 90 MnT.The production for sale of DRI or Sponge Iron has increased from 1.31 mt in 1991-92 to14.83 mt in 2016-17 (prov). India was the largest producer of DRI in the world during theperiod 2003 to 2015 and emerged as the 2nd largest global producer in 2016, based onprovisional ranking released by the World Steel Association.





DOCUMENT NO.:


NOVEMBER’ 2017 43

2.4 DEMAND - SUPPLY GAPIn order to meet the in house demand of raw material for billets and TMT bars and also tomeet the market requirement in timely manner the proposed expansion project isundertaken.2.5 IMPORTS VS. INDIGENOUS PRODUCTIONThere will be no import for the proposed expansion project. The machinery used isindigenously manufactured and will be purchased. Local villagers will be employed. Therewill be Indigenous production in the entire activity.2.6 EXPORT POSSIBILITYThe product will be used 50 % in house and 50 % of the product shall be exported in thenearby region depending on the market demand.2.7 DOMESTIC/ EXPORT MARKETSThe end products will be sold depending on the market demand shall be exported indomestic market.2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT

2.8.1 DIRECT EMPLOYMENTThe proposed expansion project generates employment for around 290 people (afterexpansion). Priority for employment is given to local persons. Following staff & workers areproposed to be employed:-Table 4: Manpower Details

S. No. Category No. of Persons

Existing Proposed Total1. Permanent Staff 355 70 4252. Skilled Workers 225 60 2853. Semi-Skilled worker 130 50 1804. Unskilled worker 250 110 360Total 960 290 1250

2.8.2 INDIRECT EMPLOYMENT

The vocational training camps and Technical Training of generating skilled manpowerfor cement plants will be done to generate potential manpower.





DOCUMENT NO.:


NOVEMBER’ 2017 44

Available for the proposed & surrounding plants of the Tehsil. The proposed employee development and welfare activities already envisaged andproposed by the expansion project aims to engage many people with various jobsindirectly. There will be development of externalities viz. local logistics, warehousing etc. assupporting services. This would create Indigenous technologies for sustainable development.

3.0 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT

PROJECTS, IF ANY.There is no interlinked or interdependent project with the proposed expansion project.3.2 LOCATION (MAP SHOWING GENERAL LOCATION, SPECIFIC LOCATION, AND

PROJECT BOUNDARY AND PROJECT SITE LAYOUT) WITH COORDINATES.The proposed expansion project is situated at Village - Samkhaiyali, Tehsil- Bhachau,District- Kutch in Gujarat. The project site falls in Survey of India Toposheet No.- 41I/7,8,11 & 12.The geographical location with respect to boundary pillars of the proposed expansionproject are:-Table 5: Geographical Position of the Boundary Pillars

N ELatitude 23°19’4.47” N Latitude 23°19’2.33” NLongitude 70°29’10.21” E Longitude 70°29’10.21” ES WLatitude 23°18’33.97” N Latitude 23°18’32.58” NLongitude 70°29’28.95” E Longitude 70°29’41.87” EThe map showing location of the project site is enclosed as Annexure – VI.

3.3 DETAILS OF ALTERNATE SITES CONSIDERED AND THE BASIS OF SELECTING

THE PROPOSED SITE, PARTICULARLY THE ENVIRONMENTAL

CONSIDERATIONS GIVEN INTOSHOULDBE HIGHLIGHTED.No alternative site was examined or chosen, as the proposed expansion is coming up inexisting land area.





DOCUMENT NO.:


NOVEMBER’ 2017 45

3.4 SIZE OR MAGNITUDE OF OPERATIONThe size and magnitude of the project area is as given below:-Table 6: Size or Magnitude

S. No. Particulars Details1. Area (Acre) 116Acres(4,73,325 Sq.m)2. Production (After Expansion) Given Below

3.5 RAW MATERIAL (Quantity and Source), PRODUCT AND MODE OF TRANSPORT

Sponge Iron Plant:Following raw materials will be required for the manufacturing of Sponge Iron Plant.Table 7: Details of Raw Material

S. No. Raw Material Existing Proposed Total Source Mode of

transportConsumption1 Iron ore 360000TPA 237600TPA 597600TPA Imported/ Indian Transported byships to nearestport and latertransported viadumper to site2 Coal 241200TPA 159192TPA 400392TPA Imported / Indian

S. No. Product Proposed (TPA)1 Sponge Iron 3,73,5002 M.S. Billets 4,29,0003 MT Bars 4,22,4004 Misrolled Bar 6,8435 Runner & Raiser 891(No change in Capacity)Power Generation6 Power Plant (AFBC) 35 MW7 Power Plant (WHRB) 16MW





DOCUMENT NO.:


NOVEMBER’ 2017 46

Table 8: Material Balance for Sponge Iron Plant

IN PUT OUT PUT

Qty / MT of Sponge Iron 100 M T/ day Qty / MT of Sponge Iron Qty /day,

1 : 100 M T /dayIron ore Pellet: 1.6 T 160 Sponge Iron. 100% 100Coal : 1.0 T 100 Coal Char 20% 33Ash 12Dolomite : 0.08 8 Waste solids 3Air : 5. 5 550 Air : 6.7 Tons 670(as waste gas for powergeneration )Total In put 818 MT Total out put 818 M T

Billets:Following raw materials will be required for the manufacturing of Ballets.Table 9: Details of Raw Material

S. No. Raw Material Existing Proposed Total Source Mode of

transportConsumption1 Sponge 148140TPA 373500TPA In-houseproduction 225360 TPA InternalTransported byTrucks2 Scrap NIL 156660TPA Local Market 156660 TPA Transported byTrucksTable 10: Material Balance for Billets (Per 100 Tons)

INPUT TONS OUTPUT TONSSponge Iron 93 Billets 100Scrap 23 Slag 15CPC, Petcoke, Silicon Mn, Ferro Al, FerroSi DDHR Sheet 3.5 Burning Loss 1.5Sodium Silicate, Casting Powder AndOther Additives 0.50 Other Miscellaneous Losses 3.5Total 120 Total 120





DOCUMENT NO.:


NOVEMBER’ 2017 47

TMT Bars

Table 11: Details of Raw Material

S. No. Raw Material Existing Proposed Total Source

Consumption1 MS Billets 341976TPA 87024TPA 429000TPA In house productionTable 12: Material Balance for TMT Bars:

IN PUT OUT PUTQty / 100 MT of billets, Qty Qty / 100 MT of TMT QtyM.S Billets : 1.03 103 TMT 100% 97Waste fines & gases 6Total Input 103 M T Total Output 103 M T

AFBC/CFBC Power PlantCoal and char will be mainly used as raw material for AFBC/CFBC power plant. The list of rawmaterial is as mentioned in:Table 13: Raw Material For Power Plant

Materials ExistingConsumption

ProposedConsumption

Totalconsumption

Source Transportation

Coal 187618 TPA 75047 TPA 262665 TPA Imported/Indian coal Transported by shipsto nearest port andlater transported viadumper to siteCoal Char 66795 TPA 26718 TPA 93512 TPA Inhouseproduction Transported byTrucks3.6 PRODUCT

Table 14: Details of Product

S. No. Product

Proposed(TPA)1 Sponge Iron 3,73,5002 M.S. Billets 4,29,0003 MT Bars 4,22,400





DOCUMENT NO.:


NOVEMBER’ 2017 48

4 MS Rolled Bar 6,8435 Runner & Raiser 891(No change in Capacity)Power Generation6 Power Plant(AFBC) 35 MW

7 Power Plant(WHRB) 16MW3.7 SOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE PROJECT.The unit will utilize all the charcoal as raw material for power generation and fly ashgenerated will sold to brick manufacturing unit or used as binding material for land filling.3.8 AVAILABILITY OF WATER, ENERGY/ POWER REQUIREMENT AND SOURCE.

3.8.1 WATER DEMANDThe fresh water requirement for the proposed expansion will be 537 KLD and the total waterdemand will be 1855KLD. The detailed breakup of the same is given below:-Table 9: Water Demand

S.No.

Particulars Water Demand (KLD)

Existing Proposed Total1. IndustrialCooling 485 133 618Boiler 428 233 661Process 145 96 2332. Domestic 215 61 2763. Plantation 45 14 59Total 1318 537 1855

Source: - Water from GWIL water supply system. Annexure- VII.





DOCUMENT NO.:


NOVEMBER’ 2017 49

3.8.2 POWER DEMANDThe total power requirement for the proposed expansion is as given below:-Table 10: Power Demand

3.8.3 MANUFACTURING PROCESS

3.8.3.1 Process Description of Sponge Iron Manufacturing Unit

ROTARY KILNThe process of the production of sponge iron consists of the reduction of Pellets with solidcarbonaceous material (coal/coke/lignite) in a rotary kiln at high temperature, cooling toroom temperature in the rotary cooler with indirect water cooling system, screening andmagnetic separation of the product. Sponge iron, being magnetic, gets attracted andseparated from the non-magnetic char.In the process for the production of sponge iron, raw materials (pellets, Sponge Iron, feedcoal and lime stone /dolomite) are fed to the rotary kiln through feed tube in a pre-determined ratio by electronic weighing equipment. Rotary kiln is generally of mts indiameter and 60 Mts. long and inclined at 2o. It is internally lined with refractory of 300 mmthick. It is rotated by an AC variable speed motor at a steeples variable speed ranging from0.2 to 1.0 rpm. Due to inclination and rotary motion of the kiln, the material moves from thefeed’s end of the kiln to the discharge end in approximately 5.5 hrs (Tendency time). Finecoal is blown counter currently from the discharge end of the kiln to maintain requiredtemperature and carbon concentration in the bed. Kiln has seven shells, air fans mounted onthe top which blow air in the respective zones to maintain the required temperature profile.Material and hot gasses move in the counter current direction and as a result, pellets getspre-heated and gradually reduced by the time it reaches discharge end.Kiln is divided into two zones namely pre-heating zone and reduction zone. The pre-heatingzone is normally 30 per cent of the total length of the kiln and rest is taken as reduction zone.Material gets heated to the reduction temperature in pre-heating zone up to 200°C, iron ore,coal and limestone gets dried and all the moisture is vapourised. Upto 800°C, pellets getsroasted and any carbonates in it get calcinated. In the coal, volatile matter starts gettingreleased. Limestone also gets calcinated and becomes active. Pellets, which are in the form of

Phase Demand (MW) Expected SourceOperational 33 MWH (Existing)18 MWH (Proposed)51 MWH (Total)Existing & proposed CPP and remaining will be met fromState grid as and when required.





DOCUMENT NO.:


NOVEMBER’ 2017 50

hematite, gets reduced to magnetite. Afterwards, materials enter to the reduction zonewhere the magnetite is reduced to wustite and then to metallic iron.Coal contains sulphur. During the decomposition of coal, sulphur is released in the form ofIron sulphide. Iron sulphide (FeS) has deleterious effect in the steel making and has to beremoved. Hence, limestone is used to prevent the sulphur pick up by sponge iron. All theabove reactions are possible only in the presence of CO. Therefore, generation of CO is mostimportant reaction, which is called as ‘Boundary reaction’. This reaction is highlyendothermic which is also reversible. Conditions favorable for the forward reaction i.e.generation of CO, is higher temperature higher the production of CO. Concentration of thereactants has to be high so that the forward reaction occurs. Low pressure also favors COgeneration.Oxygen required for the burning of these combustibles is supplied from the air tubes placedalong the length of kiln. By controlled combustion, temperature in various zones ismaintained so that the reduction is proper and to required degree. Reduction of iron ore istopo-chemical i.e. reduction proceeds from the surface to core. Iron ore on partial reductionhas all the different stages of reduction.Hot material, after reduction is complete, is transferred to the rotary cooler via transferchute. The rotary cooler is 1.8 Mts. in diameter and 30 Mts. long made up of Mild Steel shell.It is also inclined at 2° approximately and rotates at variable speed from 0.2- 1.2 rpm. It isdriven by an AC variable speed motor. Water is sprayed on the top of the shell, which coolsthe material inside the cooler indirectly. Heat from the material is extracted by the shell. Inorder to increase the surface area for the heat extraction fins are welded inside. Completeshell is covered by thin layer of water. Heat is transferred from the shell to the water byconvection. By this, the material gets cooled to 80oC and is discharged on the belt conveyorby double pendulum valve. The double pendulum valve acts as the seal for the prevention ofthe atmospheric air into kiln cooler system.The total kiln cooler system is kept under positive pressure about 0.3-0.5 mbar. Thisprevents the atmospheric air from getting into the system. The kiln has to be alwaysoperated on positive pressure, as any leakage into the system will cause the re-oxidation ofthe sponge iron there by causing the drop in the quality of the product.The material after the discharge from the cooler is dropped on to the cooler dischargeconveyor. A diversion chute is provided at head end of this conveyor for diversion of thematerial in case of break down in the production separation. The material is then sent toproduct separation system. In product separation system consisting of double deck screen,material is screened to 0-15 mm size fractions. Oversize i.e. +20 mm obtained is small





DOCUMENT NO.:


NOVEMBER’ 2017 51

quantity so it is taken on the floor or diverted to the sponge iron bin. The 0-3mm sizefraction, called as fines, are fed to a drum type magnetic separator where the magneticsponge iron fines and the non-magnetic dolochar separated and fed to the respective binsthrough the chutes and conveyor. The coarser fraction is similarly separated by anothermagnetic separator and fed so respective bins. This magnetic fraction is called the spongeiron lumps and the non- magnetic as char which is the unburned coal. This char can berecycled depending on the quality obtained after processing.The gasses, which flow in the counter current direction of the material, go to the dust-settling chamber where the heavier particles settle down. These particles are continuouslyremoved by the wet scrapper system. The gasses then pass to the after burner chamberwhere the residual carbon or CO is burned by the excess air available. The gasses are at hightemperature and have lot of heat energy, which can be utilized for the power generationthrough the waste heat recovery boiler. The hot gas after the heat recovery boiler gets cooledto 200°C. The gases are then scrubbed and let-off to the atmosphere through the chimney.Alternatively the hot gasses are quenched and scrubbed to clean all the dust in it, and thenlet off to the atmosphere through the stack.Chemical reactions taking place in reduction zone is represented by following equation:Fex Oy + CO FexOy-1 + CO2The carbon dioxide formed is converted to carbon monoxide by means of the carbon in thereductant in accordance with the boundary reaction:C + CO2 2COBurning of small amount of carbon and excess carbon monoxide by means of outside airsupplied through tubes to provide heat for the process reactions can be shown by thefollowing equations:CO + 1/2 O2 CO20It is to be noted that a reducing and oxidizing atmosphere prevail side by side in the rotarykiln. Within the material charge, it is reducing atmosphere accompanied with endothermicreaction while in the free board above are the oxidizing conditions with the exothermicreactions.The separation of the two atmospheres is ensured by the pressure generated by COemerging from the charge into the kiln free board. This avoids re-oxidation of the reducedparticles at the charge surface.





DOCUMENT NO.:


NOVEMBER’ 2017 52

Flow chart for the sponge iron manufacturing process

Raw Material Feeding AtGround Hopper(Coal, Ore)

Coal Sponge Iron Ore

Crushing Crushing

Over Size Over Size

Screening Screening

Coal Bin Iron Ore BinLimestone Bin

Setting up of Production of Mixed RawMaterials for Kiln Feed

Processed in Rotary Kiln at 1075o C withAir Control

Indirect Cooling in RotaryCooler with Water Spray

Screening of Mixed end Products(Sponge Iron and un burnt Coal)

Sponge Iron Lumps + Char Sponge Iron Fines + Dolo Char

Drum Type MagneticSeparator

Drum Type MagneticSeparator

Sponge IronLumps Bin

Char Bin Fines Bin Dolo Char Bin





DOCUMENT NO.:


NOVEMBER’ 2017 53

3.8.3.2 Process Description of Captive Power Plant

Operation of the PlantThe waste heat recovery boilers will generate around 35 TPH of steam with the outletparameters of 105 Ksc (a) and 535 Deg. C., while taking in the feed water at 165 Deg.C fromthe HP heater. The entire waste gas from the sponge iron kiln will be utilized in the wasteheat boiler for the steam generation.Circulating Fluidized Bed Combustion (CFBC) / Atmospheric Fluidized Bed

Combustion (AFBC) BoilerFluidized bed combustion is a "Clean Technology for a better tomorrow" where technologyand economy have been interwoven harmoniously in quest of a better environment. Theenvironmentally friendly perspective of this technology are as follows:At the low combustion temperature of 850°C / 900°C, no Nitrogen Oxides result from theNitrogen in the combustion air, with the end result of extremely low NOx emissions evenwith fuels rich in Nitrogen.Formation of SOX is essentially prevented by the addition of limestone. This is both mixedinto the fuel and blown into the combustion chamber. Due to the favourable conditions in thefluidised bed, about 90 per cent of the resulting Sulphur Oxides can be removed.A broad selection of fuels thereby enabling use of Char produced in the DRI Plant replacingabout 40% of coal.Better Plant flexibility at partial loads of about 25 per cent and quick load changes.LowAuxiliary Power consumption compared to other coal fired Boiler versions.The Steam Generator would be semi-outdoor type, natural circulation, balanced draft, Single-drum, designed for firing different grades of coal. Boiler is of bubbling fluidized bed type tohandle even high ash coal.Capacity of AFBC coupled with adjacent WHRB has been selected to ensure adequate marginover the requirement of turbine at 100% MCR. AFBC would be designed to operate with "TheHP heaters out of service" condition (resulting in lower feed water temperature atEconomiser inlet) and deliver Steam to meet the Turbo-Generator requirement at 100%MCR. Economiser section of the Boiler would be non-Steaming type. Super heater sectionswould be convection type and also bed super heater and designed so as to maintain ratedSteam temperature of 535°C (:i: 5°C) at super heater outlet over the control range of 60% to100%, MCR. Attemperator is provided at the outlet of convection super heater fortemperature control at Steam Generator outlet. The Boiler furnace and flue gas passageswould be designed for appropriate low velocities in order to minimise erosion.





DOCUMENT NO.:


NOVEMBER’ 2017 54

Suitable balanced draft System would be provided for the Steam Generator with two (2)forced draft and two (2) induced draft fans. Each of these fans would be capable of meetingthe air requirement at 60% Boiler MCR load. The forced draft fans would be radial type withinlet vane control for regulation of airflow. The induced draft fans would be radial type withmulti louver damper control the regulation. The forced draft fans would control total airflowto Boiler and the induced draft fan would control furnace draft of the Boiler throughautomatic control loops. In addition to the FD fan, two (2) primary air fan of 60% capacityeach shall be provided for transportation of fuel with one working and one standby.The Boiler would be top supported type and would be provided with all supporting Steelplatforms, galleries and stairways for easy approach and Maintenance of the Unit. Adequateweather protection would be provided for instruments and operating personnel. Necessaryinsulation along with skin casing to limit outside surface temperature to the safe level wouldbe provided.Capacity MW 18No of Steam Generator No. 1Superheated Steam pressure kg/cm2 (a) 105Superheated Steam, temperature °C 535+/-5Feed water temperature at economizer °C 165Flue gas temperature at AH outlet °C 140Fuel used:Main fuel Char & CoalPerformance fuel Char & CoalStartup fuel Light Diesel Oil

Char produced by DRI Kilns will have an outlet as fuel to FBC Boiler. Coal and Char will befired as a base fuel to FBC Boiler for Steam Generation with consequent proportionatereduction in fuel cost.Analysis Report of Char

Characteristics CharCarbon 40.00%Hydrogen 0.75%Oxygen 3.00%Sulphur 0.30%N2 0.74%





DOCUMENT NO.:


NOVEMBER’ 2017 55

Ash 55%Moisture NegligibleGCV 3500 Kcal /kgSteam Turbine Generators and Auxiliaries

Steam TurbineThe Steam Turbine will be of condensing type. The set will be complete with Condenser, AirEvacuation System, 2 x 100% Condensate Extraction Pumps, Generator Cooling, System,Gland Sealing with Gland Vent Condenser, Lube Oil System, LP & HP Re-generative FeedHeaters, etc.GeneratorsGenerator will be rated for 18 MW with 0.8 lagging Power Factor, delivering Power at 12 KV,3 Phase, 50 Hz Star connected in IP55 enclosure.The Generator will be provided with brush less excitation. It shall be capable of operating inIsolation or in parallel with the Power grid, with Voltage Variation of (+) 5% to (-) 5% andFrequency Variation of (+) 3% to (-) 5% with Short Circuit ratio of around 0.8.The Generator shall have class F insulation with Temperature rise limited to Class "B"insulation and shall be designed for CACW Cooling.All Six Terminals of the Generator shall be brought out and shorted, neutral point will begrounded through a Resistor. Generator shall be connected through Isolated Phase Bus ductto the 24 MVA Generator Transformer which will be provided with an "On-Load" TapChanging Gear of :I: 10% range.Excitation SystemThe Excitation System envisaged will be brush-less type. The Excitation System shall becapable of supplying the Excitation Current of the Generator under all condition of Operationof Load, Voltage and Power. Rated current and Voltage of the Exciter shall be atleast 120% ofnormal Excitation Current and atleast 110% of no Load Excitation.Voltage with maximum of 140% ceiling. The Exciter response ratio shall be greater than 1.5.The Field Breaker and Field Suppression System will also be part of Exciter System.Automatic high speed Thyristorised, Auto Manual AVR capable of maintaining Steady StateTerminal Voltage within :I: 0.5% of the preset Value under all Operating Conditions andcapable of smooth and continuous running over the Operating Range. The Generators shallbe provided with Temperature Detector embedded at different location, i.e. Stampings,Stator Windings, etc.





DOCUMENT NO.:


NOVEMBER’ 2017 56

BOILERWHRB / CFBC/AFBCTURBINE ALTERNATOR18 MW POWER

AIR COOLED CONDENSERFEED WATER PUMPMAKE UP WATER

3 %

10 MW8 MW

Process flow chart of Captive Power plant

Figure: Typical Flow Diagram of Steam Based Turbo Generator Set

Steel Melt ShopThe induction melting technology and Arc furnace technology in the Global Steel Scenariohas brought a significant change in technological and revolution where it has been provedthat the steel produced out of sponge iron mixed with Cast Iron and M.S. Melting Scrap/Pigiron coupled with electric induction furnace, medium frequency, constant power track andarc furnace rouge has become formidable process and can offer better economics at arelatively smaller scale operations.The process involves the charge mix of Raw material mainly Sponge Iron 70% to 90% andC.I.Scrap/ M.S.Scrap 15% to 30%, into molten bath with constant power track throughSolid State generator converting A.C. Power into D.C. Power and again to convert the sameinto A.C. Power after changing the frequency of cycle in between 250 to 500 HZ throughthyesisters (an electronic device). This converted A.C. power with a frequency of 250 to 500HZ is passed through capacitor Rack after achieving the de-sired voltage and the same ispassed through copper Bus Bar into Molten bath having copper coil, cooled through water





DOCUMENT NO.:


NOVEMBER’ 2017 57

circulation, transparent the heat energy into molten bath at constant voltage to melt theIron and Steel at a temperature of 1550°C.The continuous efforts made by technologists in established mini steel plants all overIndia, sponge iron manufacturers and Medium Frequency Melting Induction furnaceequipment manufacturer/arc furnace manufacturers have developed the processparameters by which considerable quantity of sponge iron are used in steel making. Thishas brought a new era in steel melting technology in the country where scrap scarcity canno more be a threat to the mini steel plants. The economy of steel making ratherintroduced Induction Furnace/arc furnace to convert sponge iron and scrap into steelwhere better productivity could be attained with proportionately lower scale.Continuous Casting Machine:Liquid Metal from Induction Furnace is carried in a ladle over the Concast Machine. Theliquid metal flows from the ladle through a slide gate system underneath it into water cooledcopper mould tubes which solidifies the liquid metal into a square shaped mould which wecall as M.S. Billets.From the considered casting cycle time, the number of strands required to cast 100 mm sq.and 110 mm sq. billets is worked out to be two (2). Based on the above, 2 strand billetcasting machine suitable for casting up to 160 mm sq. Billets have been selected. Spaceprovision will be made in the shop for installation of a second billet caster in future.





DOCUMENT NO.:


NOVEMBER’ 2017 58

Flow chart showing Process Flow for Manufacturing M.S. Billet

Rolling MillThe process involves converting the shape stock viz. Ingots/billets to desired finishedsection in hot condition by way of passing the material between a pair of grooved rolls andproviding suitable reduction at various stages. Whole operation is conducted at a particulartemperature range and within a limited time span. Stages of rolling operation are comprisedof heating of feed stock to rollable temperature, rolling the feed stock in different mill stands,cropping the hot bar during process of rolling between stands as applicable andsubsequently finishing in the form of hot rolled deformed bar in straight length. The hot barcoming out of last pass is then conveyed through TMT line and collecting in a cooling bedafter shearing. The bars at almost ambient temperature are sheared to commercial lengthstored and kept ready for dispatch. In TMT process hot bars are subjected to quenching bymeans of an intense cooling installation (cooling installation specially designed water spraysystem). This step hardens the surface layer to martensite while the core structure remainsaustenite. When the bar is free of water chamber heat flows from core to surface and surfacegets tempered to structure called tempered marten site. In the cooling bed due to

BLENDING IN PREDETERMINED RATIO

RAW MATERIAL PREPARATION SPONGE IRON SCRAPS(SIZING & PROCESSING)

MELTING IN INDUCTION FURNACE

TAPPING OF MOLTEN METAL

CASTING IN CONCAST MACHINE

BILLETS





DOCUMENT NO.:


NOVEMBER’ 2017 59

COOLING OF THE BARS ON COOLINGBED

CUTTING OF BILLET TO DEFINITELENGTH

ROLLING OF PREHEATED SOAKED STOCKSTHROUGH NUMBER OF PASSES TILL THE

REQUIRED NOMINAL DIAMETER OF BAR ISATTAINED

PREHEATING THE BILLETS IN DOUBLEROW REHEATING FURNACE/ DIRECT HOT

CHRGING

SHEARING OF THE BARS WITHFLYING SHARES

CONTROLLED SURFACE QUENCHINGOF THE BAR IN THE TMT

QUENCHING LINE

SHEARING OF BARS TOMARKETABLE LENGTH

SIZE WISE STACKING OF ROLLEDTMT BARS

DISPATCH

atmosphere cooling, the hardened zone is tempered by temperature homogenization in thecross section and the austenite core is transferred to ducktile-ferrite-pearlite core.Process flow chart of Rolling Mill

Flow chart showing Process flow chart of Rolling Mill





DOCUMENT NO.:


NOVEMBER’ 2017 60

FLUE GAS EMISSION AND CONTROL MEASURES FOR EXISTING PROJECT

S. No. Stack attachedto

StackHeightfrom GL,meters

Exit gasVelocity,m/s

TopStackDia, m

Exit gasTemp, ºC

APCM

For sponge iron/ WHRB1 Kiln No 1 & 2 35 Mtr 7-10 m/s 1 m 120 ESP/Recuperator2 Kiln No 3 & 4 35 Mtr 7-10 m/s 1 m 120 ESP/RecuperatorFor TMT

3 ReheatingFurnace 30 Mtr 5-8 m/s 1 mtr 150-180 Gas cooler + BagfilterFor AFBC/CFBC4 Boiler 90 Mtr 8-10 M/S 2 Mtr 100-120 ESPFor Billets

5 InductionFurnace No 1 & 4 48 Mtr 5-7 m/s 1 Mtr 100 Bag Filter + SparkTrapper6 InductionFurnace No 2 & 3 48 Mtr 5-7 m/s 1 Mtr 100 Bag Filter + SparkTrapper7 InductionFurnace No 5 48 Mtr 5-7 m/s 1 Mtr 100 Bag Filter + SparkTrapper

PROPOSED PROJECT

S. No. Stackattached to

Stack Heightfrom GL, meters

Exit gasVelocity,m/s

Top StackDia, m

Exit gasTemp, ºC

APCM

1 Power Plant Existing Stack ToBe Utilized,90 MTR 8-10 M/S 2 Mtr 100-120 ESP2 Kiln No. 5 48 MTR 5-10M/SEC 2 Mtr 100-120 ESP





DOCUMENT NO.:


NOVEMBER’ 2017 61

4 InductionFurnace No. 6existing stack tobe utilized,48 MTR OFFURNACE 5 5-7 m/s 1 Mtr 100 Bag Filter +Spark Trapper

*Existing stack of 25 MW CPP AFBC/CFBC will be utilized for 10 MW CFBC based CPP.#Existing stack of Induction furnace No. 5 will be utilized for Induction Furnace no. 6

3.9 QUANTITY OF WASTES TO BE GENERATED (LIQUID AND SOLID) AND SCHEME

FOR THEIR MANAGEMENT/ DISPOSAL.

3.9.1 SOLID

Particulars Waste Quantity in TPA Treatment/ disposal

Type ofWaste

Existing Proposed TotalSolid Waste (TPD) Slag 21250 5833 27083 Sold to road construction activityTotal Ash 51400 28077 79477 Sold to brick manufacturing unitor used as binding material forland filling.Municipal SolidWaste (Kg/ day) Biodegradable 480 145 625 Sent to Municipal CouncilBhachau, Gujarat3.9.2 Hazardous Waste

Particulars Hazardous Waste Quantity in TPA Treatment/ disposal

Type of Waste Existing Proposed TotalHazardousWaste Used Oil 2.063 1.13 3.19 Authorization for hazardouswaste is enclosed asAnnexure- 1.Hazardous waste manifestform is attached as Annexure-VIII.

Used Ion exchange resin 0.35 0.19 0.54Tar residue 3.6 - 3.6

3.9.3 WASTE WATER

Description Existing Proposed Total(A) IndustrialCooling 33 9 42Boiler 10.5 5.5 16Process 69 46 115Industrial Total 112.5 60.5 173(B) Domestic

105 30 135





DOCUMENT NO.:


NOVEMBER’ 2017 62

(C) Other (DM Rejects)

23 13 36

Total Waste Water Generation

(A)+(B)+ (C)240.5 103.5 344

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE

INFORMATION OF EIA PURPOSE

Project Concept

Form 1, Pre-feasibility Project Report with Proposed TOR to MoEF&CC (EAC)

Scoping by EAC(Site visit by sub group of EAC, if necessary)

TOR approved by EAC EC - rejected by MoEF&CC on recommendation of EAC

Draft EIA Report to SPCBby Project Proponent

Public Consultation process by SPCB

Summary EIA and Form 1 –display on the Website by SPCB

Proceedings of Public Consultation

Appraisal and Recommendation by EAC

Display on MoEF&CCWebsite

Display at Panchayat, ZP, DM/DC/

Dy. Com & on the SPCB website

To Proponent for Submission of Final EIA

Report/Supplementary Report to Draft EIA

Approval by MoEF&CC

Rejected Approved Display on MoEF&CC Website& Project Proponent Website

Post ECMonitoring

Submission of half yearly Compliance

Report to MoEF&CC/ RO-MoEF&CCDisplay of Compliance Reporton MoEF&CCWebsite





DOCUMENT NO.:


NOVEMBER’ 2017 63

4.0 SITE ANALYSIS

4.1 CONNECTIVITYThe existing Plant is situated at village- Samakhiyali , Taluka – Bhachau, District- -Kutch,Gujarat. This has all possible amenities that are feasible for industrial projects viability.Table 11: Connectivity

S. No. Name Distance (Km) Direction

(From Project Boundary)

Nearest Railway Station1 Samakhiyali 1.04 SENearest Airport2 Bhuj 83.31 W

Nearest Highway3 NH-8A 750 m S4. NH-15 2.90 E5. SH-42 13.62 W4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

4.2.1 LANDFORMThe proposed expansion is planned within existing land area of 116 Acre ( 4,73,325Sq.m).No additional land is required for the proposed expansion.4.2.2 LAND USEThe land use pattern is given in point no. 1.2.4.2.3 LAND OWNERSHIPThe land use is bonafide industrial Land declared by the District Collector of Kacchhenclosed as Annexure- V.

4.3 TOPOGRAPHY (ALONG WITH MAP)Topographically, the project area comprises of gently flat land sloping towards NE to SW.The highest elevation of the project area is 42MSL. The drainage of the project area istowards SW.4.4 EXISTING LAND USE PATTERN (AGRICULTURE, NON-AGRICULTURE, FOREST,

WATER BODIES (INCLUDING AREA UNDER CRZ)), SHORTEST DISTANCES FROM





DOCUMENT NO.:


NOVEMBER’ 2017 64

THE PERIPHERY OF THE PROJECT TO PERIPHERY OF THE FORESTS, NATIONAL

PARK, WILD LIFE SANCTUARY, ECO SENSITIVE AREAS, WATER BODIES

(DISTANCE FROM THE HFL OF THE RIVER), CRZ. IN CASE OF NOTIFIED

INDUSTRIAL AREA, A COPY OF THE GAZETTE NOTIFICATION SHOULD BE

GIVEN.The existing land use pattern is given in point no. 1.2.4.5 EXISTING INFRASTRUCTUREThe same has been given in point no. 3.8.1, 3.8.2 and 4.0.4.5.1 BASIC AMENITIESAt the project site first aid centre will be set up. Company will provide drinking waterand other sanitary facilities to the workers.5.6 SOIL CLASSIFICATIONThe soils found in Kachchh district can broadly be grouped into four types, i.e., ShallowBlack soils, Residual Sandy soils, Coastal Alluvial soils and Desert soils. The Shallow blacksoils are found in central and north-central parts of the Kachchh mainland and in Khadirand Bela Islands. These soils have developed from basaltic rocks and rocks of Jurassicperiod. The depth of soil ranges from a few cm to 30 cm.. Broadly, these soils are poor infertility. The Residual Sandy soils have developed in-situ from the parent materialoriginated from red sandstone and shale and are found over the areas underlain by BhujSandstone. All these residual soils are shallow in depth. They are reddish brown in colourwith fine weak granular structure to poorly developed one. These soils are sandy to loamysand in texture dominated by coarse sand. These are non-calcareous, neutral to alkaline inreaction with poor base saturation. They are affected due to salt accumulation. Fromfertility point of view, they are poorly supplied with plant nutrients and, as such, supportthe crops with short duration and less water requirement. The hilly soils occur in the hillyareas central part of the district. The soil profile is not well developed because of the steepslope and erosion. They have developed from the parent materials existing in the respectiveareas. They are shallow in depth composed of undecomposed rock fragments and poor infertility. The Coastal Alluvial soils are found all along the southern coast. These soils aresandy clay loam to clay in texture. The soil reaction varies with situation ranging fromneutral to highly alkaline. These soils are normally medium in fertility. At places, these soils





DOCUMENT NO.:


NOVEMBER’ 2017 65

are saline in nature The two Ranns (deserts) of Kutch namely little Rann and great Rannhave the soils which are formed as a result of the geological processes of Pleistocene age.The alluvial deposits due to the river system flowing through the area have subsequentlybeen overlain by the aeolian deposits. These soils are fairly deep, light grey in colour. Thetexture is sandy to sandy loam with silty clay loam in some areas. The salt content is veryhigh with the sodium chloride as the dominant salt. The profile study reveals the presenceof sufficient amount of gypsum throughout the profile.4.7 CLIMATEThe climate is characteristic of area: Temperatures vary considerably from season toseason. The summers are generally hot and winters are cool. Mean maximum temperatureranges between 26.7°C during January to about 39.5°C during May and the mean minimumtemperatures vary between 9°C during January and 27°C during June. The relative humidityin Kachchh as per IMD varies between 43.5% during March and 77% during August. Thewind velocity in the district varies from about 124 km/d during November and 375 km/dduring June. The potential Evapo-transpiration, calculated using Penman‟s Method variesbetween 3.4 mm/d during December and 9.2 mm/d during may. Long-term average annualrainfall for Bhuj IMD station is 378.2 mm. Most of the rainfall (about 345 mm) is receivedduring south-west monsoon between June and September.4.8 SOCIAL INFRASTRUCTURE AVAILABLEThe well-established social infrastructure like hospitals, temple, community centre,roads, bridges, telecommunication and others similar are available/ existing within 15km radius No new social infrastructure facility will be developed as the plot is located inindustrial area having well developed infrastructure. All facilities also available atvillage- Samakhaiyali-1.04km,SE5.0 PLANNING BRIEF

5.1 PLANNING CONCEPT (TYPE OF INDUSTRIES, FACILITIES, AND

TRANSPORTATIONETC.) TOWN AND COUNTRY PLANNING/ DEVELOPMENT

AUTHORITY CLASSIFICATION.

Gallantt Metal Limited (GML) is a large scale industrial unit which is located at Survey No.175/1, Village- Samkhaiyali, Tehsil- Bhachau, District- Kutch, Gujarat. The companymanufactures sponge iron, TMT Bars, M.S. Billets/S.S. Billets and having Captive power





DOCUMENT NO.:


NOVEMBER’ 2017 66

plants now GML has decided to expand its sponge iron, TMT Bars, M.S. Billet/ S.S. Billets andMS Rolled Bar, captive power plant capacity within existing premises of industry.5.2 POPULATION PROJECTIONThere will be recruitment of local workers approx 290 workers as per requirement ofskilled workers. Due to hiring of local people, there will be negligible change in thepopulation projection of the most nearest & farther most villages of the project. There areapproximately 17 villages in the study area as follows:-Population Profile of the study area (10.0 Km):-

Table14: Population Projection

S. No. Name Habitation Households Population Males Female1. Adhoi (Pasakayara) Rural 2401 10794 5453 53412. Amaliyara Rural 482 2262 1138 11243. Chhadavada Rural 410 1953 999 9544. Dayapar Rural 856 4398 2269 21295. Gharana Rural 705 3469 1757 17126. Lakadiya Rural 1915 8651 4427 42247. Lakhpat Rural 216 807 371 4368. Laliana Rural 525 2488 1300 11889. Nana Kapaya Rural 2276 8883 6357 252610. Rajansar Rural 122 680 340 34011. Rampar (Roha) Rural 173 861 432 42912. Rampar (Sarva) Rural 215 1124 582 54213. Samakhiari Rural 2482 10402 5748 465414. Vijpasar Rural 475 2417 1236 118115. Vijpasar Rural 144 725 357 36816. Vondh Rural 1877 6972 3462 351017. Vondhada Rural 203 913 457 456Total 15477 67799 36685 31114*Source: Census of India, 2011

5.3 LAND USE PLANNING (BREAKUP ALONG WITH GREEN BELT ETC.)The existing unit has approximately 28.08% total land area in green belt and plantation.Now, for the proposed expansion additional 10.20% green belt will be developed. Thus,after expansion the total land area in the green belt will be 38.28Acre (i.e. 33 %).





DOCUMENT NO.:


NOVEMBER’ 2017 67

The main aim of the green belt development is to improve the ecosystem to a maximumpossible extent by designing the green cover with the same native species. Photographsshowing existing Greenbelt development are enclosed as Annexure – IX.However, in order to compensate the loss of vegetation, it is suggested to carry outextensive afforestation program mainly in and around the project area. Appropriate plantspecies of different life forms have been suggested in the following table to grow and to re-establish the vegetation cover and thereby provide habitat for the faunal species. The list ofplant species suggested includes the following criteria:- Tree species which are well adapted to local environmental setting, tall, bearinglarger canopy cover and leaf area. Tree species of different size classes (small, medium and larger) were suggested tomaintain the different canopy levels at vertical profile. Fruit trees in the selection list would help to attract birds and fruit eating bats whichare locally available. Wild species were suggested to provide habitat for faunal species, increase the faunalspecies diversity and maintain the naturalness.

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)On the basis of the preliminary site visit, the infrastructure demand in the villages assessedon the basis of need and priority.The health infrastructure of the study area requires improvement. The lack of modern andspecialist facilities in hospitals needs improvement.The assessment will be identified in the socio economic survey, after the grant of TOR andwill be submitted at the time of final presentation regarding EC.5.5 AMENITIES/ FACILITIESThe project expansion envisages improvement in the facilities provided to workers.Provision for the same has been made as given below:-

Table 16: Facilities provided to workers

S.

No.

Activities Capital Cost

(Rs. In Lacs)

Recurring Cost

(Rs. In Lacs)1. Shelter/ Housing Facility 120 152. Health Facility 10 063. Drinking Water 12 02





DOCUMENT NO.:


NOVEMBER’ 2017 68

4. Sanitation Facilities 08 015. Education 05 01Total 155 25

6.0 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)The area is very well connected by road network to the site, district headquarter etc. Thearea is self sufficient to cater the needs of the project. Hence, no infrastructure is proposed.6.2 RESIDENTIAL AREA (NON PROCESSING AREA)The unit already has housing facility for operational employee.6.3 GREEN BELTThe same has been given in point 5.2.6.4 SOCIAL INFRASTRUCTUREThe existing project is situated at Tehsil – Bhachau, District – Kutch (Gujarat). Localpopulation will be employed by the company in the proposed expansion project. Further,indirect means of earnings have been created in the area of contractual jobs, vehicle driving,shops, construction etc. Therefore, this project brought a positive impact on the adjoiningsociety. The proponent will spend 1% of profit for the development of the area i.e. medicalfacilities, schools, temples and other social work. There is well developed socialinfrastructure in the area.6.5 CONNECTIVITY (TRAFFIC AND TRANSPORTATION ROAD/ RAIL/

METRO/WATER WAYS ETC.)Given in point no. 4.0.6.6 DRINKING WATER MANAGEMENT (SOURCE AND SUPPLY OF WATER)Given in point no. 3.8.1.6.7 SEWERAGE SYSTEMFor the treatment of domestic sewage, STP (500 KLD) has already provided with adequatecapacity in existing plant & colony and will be covered proposed expansion project also.





DOCUMENT NO.:


NOVEMBER’ 2017 69

6.8 INDUSTRIAL WASTE MANAGEMENTNo additional infrastructure is required for the industrial waste management for theproposed expansion project and the existing facility viz, , STP and etc. will sufficient.6.9 SOLID WASTE MANAGEMENTThe same has been given in point no. 3.9.6.10 POWER REQUIREMENT AND SUPPLY/ SOURCEThe same has been given in point no. 3.8.2.7.0 REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 POLICY TO BE ADOPTED (CENTRAL/STATE) IN RESPECT OF THE PROJECT

AFFECTED PERSONS INCLUDING HOME OUSTEES, LAND OUSTEES AND

LANDLESS LABOUR (A BRIEF OUTLINE TO BE GIVEN)Since, it is an existing project and there is no habitation in the unit area, thereforerehabilitation & resettlement plan is not required/ applicable.8.0 PROJECT SCHEDULE AND COST ESTIMATES

8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATE OF

COMPLETION (TIME SCHEDULE FOR THE PROJECT WILL BE GIVEN).

Table 17: Expected Time Schedule for the Project

S. No. Particulars Time Schedule (in month)* Remark If any

1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th1. EnvironmentalClearance2. Consent To Establish Project Establishment Period3. Consent To Operate Production Start Period*Time line may vary; subjected to rules & regulation/ & other unforeseen circumstances.

8.2 ESTIMATED PROJECT COST ALONG WITH ANALYSIS IN TERMS OF ECONOMIC

VIABILITY OF THE PROJECT.The expected capital investment for the proposed expansion will be Rs. 216Crore.Table 18: Expenditure Proposed for Environmental Protection Activities

S. No. Description of Item Capital Cost

(In Lacs)

Recurring Cost

(In Lacs)





DOCUMENT NO.:


NOVEMBER’ 2017 70

1 Air Pollution Control/ Noise 600 402 Water Pollution Control 30 043 Environmental Monitoring and Management 80 104 Green Belt Development 20 055 Occupational Health 10 06Total 740 65

9.0 ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE

BENEFITS TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN

THE AREA.There have been many social benefits from the existing manufacturing operations. Theunderlying financial and social benefits envisaged through the existing plant have beenlisted as follows:-Table 19: Financial & Social Benefits

S. No. Activities1. It aims to provide few additional employments to the local population of the proposed study area.Existing Direct employment provided: - 290 Approx.Indirect Employment to locals :- 25 + 25 Approx.2. The PP proposes for sustainable development as per the Companies Act 2013 and its subsequentnotifications regarding activities enlisted under the CSR. The PP has been undertaking need basedCSR activities annually and the same will be given in the EIA / EMP report.The CSR activity envisaged by the Gallantt Metal Limited has been given as follows and theyshall continue to allocate sustainable welfare activities with an allocated budget of 2% ofthe average annual profit of last three years for the forthcoming years CSR.

Swachchh Bharat Mission 2016-2017M/S Gallantt Metal Limited,Samakhiyali,Bhachau,Dist :-KutchObjectives of the Project For better livelihoodBeneficial community and its numbers/Geographical 1)Total No.132/ SamakhiyaliBathrooms Construction for 241 households 1)Total No.109/AmliayaraGrand Total :- 241Approach method Supervision by the CompanyImplementing partner/ agency Through Agency





DOCUMENT NO.:


NOVEMBER’ 2017 71

Tenure of Project (in Months / Year) 2.5 MonthsTotal Project Cost (in INR in lacs ) Rs.51,81,500/-Source of Fund

Provided by M /S Gallantt MetalLimited, Samakhiyali, Bhachau, Dist :-KutchPress coverage, if any YesDate Payment Mode Others Financial Assistance 2016-2017 Amount

4/3/2016 Cash Hajipeer Patyatri Camp SamakhiyaliFor Yarti Bohjnalay 11000/-4/5/2016 SBI

Prjapati Dharamsibhai Pancha Bhai

Samakhiyali For Ramdev Babab Temple

Work SMK 101000/-

4/5/2016 Cash Amarabhai Bada ( Ex Sarpanch ) SMKFor Ramdev Babab Temple Work SMK 50000/-4/24/2016 Cash Girnari Eduction Chritable Trust SMKFor School Bhojnalya 6000/-5/3/2016 452640 SBI

Rebari Deva Bhai

Water Pipeline Work Samakhiyali To

Amliyara 201600/-

5/9/2016 452653 SBI Shri Shiv Shakti Chritable Trust,JamnagarFor Construction of Trust Office 11000/-5/21/2016 Cash Girnari Eduction Chritable Trust SMKFor School Bhojnalya 6000/-6/20/2016 Cash Girnari Eduction Chritable Trust SMKFor School Bhojnalya 6000/-

7/16/2016 252992 SBI

Shri Gaushla ,GHARANA

For Construction of Gaushla ,GAHARANA 250000/-

7/21/2016 Cash Girnari Eduction Chritable Trust SMKFor School Bhojnalya 6000/-8/3/2016 BILL

SAMAKHIYALI Gram Panchyat

For Construction of Muslim Comnutity

Hall,SMK 68586/-

8/18/2016 Cash Girnari Eduction Charitable Trust SMKFor School Bhojnalya 6000/-9/9/2016 711862 SBI Durga PoojaFor Donation Durga Pooja ,GHARANA 15000/-9/9/2016 711863 SBI Bangali Association ,Gandhidham 21000/-





DOCUMENT NO.:


NOVEMBER’ 2017 72

For Donation Durga Pooja ,Gandhidham9/19/2016 Cash Girnari Eduction Chritable Trust SMKFor School Bhojnalya 6000/-

10/15/2016 Cash Girnari Education Charitable Trust SMKFor School Bhojnalya 6000/-12/17/2016 452640 SBI - 7000/-The CSR of the existing project is enclosed as Annexure- X.The proposed expansion project aims to continue the sustainable social development. TheProject authorities are committed towards fulfilling its corporate social responsibility.After the analysis of the baseline data generation and socio – economic survey, and thepublic hearing, the appropriate sustainable development plan will be contributed on thebasis of need based analysis and projected by the corporation.The appropriate amount of CSR will be proposed by the M/s Gallantt Metal Limited as perthe Companies Act, 2013 with an appropriate 2% of the next three years average annual netprofits of the coming years.Adequate budgetary provisions have been made by the management for execution ofenvironmental management plans.

10.0 CONCLUSIONGallantt Metal Limited is proposing expansion of the existing manufacturing Iron, TMT Bars,M.S. Billet/ S.S. Billets and Coal based Captive Power Plant and WHRB will not onlycontribute to the growth of Indian economy but also strengthen the socio-economic values/status in the area. All the latest and environment friendly technology will be adopted. Theunit will adopt all measures like; pollution control equipments, effective EMP & DMP toprevent harm/ damage to the environment. Green belt development in & around the areawill increase aesthetic value, as tool for effective pollution mitigate measure, and will alsoserve as biological indicators for that particular site.*****************

Date post:	18-Feb-2019
Category:	Documents
Upload:	nguyentram
View:	240 times
Download:	2 times

PRE – FEASIBILITY REPORT - Welcome to...

Documents