PRE-FEASIBILITY REPORT
FOR
EXPANSION UNIT
OF
STAINLESS STEEL BILLETS FROM 60,000 MTPA TO
1,80,000 MTPA
Plot no 32, 33-B, 34, 35 & 36, Umbargaon Industrial Area,
Dist Valsad, Gujrat
M/S CHANDAN STEEL LIMITED
EIA Consultant: Pollution and Ecology Control Services
(PECS), Nagpur, Maharashtra
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1.0 INTRODUCTION
1.1 PREAMBLE:
The demand for Stainless Steel has been increasing enormously due to the significant use
and need in day-to-day life in the form of coils, sheets, plates, bars, wire, tubing, etc., to
be used in cookware, cutlery, hardware, surgical instruments, major appliances, industrial
equipment etc. Stainless Steel could very well be the metal of future as it is lustrous,
ability to combat corrosion, 100% recyclable, hygienic and long-term value. Furthermore,
riding on strong growth for steel demand, the company is proposing to expand its
capacity in producing Stainless steel along with Oxygen and Nitrogen gas production.
1.2 PROJECT DISCRIPTION:
The production details of the proposed expansion and new unit are given below
Stainless Steel Billets – Existing production – 60,000 M.T. Per Annum,
Proposed expansion:
1,20,000 M.T. Per Annum after Expansion production = 1,80,000 M.T. Per Annum
After Expansion:
Oxygen Gas – 15.0 Lacs M3 / Month
Nitrogen Gas – 9.0 Lacs M3 / Month
SITE DESCRIPTION:
The proposed project is located in plot no 32, 33B, 34, 35 & 36, GIDC, Umbargaon,
Valsad District, Gujarat State.
SITE LOCATION:
The nearest Railway station is Umbargaon and the nearest district head quarters to the
proposed site is Valsad which is in North direction. The nearest airport is Mumbai – 150
km away.
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Umbargaon Railway Station is at 2.7 km away from the project site and highway (NH8)
is at 14km away. This facilitates transportation of the raw materials and finished product
to major markets. Even for exports, the location is ideal as the Jawaharlal Nehru Port
Trust (JNPT) is 140 km away in SSE direction from the project site.
Figure 1: Study Area
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SOURCE & AVAILABILITY OF WATER:
Water will be sourced from GIDC and the total water requirement will be 190 KLD.
POLLUTION CONTROL MEASURES:
The pollutants in the form of solids, liquids and gases are generated from various
technological units and, if let out as such, will have hazardous effects on the
environment. Pollution of the environment, not only adversely affects the flora and fauna,
but also shortens the life of plant and equipment. This vital aspect, therefore, has been
taken into account while planning the plant and equipment and adequate measures have
been proposed to limit the emission pollutants within the stipulations of statutory norms.
• During construction only domestic waste shall be generate and will get treat in septic
tank.
• Dust will be generated during transportation, storing of raw material and construction
activities. The dust emission shall be mitigated by water spraying on the roads within
the plant premises.
• Domestic / sewage effluent shall be sent to septic tank followed by soak pit.
2.1 INTODUCTION OF THE PROJECT AND BACKGROUND OF PROJECT
PROPONENT
M/s. Chandan Steel Ltd (CSL) was incorporated on 8th
November, 1989 with no loss
track record since its inception and the Certificate for Commencement of Business was
issued on 06.02.1990. The objective of business is to manufacture Stainless Steel
materials like Bright Bars, Angles, Wires, Flat Bars and Flanges with annual production
capacity of 60000 MT.
Currently, the company has a 25 tons induction furnace with a 15 tons Argon Oxygen
De-carbonization vessel with a micro-processor based gas mixing station.
2.2 JUSTIFICATION :
The demand for steel in the country is currently growing at the rate of over 8% and it is
expected that the demand would grow over by 10% in the next five years. However, the
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steel intensity in the country remains well below the world levels. This indicates that
there is a lot of potential for increasing the steel consumption in India. To meet the
increasing demand and to stimulate economic growth the proponent has proposed the
expansion of the existing unit.
Government policy is to achieve global competiveness not only in terms of cost, quality
and product-mix but also in terms of global benchmarks of efficiency and productivity.
This will require indigenous production of steel over 100 million tons (MT) per annum
by 2019-20 from 30 MTPA in 2004-05. This implies a compounded annual growth of
7.3% per annum. Projected gap between Supply & Demand for steel is expected to
further increase in production by 2014.
2.3 EMPLOYMENT GENERATION (DIRECT & INDIRECT):
The proposed expansion project creates direct and indirect employment to 35 people.
3.0 PROJECT AT GLANCE
Particulars Details
Location Plot No. 32, 33B, 34, 35 & 36, GIDC, Umbargaon ,
Valsad District, Gujarat State
Geographical Positions Latitude – 20° 09’ 39” N
Longitude – 72° 46’ 22” E
Elevation 22 m
Land Area 4.20 Acres
Present Land use Industrial
Nature of Terrain Flat
Predominant Wind direction West (Summer Season)
Nearest Highway NH 8 – 14 km, East
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Nearest Railway Station Umbargaon – 2.7 km, South East
Nearest Airport Chhatrapati Shivaji International Airport (Mumbai) –
150 km, South
Nearest District Head Quarters Valsad – 42 km, North
Nearest Sea Port Jawaharlal Nehru Port Trust (JNPT)- 140 kms SSE
Nearest Village Dahad – 1.5 km, South
Solsumba – 1.6 km, North East
Nearest State Boundary Gujarat – Maharashtra, 3.0 km, South East
Monuments Nil
Archaeologically important places None
National Parks None in 25 km radius
Forests None in 25 km radius
Seismicity Zone III
Water Bodies Varoli River – 4.4 km North East,
Arabian Sea – 3.5 km East
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4. Raw Material Requirement :
The raw material requirement is given in the table given below.
RAW MATERIAL CONSUMPTION PER HEAT FOR PROPOSED EXPANSION
PROJECT
Sr.
No. In-puts Description Qty (kg)
( A ) Raw Material
Charging
Qty
Finish Liquid
Metal Slag
1 Hot Metals 45000 74874 10350
2 H.C Ferro Chrome 2490
3 H.C Ferro Manganese 1995
4 Ferro Silicon 1680
5 Ferro Nickel 1500
6 Scrap Coolant 24900
( B ) FLUXES
1 Lime 2560
2 Dolomite 1280
Total 45995 74874 10350
5. POWER REQUIREMENT:
The power required will be supplied by State Electricity Board. The power requirement
for the proposed project will be 1200 KV.
3.1 PROCESS DETAILS
The technology for manufacturing the S.S. products has been developed in-house based
on several years of experience in this field and also based on the inputs received by the
company from its own in-house technical team or Metallurgist who are expert in this
field.
The production process is broadly referred to as to “DUPLEX REFINING”. The crux of
the production process is input of low value high carbon steel and Ferro Alloys and
production process is broadly as follows:
• Medium frequency Induction Furnace (melting)
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• Argon Oxygen Decarbonisation (AOD) Convertor.
• Ladle Refining Furnace (LRF).
• Continuous Casting in a Concast billet Machine.
• Hot rerolling of billets into hot rolled bars, angles, stub ends and Flats.
The ferrous charge containing Steel Scrap and Ferro Alloys is melted in an Induction
Furnace as per the calculated quantities to get the desired steel chemistry. After
temperature adjustment and slagging off, the liquid metal is transferred to the pre- heated
AOD Vessel. Calculated quantities of lime are added in the hot metal and processed by
gas blowing in pre- fixed ratios Oxygen & argon/nitrogen. The Oxygen, Argon/ Nitrogen
start to decarbonize the melt. Blowing is done in three or four stages with changing ratios
of Oxygen and inert gases as per the carbon level of the liquid metal. During blowing,
due to several exothermic oxidation reactions, the temperature of the bath goes up, but it
has to be controlled by addition of coolant scrap.
During refining, decarbonisation, the chromium and manganese also gets oxidized and go
to slag. After decarbonisation, a reducing mixture containing Ferro Silicon and lime is
added to the liquid bath in order to reduce the oxidized chromium/ manganese, so that the
desired level of chromium and manganese are restored in the final steel output. After
degassing, composition of refined steel is checked and alloying additions are made, if
necessary.
The plant has got facility for duplex refining as a result of the L.R.F. In the AOD
conversion with the passing of Oxygen, first the temperature goes up, however, with the
addition of non-ferrous metal and of the refining process, the temperature of the molten
metal drops to a level barely adequate for pouring into the L.R.F. In the L.R.F., the
temperature of the metal is raised to the desired level. Here the process broadly intends to
attain the following:
• Fine tuning of refining to maintain desired level of composition of inputs.
• Removal of inclusions by argon purging.
• Removal of excess quantities of oxygen, by purging.
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• Bringing floating inclusions at slag level.
The AOD process will be fully computerized in this plant thereby enabling dynamic
control of the refining process. The refined metal will be fed to continuous caster to
produce billets of standard sizes. The continuous caster envisaged in the project is a two
strand make so that productivity is enhanced and the cost is reduced and quality will be
improved. The stainless steel billets can be hot rolled in the flats of required dimensions
to be cold rolled into sheets for making end products such as utensils. The AOD
convertor method of Steel refining has several advantages, which have made it the most
popular process for making stainless steel and alloy steel. In fact, about two third of the
world use this process to make stainless steel and alloy steels. The major attributes of the
AOD process are raw-material and processing flexibility, scrap melting potential, low
energy consumption, slag handling capability, optimization of melting potential, low
operational costs, ease of maintenance, use of low cost high carbon Ferro alloys, higher
alloy recovery and high productivity.
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4.0 SELECTION OF SITE & LOCATION OF PLANT
Selection of the site for any project is the most important aspect for it’s successful
operation & better economic viability. Proximity to Raw material source, assured supply
of fuel and other infrastructural support are required to be essentially examined while
selecting the site of the plant. The following basic requirements are necessarily required
to be fulfilled.
i. Easy & nearer access to Raw Material.
ii. Availability of water from continuous source.
iii. Power supply/ evacuation arrangement.
iv. Nearer access through road.
4.1 LOCATION:
The nearest Railway station is Umbargaon and the nearest district head quarters to the
proposed site is Valsad which is in North direction. The nearest airport is Mumbai – 150
km away.
Umbargaon Railway Station is at 2.7km away from the project site and highway (NH8)
is at 14km away. This facilitates transportation of the raw materials and finished product
to major markets. Even for exports, the location is ideal as the Jawaharlal Nehru Port
Trust (JNPT) is 140 km away in SSE direction from the project site.
4.2 SITE ANALYSIS
LAND USE
The existing land is industrial land.
TOPOGRAPHY
The topography of the land is plain.
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EXISTING LAND USE PATTERN
The existing land is industrial land.
EXISTING INFRASTRUCTURE
All required infrastructure is prevailing in the site.
GREEN BELT
33% of total land will be developed as Green belt.
SOCIAL INFRASTRUCTURE
Social infrastructure will be developed as per need based in the Villages
4.3 Availability of Utilities
For successful running of any unit most important factor is the availability of Raw
Materials, as well as Utilities & Power, Water Connectivity which are required to
efficiently run the Equipment.
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5.0 Water System & Plant Utilities:
5.1 Source of Water
Water required for the plant will be provided by GIDC
5.2 Water Consumption
The total water requirement for the project will be about 190 KLD for the process.
5.3 Fire Protection System
The fire fighting system will be designed in conformity with the recommendations of the
Tariff Advisory Committee (TAC) of Insurance Association of India. While designing
the fire protection systems for proposed facilities its extreme ambient conditions need
special attention. Codes and Standards of National Fire Protection Association (NFPA)
will be followed, as applicable.
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6.0 ENVIRONEMENTAL MANAGEMENT PLAN
6.1 Sources of Pollution
The major sources of pollution from proposed units can be classified under the following
heads:
• Pollutants in the waste gases namely, suspended particulate matter (SPM), sulphur
dioxide, NOX and Carbon monoxide, etc.
• Fugitive dust generated during vehicular movement
• Noise pollution
• Waste water and sewage
• Solid Waste Generation
The various measures proposed to mitigate the impact of these pollution sources on the
environment are discussed below:
6.2 Pollution Control Measures
6.2.1 Air Pollution
Proper care will be taken by installing Bag filters followed by Stack to control source
emission. Hence there will not be any major deposition of pollutants into air, land and
water.
To control fugitive dust emissions due to vehicular movement water sprinkling and
spraying system will be installed. Internal roads will be asphalted.
6.2.2 Water Pollution
It is estimated that total effluent generation from the proposed expansion plant will be as
domestic effluent. The domestic effluent will be treated through septic tank followed by
soak pits and no effluent remains after soak pits for further disposal.
Zero discharge condition from the proposed expansion plant will be maintained.
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6.2.3 Noise Pollution
There will no such high noise generate due to operation of proposed expansion units,
however Noise generation may occur due to handling of raw materials and finished
products. For that Ear plugs/ ear muff will be provided to the workers working in noisy
area.
6.2.4 Solid Waste Management
Following are the solid waste generation due to operation of proposed expansion units:
b. Slag from Induction Furnace
Disposal of Slag from Induction Furnac:
Slag generated from manufacturing of Billets will be sold to manufacturer of brick
manufacturers.
6.2.6 Plantation
The plantation scheme covers the plantation of ornamentals plants and some local fruit
bearing species.
Selection Criteria of plant species for Green Development Plant
The selection of plant species for the development depends on various factors such as
climate, elevation and soil. Area falls under the tropical region and thus the plants that
area adapted to this condition should be selected. The plant should exhibit following
characteristics in order to be selected for plantation.
1. The species should be fast growing and providing optimum penetrability.
2. The species should be wind firm and deep rooted
3. The species should form a dense canopy.
4. As far as possible, the species should be indigenous and locally available
5. Species tolerance to air pollutants like SPM, SO2, and NOx should be preferred.
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6. The species should be permeable to help create air turbulence and mixing within the
belt.
7. There should be no large gaps for the air to spill through.
8. Tree with high foliage density, leaves with larger leaf area and hairy on both the
surface.
9. Ability to withstand conditions like inundation and drought.
10. Soil improving plants (Nitrogen fixing, rapidly decomposable leaf litter).
11. Attractive appearance with good flowering and fruit bearing.
12. Bird and insect attracting tree spacing.