addition of new peoducts in existing … report for addition of new peoducts in existing product mix...

PRE-FEASIBILITY REPORT

FOR

ADDITION OF NEW PEODUCTS IN EXISTING

PRODUCT MIX WITHOUT CHANGING THE

EXISTING TOTAL CAPACITY

At Plot no. C-235, MIDC Butibori, District Nagpur

Maharashtra

M/s. DS ALLOYD PRIVATE LIMITED

EIA Consultant: Pollution and Ecology Control Services

(PECS), Nagpur (MS).

Pre-Feasibility Report: M/s D.S. Alloyd Pvt. Ltd.

1

1.0 INTRODUCTION

1.1 PREAMBLE:

Ferroalloy refers to various alloys of iron with a high proportion of one or more

other elements such as manganese, aluminum, or silicon. They are used in the production

of steels and alloys. The alloy impart distinctive qualities to steel and cast iron or serve

important functions during production and are, therefore, closely associated with the iron

and steel industry, the leading consumer of ferroalloys. The leading ferroalloy-producing

countries in 2008 were China, South Africa, Russia, Kazakistan and Ukraine, which

accounted for 77% of the world production. World production of bulk chromium,

manganese and silicon ferroalloys was estimated as 29.1 million tonnes (Mt) in 2008, a

3% decrease compared with 2007.

Ferro-alloys are among the essential inputs required for steelmaking. It improves the

quality of steel, by controlling the harmful impurities and at the same time improves the

mechanical properties of steel through alloying. Growth in Global as well as domestic

steel industry directly drives the demand of Ferro-alloys. Since Indian steel industry is

under massive expansion, there is a tremendous potential for investment in Ferro-alloy

production.

The increasing demand of Ferro Alloys, which is used as raw material in steel and

stainless steel industries, prompted M/s. D S Alloyd Private Limited to add new products

in existing plant without changing the total production of the Product Mix.

M/s. DS Alloyd Private Limited is applying for grant of Environmental Clearance for

Addition of Products in the existing Product Mix without change in the Total Capacity

under Para 7 (ii) (a) of Gazette Notification dated 23.11.2016.

The cost of the project is Rs. 3.87 Crores.

http://en.wikipedia.org/wiki/Chemical_element

http://en.wikipedia.org/wiki/Manganese

http://en.wikipedia.org/wiki/Aluminium

http://en.wikipedia.org/wiki/Silicon


2

1.2 PROJECT DISCRIPTION:

The production details of the proposed unit are given below

SR.

NO.

NAME OF ITEMS EXISTING CAPACITY PROPOSED

CAPACITY Capacity

(TPA)

As per EC

Dated

17th

July 2008

Capacity

(TPA)

As per

Consent to

Operate

1. Low Carbon Ferro Manganese 3600 3600 2880

2. Medium Carbon Ferro

Manganese 3600

3600 3000

3. Ferro Titanium 3600 600 240

4. Ferro Molybdenum 3600 480 1920

5. Aluminium Ingots 2400 1800 120

6. Ferro Vanadium - - 720

7. Moly Oxide Briquettes - - 720

8. Manganese Metal Briquettes - - 480

Total 16800 10080 10080

SITE DESCRIPTION:

The plant of M/s. D S Alloyd Pvt. Ltd. proposed to manufacture Ferro Alloys, Noble

Alloys & Foundry Alloys. The shed is in ButiBori Industrial Area Plot no. C-235, MIDC

Butibori, District Nagpur. Butibori MIDC is notified industrial area. The area of shed is

6000 sq mt.

SITE LOCATION & ITS ADVANTAGES:

The proposed unit is located at MIDC, Butibori. The place is very well connected

by road to neighboring cities.

The water required for the unit is available from MIDC.

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

infrastructure facilities like Power, Water, Labour, etc.


3

Degama RF

291

Kinara

304

Power line

323

297

Open mixed jungle

Vanadongri

10r

Singardip

323

Nanhi

343

310

323

310

278

328

3rOpen scrub

Fairly dense mixed jungle mainly salaiBID SUKLI RF

jungle mainly salaiFairly dense mixed

333

Open mixed jungle

Sivnal

Khairi Khurd

299

312

282

Asola

mainly salaiFairly dense mixed jungle

Can

al

298

5r

290

319

286

Open mixed jungle344

392

394

326

348

Pitesur

Kohal

5r

370

2r382

Vayphad

294

5r

Open mixed jungle

377

3r

507Gangapur

Vateghat

PO

Murjhari

275

Khairmixed jungle mainly

Fairly dense

Kanholi distributary

JunapaniJUNAPANI RF

278

DONGARGAON R F

mainly khairFairly dense mixed jungle

PO

Menghat

284

Hospital

315

2r

BM 276.2

319

279

Dongargaon

4rKrishna Nala3r

265

RUI

4r

4r

4r

Open scrub

Sukli

301

4r

3r

5r

284

3r

Devli Peth

3r276

295

NH

- 7

5r

272

5r

INJOLI RF

4r

4r

Pow

er li

ne

263

Tele

phon

e lin

e

Pow

er li

ne

266

3r

286

Mandva

Borgaon

Ajangaon

Varanga

Khadki

Lakhimapur

Khapri

Tembhari

Devapur

Kinhi khurd

Ghodeghat

SavangiVeterinary

Bothli

PipriDevli

Masalkund

Bhansuli

Pipaldhara

Nagajhari

Katandhara

Khapri

Mandva

Sukli

AmgaonKhapa

Takalghat

Tarsi

Khairi Buzurg

Khairi Buzurg

CHICHOLI

Datal

Umri

Borkhedi

Jangeshwar

Murharpur

Bid Ganeshpur

kinhi Buzurg

BharkasTurakmari

Salai Dabha

Madnapur Vadgaon

Vathoda

Sirur

Kanholi Khurd

BothliMohagaon

Borkheri

Ziarat

Bori

Weir

Masala

Amgaon

DeoliBorgaonSaongi

Dhanoli

Dudha

Pohi

Village - MIDC Butibori, Tahsil - Nagpur, Dist. - Nagpur.

STREAMS

RIVER / NALA

POND

ROAD

HABITATION

GRID

INDEX

FOREST AREA

PROJECT SITE

PREPARED BY-POLLUTION AND ECOLOGY CONTROL SERVICES

10 KM. STUDY AREA

TOPO SHEET NO.55 K/16,55 P/1,55 O/4,55 L/13

M/s. D.S. Alloyd Pvt. Ltd.

78°55' 79°00'

20°55'

21°00'

20°55'

21°00'

78°55' 79°00'

3r3r

Kanholi

Khadki Canal

CanalKris

hna

Nala

VE

NA

RIV

ER

Figure 1: Study Area

SOURCE & AVAILABILITY OF WATER:

Water will be sourced from MIDC and the total water requirement for the project will be

25 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,

D.S. Alloyd

Private

Limited


4

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

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

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

Dust suction system controls fugitive emission due to material handling.

Dust suppression system provided in the form of water sprinklers.

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

prevent leakages of dust.

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

provided with dust suppression system.

Wet scrubbers have been provided for the extraction of dust particles.

Dust generated during transportation, storing of raw material and construction

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

plant premises.

Domestic / sewage effluent will be treated in Packaged type STP.

2.1 INTODUCTION OF THE PROJECT AND BACKGROUND OF PROJECT

PROPONENT

DS Alloyd Private Limited is registered as small scale industry, a manufacturing unit of

Ferro Alloys, Noble Alloys & Foundry Alloys catering to almost all the finest steel

makers & Casting industry across the country. The production processes will be carried

out in well-equipped unit in MIDC Industrial area Butibori Nagpur. The location map is

shown in Fig. 2 and the details of the project are presented in Table 1.The satellite image

showing project site is given below in figure no. 3.


5

Source: mapsofindia.com

Figure 2: Location of Project Site


6

Source: NRSA, Hyderabad

Figure 3: Satellite Image

Source: NRSA, Hyderabad


7

Environmental Setting of the Proposed Project Site

Sr. No. Particulars Details

1. Project Site MIDC - Butibori

Dist. - Nagpur

State - Maharashtra.

2. Total Area with shed leased

out by MIDC Butibori

22334.5Sqmt Plot Area

6000 Sqmt Shed Area

3. Nearest major road SH 262 : 6.4 Km in East direction

NH-204 : 5 Km in SE direction

4. Coordinates Latitude - 20°56'11.25"N

Longitude - 78°56'35.70"E

5. Nearest railway station Butibori railway station 8.0 km (E)

6. Elevation above MSL 970 Ft

7. Toposheet 55 L/13,55K/16,

55 P/1 and 55 O/4

8. Climatic conditions

(Based on IMD) Annual Average Maximum Temp : 47

0

C

Annual Average Minimum Temp : 100

C

Annual Average Rainfall : 800 - 900 mm

Annual Average Humidity : 44- 60%

9. Nearest village Wateghat : 0.5 km in South direction

Tembhari : 1.20 Km in SE direction

10. Nearest major city Nagpur - 27Kms (NE)

11. Nearest water body Vena river : 4 km(E)

Krishna nala: 4 km (SW)

Khadki Canal :6 km (W)

Kanholi Canal :5 km (SW)

12. Defense Installation Ambazari Ordnance Factory : 22 kms NE

13. Sensitive locations Archaeological structures, Historical places,

Sanctuaries and Biosphere None within 10 km

14. Nearest forest Reserve forest :

Degma R.F. : 9.5 km (NW)

Dongargaon R.F. : 5.0 km (SE)

Junapani R.F. : 7.0 km (S)

Bid Sukuli RF : 5.0Km (NW)


8

Source: Google Earth

Google Image

Nearby Industries

Sanvijay Rolling & Eng. At 1.0 Km (East)

Inox Air Product at 0.50Km (SE)

Reliance Power Plant at 1.5 km (SW)

CRITERIA FOR LAND IDENTIFIED

Addition of Products in the existing Product Mix without change in the Total

Capacity in existing shed.

No Rehabilitation/Resettlement issues.

Availability of Raw Material.

Assured Water Supply from MIDC.

Assured Power Supply.

Market available for finished products.

Availability of man power.

Availability of industrial infrastructure.

Total Plot area of Plant is 22334.5 m2 and 6000 m

2 shed is already constructed

and sufficient for proposed activities.


9

2.2 POWER REQUIREMENT

The power required will be supplied by Maharashtra State Electricity Distribution

Company Limited. The power requirement for the proposed project will be 250 KVA.

2.3 LAND REQUIREMENT

M/s. DSAPL is in possession of 22334.5 m2of land, 6000 m

2 shed is existing and

sufficient for proposed activities.

2.4 EMPLOYMENT POTENTIAL

The total direct employment and indirect employment is 46.

2.5 TRANSPORT

SH 262 is at a distance of 6.4 km; East from the project site and Butibori railway station

is just 8 Kms from the project site.


10

3.0 PROJECT AT GLANCE

1. Name of the Project : M/s DS Alloyd Private Limited .

2. Location of the proposed unit: At Plot No.C-235, MIDC Butibori

District: Nagpur

State: Maharashtra

3. Products to be manufactured:

SR.

NO.

NAME OF ITEMS EXISTING CAPACITY PROPOSED

CAPACITY Capacity

(TPA)

As per EC

Dated

17th

July 2008

Capacity

(TPA)

As per

Consent to

Operate

1. Low Carbon Ferro Manganese 3600 3600 2880

2. Medium Carbon Ferro

Manganese 3600

3600 3000

3. Ferro Titanium 3600 600 240

4. Ferro Molybdenum 3600 480 1920

5. Aluminium Ingots 2400 1800 120

6. Ferro Vanadium - - 720

7. Moly Oxide Briquettes OR, - - 720

8. Manganese Metal Briquettes - - 480

Total 16800 10080 10080

4. Raw Material Requirement for Proposed Product Mix:

Sr.

No. Product Name Raw Material Quantity

required

(TPA)

Product (TPA) & Balance of Input (approx)

1&2 Low / Med. Carbon Fe. Mn. Manganese Ore 5586 Total Raw Material input – 11401 MT Product Out put FeMn - 5880 MT

Handling loss - 13.68 MT

Fuming/evaporation loss - 9.12 MT

Slag - 5498.20 MT

Aluminium

Scrap (18%) 1005

Lime Powder/

Flourspar (24%) 1340

Silico

Manganese

(62%)

3470


11

3 Ferro Titanium Ilmenite 315 Total Raw Material input – 640 MT Product Out put FeTi - 240 MT



Slag - 398.72 MT

Aluminium

Powder (44%) 140

Lime Powder

(10%) 35

Iron Ore/ Mill

Scale (48%) 150

4 Ferro Molybdenum. Moly Oxide 1940 Total Raw Material input – 4195 MT

Product Out put FeMo -1920 MT



Slag - 2266.61 MT

Aluminium

Powder (12%) 235

Lime Powder

(10%) 195

Iron Ore/ Mill

Scale (56%) 1085

Ferro Silicon

(38%) 740

5 Ferro Vanadium. Vanadium

Pentoxide

(flakes)

691 Total Raw Material input – 1476 MT Product Out put FeV - 720 MT



Slag - 753.05 MT Aluminium

Shots (52%) 360

Flourspar

Powder (7%) 50

Iron Scrap (54%) 375

6 Aluminium Ingots Aluminium

Scrap

145 Total Raw Material input – 145 MT

Product Out put -120 MT



Slag - 24.71 MT

7 Moly Oxide Briquettes Molybdenum

Concentrates


Product Out put - 720 MT

Binding Material

(5%)

35

8 Manganese Metal

Briquettes

Mn. Metal

Powder


Product Out put - 480 MT

Binding Material

(5%)

20

5. POWER REQUIREMENT:

The power required will be supplied by Maharashtra State Electricity Distribution

Company Limited. The power requirement for the proposed project will be 250 KVA.


12

3.1 PROCESS DETAILS

Manufacturing Process of Ferro Alloys

Manufacturing of Ferro Alloys through Thermite Process is very easy and simple

Principal of Thermite Process:

Aluminothermic Process aims at the production of Ferro Alloys from the oxides of

elements by reduction with Aluminum powder using exothermic heat of the reaction for

smelting purpose. The highly exothermic reaction raises the temperature of the reaction

to above 2000 0c or even more.

Metal Oxide + Al Metal + Al2O3

On ignition of the reaction mixture consisting of the oxide ore whose metal is to be

obtained with aluminum powder/telic, aluminum readily reacts with the oxygen of the

metal oxide liberating heat, which raises the temperature of the reacting substance and

reacts thereby yielding the Ferro Alloys Slag. The process flow chart is presented in the

Figure 4.


13

Figure 4: Process flow Chart

Raw ore Crushing on the Pulverizer/Crus

her

Reaction Vessel ( Aluminothermic

Process)

Slag

Solidification and Cooling

(12-24 hours)

Breaking, Cleaning and

packing of the finished goods

Testing/ storage and

Dispatch

Construction of Boundary Walls

Tiles Manufacturing

Preheating for removal of moisture

Aluminum Powder

Suction Hood

&

Wet Scrubber

s


14

4.0 SELECTION OF SITE & LOCATION OF PLANT

o Addition of Products in the existing Product Mix without change in the Total

Capacity in existing shed.

o No Rehabilitation/Resettlement issues.

o Availability of Raw Material.

o Assured Water Supply from MIDC.

o Assured Power Supply.

o Market available for finished products.

o Availability of man power.

o Availability of industrial infrastructure.

o Total Plot area of Plant is 22334.5 m2 and 6000 m

2 shed is already constructed

and sufficient for proposed activities.

4.1 LOCATION:

The project is situated at Plot no. C-235, MIDC Butibori, District Nagpur Maharashtra.

4.2 TYPE OF THE PROJECT:

The proposed project involves addition of products in the existing product mix without

changing the total manufacturing capacity.

4.3 SITE ANALYSIS

LAND USE

The existing land is industrial land.

TOPOGRAPHY

The topography of the land is plain.

EXISTING LAND USE PATTERN

The existing land is industrial land.


15

EXISTING INFRASTRUCTURE

All required infrastructure is prevailing in the site.

GREEN BELT

The Company has already planted 400 no. of trees and proposed to plant 800 no. of trees

in and around the premises. During plantation landscaping pattern will be considered.

The plantation scheme covers the plantation of ornamentals plants and some local fruit

bearing species.

SOCIAL INFRASTRUCTURE

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

4.4 Availability of Utilities

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

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

efficiently run the Equipment.


16

5.0 Water System & Plant Utilities:

5.1 Source of Water

Water required for the plant will be drawn from MIDC.

5.2 Water Consumption

Water will be sourced from MIDC and the total water requirement for the project will be

25 KLD.


17

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 is taken by installing Wet Scrubbers 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 is installed.

6.2.2 Water Pollution

It is estimated that total effluent generation from the proposed project is from wet

scrubbers & washing. This wastewater is being treated in settling tank and is reused in the

process & green belt development. The domestic effluent will be treated in proposed

packaged type STP.


18

6.2.3 Noise Pollution

There is no such high noise generate due to operation of units, however Noise generation

may occur due to handling of raw materials and finished products. For that Ear plugs/ ear

muff are provided to the workers working in noisy area.

6.2.4 Solid Waste Management

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

a. Slag (8941.29 TPA) from Crucible / Vessel.

6.2.6 Plantation

The Company has already planted 400 no. of trees and proposed to plant 800 no. of trees

in and around the premises.

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

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

Selection Criteria of plant species for Green Development Plant

The selection of plant species for the development depends on various factors such as

climate, elevation and soil. Area falls under the tropical region and thus the plants that

area adapted to this condition should be selected. The plant should exhibit following

characteristics in order to be selected for plantation.

1. The species should be fast growing and providing optimum penetrability.

2. The species should be wind firm and deep rooted

3. The species should form a dense canopy.

4. As far as possible, the species should be indigenous and locally available

5. Species tolerance to air pollutants like SPM, SO2, and NOx should be preferred.

6. The species should be permeable to help create air turbulence and mixing within the

belt.


19

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.

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