pprre e sffeaasiibbiilliittyy rreeppoorrttenvironmentclearance.nic.in/writereaddata/online/... ·...

PPRREE FFEEAASSIIBBIILLIITTYY RREEPPOORRTT

FOR

PROPOSED 2X150 KTPA/300 KTPA OF DUCTILE IRON SPUN PIPE

PLANT

AT

NAVELIM VILLAGE, BICHOLIM TALUKA,

NORTH GOA DISTRICT, GOA

Submitted to

Ministry of Environment and Forests

New Delhi

Project Proponent:

M/s. Vedanta Limited

(Formerly Sesa goa Limited)

Goa

Environment Consultant:

Vimta Labs Ltd. 142, IDA, Phase-II, Cherlapally

Hyderabad–500 051

[email protected], www.vimta.com

(QCI/NABL Accredited and ISO 17025 Certified Laboratory,

Recognized by MoEF, New Delhi)

April, 2016

Pre-feasibility report for Proposed 2x150 KTPA/300 KTPA of Ductile Iron Pipe Plant at Navelim village,

Bicholim taluka, North Goa district, Goa

Pre-Feasibility Report

VIMTA Labs Limited, Hyderabad

TABLE OF CONTENTS

Sr. No. Particulars Page No

1.0 Executive Summary 1

2.0 Introduction of Project 2

3.0 Project Description 9

4.0 Site Analysis 23

5.0 Planning 24

6.0 Rehabilitation and Resettlement (R&R) Plan 25

7.0 Project Schedule and Cost Estimates 26

8.0 Analysis of Proposal 26




VIMTA Labs Limited, Hyderabad 1

1.0 Executive Summary

Vedanta Limited (formerly known as Sesa Sterlite Ltd) is India’s only diversified Natural

Resources Company. The company’s main businesses focus on zinc, lead, silver,

Aluminum, copper, iron ore, oil & gas and commercial power, while its operations

span across India, South Africa, Namibia, the Republic of Ireland, Australia, and

Liberia.

Vedanta Ltd has a portfolio of world-class, low-cost, scaleable assets that consistently

generate strong profitability and have robust cash flows. The company holds

industry-leading market shares across its core divisions

Our Plant is located in village Amona/Navelim, Taluka Bicholim, District North Goa,

state Goa, India. It is approximately 25 kms to the east of Panaji city and the nearest

domestic airport is Dabolim, Goa about 40 kms from our Plant. A double lane road

taking off from Amona to Navelim is running adjacent to the site. The National

Highway is approximately 10Kms from the site. The Pig Iron Plant-II is located in Goa

Industrial Development Corporation having total about 293Acres

We have the following facilities at our Plant;

• Three Blast Furnaces BF#1, BF#2 & BF#3 altogether having Pig Iron production

capacity of 832 KTPA

• Battery-I and II having Met Coke Production Capacity of 620 KTPA

• Two number of Waste Heat Recovery Power Plant having generation capacity of

60 MW (2 x 30MW)

We proposed to set up DI Pipe Plant of capacity 0.30MTPA either in one go or in two

phases, the Phase-I of 0.15 MTPA would be completed in 18months time and

construction of second phase would be taken up after commissioning of first phase.

The location of Plant is very adjacent to BF#3 in Pig Iron Plant-II premises, having area

200 x400M (19.76acres) including area for storage of finished products.

The site is situated within the geographical coordinates.

Sr No Latitude Longitude A 15° 30’ 52.89’’ N 74° 00’ 09.47’’ E

B 15° 30’ 55.70’’ N 74° 00’ 15.40’’ E

C 15° 30’ 44.75’’ N 74° 00’ 22.70’’ E

D 15° 30’ 42.10’’ N 74° 00’ 16.87’’ E

It is in the terrain which is having a slope from 40m to 10m and proposed to put the

plant at FGL of 25 m to optimise the cutting and filling of rocks.

Total water requirement will be 1200m3/day and the source of water is from Bandara

which is about 10km away from the Plant and connected with the pipeline. Make-up

water will be drawn from Bandara & stored in raw water sump. The permission to

draw the water upto 6000m3/day from Bandara has already been granted by

GWRD-Goa government.





DI Pipe Plant will require about 12 MW of power to operate the Electric/induction

furnaces, casting machines and other equipment. Required power will be sourced

internally from our 2*30MW heat recovery Power Plant. If planned to be installed in

two phases of equal capacity of 150 KTPA then,in Phase-I either pig iron received

from BF#3 will be re-melted into electric arc furnace/induction furnace/cupola or hot

metal will be directly used and proceed further for desulphurisation, scrap charging

etc, however, in Phase-II rail track will be laid from BF#3 to DI pipe plant for hot metal

transportation for better realisation and power saving. If depending on financial

viability a decision is taken to install 300 KTPA plant at one go then hot liquid metal

from Blast Furnace will be utilised as 90% raw material.

Manufacturing of DI pipe is a continuous sequential process involving several sub-

processes. The process starts with receipt of Pig Iron/hot metal/scrap, melting into

induction/electric arc furnace, desulphurisation, scrap charging and super heating

of molten metal in induction furnace. The process flow chart for production of DI Pipe

is given below,

2.0 Introduction of Project

Identification of project proponent

Sesa Sterlite, a Vedanta Group company is one of the world's largest global

diversified natural resource majors, with operations across zinc-lead-silver, oil & gas,

iron ore, copper, aluminium and commercial power. The name of the company has

been changed to M/s Vedanta Limited w.e.f. 31.03.2015 post issue of Fresh

Certificate of Incorporation issued by the Registrar of Companies, Goa, Ministry of

Corporate Affairs (MCA), Govt. of India

Vedanta Limited (Vedanta Ltd) is a diversified natural resources company, whose

business primarily involves exploring and processing minerals and oil & gas. The

Company produces oil &gas, zinc, lead, silver, copper, iron ore, aluminium and

commercial power and has a presence across India, South Africa, Namibia, Ireland,

Australia, Liberia and Sri Lanka.

Vedanta Ltd, formerly Sesa Sterlite Limited, is the Indian subsidiary of Vedanta

Resources Plc, a London listed company. Sustainable Development is at the core of

Vedanta's strategy, with a strong focus on health, safety and environment and on

enhancing the lives of local communities. Vedanta Ltd is listed on the Bombay Stock

Exchange and the National Stock Exchange in India and has ADRs listed on the New

York Stock Exchange.

Vedanta Limited (Formerly Sesa Goa Limited, the flagship company of Sesa Group) is

India's largest exporter of iron ore in the private sector. For the past five decades, the

Group has been involved in iron ore mining, beneficiation and exports, with a group

turnover of around Rs. 4900 crores. Over the last decade, it has diversified into

manufacture of foundry and SG grades of pig iron and metallurgical coke. The

Group operated a 320,000 TPY metallurgical coke plant and a 292,000 TPY pig iron

plant.





Sesa Goa Limited has mining operations in Goa and Karnataka.

Sesa Goa's Met Coke Division manufactures metallurgical coke. It has 84 coke ovens

with a capacity of 320,000 tonnes. Sesa has developed an Heat recovery

technology (called Sesa Goa Technology) to manufacture coke, compliant with

advanced global emission norms.

Vedanta Limited successfully commissioned its expansion project for the pig iron and

met coke manufacturing facilities. with the commissioning of the 450 m3 blast

furnace and 2 batteries of 36 coke ovens each, its pig iron production capacity has

increased to0.742 MTPA and met coke production to 0.6 MTPA. it has also

successfully commissioned the associated 1 mtpa Sinter Plant and 30 MW waste gas

based Power Plant (utilising Blast Furnace Gas and Coke Oven Flue Gas)

Need for the Project and its Importance to the country

Economic Growth

Indian economy is likely to grow in the range of 6.3 to 6.9 per cent in 2017-18 and the

outlook is very positive. The average consumer spending has increased significantly

which has fuelled demand for quality infrastructure services like roads, electric

power, transportation, water supply, sanitation, communication, etc.

Demand for pipes for supplying Water

Water is a precious resource in India because the country accounts for 16% of the

world population as against just 4% of global water resources. The water use

efficiency is low in the country compared to international standards. As in the

previous years, agriculture will continue to be the major demand segment for water

in India. However, the demand from industries is expected to grow faster than the

demand from agriculture and domestic sectors. It is understood that the use of water

in Indian industries is high due to a combination of factors such as obsolete process

technology, poor recycling and reuse practices, and poor wastewater treatment.

Use of water in industries is closely linked to the economy of a country. The major

water guzzling industries are pulp and paper units, thermal power plants, fertilizer

units, iron and steel plants, sugar plants, and textile units.

Estimates vary with respect to the requirement of water for industries. According to

the MoWR, the requirement will increase from 30 billion cubic metre in 2000 to 120

billion cubic metre by 2025. According to the World Bank, the water demand for

industrial uses and energy production will touch 228 billion cubic meter by 2025. As

per the Tenth Plan, the stipulated norms are 40 litres per capita per day (lpcd) of safe

drinking water within a walking distance of 1.6 km and at least 1 hand pump for

every 250 persons. The norm will be relaxed to 55 lpcd in states where the 40-lpcd

norm has been achieved already. The above-mentioned norms are quite

reasonable because it is reported that in many large cities, water withdrawal

amounts to 300 to 600 lpcd.

In contrast, the consumption in the developed countries of Europe and North

America had already touched 500-1000 lpcd by the turn of the last century. Water

demand projection varies from agency to agency. Consumption of water by 2020 in





different sectors as projected by Water Resources Division, Planning Commission is

given below.

Projected Water Consumption in 2020 (Billion cubic metres)

End Use Normal Pessimistic

Irrigation 640 602

Manufacturing 56 51

Domestic 57 57

Power 28 27

Total 781 737

According to a WHO-UNICEF Sponsored Study (India Assessment 2002-Water Supply

& Sanitation), the total water requirement by 2050 will be 1,422 billion cubic metre.

Tata Energy Research Institute (TERI) has estimated that the overall water demand

will virtually double from 564 billion cubic metres in 1997 to 1,048 billion cubic metre in

2047.

MoWR has assessed the water requirement at 694 cubic km in 2010, 784 cubic km in

2025, and 973 cubic km in 2050. As against the projected demand, the availability of

water in 2050 is estimated at 996 cubic km.

At the national level, it will be a difficult to increase the availability to the projected

levels as most of the water resources are concentrated in a few river basins.

Transporting huge quantity of water from like rivers, lakes, wells, and treatment plants

to millions of homes would require a reliable pipeline system that will serve for years

without leaks and contamination. The increase in demand for water will call for

enormous efforts to capture, preserve, and distribute available water equitably.

Urbanization

It is estimated that by the end of the 12th Plan in 2017, approximately 40% of the

country’s population will live in cities and towns. This fast pace of urbanization will

increase the demand for piped water supply. Thus, the increase in population

accompanied by the fast pace of urbanization will together contribute for the

growth in demand for pipes.

Improvement in Water and Sanitation Coverage of Government to provide drinking

water & sanitation to100% of the population:

Thrust of government to provide drinking water & sanitation to100% of the population.

Government’s focus to improve the urban infrastructure has increased significantly

during the last 10 years. The investment allocation to water supply & sanitation during

five year plan is INR 423 Bn.

• The year wise fund allocation growth rate in this five year plan is 21% which is higher

than the year wise growth rate of 15% during last five year plan

• The JNNURM scheme commenced during the five year plan is the main driver for

urban infrastructure development. JNNURM scheme is focused towards strengthen





the infrastructure in 63 cities, the other schemes UIDSSMT & AUWSP focuses on

other cities/towns

• Water PPP’s have emerged during the last 10 years & are fairly successful in India;

the central Government has planned to increase the number of PPP projects in-

order to support state water authorities in improving the system efficiency

• The depletion of fresh water sources is driving the need of desalination projects &

these projects are expected to drive the growth of urban water infrastructure in

the coming years. The desalination projects are being planned & ongoing in

certain coastal cities

Source: JNNURM Website & Frost & Sullivan Primary Research & Analysis

Demand Analysis for DI Pipes

The demand drivers for pipes in general and DI pipes in particular are:

Economic growth

Demand for water

Urbanization

Improvement in water supply and sanitation coverage

Awareness on safety and hygiene

Investment by the Central and State Governments in Water and Sanitation

schemes

Assistance from external agencies

Inter-linking of rivers

Export potential

Investment in Water Projects and Role of Government Bodies

The central government had given thrust to improve the urban infrastructure during

the last 10 years and have been implementing various programs & schemes in the

WSS sector. Apart from the state governments also funds & undertake various

schemes. The funds for certain WSS projects are pooled from international banks &

financial institutions (World Bank, JICA, ADB etc. Key WSS Programs in India JNNURM

(Jawaharlal Nehru National Urban Renewal Mission) UIDSSMT (Urban Infrastructure

Development Scheme for Small and Medium Towns) AUWSP (Accelerated Urban

Water Supply Programme) Program Description

Flagship program for improving urban infrastructure

Focuses on 63 mission cities

Program covers the cities & towns which are not covered under JNNURM

Focuses on improvement on urban infrastructure facilities & PPP projects

Aimed at extending WSS services in smaller cities & towns

Partly funded by central government & partly by state government/municipal

bodies





Government/municipal bodies: It is estimated that at the current rate of growth, in

about two decades, water demand in India and China together will be thrice the

world’s current consumption. Budgetary outlay for Indian government’s 12th 5-yr plan

2012-17 for water supply and sanitation is more than Rs. 255,310 crores which is

significantly higher than previous plan.

Increasing investment of government in water and sanitation projects, the main

driver for DI pipe demand is evident from the figure below.

External Aid

Water resources projects in India are supported by multilateral or bilateral aid, grants,

loans, and commodity aid from foreign countries as well as donor agencies such as

the International Bank of Reconstruction and Development (IBRD) commonly known

as the World Bank. During 2013, the Sian Development Bank has sanctioned projects

worth Rs 8800 crores for projects to improve drinking water and sanitation in major

cities like Delhi and Kolkata along with projects in Rajasthan. The National Ganga

River Basin Authority (NGBRA) has received one Billion USD financing from the World

Bank.

The Ministry of Water Resources, Government of India assists the state governments in

tying up external assistance from different funding agencies to fill up the resource

gaps.

Water resources projects have also been funded through bilateral support of France,

Australia, Canada, Germany, and the Netherlands

Industry Analysis

While the purchase of pipes in general has increased, the share of DI pipes in the

total purchase of pipes has increased significantly from 33% to 52%. The share of

other pipes has been either declining or stagnant. The plastic pipes used are

predominantly PVC pipes and recent increase in use of HDPE pipes in competition for

PVC pipes. The other pipes include GRP, BWSCC pipes, Hume pipes, stoneware

pipes, etc. GRP pipes, RCC pipes, and stoneware pipes are used predominantly in

sewerage applications. The increasing share of DI pipes obviously indicates its rising

acceptance by customers and its growing popularity. The increasing share of DI

pipes indicates that DI pipes are gradually replacing all other pipes, especially steel

pipes. The government bodies have virtually stopped purchase of CI pipes for

potable water supply and the existing CI pipelines are increasingly being replaced

by DI pipes. Plastic pipes and cement pipes (AC/RCC/PSC) are also being replaced

in urban and semi-urban areas; however, in rural water supply schemes they still exist

due to the low initial investment.

Preference of Pipe Materials

The choice of the pipe material, on technical grounds, is governed by two major

factors: the pipe diameter and the area of application, i.e., transmission or

distribution. The general preference of pipe materials for water supply projects are

available in three different diameter ranges and used in urban, semi-urban, and rural

areas. DI pipes are widely preferred in urban and semi-urban areas. In urban and





semi-urban areas, uncovered water is considered unsafe and it is mandatory to

provide piped water supply to prevent pollution and contamination of drinking

water. Moreover, in the urban and semi-urban areas, DI pipes are preferred because

they are the best suited in places where heavy traffic loads, digging for cable laying

and bridges/flyover, etc. are quite common. In diameter sizes above 600 mm, MS

pipes are preferred because the initial investment is less as compared to that of DI

pipes. DI pipes are preferred in the lower diameter sizes, for both high-pressure

transmission and low-pressure distribution system. However, the users are increasingly

considering the life cycle cost (LCC) rather than just the initial investment because

this factor is being focused in tender evaluation as well. The government

departments and organizations are well aware of the long-term economic benefits

of using DI pipes in water supply and sanitation projects.

Inter Linking of Rivers (ILR) Project

Inter Linking of Rivers (ILR) project is Government of India’s proposal to link 37 rivers

through 30 links, dozens of large dams and thousands of miles of canals, making it

the largest water project in the world. Once this project is set in motion, there will be

an unprecedented demand for not only DI pipes and fittings, but also services for

design, implementation, project management, and maintenance.

Export Potential

Total global DI pipe production is about 5.4 million TPA, out of which dependence on

import by various countries is about 500,000 TPA. Export ratio is 10 – 40%. Middle East

and Asia is everybody’s target. Low domestic capacity and production has been the

major constraint that inhibited exports of DI pipes from India. India has the

competitive advantage of being strategically located to cater to Asian, South Asian,

and Middle East countries. The Middle East is a very prospective region for DI pipes

because being water scarce, as the countries in the Middle East give special focus

on water supply and sanitation. During the last four years, India exported DI pipes to

as many as 37 countries of which the regular destinations have been Algeria, Brunei,

Hong Kong, Qatar, Singapore, Spain, Sri Lanka, Sultanate of Oman, and UK. Thus, DI

pipes will continue to be in good demand in these countries in the forthcoming years

as well.

Domestic Manufacturers of DI pipe

There are three major units engaged in the manufacture of DI pipes in India

I Electrosteel Castings Ltd. (ECL);

ii Electrosteel Steels Lts (ESL)

iii Jindal Saw Ltd. (JSL).

iv Tata Metalliks DI Pipes Ltd (TMDIPL)

v Lanco (Srikalahasthi Pipe Ltd) SPL

vi Electrotherm (ET)

vii Jai Balaji Group (JB Group)





viii Rashmi Metaliks (RML)

Electrosteel and Jindal Saw are the market leaders in the domestic market.

The total installed capacity (as on June 2015) is around 1.72 MT (Million Tonne).

However due to non operation of plants of M/s Electrotherm & M/s Rashmi

Metaliks, the actual capacity was 1.42 MT only.

There is an addition of capacity in the current FY 2014-15 by year of 0.3 MT

The average capacity utilization is around 60%, which may go up to 70% during

2016-17 and he production is likely to go up to 1.70 MT during 2016-17

Demand – Supply gap :

Based on past records, the demand for DI pipes used in a large way for the

transportation of water is expected to grow by 15 to 20 % year on year. The various

demand projections studies made by different national and international

institutions/organizations have estimated the demand of DI Pipes to increasing

rapidly.

Considering the present producers of Ductile Iron pipe plants in India, their current

production trends and known capacity expansion being planned, the demand

supply gap of DI pipes for next 11 years is shown below in Table-1.

Table-1

Demand of Ductile Iron Pipes in India (At 14 % CAGR)

Year

Deman

d in

million

tonnes

Capacity*

*

Productio

n at

Present

Trend

Gap (MT) vis-

à- vis present

production

trend

Gap w.r.t

100

%

production

at Rated

Capacity

Remarks

2014 1.20 1.115 0.7 0.50 0.09 2015 1.37 1.315 0.9 0.47 0.05 JS Cap

Addition 2016 1.56 1.505 1.06 0.50 0.05 TMDIP Cap

Add 2017 1.78 1.505 1.36 0.42 0.27 2018 2.03 1.505 1.66 0.37 0.52 2019 2.31 1.505 1.96 0.35 0.81 2020 2.63 1.505 2.26 0.37 1.13 2021 3.03 1.505 2.56 0.47 1.52 2022 3.48 1.505 2.86 0.62 1.98 2023 4.01 1.505 3.16 0.85 2.50

2024 4.61 1.505 3.46 1.15 3.10 2025 5.30 1.505 3.76 1.54 3.79





(v) Imports Vs Indigenous production:

With Make in India concept and accelerated growth potential of Indian economy,

utilising existing natural resources to produce hot metal and convert into Value Added

Products such as Ductile Iron Pipes is better option than spending Foreign Exchange

on import of Ductile Iron pipes.

(vi) Export Possibility:

There is a big potential for export of D.I. spun pipe especially to the Eastern Europe.

South America, Africa, Africa, South East Asia and other ASEAN & SARC countries

apart from traditional exporting countries of Middle East & Western Europe.

(vii) Domestic / Export Markets: Based on past records, the demand for DI pipes used in a large way for the

transportation of water is expected to grow by 15 to 20 % year on year. The various

demand projections studies made by different national and international

institutions/organizations have estimated the demand .of DI Pipes to increasing

rapidly.

The demand of Ductile Iron pipe is directly proportional to the investment made in

Water, Sanitation, Irrigation and waste water treatment by all the concerned agencies

of Central Government, State Government, Municipal Corporations, Local Bodies,

Private bodies, and international banks & agencies

(viii) Employment Generation (Direct & Indirect) due to project: The proposed project will generate additional direct employment of approx. 400

manpower including contract labour. It will provide new opportunities for local

people also resulting in indirect employment for more than 1000 manpower. Training

programs will be set up for the development of local community as per the work

requirement.

3.0 Project Description

Type of Project

Vedanta proposes to set up either 300 KTPA Ductile Iron pipe or 2 phases of 150 KTPA

Ductile Iron Pipe Plant within the existing Pig Iron Plant complex, which is a notified

industrial area.

Location

The plant site of the proposed Ductile Iron Pipe Plant of Vedanta DI Pipes Limited will

be located inside the existing plant site at Navelim village, Bicholim taluka, North

Goa district, Goa, about 5 km from Sankhali Town and 21.2 km from Mapusa.





The proposed site is located southwards of Mini Blast Furnace of Vedanta Limited

within the existing pig iron plant. National Highway NH-4A, which runs between

Panjim and Bangalore, runs at about 5.3 km from the proposed plant site in its WSW

side.

Road Linkages

National highway NH-4A, which runs between Panjim and Bangalore, runs at about

5.3 km from the proposed plant site in its WSW side. DI pipes will be shipped by road

or/and then through Marmugoa Port Trust (MPT)

Rail Linkage

Carambolim (Karmali) Railway Station is located at a distance of 8 km in WSW

direction from the plant boundary. DI pipes, however, are not proposed to be

shipped by rail.

Port

Marmagao port, the nearest port for the despatch of finished product is about 45 km

away from the plant. All export of DI pipe will be through this port.

The Dabolim Airport is located at a distance of 21 km in SW direction, connects the

city to the rest of the world by air.

The Index map and study area map are presented in Figure-1 and Figure-2

respectively.





FIGURE-1

INDEX MAP

Plant SitePlant Site





FIGURE-2

STUDY AREA MAP





Coverage of the Study Area

The study area of this project encompasses all areas, falling within a 10 km radius with

the plant site as centre.

Topography

The district has hilly terrain especially on its western side where lies the southern ends

of the Sahyadri range. The terrain is intersected by a number of rivers flowing west

wards and meet the Arabian Sea. These rivers provide network of internal water

ways. The important rivers are Mandovi, Zuvari, Terekhol and Chapora which are

navigable and as such most for the economy of this district. Inland waterways play

an important role in transporting of mineral ores from the mining sites.

Land & Terrain

The proposed plant area is located in a sloping terrain with an average elevation of

34 m above mean sea level (MSL). The area presents a gradually sloping topography

with Laterite structures covered with dense bushes and shrubs. The general slope in

the study area is about 1 in 50.

The present and proposed FGL of Blast Furnaces is indicated as 38 m. The

proposed location of the DI Plant will be located in the terrain which is having a

slope from 40m to 10m. It is proposed to locate the plant at FGL of 25 m to

minimize the cutting and filling of rocks. BF Hot metal will be transferred by rail track

to be provided in trench to suit the terrain near PCM and transported to DI plant .

Climate

The climate in the study area is typically warm and humid. From June to September

heavy rainfall is received every year from the southwest monsoon which ranges

between 2500 to 4300 mm. The year round temperature ranges from 22 to 37oC.

Water Bodies

Water Bodies in the radius of 15 km radius from the plant

1. Arabian sea - about 15 km, SW

2. Mandovi River – 0.5 km, West

3. Mapuka River - 13.4 km, NW

4. Karmali lake- 7.6 km, SW

5. Kudne River- 1.5 km, North

6. Zuvari River- 12.7 km, SSW

Industries

The major industries within the study area (10 km radius) are





1. 292 KTPA pig iron plant, 1 MTPA sinter plant 540 KTPA pig iron plant, 2x300 KTPA

coke oven plant and 2x30 WHRB power plant of Vedanta.

2. Planned phase-II, 450 KTPA pig iron plant, 300 KTPA coke plant, 1 MTPA sinter

plant and 30 MW WHRB power plant of Vedanta

3. Syngenta pesticide plant

4. Alcon cement plant

5. Desai cement plant

6. Iron ore mine of Sesa, Salgaonkar

7. Beneficiation plant of Damodar Mangalji

8. Small scale industries like Ulka sea food processing, Orgoa

9. Laterite stone quarries

10. Kundai Industrial estate

Sensitive Areas

Following are the sensitive areas in the study area

Dr.Salim Ali Bird Sanctuary- 14.3 km, West (for this sanctuary ESZ is 100 m)

Mhadei WLS: 9.5 km, NE (ESZ is 1 km)

Bondla WLS : 10.7 km, SE (ESZ is I km)

Old Goa Church- Approx 6 km

Mandovi river estuary- About 14 km

3.3 Project Description with Process Details

Manufacturing Process

The manufacturing process of DI pipe is a continuous sequential process involving

several sub-processes. The process starts with receipt, desulphurization, scrap

charging and super heating of molten metal in induction furnace; pipes are

centrifugally cast using molten metal; heat treatment follows in annealing furnace to

give ductility to the pipes cast; lining and coatings are carried out to manufacture

finished pipes.

A schematic process flow diagram is given in Figure-3.

Desulphurization

Sulphur content in the molten metal from Mini Blast Furnace (MBF) is reduced to a

level of 0.02 % as low sulphur level is a prerequisite for magnesium treatment.

Scrap Addition & Super Heating

Desulphurized molten metal is poured in the induction furnace. Scrap and Ferro

Alloys are added to arrive at the required chemical composition. Metal is super

heated to the desired pouring temperature.





Magnesium Treatment

Magnesium is introduced in the molten metal to change the shape of the graphite

after solidification. Magnesium converts the flake shaped graphite to a nodular

shape. The nodular shape of graphite leads to better mechanical properties of

ductile iron.

Centrifugal Casting

Pipes are cast by continuously pouring liquid metal in rotating, water-cooled, metallic

moulds fitted in the spinning machine. Metal is poured at a fixed rate from the

holding hopper on to the rotating moulds.

Pipes get their extended hollow cylindrical shape through simultaneous rotation to

the moulds and downward traverse movement of the spinning machine.

Appropriate addition of inoculants is made to get the correct micro-structure and

good surface finish of pipes.





Figure-3. A schematic process flow diagram

Heat Treatment

Pipes are heat treated in an annealing furnace to attain mechanical properties

stipulated by standards. Each pipe is subjected to annealing process to dissolve

cementite and formation of ferrite in the matrix. This results in the attainment of





desired mechanical properties. Annealing is a four stage process involving heating,

soaking, rapid cooling and slow cooling. After annealing, mechanical tests are

carried out at a regular interval to check the ductility and tensile strength of the

pipes.

Marketing & Stencilling

Name and logo of the manufacturer, year of manufacture, class of pipe, quality

certificate number are marked on the external surface of the pipes using stencils.

Some of those marked information are requirements of the applicable standards.

Storage, Packing & Despatch

Finished pipes are stored in the stockyard in stacks normally in three ways, viz., square

stacks, pyramidal stacks and parallel stacks.

Pipes of less than DN 400 size are normally bundled after putting wooden bars

between pipe layers for the purpose of separating. Pipes are despatched in trucks

and trailers.

Support Processes

Socket Core Making

Sand core is needed to give the internal profile of socket during casting. One core is

required to manufacture one pipe as the core gets burnt in the production process.

Sand and binders are used in the ore shooting machines to manufacture cores.

Mould Maintenance

Mould maintenance involves three activities, viz., grinding, peening and welding.

Grinding removes heat cracks on moulds which appear during casting of pipes.

Peening makes the moulds’ internal surface rough to get desired external surface of

pipes. Welding is used to repair deep heat cracks on moulds which grinding cannot

remove.

Main Plant & Equipment

The proposed DI plant will have a capacity to produce 2x150 KTPA/300 KTPA of DI

pipes having a size range of DN 80 to DN 1200.

Manufacturing Facilities (Phase I) – (tentative)

1. Liquid Metal Holding 150 t : 1 no.(Optional)

2. Induction Furnace 20t x 3 crucibles (Dual Track type)

3. Magnesium Converter 5t x 2 nos.





4. Casting Machines (total 5 nos.)

a. DN 100 – 300 : 2 nos.

b. DN 350 – 800 : 2 nos.

c. DN 800 – 1200 : 1 no.

5. Annealing Furnace 58 m long 40 tph : 1 no.

6. Core Making Equipment

7. Mould maintenance Equipment.

8. Inspection & QC equipment

9. Finishing Lines 2 no.(Duplex Station)

a. DN 100 - 400

b. DN 450-1200 mm

10. Coating Line : 2 no.(Duplex Station)

a. DN 80-400

b. DN 450 – 1200

11. Hoisting & Handling equipment (EOT Cranes, Electric Hoist, Chain Pulley Blocks)

12. Transfer Cars

13. DM Plant for Soft Water

Water cooling Recirculation System (Circulating Pumps, Cooling Tower, Pipes,

valves & fittings)

14. Drinking water & Firefighting

Raw Material Requirement

The Consumption of Raw Materials and Fuel for rated capacity of production of DI

Pipes are shown in the table-1.3

TABLE-1.3

SPECIFIC CONSUMPTION RAW MATERIALS & UTILITIES

Sr. No. Raw Material kg/t of Cat Pipe

1 Hot Metal 1083.0

2 MS Scrap 100-130

3 Ferro Silicon 10

4 Zn Wire 1.73

5 Bitumen Coal Tar 2.15

6 Magnesium 1.3-1.4

7 Sand for core making 55

8 Graphite Powder/ 0.67

9 Binder 1.3-1.4

10 Catalyst 0.27

11 BF Gas, nm3/t 500-600

12 Cement 30

13 Calcium carbide 14-15

14 Sand for Lining 130-165

15 Utilities - Power kwh/t 350.0

16 Utilities - Water - Make Up -m3/t 1.02-1.05 m3/t

17 Compressed Air, m3/t 70





Raw Materials, Fuel and Production Balance

The material balance has been estimated for 1,50,000 t DI plant and is shown in

Table-1.4

TABLE 1.4

M A T E R I A L B A L A N C E

Input % t/h Out Put % t/h

HOT METAL 91.31% 20.58 Melting

Skull/Slag 7.14% 1.61

SCRAP/Pipe Rejets 6.53% 1.47 Rejections 6.52% 1.47

Other Ferrous Inputs

2.16%

0.49 Runner Sand Bag

& Slag

7.41%

1.67

To Casting Machine 100.00% Other Losses 2.04% 0.46

Coating & Lining

(Ave)

7.40% 1.67 Finished Pipe 84.29% 19.00

107.40% 24.21 107.40% 24.21

Material balance for 0.3MTPA DI Pipe Plant.

Material Balance

Input % t/h Out Put % t/h

HOT METAL

91.31%

41.16000

Melting Skull/Slag

7.14%

3.2200

SCRAP/Pipe Rejets 6.53% 2.94000 Rejections 6.52% 2.9400

Other Ferrous Inputs

2.16%

0.98000

Runner Sand Bag & Slag

7.41%

3.3400

To Casting Machine 100.00% 45.08000 Other Losses 2.04% 0.9300

Coating & Lining (Ave) 7.40% 3.35000 Finished Pipe 84.29% 38.00

107.40% 48.43000 107.40% 48.4300





Energy Balance

The average energy balance per t of production of DI Pipe has been shown in

Table1.5

TABLE- 1 . 5

ENERGY BALANCE

Per t of DI Pipe

S No

Input (kWH) Output (KWH)

Power

Consumed

Percent Consumer Power

Consumed

Percent

1 350.00 100.00% Holding/Melting Furnace

& Converter

208.60 59.60%

2 Casting 14.00 4.00%

3 Annealing 14.00 4.00%

4 Moulding 12.95 3.70%

5 Core Making 2.63 0.75%

6 Zinc Coating 6.13 1.75%

7 Cement Coat 3.15 0.90%

8 Finishing Operations 3.12 0.89%

9 Pump House 16.59 4.74%

10 Compressor 41.83 11.95%

11 Hoisting & Handling 2.10 0.60%

12 Admin Office Lab Stores 0.60 0.17%

13 Illumination Shop, Area

Lighting, Utilities

21.00 6.00%

14 Dedusting 3.33 0.95%

15 Total 350.00 350.00 100.00%

Services and Utilities

Water Supply Facilities

Pipe making is a heat intensive process wherein a considerable quantity of cooling

water is required for control of metallurgical processes as well as for dissipation of

unutilized heat. In order to conserve precious fresh water demand, closed circuit

water re-circulation systems have been planned as far as possible in order to effect

extensive recycling and reuse of return water from plant processes. Industrial quality

clarified water will be used in most of the cases except induction furnaces where DM

water will be required. Cooling towers will be provided for cooling industrial hot re-

circulating water. Process water losses will be compensated by adding make-up

water.

Water Requirement

Total water requirement will be 1200 m3/day and the source of water is from

Bandara which is about 10 km away from the Plant and connected with the

pipeline. Make-up water will be drawn from Bandara & stored in raw water





sump. The permission to draw the water upto 6000 m3/day from Bandara has

already been granted by GWRD-Goa government.

Circulating Water requirement for the proposed project will be 1183 m3

/h.

Total water requirement after expansion project will be supplied from

existing water supply network of M/s Vedanta Limited. The water

requirement for different processes is shown in the Table 1.6

TABLE 1.6

WATER REQUIREMENT

S

No.

Unit

Circulating Water Requirement

(m3/h)

Make up

water(m3/h)

Waste

Water Proposed Future

Expansion

Total

(m3/h)

Propose

d

Expansio

n

m3/h (Total)

1

Induction Furnace

300

300

600

2

2

2 Casting

500

500

1000

5

5

3

Annealing Furnace & Boiler

200

200

400

3

3

4 Zinc 15 15 30 0 0

5 HPTM

90

90

180

1

1

6

Cement lining

48

48

96

1

1

7 Coating

15

15

30

0

0

8 Curing 10 10 20 1 1

9 Hydraulics 5 5 10 0 0

10

Mis

c

0 2 2 2

11

Gardening, Road Sprinkling

5

5

4

13 Total

m3/h

1183 1183 2366 20 20 6

14

Make up

water Per

t

1.05

1.05

0.32

Water Recirculation System

The water recirculation systems will comprise the following main units:

Pump house & sumps;

Circulating water pumps & electrics;

Make-up water pumps & electrics;

Strainers;

Interconnecting piping;

Cooling tower; and

Emergency overhead tank for induction furnace.





Make Up Water System

Raw water will be stored in make-up water sump. Make-up water will be pumped to

different consumers, sumps, etc. through MS pipeline network complete with pumps,

valves and fittings. The make-up water pumps will be housed in a proposed common

pump house for make-up cum drinking and fire fighting.

Drinking Water System

Raw water after necessary clarification and filtration will stored in the drinking water

storage tank and will be supplied to various consumers of the pipe plant by means of

drinking water piping network, complete with pumps, valves and fittings.

Fire Fighting Water System

The fire fighting water network will be provided with adequate number of yard

hydrants and in-shop landing valves to combat fire hazards in the plant. The piping

network will be provided complete with pumps, pipelines, valves, hydrants and

fittings.

Design Criteria

Efficiency, reliability and flexibility of operation and maintenance will be the guiding

criteria for the design of the water system of the proposed plant. Pumping systems will

be provided with adequate instrumentation, controls and process interlocks to ensure

reliability of operation and safety of the plant and personnel. Cooling towers for re-

cooling of circulating water will be cross-flow/counter flow induced draft with

recovery type fan stack. DM plant will be installed for supply of soft DM water to

induction furnaces. Emergency overhead tank will be provided for meeting

emergency water requirement of the induction furnaces.

Water Pollution Control & Conservation

Extensive recycling has been adopted in the design of plant water systems. Quality of

circulating water will be maintained through dosing of conditioning chemicals for

controlling corrosion, scale deposit and microbial growth. Waste water from

treatment plant and DM plant will be neutralized before discharge from the plant.

Through cascaded reuse of blow down, the water scheme ensures minimization of

waste water discharge from the industrial water circuits.

Blast Furnace Gas System

Blast Furnace (BF) gas will be used as fuel in the annealing furnace. Required BFG

(5,000–8,000 Nm3/h) shall be made available from BF#3 which will meet the fuel

requirement of annealing furnace. Balance requirement of fuel for heating/drying will

be met with LPG/BFG. The plant will be connected with the BF gas grid of our existing

Plant.





LDO System

Power Requirement

DI Pipe Plant will require about 12 MW of power to operate the Electric/induction

furnaces, casting machines and other equipment. Required power will be sourced

internally from our 2*30MW heat recovery Power Plant. In Phase-I either pig iron

received from Bf#3 will be re-melted into electric arc furnace/coupola or hot liquid

metal will be transportedand proceed further for desulphurisation, scrap charging

etc, however, in Phase-II rail track will be laid from BF#3 to DI pipe plant for hot metal

transportation for better realisation and power saving. Depending on Financials, if at

one go 300 KTPA plant is installed then entire liquid hot metal will be utilised for DI pipe

production.

Quality Assurance

DI pipes need to conform to stringent quality standards as they are used to transmit

drinking water. Pipes are produced according to the stipulations of applicable quality

standards as below:

Indian standard - IS 8329: 2000, and

International standards – ISO:2531

International standards - BS EN 545: 2002

In order to attain stipulated specifications, stringent quality assurance measures will

be enforced at every stage of production which will include chemical analysis, visual

inspection, pressure testing, pipe thickness measurement, cement lining thickness

measurement, bitumen coating thickness measurement, physical testing, etc.

4.0 Site Analysis

The proposed 2x150 KTPA Ductile Iron Pipe Plant will be located within the existing

plant of Vedanta Limited at Navelim village, Bicholim taluka, North Goa district, Goa,

The majority of data on physiographic, geological features, infrastructure and

population have been collected from various reports, while data for soil, air, water,

noise and ecology was collected during field survey and monitoring. Climatological

data was collected from meteorological office. The data has also been compared

with data collected during study period.

Seismicity

According to IS : 1893 – 1984, the study area falls in Zone-III (which can be considered

as calm zone). There is no major earthquake episode recorded in the study area.





5. Planning Brief

(i) Planning Concept (types of industries, facilities, transportation etc) Town

and Country planning/Development authority Classification:

This is ‘A’ Category Project as per EIA Notification 14-9-2006 and requires

EC.

(ii) Population Projection:

The additional manpower is around 400 direct & indirect for 300 KTPA DI Pipe

Project

(iii) Land use planning (breakup along with green belt etc):

Out of 104 ha land taken 33 ha land has been already developed as

greenbelt. DI Plant will be of around 20 acres are and situated within existing

land, which is Notified as Industrial Area.

(iv) Assessment of infrastructure demand (Physical as well as social):

Induction holding furnaces, core making shops, Mg treatment furnaces,

annealing furnaces, etc. mentioned in process flow chart will be set up either

in 2 phases of equal 150 KTPA or at a stretch 300 KTPA facility.

(v) Amenities / Facilities:

No additional amenities / facilities is required for capacity enhancement. The

existing amenities / facilities are adequate for the proposed DI plant

The existing social infrastructure includes the following.





Bus Station;

Fire Station;

Senior Secondary School;

Shopping Complex;

Sports Infrastructure;

Self Help Groups;

Community Halls; and

Primary Health Care Centre. Hospitals are also there.

Drinking Water Management

Drinking water requirement needs will be met from overhead tank which will flow by

gravity to different consumer points. Potable water supply pumps will take suction

from filtered water tank.

Sewerage System

Proposed to either use Sewage Treatment Plant or treat sewage in septic tank-soak

pit

Industrial Waste Water management

Proposed project is designed for maintaining zero discharge except during monsoon.

The storm water and drains will be separately constructed to minimize storm water

contamination with process water.

Solid Waste Management

About 500 m3 of earth and rocks will be generated during the ground preparation

required which will be utilized within the plant premises itself.

Waste oil, used oil and other hazardous wastes will be safely stored in

drums/tanks/covered shed and sold to authorized recyclers.

Organic waste will be used as organic manure in the green areas. The municipal

waste will be given to authorized agencies for suitable disposal.

The waste generated due the proposed DI pipe plant will be handled as per the

existing practices. Sewage will be treated in existing sewage treatment plant. The

sludge will be used in green areas of the guest house and plant site.

6.0 Rehabilitation and Resettlement (R&R) Plan

The project is a brown field project. The entire land required for proposed DI pipe

plant is already in possession of Vedanta. The land is already is under industrial use

and does not have any settlement. Hence, there are no Rehabilitation &

Resettlement (R&R) issues.

7.0 Project Schedule and Cost Estimates





Project Schedule

Project will be implemented in single phase:

The implementation schedule for the proposed project is 24 months from the date of

Environmental Clearance (EC). This includes 6 months for the preparation of Basic /

Detailed Engineering, 15 months construction period and 3 months for commissioning.

Capital Cost Estimates

The capital cost of the DIP expansion plant is estimated at Rs. 550 Crore. Phase -1 of

150 TPA will be executed immediately after grant of EC. Phase -2 will be installed at a

later stage. Cost of Phase-1 is Rs 300 Cr and Phase -2 is Rs 250 Crs. Depending on

financial viability, entire 300 KTPA DI plant can be isnatalled at one go.

Expenditure on Environment in Project Cost

The overall cost on measures for the environment protection will be about 5 % of the

total project cost. The cost will include the plantation cost, setting up of emission

control and environmental monitoring equipments and stations and development of

the green land as per the government rules.

8.0 Analysis of Proposal

Financial Benefit

This will also generate revenue to the state government as well as central

government in the form of taxes and duties. The people around the region will get

direct and indirect employment thus improves the financial status

Social Benefits

The proposed project shall proactively participate in the upliftment of socio

economic index of the communities around the project site by way of financial and

administrative support. The project will open up employment opportunities, directly

and also indirectly. There shall be opportunities for entrepreneurs to engage in many

service sectors directly or indirectly associated with the project.

The CSR approach of the company shall be towards sustainable livelihood

management of the community around. There shall be focus on education, health,

sanitation, drinking water, agriculture, water shed management, culture identity

preservation, tribal welfare, welfare of socially weaker sections and marginalized

people.

pprre e sffeaasiibbiilliittyy rreeppoorrttenvironmentclearance.nic.in/writereaddata/online/... ·...

Documents